Home

1 - Free

1. A C GENERATOR INSPECTION 17 4 CDI UNIT RESISTANCE INSPECTION 17 5 17 0 4O KYMCO 17 IGNITION SYSTEM Bet amp Win 125 150 IGNITION SYSTEM LAYOUT CDI Unit Ignition Coil Ignition Switch X 14 af Pulser Coil A C Generator IGNITION CIRCUIT LYCGAWB C m SF Ignition 3 Fh G G G BY zin CDI Unit z Pulser 7 Coil Spark A C Plug Generator 17 1 17 IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO Bet amp Win 125 150 Check the ignition system according to the sequence specified in the Troubleshooting 1 28 The ignition system adopts CDI unit and the ignition timing cannot be adjusted f the timing is incorrect inspect the CDI unit and A C generator and replace any faulty parts Inspect the CDI unit with a CDI tester Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation Use of spark plug with improper heat range 15 the main cause of poor engine performance The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance 15 also described in this section nspect the ignition switch according to the continuity table specified in page 20 3 nspect the
2. 13 15 LOATI T LIN P COTON eee 13 16 VACUUM CHAMBER ASSEMBLY 13 16 CARBURETOR INSTALLATION 13 17 FUEL PUMP REMOVAL DISASSEMBLY 13 18 EUEL PEMPTNSPECHIION eee 13 19 FUEL PUMP ASSEMBLY 13 19 FUEL PUMP INSTALLATION 13 20 EUBL TANE RE MOV Sed 13 20 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL SYSTEM 13 1 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK KYMCO Bet amp Win 125 150 SCHEMATIC DRAWING TUTTI PACU ner 13 2 13 FUEL SYSTEM CARBURETOR GQ KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 OPERATION OF CARBURETOR JETS l LOW SPEED X Air Venturi slightly bain Bleed Holes Mixture Low Speed Air Inlet X Fuel in Float Chamber Slow J 4 4 Low Speed Small Jet Holes 2 MIDDLE SPEED x Air venum opened throttle aver Av iced Holes gt NIKE High Speed Air Jet f X Fuel in Float Chamber Main Jet Main Jet The slow jet also works Low amp Middle Speed Supplementary Device Vacuum Tube Low Speed Air Jet Vacuum Diaphragm Throttle Valve lt Air Pilot Screw 9 i Main Jet Bypass Jet Slow Jet Low amp Middle Speed Supplementary Fuel Inlets 13 3
3. 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 DRIVE AND DRIVEN PULLEYS KICK STARTER SCT MATIC DRA WING 8 1 SERVICE INFORMATION 8 2 8 2 EEFT CRANK CAST COV BR eases 8 3 DRIVE POLII Y 8 4 CLUTCH DRIVEN PULLEY 8 8 KICK STARTER 8 15 9 0 8 DRIVE AND DRIVEN PULLEYS O KYMCO SCHEMATIC DRAWING 8 1 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley clutch and driven pulley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS Movable drive face bushing I D 33 000 33 025 33 06 Drive face collar O D 32 006 32 009 31 90 Drive belt width 17 5 Clutch lining thickness 3 963_ 4 037 TORQUE VALUES Drive face nut 490 58 8N m Clutch outer nut 49 0 58 8N m Clutch drive plate nut 49 0 58 8N m SPECIAL TOOLS Universal holder Clutch spring compressor Bearing driver Lock nut wrench 39mm Kick starter spring remover TROUBLESHOOTING Engine starts but motorcycle won t mo
4. e rere rene rece rene eee 15 2 FE RR ec 15 3 BR A OR 2 15 4 REAR WHEEL 15 4 REAR SHOCK ABSORBER 15 5 15 0 15 REAR BRAKE REAR FORK REAR KYMCO SCHEMATIC DRAWING Ak 4 BAN f 7 s oS a E y CA 15 REAR BRAKE REAR FORK REAR KYMCO ___ WHEEL REAR SHOCK ABSORBER 8 Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Rear brake disk thickness 5 3 8 Rear brake disk runout Rear brake master cylinder I D TORQUE VALUES SPECIAL TOOLS Exhaust muffler lock bolt 294 39 2N m Rear shock absorber remover Rear axle nut 78 4 98N m Shock absorber spring compressor Rear shock absorber lower mount bolt 19 6 29 4N m Rear shock absorber upper mount bolt 39 2N m Rear damper lock nut 14 7 24 5N m apply locking agent Rear brake caliper bolt 19 0 29 4N m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteriorated brake fluid Axle not tightened properly Contaminated brake pad surface Worn brake pads Soft rear shock absorber Clogged brake fluid line Weak shock absorber spring Deformed brake
5. Worn brake linings 2 Foreign matter on brake linings Sluggish or elongated brake cables 2 Brake shoes improperly contact Water and mud in brake system or grease on brake linings 1 28 2 EXHAUST MUFFLER FRAME COVERS Bet amp Win 125 150 2 EXHAUST MUFFLER FRAME COVERS SCHEMATIC DRAWING 2 1 SERVICE INFORMATION 2 2 TROUBLESHOOTING 22 FRAME COVERS 2 EXHAUST MUFFLER REMOVAL 2 6 2 0 4O KYMCO 2 EXHAUST MUFFLER FRAME COVERS Bet amp Win 125 150 SCHEMATIC DRAWING 2 1 KYMCO 2 EXHAUST MUFFLER FRAME COVERS _ Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler lock bolt 34 3N m Exhaust muffler joint lock nut 1 1 8N m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler Exhaust muffler air leaks KYMCO 2 EXHAUST MUFFLER FRAME COVERS Bet amp Win 125 150 Bolts Nuts FRAME COVERS REMOVAL REAR CARRIER amp HAND RAIL RE
6. float up and down Float up Full Float down Empty Pointer moves Check operation of 0 pointer by md TREE shorting fuel unit terminal on wire harness side Pointer does not Check connectors for connection 2 Pointer fluctuates or DEM Ignition switch ON Inspection Adjustment Check battery circuit operating turn signals and horn Signals operate Signals dim Demon fuel nn roperl remain Remove fuel unit and property mE Pointer does not move check operation of pointer by moving float up and down MEM Move float up and down rapidly 1 round gt to check the gt Operation of pointer UNA Pointer moves Pointer does not accordance with move in accord float ance with float Check connectors for proper connection Pointer moves move KYMCO Bet amp Win 125 150 Probable Cause OBurned out fuse 2 Weak or dead battery Faulty ignition switch 2 Loose or disconnected connectors Broken wire harness O Faulty float or shorted fuel unit wire Disconnected connector Incorrectly connected connector Broken or shorted wire in fuel gauge Probable Cause Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness OD Poor contact in fu
7. 1 Outer Bearing Bearing Driver Seat the snap ring in its groove Apply grease to the driven face bore areas Pack all bearing cavities with9_ 9 56 grease 8 11 8 DRIVE AND DRIVEN PULLEYS KYMCO Press a new needle bearing into the driven face Bearing Driver CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Keep grease off the clutch linings Clutch Lining Retainer Plate 8 12 8 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER Bet amp Win 125 150 CLUTCH ASS EMBLY Install the damper rubbers on the drive plate Circlips pins Install the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips Drive Plate Movable Driven Face CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease from them Apply grease to the O rings and install them onto the moveable driven face 8 13 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Guide Roller Guide Roller Pin Install the movable driven face onto the driven face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Driven Face Movable Driven Face Seal Collar Install the seal collar Remove any excessive grease Be sure to clean driven face off any grease Set the driven pulley
8. 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL PUMP CONSTRUCTION The fuel pump adopted for this model is a vacuum type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve FUEL PUMP CONSTRUCTION Outlet Outlet Valve Diaphragms Suction Valve Pulsating Pressure from Crankcase Inlet 13 4 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly Before float chamber disassembly drain the residual gasoline from the float chamber Do not try to disassemble the auto bystarter When assembling the vacuum chamber and air cut off valve be careful not to damage the diaphragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away from the working area When removing the fuel tank the remaining fuel in the tank must belowerthan ofthe fuel tank capacity to avoid gasoline overflowing Fuel tank capacity 10 5 liters SPECIFICATIONS 150 Venturi dia mm VE26
9. 6 1 KYMCO 6 CYLINDER HEAD VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water Jacket must be drained first When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts order When assembling install them the reverse order of removal SPECIFICATIONS Valve clearance col Cylinder head compression pressure 15kecm 15kecm 4 Cylinder head warpage __ _ 1 905 005 30 8763 30 8763 30 75 30 75 5 30 4081 30 4081 30 26 30 26 10 00 100181000 10 018 1010 10 10 n 10 00 100181000 10 018 1010 10 10 Valve rocker arm shaft 9972 9987 9972 9 987 99 99 O D 9972 9 987 9 9727 9987 99 99 Caio 1 2 1 2 1 8 E e Valve guide LD Valve stem to guide clearance 0 030 0 057 0 030 0 057 TORQUE VALUES Cylinder head cap nut 19 6N m Apply engine oil to threads Valve clearance adjusting nut 8 8N m Apply engine oil to threads Cylinde
10. front axle Bent spoke plate Faulty tire mproperly tightened axle nut Soft front shock absorber Weak shock springs nsufficient damper oil Front shock absorber noise Slider bending fork fasteners Lack of lubrication 14 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 125 1 59 Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers 2 6 Remove the front and rear brake master cylinder attaching bolts Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove the floor board 2 4 Remove the leg shield 2 5 Bolts Throttle Grip Remove the four screws attaching the right and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Screws Throttle Cable Remove the handlebar lock nut and take out the bolt Remove the handlebar Bolt INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 39 2 49N m Lock Nut Collar I4 STEERING HANDLEBAR FRONT WHEEL FRONT __ SHOCK ABSORBER FRONT FORK Bet amp Win 1257150 Lubricate the throttle grip front end with grease and then install the throttle grip Connect the throttle cable to the throttl
11. yo atei n PAssING o t to STOP SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the front rear stop switch wire couplers Check for continuity between the wire terminals when the front brake lever is applied Brown Blue Green Yellow Horn Button Turn Signal Switch Dimmer Switch PASSING Stop Switch 19 4 19 SWMICHESHORN FUELUNITTHERMOSTATICSWITCH IFMPFRATUREGAUGEINSTRUMENTSI IGHIS HORN INSPECTION Remove the front upper cover 2 5 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery 1s connected across the horn wire terminals FUEL UNIT FUEL UNIT INSPECTION Remove the fuel unit Disconnect the fuel unit wire connectors Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions Wire Terminal Q Q Q Q Q FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Lower Fuel Unit Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down 5 Needle Position F Full E Empty Needle Position YW G L W The fuel gauge is normal if it operates as above indicated If not check for loosely tightened nut
12. SPECIAL TOOLS Float level gauge Fuel unit remover 13 5 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK TROUBLESHOOTING Engine does not start No fuel in tank Restricted fuel line Too much fuel getting to cylinder Clogged air cleaner Contaminated fuel Faulty fuel pump Throttle does not open fully so engine stalls Damaged vacuum piston diaphragm Clogged diaphragm hole Lean mixture Clogged fuel jets Clogged fuel tank cap breather hole Clogged fuel filter Bent kinked or restricted fuel line Faulty float valve Float level too low Faulty fuel pump or insufficient output Engine is hard to start No fuel in tank Restricted fuel line Clogged fuel strainer Faulty fuel pump Broken or clogged vacuum tube Faulty or clogged charcoal canister Lean mixture Clogged charcoal canister Bent kinked or restricted fuel line Clogged fuel strainer Float level too low Bet amp Win 125 150 Engine idles roughly stalls or runs poorly ncorrect idle speed Rich mixture Lean mixture Clogged air cleaner ntake air leak Contaminated fuel Faulty air cut off valve Damaged vacuum tube and connectors Damaged carburetor insulator Rich mixture Auto bystarter valve opens excessively Faulty float valve Float level too high Clogged air Jets Auto bystarter valve set plate installed in the wrong groove C
13. SPECIFICATIONS Radiator cap relief pressure 0 9 0 15kg cm a 802 C DE Thermostat temperature Full open 2 Valve lift 35 45mm Coolant capacity Total system 1165cc penc a AN COOLANT GRAVITY See PPE EPP PEE concentration 1 045 1 044 1 043 06 06 07 08 091 095 COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing Point Distilled Water 95 206 psc 575 50 445 C 5 Cautions for Using Coolant Use coolant of specified mixing rate The mixing rate of 360cc KYMCO SIGMA coolant concentrate 825cc distilled water 1s 30 Do not mix coolant concentrate of different brands Do not drink the coolant which 15 poisonous The freezing point of coolant mixture shall be5 C lower than the freezing point of the riding area 12 3 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Radiator Tester COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it It must hold specified pressure for at least six seconds Apply water to the cap sealing surface before testing Radiator Cap Relief Pressure 0 9x0 15kg cm Radiator Cap Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks The test pressure should
14. Thermosensor 0 6 1 lf fil 19 1 19 SMICHESHORN FUELUNITTHERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSI IGHIS Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS After installation of each switch a continuity check must be performed A continuity check can usually be made without removing the part from the motorcycle TESTING INSTRUMENT Electric tester SPECIAL TOOL Fuel unit wrench TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON Burned bulb Faulty switch correctly Faulty temperature gauge Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between temperature gauge and thermosensor Fuel gauge pointer does not move or register correctly Faulty fuel gauge Faulty fuel unit Poorly connected wire between fuel gauge and fuel unit Fuse burned out SPECIFICATIONS Fuse Headlight bulb Turn signal light bulb Stoplight taillight License plate light Instrument light Position light Turn signal indicator light 20A 12V 35W 35W 12V 10W 12V 21 5W 12V 5W 12V 1 7W 12V 5W 12V 3 4W 19 2 19 SMICHESHORNFUELUNITIHERMOSTATICSWI ICH KYMCO IFMPERATUREGAUGEINSTRUMENTSI IGHIS Bet amp Win 125 150 SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the ignition swi
15. 9 2 TROUBLESHOOTING e e 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION INSPECTION 9 3 FINAL REDUCTION ASSEMBLY 9 6 9 0 4O KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 SCHEMATIC DRAWING 9 1 KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The servicing operations of this section can be made with the engine installed When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified SAE 907 Oil Capacity At disassembly 0 2 liter At change 0 195 liter TORQUE VALUES Transmission case cover bolt 25 5 31 4N m Oil check bolt 0 8 14 7N m SPECIAL TOOLS Bearing remover 12mm Bearing remover 15mm Pilot 12mm Pilot 15mm TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged oil seal 4O KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 FINAL REDUCTION DISASSEMBLY Bolts Remove the exhaust muffler 2 6 Remove the rear brake caliper 15 3 Remove the right rear shock absorber 15 5 Remove the rear fork 15 4 Remove the rear wheel 15 4 Remove the left crankcase cover 8 3 Remove
16. Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot D Worn or slipping drive belt 2 Worn weight rollers Seized drive pulley bearings Weak driven face spring or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers 9 or seized driven pulley bearings or grease fouled drive belt 2 Worn drive belt Weak driven face spring 4 or seized driven pulley bearings 1 GENERAL INFORMATION STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Lac operation of stop switch b applying brake Stoplight does not Stoplight comes SU Check battery circuit by operating turn signals n operate Check operation of properly starter relay by depressing starter button signals dim remain on or don t Connect starter motor directly to battery epit n 2 Starter motor KYMCO Bet amp Win 125 150 Probable Cause O Burned out fuse 2 Weak or dead battery Faulty stop switch 2 Loose or disconnected connectors Broken or shorted ignition switch wire DFaulty or weak battery D Poor starter button connection 2 Open or shorted starter relay QGLoose or disconnected connectors Worn brushes 2 or shorted wires or rotor 9 Open star
17. Place the motorcycle on its main stand on level ground Check the coolant level of the reserve tank and the level should be between the upper and lower level lines If necessary fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 30 The coolant level does not change no matter the engine is warm or cold Fill to upper line COOLANT REPLACEMENT Perform this operation when the engine is cold Remove the front cover Remove the radiator cap Remove the drain bolt to drain the coolant and tilt the motorcycle to the right and the coolant will drain more easily Drain the coolant in the reserve tank Reinstall the drain bolt Fill the radiator with the specified coolant The coolant freezing point should be 5C lower than the temperature of the riding area 3 9 4O KYMCO Bet amp Win 125 150 Upper Line Lower Line Radiator Cap Reserve Tank KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 Coolant capacity 1165cc Radiator capacity 825cc Reserve tank capacity 340cc start the engine and check if there 1s no bubbles in the coolant and the coolant level 1s stable Reinstall the radiator cap If there are bubbles in the coolant bleed air from the system Fill the reserve tank with the recommended coolant up to the upper line BRAKE SYSTEM BRAKE LEVE
18. Remove the final shaft oil seal Drive Shaft Bearing m Pilot 12mm Drive new bearings into the transmission case cover BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover 15mm KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive Shaft Install the final gear and final shaft into the left crankcase 9 FINAL REDUCTION Install the countershaft and gear into the left crankcase Install the resin washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Install other removed parts in the reverse order of removal 9 7 Countershaft dC KYMCO Bet amp Win 125 150 Washer Transmission Case Cover dC KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 Oil Check Bolt Hole Oil Filler After installation fill the transmission case E with the specified oil Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity _ At disassembl
19. Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench Lock Nut Wrench 39mm Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar 8 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER Bet amp Win 125 150 Guide Roller Pin Guide Roller Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Movable Driven Face O ring Remove the oil seal from the movable driven Oil Seal face INSPECTION Measure the driven face spring free length Service Limit 83 2mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below 9 10 8 DRIVE AND DRIVEN PULLEYS KYMCO Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play Drive the inner needle bearing out of the driven pulley face Discard removed bearing and replace with a new one Inner Bearing Remove the snap ring and drive the outer bearing out of the driven face Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up
20. clutch driven pulleys 8 4 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Final Shaft Dowel Pin Drive Shaft Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft Final Gear Countershaft Dowel Pin Washers FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft 9 FINAL REDUCTION Inspect the final gear and final shaft for wear damage or seizure Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage a Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal KYMCO Bet amp Win 125 150 Drive Shaft Bearing EN I z i 1 E Di 4 N 1 a Final Shaft Bearing Countershaft Bearing Final Shaft Bearing Drive Shaft Bearing 9 4 KYMCO 9 FINAL REDUCTION Bet amp Win 125 150 Bearing Remover 12mm BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using the bearing remover
21. rings should be installed with the markings facing up After installing rings they should rotate freely without sticking Stagger the ring end gaps as figure shown KYMCO 7 CYLINDER PISTON Bet amp Win 125 150 PISTON INSTALLATION Remove any gasket material from the crankcase surface Be careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip Position the piston IN mark on the intake valve side Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Piston Pin Clip Piston Pin Dowel Pin CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Gasket Cylinder Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Be careful not to damage or break the piston rings The piston ring end gaps should not be parallel with or at 90 to piston pin dC KYMCO 7 CYLINDER PISTON Bet amp Win 125 150 Cylinder Base Bolt ET ln 11 Y P vn 1 Tighten the cylinder base bolt Install the cam chain guide Insert the tab on the cam chain guide into the cylinder groove Connect the water hose to the cylinder Install the cylinder head 6 9 Tighten the cylinder base bolt
22. 14 16 17 19 N N N N
23. CARBUREDUMY 19 9 TEXT A C GENERATOR INSPECTION A C GENERATOR INSPECTION AIR CLEANER AIR CUT OFF VALVE AUTO BYSTARTER INSPECTIONREMOVAL AUTO BYSTARTER INSTALLATION BATTERY BRAKE SYSTEM CABLE amp HARNESS ROUTING CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CARBURETOR IDLE SPEED CARBURETOR INSTALLATION CARBURETOR REMOVAL CDI UNIT RESISTANCE INSPECTION CHARGING INDICATOR INSPECTION CHARGING SYSTEM LAYOUT CHARGING SYSTEM CLUTCH SHOE WEAR CLUTCH DRIVEN PULLEY COOLING SYSTEM TESTING COOLING SYSTEM CRANKCASE ASSEMBLY CRANKCASE SEPARATION CRANKSHAFT CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL 16 5 17 4 3 5 3 219 13 14 16 4 3 10 1 12 6 10 6 4 3 6 13 17 B 9 5 16 7 16 1 16 5 3 9 8 8 12 4 Bep ll 5 ll 3 1 4 6 8 6 11 6 4 6 7 6 9 6 6 Bet amp Win 125 150 CYLINDER INSTALLATION CYLINDER REMOVAL DRIVE BELT DRIVE PULLEY ELECTRICAL EQUIPMENT LAYOUT ENGINE INSTALLATION ENGINE OIL ENGINE OIL OIL FILTER ENGINE REMOVAL ENGINE SERIAL NUMBER EXHAUST MUFFLER REMOVAL FINAL REDUCTION ASSEMBLY FINAL REDUCTION DISASSEMBLY FINAL REDUCTION GEAR OIL FINAL REDUCTION INSPECTION FLOAT CHAMBER ASSEMBLY FLOAT CHAMBER DISASSEMBLY FLOAT LEVEL INSPECTION FLYWHEEL INSTALLATION FLYWHEEL REMOVAL FRAME COVERS REMOVAL FRONT B
24. CLUTCH SHOE WEAR 3 9 COOLING SYSTEM 3 9 BRAKE SYSTEM 3 10 NUTS BOLTS FASTENERS 3 11 WHEELS TIRES 3 1 STEERING HANDLEBAR 3 11 SUSPENSION lt 3 11 KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 SERVICE INFORMATION GENERAL Before running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6mm Spark plug NGK DPR7EA9 Spark plug gap 0 9mm Valve clearance IN 0 1mm EX 0 1mm Idle speed 1600rpm Engine oil capacity Cylinder compression 15 2kg cm At disassembly 1 1 liter Ignition timing BTDC 10 3 1500rpm At change 0 9 liter Coolant capacity 1165cc Gear oil capacity Radiator capacity 825cc At disassembl
25. Cam Chain Guide Dowel Pins Install the cylinder head and take out the cam chain Cam Chain Assemble the camshaft holder Valve Rocker Arms First install the intake and exhaust valve rocker arms then mstall the rocker arm shafts Install the exhaust valve rocker arm shaft on side of the camshaft holder and the exhaust rocker arm shaft 1s shorter Clean the intake valve rocker arm shaft off any grease before installation Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder Camshaft Holder KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 CAMSHAFT INSTALLATION Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear Install the dowel pins Dowel Pins Install the camshaft holder washers and nuts Washer Nut on the cylinder head a i Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder Torque Cylinder head cap nut 19 6N m Cylinder amp cylinder head bolt 78 11 8 j pd Apply engine oil to the threads of the cylinder head cap nuts Diagonally tighten cyli
26. FINAL REDUCTION GEAR OIL Place motorcycle its main stand on level ground Stop the engine and remove the oil check bolt The oil level shall be at the oil check bolt hole If the oil level 1s low add the recommended oil SAE90 to the proper level Install the oil check bolt Make sure that the sealing washer is in good condition OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt P Ww Torque 9 8N m Make sure that the sealing washer is in e 5 Bolt Sealing good condition asher Fill the final reduction with the recommended oil SAE9O Gear Oil Capacity At disassembly 200cc At change 180cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the left crankcase cover Drive Belt Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule 3 INSPECTION ADJUSTMENT HEADLIGHT AIM Turn the ignition switch ON Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary COOLING SYSTEM COOLANT LEVEL INSPECTION
27. SPECIAL TOOLS KYMCO Bet amp Win 125 150 alve guide driver alve guide reamer alve spring compressor Lock nut wrench 39mm Bearing driver Bearing remover 12mm Remover shaft Remover weight Bearing remover 15mm Bearing driver Clutch spring compressor Ball race remover extension Ball race remover Spring compressor Mechanical seal driver Kick starter spring remover Gear remover alve seat cutter 45 alve seat cutter 32 alve seat cutter 60 Cutter clip 5mm niversal holder Bearing driver 32x35mm Pilot 12mm Pilot 17mm Flywheel puller Rear shock absorber compressor Steering head bearing remover Flywheel holder Reamer clip Fuel unit wrench 1 9 Valve guide removal installation Valve guide grinding Valve removal Clutch disassembly Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Clutch disassembly Ball race removal Ball race removal Spring removal Water pump mechanical seal removal installation Kick starter spring removal Starter gear removal Tapper adjustment Carburetor fuel level check Valve seat refacing Valve seat refacing Valve seat refacing Holding clutch for removal Bearing installation Bearing installation Bearing installation Bearing installation A C generator flywheel removal Rear shock absorber disassembly Steering head bearing removal A C generator flywheel holding Fuel unit removal 1 GENERAL INFO
28. STARTING SYSTEM Bet amp Win 125 150 STARTER MOTOR REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see 1f the starter motor operates properly Starter Motor Cable Remove the seat met in box and frame center cover 2 3 Motor Case Remove the waterproof rubber jacket and disconnect the starter motor cable Remove the two starter motor mounting bolts and the motor DISASSEMBLY Remove the two starter motor case screws front cover rear cover motor case and other parts Case Screws Front Cover C tat INSPECTION SAC EUIS Inspect the removed parts for wear damage or discoloration Replace if necessary Clean commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity 18 3 dC KYMCO 18 STARTING SYSTEM Bet amp Win 125 150 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there 15 no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush Replace if necessary Wire Terminal Measure the length of the brushes Service Limit 8 5mm replace if
29. Win 125 150 QQ ENGINE REMOVAL INSTALLATION SCHEMATIC DRAWING 5 1 SERVICE INFORMATION 5 2 ENGINE REMOVAL a 5 3 5 5 5 0 KYMCO 5 ENGINE REMOVAL INSTALLATION Bet amp Win 125 150 SCHEMATIC DRAWING 5 1 5 ENGINE REMOVAL INSTALLATION Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS A floor jack or other adjustable support is required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal Use shop towels to protect the motorcycle body during engine removal Drain the coolant before removing the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine dry weight 30kg Engine oil capacity at disassembly 1 1 liter Coolant capacity Total capacity 1165cc Radiator capacity 825cc Reserve tank capacity 340cc TORQUE VALUES Engine mounting bolt 49N m Rear shock absorber upper mount bolt 39 2N m 4O KYMCO 5 ENGINE REMOVAL INSTALLATION Bet amp Win 125 150 Wire Connectors ENGINE REMOVAL Disconnect the batt
30. amp Win 125 150 4O KYMCO 11 CRANKCASE CRANKSHAFT SCHEMATIC DRAWING 11 1 KYMCO 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft The engine must be removed for this operation When separating the crankcase never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces When installing the crankcase do not use an iron hammer to tap it The following parts must be removed before separating the crankcase Cylinder head 6 4 Cylinder piston 7 3 Right crankcase cover drive and driven pulley 8 3 A C generator starter clutch 10 3 Rear wheel rear shock absorber 15 4 Starter motor 19 3 Oil pump 4 4 SPECIFICATIONS lem Standard mm Service Limit mm _ Connecting rod big end side clearance 0 15 0 35 u Crankshaft Connecting rod big end radial clearance 0 008 Runout TORQUE VALUES Crankcase bolt Cam chain tensioner slipper bolt SPECIAL TOOL Gear remover TROUBLESHOOTING Excessive engine noise Excessive bearing play Excessive crankpin bearing play Worn piston pin and piston pin hole 11 2 KYMCO 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt Remove the cam chain tensioner slipp
31. amp Win 125 150 STARTING SYSTEM LAYOUT Stop Switches v a Lo Starter Relay 74 74 4 I Starter Button a LL al Starter Motor STARTING CIRCUIT Stop SW GiY SILarber Motor Battery 12V8AH Starter Relay 4 6 1 18 1 KYMCO 18 STARTING SYSTEM Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The removal of starter motor can be accomplished with the engine installed For the starter clutch removal refer to page 10 3 After the starter clutch is installed be sure to add the engine oil and coolant and then bleed air from the cooling system SPECIFICATIONS Standard mm service Limit mm TORQUE VALUES Starter motor mounting bolt 6 7 10 8N m Starter motor case screw 29 4 9N m Starter clutch bolt 9 8 13 7N m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not start Faulty starter motor Faulty starter pinion Starter motor rotates reversely Weak battery 18 2 KYMCO 18
32. 7N m ON js m 12 1 12 COOLING SYSTEM Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame The engine must be cool before servicing the cooling system When the coolant temperature is over 100 never remove the radiator cap to release pressure because the boiling coolant may cause danger Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9 8 13 7N m Water pump cover bolt 7 8_ 11 8N m TROUBLESHOOTING Engine temperature too high Coolant leaks Faulty temperature gauge or thermosensor Faulty pump mechanical water seal Faulty radiator cap Deteriorated O rings Faulty thermostat Damaged or deteriorated water hoses nsufficient coolant Passages blocked in hoses or water jacket Clogged radiator fins Passages blocked in radiator Faulty water pump Temperature gauge pointer does not register the correct coolant temperature Faulty temperature gauge or thermosensor Faulty thermostat 12 2 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150
33. A C V ASSEMBLY Install the O ring onto the air cut off valve body and then install the valve body to the carburetor with the two screws Install the O ring with the flat face toward the valve body side 13 FUEL SYSTEM CARBURETOR GO KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 Install the O ring onto the air cut off valve Diaphragm O ring body securely Install the O ring with the flat face toward the valve body side Install the diaphragm spring and cover Cover Spring Install and tighten the two screws attaching the air cut off valve cover Connect the hose Screws AUTO BYSTARTER INSTALLATION Auto Bystarter Screws Install the auto bystarter and set plate Install and tighten the two screws nsert the auto bystarter into the carburetor body until it bottoms and position the set plate into the upper groove in the bystarter nstall the set plate with its round face facing down Set Plate 13 14 13 FUEL SYSTEM CARBURETOR C KYMCO _ FUEL PUMP FUEL Bet amp Win 125 150 FLOAT CHAMBER ASSEMBLY Slow Jet Main Jet Install the main jet Install the slow jet Install the pilot screw Be sure to record the rotating turns when it 1s removed Pilot Screw Install the float valve float and float pin Float Valve Float Pin 13 1 5 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FLOAT LEVEL
34. Measure the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over Pump Body Rotor End Dowel Pin Pump Body OIL PUMP ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin There is one mark on the surface of the inner rotor and outer rotor The mark is upside 4 5 Outer Rotor Inner Rotor Pump Shaft 4 LUBRICATION SYSTEM Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding OIL PUMP INSTALLATION Install the oil pump and oil separator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and driven gear then set the circlip securely on the pump shaft Install the oil separator cover properly l Fit the tab of the separator cover into the slit in the separator Install the A C generator starter driven gear 10 5 KYMCO Bet amp Win 125 150 Pump Hole Screw Oil Separator Bolts Pump Drive Circlip Pump Driven Gear Bolt Oil Separator Cover 4 6 5 ENGINE REMOVAL INSTALLATION Bet amp
35. SYSTEM Bet amp Win 125 150 THERMOSTAT INSPECTION suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data Thermostat Thermometer Valve lift 3 5 4 5mm O ring Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room temperature Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 THERMOSTAT INSTALLATION The installation sequence 15 the reverse of removal Replace the O ring with a new one and apply grease to it Fill the cooling system with the specified coolant 3 9 12 17 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL SYSTEM CARBURETOR FUEL PUMP FOLL 13 1 SCHEMATIC DRAWING ae eee re ete i552 OPERATION OF CARBURETOR JETS 13 3 SER VICE UNPOR A TION 13 5 CARBURETOR REMOVAL 13 7 VACUUM CHAMBER DISASSEMBLY 15 3 FLOAT CHAMBER DISASSEMBLY 13 9 AUTO BYSTARTER INSPECTION REMOV AL 13 11 AIR CUT OFF VALVE A C V 13 12 AUTO BYSTARTER INSTALLATION 13 14 FLOAT CHAMBER ASSEMBLY
36. SYSTEM Bet amp Win 125 150 THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat met in box and center Drain coolant Disconnect the thermosensor wire Remove the thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance Thermosensor through the sensor as the water heats up cm eem pm C THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads and install it into the thermostat housing Connect the thermosensor wire Fill the radiator with coolant 3 9 Install the center cover met in box and seat 2 3 Be sure to bleed air from the cooling system Thermosensor Wire 12 5 d Thermosensor dC KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 THERMOSTAT THERMOSTAT REMOVAL Remove the seat met in box and center cover Drain the coolant Disconnect the thermosensor wire from the thermosensor Disconnect the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Water Hose Air Vent Tube Bolts Remove the two bolts and separate the thermostat housing halves Thermostat Thermostat Remove the thermostat from the thermostat housing 12 16 KYMCO 12 COOLING
37. Yellow Black White Black Red CDI UNIT i RESISTANCE INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not within the specifications in the table below Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings pc EO EQ 6020000 or Kowa Electric Tester Bine Yellow Green Green White 5 n this table Needle swings then returns indicates that there is a chargng current applied to a condenser The needle will then remain at eo unless the condenser 15 discharged Use the x range for the Sanwa Tester Use the x 100 2 range for the Kowa Tester Unit SW EXT PC IGN Black White Black Red Blue Yellow Green White Black Y ellow SW Black White ne ne EM swings then swings then ace returns returns PC Green White IGN Black Y ellow 5 10 50 20 17 5 18 STARTING SYSTEM Bet amp Win 125 150 STARTING SYSTEM STARTING SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 18 2 STAPTER MOTOR 18 3 STARTER CLUTCH 18 5 STARTER RELAY INSPECTION 18 6 18 0 4O KYMCO 18 STARTING SYSTEM Bet
38. apply too much force Front Fork ip Mount Bolts Shock Absorber Dust Boot Circlip Dust Seal Copper Washer Hex Bolt Lock Nut Shock Absorber Tube 14 14 I4 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK 5 Wn 129 159 Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary Front shock absorber tube bending damage Or wear Weak front shock absorber spring and damper rod bending seal damage or wear Measure the front shock absorber spring free length Service Limit 233mm replace if below 14 15 14 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK amp Win 1257150 ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube Install the shock absorber spring onto the front shock absorber tube Set the front shock absorber tube in a vise and then tighten the lock nut When holding the shock absorber tube place a shop towel to protect it and do apply too much force Set the front shock absorber in a vise Insert the shock absorber tube into the shock absorber and then install the copper washer and tighten the damper rod hex bolt Apply locking agent to the washer and hex bolt and install them together Add engine oil into the front shock absorb
39. assembly driven face spring and clutch assembly onto the clutch spring compressor Align the flat surface of driven face with the flat on the clutch drive plate Clutch Spring Compressor nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 49 0 58 83 Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor Outer Driver 32x35mm INSTALLATION Install the clutch driven pulley onto the drive shaft Keep grease off the drive shaft Clutch Driven Pulley 8 DRIVE AND DRIVEN PULLEYS KYMCO Clutch Outer Install the clutch outer gt 1 Hold the clutch outer with the universal holder Install and tighten the clutch outer nut Torque 49 0 58 8kg m Universal Holder Install the drive belt 8 7 Install the left crankcase cover 8 3 Kick Lever KICK STARTER REMOVAL Remove the left crankcase cover 8 3 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Kick Starter Spindle Starter Driven Gear Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Friction Spring Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing 8 15 8 DRIVE AND
40. green wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage 15 blocked the auto bystarter 15 normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter 1s normal Hose Auto Bystarter Screws AUTO BYSTARTER REMOVAL Remove the two set plate screws and set plate and then remove the auto bystarter from the carburetor body Set Plate 13 11 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part 15 found replace the auto bystarter with a new one AIR CUT OFF VALVE A C V A C V REMOVAL Remove the two screws and the air cut off valve cover Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage KYMCO Bet amp Win 125 150 Bystarter Needle Bystarter Valve Air Cut off Valve Cover Screws Diaphragm Cover Spring 13 12 13 FUEL SYSTEM CARBURETOR C KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 Disconnect the hose at the valve seat Hose Air Cut off Valve Body Remove the two screws and the air cut off valve body Screws CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body Make sure that no fuel jet 1s clogged Air Cut off Valve Body
41. not exceed 1 05 kg cm Excessive pressure can damage the radiator and its hose connectors RADIATOR RADIATOR INSPECTION Remove the front upper cover 2 5 Remove the front lower cover 2 5 12 4 KYMCO Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed air If insects etc are clogging the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain coolant 3 9 Disconnect the air vent tube from the radiator filler Remove the overflow tube clamp and disconnect the overflow tube Air Vent Tube Upper Hose Wim Loosen the hose band and disconnect the upper hose and lower hose from the radiator Radiator 12 5 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Thermostatic Switch Wire Thermostatic Switch Disconnect the thermostatic switch wire coupler Disconnect the fan motor wire coupler Fan Motor Wire Coupler Radiator Remove the two bolts and two nuts on the radiator Nuts Bolts Fan Shroud RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan shroud from the radiator 12 6 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Battery Check fan motor by battery Fan Motor Thermostatic Switch n CHECK THERMOSTATIC SWITCH When coolant temperature lower then eT 85 90 the th
42. rubber cup During assembly the main piston and spring must be installed as a unit without exchange When assembling the piston soak the C D cups in brake fluid for a while nstall the cups with the cup lips facing the correct direction in pi i Snap Rin Rubber Cover Install the main piston spring and snap ring pas M Install the rubber cover Fluid Tube Bolt Punch Mark Install the brake lever Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 9 8 13 7N m Install the brake fluid tube with the attaching bolt and two sealing washers 14 9 14 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 125 1 59 Connect the front stop switch wire connector Install the handlebar covers 2 6 BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add DOT 3 brake fluid to the brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder follow the manufacturer s instructions Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system BRAKE FLUID BLEEDIN
43. wet 10 6 liters VE Type CDI Ignition timing BTDC 10 1 Contact breaker Non contact point type NGK DPR7EA 9 84 on 107911926 eounoo q 54 uous Spark plug Operation Automatic centrifugal Reduction 2 8 1 0 Bue Compression ratio 10 6 1 Front Caster angle UIo9 s S IOMOd eor ee pressure Axle Connecting rod rpm P Intake Pen ATDC 35 angle min BDDC 28 Brake svstem Disk brake type Rear Disk brake Imm Close 0 FT scsension type t 8 Valve Ll clearance cold 0 1 Shoel Front Idle speed rpm 1500rpm P Borced pressure amp IPE Rear Double swing Oil filter type Full flow filtration ourgu SUMON Uonevu 1 2 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 __ SPECIFICATIONS ame amp Model No SH30CA Motorcycle Name amp Type D 84 on 107911926 eounoo q 54 uous 9 lt Yn lt eor SUMON ourgu Overall length 1940mm Overall width Air cleaner type amp No Overall height 1145mm 10 6 liters VE Engine ype idis OHC engine Fuel Used 925 nonleaded gasoline Fomm s4 gnition timing BTDC 10 1 et weight kg Contact breaker Non contact point eae T NGK 138 DP7EA 9 Tires 120 70 12 56 130 70 12 59
44. 125 150 ENGINE INSTALLATION Install the engine in the reverse order of removal Tighten the engine mounting bolts Torque 49N m Engine Hanger Bolt Engine Mounting Bolt Tighten the rear shock absorber upper mount bolts Torque 39 2N m After installation inspect and adjust the following Throttle grip free play 3 3 Fill the rear brake reservoir with brake fluid and bleed air from the rear brake Fill the cooling system with coolant and start the engine to bleed air from the system Rear Shock Absorber Upper Mount Bolts 6 CYLINDER HEAD VALVES Bet amp Win 125 150 CYLINDER HEAD VALVES SCHEMATIC DRAWING 6 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER HEAD COVER REMOVAL 6 4 CAMSHAFT REMOVAL 6 4 CYLINDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD ASSEMBLY 6 6 CYLINDER HEAD INSTALLATION 6 9 CAMSHAFT INSTALLATION 6 10 CYLINDER HEAD COVER INSTALLATION 6 11 6 0 KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 SCHEMATIC DRAWING
45. 7 0 9mm Batter 12V8AH Perform Braking distance m 30km hr4 4m Clutch Dry multi disc clutch S Non stage transmission ance 2300mm n Starting system kick starter Gasoline 4 stroke Single cylinder Two stage reduction Combustion chamber type Reduction l st 2 8 1 0 ratio 8 82 P Axle Compression pressure kg cm_ rpm Tire pressure 9 1 7500 kg cm_ 2 25 11 6 6500 Turning Intake BTDC 12 angle POM ay Brake svstem Disk brake timin Exhaust BDDC 28 Disk brake g mm close Valve am clearance cold Shock absorber Idle speed rpm 1500rpm Double swing Lubrication type Forced pressure amp prr wet sump S Oil pump type Inner outer rotor 5 Oil filter type Full flow filtration 1 3 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling a LO p wu o o B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally When servicing the motorcycle be sure to use special tools for removal and installation After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly KYMCO Bet amp Win 125 150 E Apply or add designated greases lubricants to the specified lubric
46. ANK STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER BATTERY CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM SWITCHESHORN FUEL UNIT T HERMO STATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 GENERAL INFORMATION ENGINE SERIAL NUMBER 1 1 SPECTEICA 1 2 SERVICE 6 1 4 TORCOUE 1 8 TOOL ac ce ssc 1 9 LUBRICATION PON 1 10 CABLE amp HARNESS 1 12 WIRING 1 17 TROUBLESHOOTING 1 18 1 0 dC KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 SERIAL NUMBER Vehicle Identification Serial Number r4 3 E T Location of Frame Serial Number Location of Engine Serial Number KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 ame amp Model No SH25CA Motorcycle Name amp Type verall length verall width verall height 1145mm Wheel base 1390mm Enoi Water oooled 4 stroke Engine pe et weight kg aan 130 70 12 59J Ground clearance 155mm 155mm E Starting motor amp 1940mm 750mm Air cleaner type amp No Paper element
47. AR FRONT WHEEL FRONT KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 125150 Brake Fluid Tube Connect brake fluid tube to brake caliper and tighten the fluid tube bolt Torque 24 5 34 3N m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 14 10 When installing the brake fluid tube be sure to install the two sealing washers Fluid Tube Bolt Washers 14 13 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK amp Win 1257150 FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove front wheel 14 5 Remove front brake caliper 14 11 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers DISASSEMBLY Remove the dust boot Remove the dust seal Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube After the hex bolt is removed place a container under the front shock absorber to drain the engine oil from it Set the front shock absorber tube in a vise Remove the lock nut on the front shock absorber tube Take out the shock absorber spring and damper rod When holding the shock absorber tube place a shop towel to protect it and do
48. DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 INSPECTION Spindle Plastic Bushing Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushings for wear or damage Return Spring Spindle Bushing Friction Spring Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or damage Starter Driven Gear _ Kick Starter Spindle Forcing Part Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover When installing the return spring use screw driver to press the inward and outward return spring hooks into their original positions respectively Install the starter driven gear and friction spring as the figure shown am Kick Starter Spindle 9 16 Friction Spring 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Install the kick lever Install the left crankcase cover and tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw 8 17 9 FINAL REDUCTION Bet amp Win 125 150 FINAL REDUCTION SCHEMATIC DRAWING 9 SERVICE INFORMATION
49. E INFORMATION 19 2 PISTON INSTALLATION 7 7 SERVICE INFORMATION 2 2 PISTON REMOVAL 7 3 SERVICE INFORMATION 3 1 RADIATOR 12 4 SERVICE INFORMATION 4 2 REAR BRAKE 15 3 SERVICE INFORMATION 5 2 REAR FORK 5 4 SERVICE INFORMATION 6 2 REAR SHOCK ABSORBER 15 5 SERVICE INFORMATION 7 2 REAR WHEEL 15 4 SER VICE INFORMATION 8 2 REGULATOR RECTIFIER INSPECTION 16 6 SER VICE INFORMATION 9 2 RIGHT CRANKCASE COVER INSTALLATION 10 6 SERVICE PRECAUTIONS 1 4 RIGHT CRANKCASE COVER REMOVAL 10 3 SPARK PLUG 17 3 SCHEMATIC DRAWING 10 1 SPARK PLUG 3 5 TEXT Bet amp Win 125 150 SPECIFIC ATION 1 2 TROUBLES HOOTING 7 2 STARTER CLUTCH INSPECTION 18 5 TROUBLESHOOTING 8 2 STARTER CLUTCH 10 4 TROUBLES HOOTING 9 2 STARTER MOTOR 18 3 VACUUM CHAMBER ASSEMBLY 13 16 STARTER RELAY INSPECTION 18 6 VACUUM CHAMBER DISASSEMBLY 7 STARTING SYSTEM LAYOUT 18 1 VALVE CLEARANCE 3 6 STATOR INSTALLATION 10 6 WATER PUMP 12 10 STATOR REMOVAL 10 3 WHEELS TIRES 3 1 STEERING HANDLEBAR 14 4 WIRING DIAGRAM 1 17 STEERING HANDLEBAR 3 11 SUSPENSION 3 11 S WITCHES 19 3 TEMPERATURE GAUGE 19 6 THERMOS ENS OR 12 16 THERMOSTAT 12 17 THERMOSTATIC SWITCH THROTTLE OPERATION TOOLS TORQUE VALUES TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING 19 10 12
50. Fluid Tube Bolt Brake Caliper Bolts Brake Disk uM S e t i i a M P p n Brake Pads Wear Indicator Mark Copper Washers Fluid Tube Bolt Bolts 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER 4 amp Win 125 150 REAR FORK Shock Absorber Lower Mount Bolt REMOVAL Remove the exhaust muffler 2 6 Remove the rear brake caliper 15 3 Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork amp 4 The installation sequence 15 reverse of removal SR s Axle Nut Collar Rear Fork Turn the inner race of each bearing with your finger to see 1f they turn smoothly and quietly Also check 1f the outer race fits tightly in the hub Replace the bearings 1f the races do not turn smoothly quietly or if they fit loosely in the hub Rear Brake Disk REAR WHEEL REMOVAL Remove the exhaust muffler 2 6 Remove the rear brake caliper 15 3 Remove the rear fork Remove the rear axle collar Remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 15 4 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER Bet amp Win 125 150 INSTALLATION The installation sequence 1s the reverse of removal Torque Rear s
51. G Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add the specified brake fluid to the upper limit Do not allow dust or water to enter the brake system during refilling When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system 15 free of air Bleed Valve 1 4 1 0 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Pet amp Win 125 150 BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system Remove the brake fluid tube bolt Remove the two bolts attaching the brake caliper Remove the brake caliper DISASSEMBLY Remove the two brake pads dowel pins from the brake caliper Remove the brake pads Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the c
52. INSPECTION Measure the float level at the location of the main jet just contacting the float valve Float Level 18 5 1 0mm Replace the float if the level 15 incorrect Check the operation of the float and then reinstall the float chamber Float Vacuum Piston VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Jet Needle Spring Needle Holder Vacuum Piston Install the vacuum piston into the carburetor body Align the hole in the diaphragm with the hole in the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Be careful not to let the diaphragm slip f the diaphragm cannot be positioned correctly because of expansion dry the diaphragm before installation Spring Diaphragm 13 16 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 Check the heater with battery If the heater is getting hot means the heater without problem otherwise the heater has to be changed Heater Throttle Cable CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold and tighten the band Install the air cleaner connecting tube and tighten the band Connect the throttle cable to the carburetor After connecting the throttle cable adjust the throttle grip free
53. KS POWER Inspection Adjustment Start engine and accelerate lightly for observation Check ignition timing using a timing light Check carburetor for clogging Remove spark plug and Inspect Remove oil dipstick and check oil level and condition Remove cylinder head oil pipe bolt and inspect Rapidly accelerate or run at high speed 1 19 Engine speed does Correct timing Incorrect timing Engine does not knock Engine knocks KYMCO Bet amp Win 125 150 Probable Cause O Clogged air cleaner Restricted fuel flow 3 Clogged fuel line between fuel tank and carburetor Clogged exhaust muffler 5 Faulty auto bystarter Split carburetor vacuum piston diaphragm DFaulty CDI unit Faulty A C generator OImproper valve clearance adjustment 2 Worn valve seat valve stem too protruding OImproper valve and seat contact Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head Improper valve timing Clogged carburetor jets OFouled spark plug 2 Incorrect heat range plug level too high level too low Oil not changed O Clogged oil pipe Faulty oil pump DInsufficient coolant Faulty thermostat Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Air in cooling system DExcess
54. MOVAL Remove the met in box First remove the two bolts and two nuts attaching the met in box Remove the battery C D I fuse Remove the met in box Fuse Hex Bolts Remove the hand rail right and left lock hex bolts Remove the four hex bolts Remove the rear carrier and hand rail Hex Bolts Center Cover Frame Body Cover FRAME BODY COVER REMOVAL Remove the one screws on the bottom of the center cover Remove the center cover Remove the two screws attaching the front part of the frame body cover Screws Screws Remove the right and left screws on the rear part of the frame body cover Disconnect the seat lock wire Remove the frame body cover Screws dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS _ Bet amp Win 125 150 Remove the midst screw attaching the right and left side covers Sciews Side Cover Remove the screws attaching the right and left side covers Screw Screws FLOOR BOARD REMOVAL Remove the floor mat Remove the center cover 2 3 Remove the five screws and four screws attaching the front right and left side covers Remove the two bottom cover adjusting screws Remove the front right and left side covers Screw Adjusting Screws Nuts Prop Screw Remove the air box four screws Remove the prop two bolts Remove the two nuts Remove the six bolts attaching the floor board Remove the floor board The installation sequence is the reverse of remov
55. N Remove the seat and met in box 2 3 Remove the ignition coil Ignition Coil Primary Coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil This 1s a general test Accurate ignition coil test must be performed with a CDI tester Ignition Coil Secondary Coil Measure the ignition coil resistances at 3 C SECONDARY COIL WITH PLUG CAP Secondary coil without plug cap 3 4 46 Secondary coil with plug cap 7 6_ 9 6KQ SECONDARY COIL WITHOUT PLUG CAP 17 3 17 IGNITION SYSTEM A C GENERATOR INSPECTION EXCITER COIL PULSER COIL INSPECTION This test is performed with the stator installed in the engine Remove the frame right cover 2 4 Disconnect the A C generator connector Measure the exciter coil resistance between the black red wire terminal and ground Black red Ground 50 2500 Measure resistance in XQ range For A C generator removal installation refer to pages 10 3 and 10 6 Disconnect the pulser coil wire coupler Measure the pulser coil resistance between the blue white and green white wire terminals Blue white Green white 50 170 KYMCO Bet amp Win 125 150 E We Generator Connector r Pulser Coil Wire Couple 17 4 dC KYMCO 17 IGNITION SYSTEM Bet amp Win 125 150 IGN SW EXT Black
56. Normal Direction Continuity Orbe Reverse Direction No Continuity Normal MEN Probe Probe Direction VOLTAGE REGULATION TEST Connect a voltmeter across the battery terminals Start the engine and gradually increase the engine speed The battery terminal voltage should be within 14 0 15 0 Direction 16 6 KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 CHARGING INDICATOR INSPECTION Use Sanwa electric tester for testing Take readings in XKQ range Unit Red Black Brown Blue Red Brown Red Blue Bice ed meme Charging indicator inspection 1 Turn ignition switch The Charging lamp should be lighten 2 Start engine The Charging lamp should be went out 3 Inspect the output voltage of Charging indicator Disconnect the battery cable Use the voltmeter Connect the voltage cable to the red wire of charging indicator Connect the voltage cable to the ground Start the engine Open the throttle valve to keep at 8000 rpm Standard output voltage is 12 14V Green Red Blue 1 e N 16 7 17 IGNITION SYSTEM Bet amp Win 125 150 IGNITION SYSTEM IGNITION SYSTEM LAYOUT 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING ee e 10 5 SPARE PLU e 17 3 IGNITION COIL INSPECTION
57. PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO Bet amp Win 125 150 Section 1 contains the precautions for all operations stated 1n this manual Read them carefully before any operation 15 started Section 2 is the removal installation procedures for the frame covers which are subject to higher removal installation frequency during maintenance and servicing operations Section 3 describes the inspection adjustment procedures safety rules and service information for each part starting from periodic maintenance Sections 5 through 13 give instructions for disassembly assembly and adjustment of engine parts Section 14 is the removal installation of chassis Section 16 states the testing and measuring methods of electrical equipment Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section The information and contents included in this manual may be different from the motorcycle in case specifications are changed KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION SISSVHO LNHINdl 10H IV OTSELOH T KYMCO Bet amp Win 125 150 TABLE OF CONTENTS EXHAUST MUFFLER FRAME COVERS ENGINE REMOVAL INSTALLATION 5 DRIVE AND DRIVEN PULLEYS KICK STARTER A C GENERATOR STARTER CLUTCH 1 PUMP FUEL T
58. R Measure the front and rear brake lever free plays Rear Brake Reservoir Front Brake Reservoir BRAKE FLUID Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit If the brake fluid 15 insufficient fill to the upper limit Specified Brake Fluid DOT 3 The brake fluid level will decrease if the brake pads are worn BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk runout 1s within the specified service limit Check if the brake pad wear exceeds the wear indicator line vie Keep grease or oil off the brake disk to avoid brake failure Brake Disk Wear Indicator Line 3 10 KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure P Tire pressure should be checked when tires are cold Tire Pressure 1 75 _ 1 75 2 00kg cm 2 25kg em STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the
59. R DISASSEMBLY Remove the four float chamber screws and the float chamber Screws Float Remove the float pin float and float valve Float Pin Float Valve Float Valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Valve Seal 13 9 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 JETS SCREWS REMOVAL Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record the rotating turns Do not force the pilot screw against its seat to avoid seat damage Pilot Screw P S Main Jet Remove the main jet needle jet holder and needle jet Remove the slow jet Slow Jet Needle Jet Slow Jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil Be sure to use clean detergent oil Pilot Screw Needle Jet Holder Main Jet 13 10 13 FUEL SYSTEM CARBURETOR GQ KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 AUTO BYSTARTER INSPECTION REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 1092 10 minutes minimum after stopping the engine If the reading 15 not within limit replace the auto bystarter with a new one Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter yellow wire to the positive terminal of a battery and
60. RAKE FRONT FORK FRONT SHOCK ABSORBER FRONT WHEEL FUEL LINE FUEL FILTER FUEL PUMP ASSEMBLY FUEL PUMP INSPECTION FUEL PUMP INSTALLATION FUEL PUMP REMOVAL DIS ASSEMBLY FUEL SYSTEM FUEL TANK REMOVAL 7 7 7 3 38 8 4 19 1 5 5 3 4 4 3 5 3 1 1 2 6 9 6 9 3 3 8 9 3 13 15 13 9 13 16 10 5 10 3 23 14 8 14 17 14 14 14 5 3 3 13 19 13 19 13 20 13 13 13 TEXT Bet amp Win 125 150 FUEL UNIT 19 5 SCHEMATIC DRAWING ll 1 HEADLIGHT AM 3 9 SCHEMATIC DRAWING 12 1 HEATER WIRING DIAGRAM 19 9 SCHEMATIC DRAWING 2 HORN INSPECTION 19 5 SCHEMATIC DRAWING 14 1 IGNITION COIL INSPECTION 17 3 SCHEMATIC DRAWING 15 1 IGNITION SYSTEM LAYOUT 17 1 SCHEMATIC DRAWING 2 1 IGNITION TIMING 3 7 SCHEMATIC DRAWING 5 1 INSTRUMENTS 19 7 SCHEMATIC DRAWING 6 1 KICK STARTER 8 15 SCHEMATIC DRAWING 7 1 LEFT CRANKCASE COVER 8 3 SCHEMATIC DRAWING 8 l LIGHTS 9 8 SCHEMATIC DRAWING 9 LUBRICATION POINTS 10 SERVICE INFORMATION 10 2 LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE INFORMATION 11 2 MAINTENANCE SCHEDULE 342 SERVICE INFORMATION 12 2 NUTS BOLTS FAS TENERS 3 1 SERVICE INFORMATION 13 5 OIL PUMP ASSEMBLY 4 6 SER VICE INFORMATION 14 2 OIL PUMP DISASSEMBLY 4 4 SERVICE INFORMATION 15 2 OIL PUMP INSPECTION 4 5 SERVICE INFORMATION l6 2 OIL PUMP INSTALLATION 4 6 SER VICE INFORMATION 17 2 OIL PUMP REMOVAL 4 4 SERVICE INFORMATION 18 2 OPERATION OF CARBURETOR JETS 3 SERVIC
61. RMATION LUBRICATION POINTS ENGINE Valve guide valve stem movable part e Genuine KYM CO Engine Oil SAEI5W 40 Camshaft protruding surface SE SF or SG Egnine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft Cranksahft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip Starter idle gear Friction springmovabke part shaft movablepart High temperature resistant grease Shaft movable grooved part Starter spindle movable part Starter one way clutch threads Thread locking agent A C generator connector 5 Adhesive Transmission case breather tubee KYMCO Bet amp Win 125 150 1 10 dC KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 FRAME The following 15 the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle _ Grease Engine Oil Front Brake Lever Pivot Speedometer Cable Throttle Cable Grease Seat Lock 7 E Pal 2 mda E i m
62. aches its service limit After the oil pump 16 installed check each part for oil leaks SPECIFICATIONS OIL PUMP sir iy Service i Outer rotor to pump body clearance 0 15 0 20 Rotor end to pump body clearance 0 04 0 09 ENGINE OIL Engine Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAEISWAOZ API SG CD TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter or oil passage Worn piston rings Faulty oil pump Worn valve guide Worn valve guide seal Oil contamination Oil not changed often enough Faulty cylinder head gasket Loose cylinder head bolts dC KYMCO 4 LUBRICATION SYSTEM Bet amp Win 125 150 ENGINE OIL OIL FILTER Place the motorcycle upright on level ground for engine oil level check Run the engine for2_ 3 minutes and check the oil level after the engine is stopped for 2_ 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level 1s near the lower level fill to the upper level with the recommended engine oil Oil Dipstick OIL CHANGE The engine oil will drain more easily while the engine is warm Remove the oil drain bolt located at the left side of the engine to drain the engine oil After the oil has been completely drained install the aluminum washer and tighten the oil drain bolt Torq
63. ake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove the two bolts attaching the brake 4 master cylinder Stop Switch Wire Connector Remove the brake master cylinder When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage snap Ring DISASSEMBLY Remove the brake lever bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder snap Ring Pliers Close TE Master Cylinder Spring Main Piston Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid bi TI v snap Ring Rubber Cover 14 8 I4 STEERING HANDLEBAR FRONT WHEEL FRONT 4O KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 1231130 INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 645mm Before assembly inspect the Ist and 2nd rubber cups for wear ASSEMBLY Before assembly apply brake fluid to all Master Cylinder Spring Main Piston removed parts Install the spring together with the Ist
64. al Floor Board Bolts KYMCO 2 EXHAUST MUFFLER FRAME COVERS Bet amp Win 125 150 FRONT UPPER COVER REMOVAL Remove the four screws on the front upper Remove four screws on back of front upper cover Remove the front upper cover The installation sequence 1s the reverse of removal Screws Screws FRONT LOWER COVER REMOVAL First remove the front upper cover Remove the two screws attaching the front lower cover Remove the four screws on the back of the front lower cover Disconnect the right left turn signal light wire connectors Remove the front lower cover The installation sequence 1s the reverse of removal Screws Key Moldings BACK COVER REMOVAL Remove the front cover Remove the key moldings Remove the fuel cap moldings Remove the back cover bolt Bolt Fuel Cap Moldings Remove the fuel tank inlet tube join Fuel Tank Inlet Tube Remove the fuel tank breather tube join Remove the back cover 2 5 KYMCO 2 EXHAUST MUFFLER FRAME COVERS _ Bet amp Win 125 150 HANDLEBAR COVER REMOVAL First remove the seven screws attaching the handlebar back cover Remove the handlebar back cover Screws BOTTOM COVER REMOVAL Remove the side stand Remove the four bolts attaching the bottom cover Remove the bottom cover Bottom Cover Side Stand Bolts FRONT FENDER REMOVAL Remove the two bolts attaching the fender Remove the front fen
65. aliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface 14 11 KYMCO Piston Oil Seal 14 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK amp Win 1257150 Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 25 30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 45mm ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3_ 5mm beyond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper to the shock absorber and tighten the two bolts Torque 24 5 34 3N m When installing the brake caliper be sure a n 4 to position brake disk between Brake Caliper 14 12 two brake pads 14 STEERING HANDLEB
66. amage Do not allow any foreign matter to enter the fuel pump during assembly gt Fuel Pump Body Dowel Pin Holes R D SP _ _ _ 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts T B Connect the fuel pump inlet outlet and vacuum tubes Install the seat met in box and frame center cover Vacuum Tube Fuel Strainer Outlet Tube Fuel Pump Measure the fuel pump output Start the engine and disconnect the fuel outlet tube and place a clean container under the tube to check the fuel output Output 40cc 1500rpm 10 seconds Container Fuel Unit Fuel Vapor Tube FUEL TANK REMOVAL Remove the floor board 2 4 Remove the leg shield 2 5 Disconnect the fuel unit wire connector Remove the fuel tube between the fuel tank and the fuel filler Disconnect the fuel vapor tube Remove the fuel tank The installation sequence 1s the reverse of removal Fuel Strainer Tube to Fuel Filler 13 20 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank INSPECTION Inspect if the fuel strainer 15 clogged and clean it with compressed air When removing the fuel strainer do not allow flames or sparks near the working area and drain the resid
67. and 90 to the piston pin hole Service Limit 57 90mm replace if below SH30CA 57 30mm replace if below SH25CA 52 30mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin both X and Y directions Service Limit 58 1 0mm repair or replace if below SH30CA 57 50mm rep air or rep lace if over SH25CA 52 50mm air or rep lace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if OVer The true roundness 15 the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels 15 subject to the maximum value calculated Service Limits True Roundness 0 05mm repair or replace p if over Bottom Cylindricity 0 05mm repair or replace if over i Middle 7 5 KYMCO 7 CYLINDER PISTON Bet amp Win 125 150 Inspect the top of the cylinder for warpage Service Limit 0 05mm or replaceif over Measure the connecting rod small end I D Service Limit 15 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Be careful not to damage piston and piston rings during assembly
68. ase to the lip of the oil Install the two dowel pins and a new gasket Place the right crankcase over the crankshaft and onto the left crankcase Install the right crankcase squarely and do not tap it with an iron or plastic hammer Install and tighten the right and left crankcase attaching bolts Torque 7 8 10 85N m KYMCO Bet amp Win 125 150 Dowel Pins Gasket Right Crankcase c Left Crankcase Bolts PEU Bi f 11 6 KYMCO 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 Cam Chain Tensioner Slipper Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 7 85 11 8N m 11 7 12 COOLING SYSTEM Bet amp Win 125 150 COOLING SYSTEM SCHEMATIC DRAWING SERVICE INFORMATION TROUBLESHOOTING COOLING SYSTEM TESTING RADIATOR aaa as ee WATER PUMP THERMOSENSOR 12 0 Bet amp Win 125 150 12 COOLING SYSTEM SCHEMATIC DRAWING 13
69. ation points gt FR du n a gi zig Gi ot E B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface 522 LA B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first After connection apply grease to battery terminals B Terminal caps shall be installed securely 1 4 1 GENERAL INFORMATION B If the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity r e Confirm A 2 i d B After operation terminal caps shall be installed securely DG B When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connecting or disconnecting it B Do not pull the connector wire age RT Foam e UT d OPER lO PF Ed AU d Check if any connector terminal is bending protruding or loose 1 5 dC KYMCO Bet amp Win 125 150 B The connecto
70. below Check for continuity between the brushes If there is continuity replace with new ones Bushing Check if the needle bearing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage Dust Seal 18 4 KYMCO 18 STARTING SYSTEM Bet amp Win 125 150 ASSEMBLY Apply grease to the dust seal in the front cover Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shaft Insert the commutator into the front cover Front Cover Tab Groove O ring Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws Motor Case INSTALLATION Connect the starter motor cable Check the O ring for wear or damage and replace if necessary Apply grease to the O ring and install it to the starter motor Tighten the two mounting bolts Starter Motor Cable STARTER CLUTCH INSPECTION Refer to pages 10 4 and 10 5 for the starter clutch removal inspection and installation 18 5 KYMCO 18 STARTING SYSTEM Bet amp Win 125 150 STARTER RELAY INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire terminal and ground There should be continuity when the starter button 15 depressed If there 15 no contin
71. der cover The installation sequence is the reverse of removal EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar The installation sequence 1s the reverse of removal Torque Exhaust muffler joint lock nut 11 8N m d Exhaust muffler lock bolt 34 3N m Joint Lock Nut 2 6 KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 gt INSPECTION ADJUSTMENT SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 2 2 FUEL LINE FUEL FILTER 2 5 THROTTLE OPERATION 3 3 ENGINE ores tte 3 4 ATR CLEANER enenatis teas 2 5 SPARK PLUG 2 n enen estes eee 3 5 VALVE CLEARANCE 3 6 CARBURETOR IDLE SPEED 3 6 IGNITION TIMING 2 7 CYLINDER COMPRESSION 2 7 FINAL REDUCTION GEAR OIL 2 5 DRIVE BELT 3 8 HEADLIGHT lt lt lt lt lt 3 9
72. der head cover CAMSHAFT REMOVAL Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Hold the round hole on the camshaft gear facing up and the location 1s the top dead center on the compression stroke Remove the two bolts attaching cam chain tensioner and the tensioner Cam Chain Tensioner Round Hole 1 First remove the two bolts between the cylinder head and cylinder Then remove the four cap nuts attaching the cylinder head Diagonally loosen the cylinder head cap nuts in 2 or 3 times Remove the camshaft holder and dowel pins 4O KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Cam Chain Remove the camshaft gear from the cam chain to remove camshaft F Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits SH30CA IN 30 75mm replace if below SH25CA EX 30 26mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play Ive Rocker A CAMSHAFT HOLDER DISASSEMBLY Valve Rocker Arms Take out the valve rocker arm shafts using a 6mm bolt Remove the valve rocker arms 6mm Bolt Rocker Arm Shafts dC KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Camshaft Holder CAMSHAFT HOLDER INSPECTION Ins
73. disk Damper oil leaks Unevenly worn brake caliper Rear wheel noise Worn rear wheel axle bearings Worn rear fork bearings Deformed rear fork 15 2 15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler 2 6 Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove the two bolts attaching the rear brake caliper Remove the rear brake caliper When removing the brake fluid tube use shop towels to cover plastic parts and coated surfaces to avoid damage INSPECTION Inspect the brake pads and brake disk Visually check the brake pad thickness and it should not exceed the wear indicator mark Measure the brake disk thickness Service Limit 3 0mm replace if below DISASSEMBLY Disassemble the rear brake caliper 14 11 Inspect and assemble the rear brake caliper 14 12 Note The rear brake caliper and front brake caliper have the same specification INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts Torque 24 5 34 3N m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 14 10 When installing the brake fluid tube be sure to install the two copper sealing washers 15 3 4O KYMCO Bet amp Win 125 150
74. e Face Remove the drive belt from the movable drive Drive INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 17 5mm replace if below Use specified genuine parts for replacement 8 DRIVE AND DRIVEN PULLEYS O KYMCO Drive Pulley Collar Remove the movable drive face assembly Ta Remove drive pulley collar Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate Remove the weight rollers Weight Roller INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 16 00mm replace if below 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Measure the movable drive face bushing assemblyy I D Service Limit 27 20mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 26 90mm replace if below ASSEMBLY Ae Install the weight rollers into the movable drive face Weight Roller 8 6 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Ramp Plate Install the ramp plate Drive Pulley Collar Insert the drive pulley collar into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Movable Dr
75. e grip Install the right and left handlebar switches and tighten the screws Adjust the throttle grip free play to the specified range of 2 6mm Install the front and rear brake master cylinders s Install the brake master cylinders by aligning the index marks FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Remove the front axle nut to pull out the axle Remove the front wheel and the speedometer gear unit INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is of the total indicator reading Service Limit 0 2mm replace if over 14 5 4O KYMCO Throttle Cable Throttle Grip Brake Master Cylinder Axle Nut Speedometer Gear Unit 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK 5 Win 125150 WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Wheel Bearing BEARING REPLACEMENT Remove the front wheel bearings and distance collar Special Tools Bearing Remover Bearing Re
76. e installed 1n the frame When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS LD __ 7os __s7 szao0 _2 3130 Cylinder Ring to groove 0015 0050015_ 005 009 0 09 clearance Second 0015 0 050 015 005 009 0 09 Piston Ring end gap piston ring Oil side rail 602 09 02 09 TROUBLESHOOTING When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke 15 found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler Worn or damaged cylinder and piston rings Worn or damaged piston rings Worn stuck or broken piston rings Worn or damaged cylinder and piston Compression too high Abnormal noisy piston Excessive carbon build up in combustion Worn cylinder piston and piston rings chamber or on piston head Worn piston pin hole and piston pin ncorrectly installed piston 7 2 Bet amp Win 125 150 7 CYLINDER PISTON CYLINDER REMOVAL Remove cylinder head 6 7 Remove the water hose from the cylinder Remove the cylinder base bolt Remove the cam chain guide Remove the cylinder Remove the cylinder gasket and dowel pins Clea
77. ear Flywheel TEN Groove Flywheel Holder KYMCO 10 A C GENERATOR STARTER CLUTCH _ Bet 8 Win 125 150 STATOR INSTALLATION A C A Stator Screws Install the A C generator stator on the right crankcase cover and secure it with the three bolts Install the pulser coil on the right crankcase cover and secure it with the two screws Install the wire grommet in the groove in the right crankcase cover securely 3t Be sure to route the stator wire under the pulser coil RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket Gasket Right Crankcase Cover Install the right crankcase cover over the NI _ crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Connect the water hoses to the right crankcase cover Add the recommended engine oil 4 3 Fill the cooling system with the specified coolant 3 9 Be sure to bleed air from the water Jacket after filling the coolant Oil Pump Shaft Water Pump Shaft 10 6 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 CRANKCASE CRANKSHAFT SCHEMATIC DRAWING 11 1 SERVICE INFORMATION 11 2 TOW OO TIN ese 11 2 CRANKCASE SEPARATION 11 3 11 4 CPANKCASE ASSEMBLY 11 5 11 0 Bet
78. el unit OInsufficient damping oil in fuel gauge or disconnected connector Broken or shorted wire in fuel gauge 1 GENERAL INFORMATION KYMCO Bet amp Win 125 150 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Steering is heavy Front or rear wheel 15 wobbling Steering handlebar pulls e 1 1 5 un E A POOR SUSPENSION PERFORMANCE Symptom Suspension is too soft Suspension is too hard Suspension is noisy LN POOR BRAKE PERFORMANCE Symptom Soft brake lever Hard brake lever Hard to brake Brake squeaks 9 M o Probable Cause Front and rear tire pressures are normal DSteering stem nut too tight 2 Broken steering steel balls Excessive wheel bearing play Bent rim 2Loose axle nut DMisaligned front and rear wheels 2 Bent front fork Probable Cause Front and rear tire pressures are normal D Weak shock spring 2 Excessive load GShock damper oil leaking Bent fork tube or shock rod D Fork tube and slider binding Fork spring and slider binding GO Damaged shock stopper rubber Loose steering stem nut Probable Cause brake linings 2Foreign matter on brake linings Rough brake drum contacting area brake linings 2 Foreign matter on brake linings Rough brake drum contacting area DWorn brake linings 2 Worn brake cam contacting area
79. er Torque 4 9 29 4N m Specified Oil SS 8 Hex Bolt Copper Washer Circlip Dust Boot Oil Capacity 81 Install the oil seal Install the circlip Install the dusts seal and dust boot Dust Seal INSTALLATION Install the front shock absorbers onto the front fork Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align the upper mount bolt hole with the groove on the front fork Install the front wheel 14 7 14 16 I4 STEERING HANDLEBAR FRONT WHEEL FRONT 4O KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 1231130 Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers 2 6 Remove the steering handlebar 14 4 Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove the front inner fender 2 6 4 Remove the front wheel 14 5 PN Remove front brake caliper 14 11 Hold the steering stem top cone race and remove the steering stem lock nut Loo Na Wrench Remove the top cone race and remove the front fork o Be careful not to lose the steel balls 26 on top race and 19 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and fr
80. er and cam chain Remove the two right crankcase attaching bolts Remove the five left crankcase bolts Left Crankcase Right Crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Never use a driver to pry the crankcase mating surfaces apart Remove the gasket and dowel pins Left Crankcase Remove the crankshaft from the left Crankshaft crankcase E Left Crankcase 11 3 KYMCO 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 Oil Seal Remove the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end I D Service Limit 15 06mm replace if over 11 4 KYMCO 11 CRANKCASE CRANKSHAFT Bet amp Win 125 150 Measure the crankshaft runout Service Limit 0 10mm replace if over Measure the crankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces Install a new oil seal into the left crankcase Left Crankcase 11 5 11 CRANKCASE CRANKSHAFT Place the left crankcase down and install the crankshaft into the left crankcase Avoid damaging the oil seal Apply gre
81. erminal and connect an ammeter between the red wire lead and the fuse terminal Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 14 15 0 5 max 5000rpm max If the limit voltage 15 not within the specified range check the regulator rectifier PERFORMANCE TEST Engine Speed 2500rpm 5000rpm Charging Current When measuring the charging current disconnect the black wire from the regulator rectifier wire coupler If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION This test be made without removing AC Caneritor Connector the stator from the engine Disconnect the yellow wire from the auto bystarter Remove the frame center cover Disconnect the A C generator connector Check the continuity between the yellow wires and ground There should be continuity between the yellow wires and no continuity between each yellow wire and ground Resistance 16 5 16 BATTERY CHARGING SYSTEM KYMCO Bet amp Win 125 150 A C Generator Stator Pulser Coil A C GENERATOR REMOVAL A C generator removal 10 3 A C generator installation 10 6 REGULATOR RECTIFIER INSPECTION Remove the frame front cover 2 5 Remove the regulator rectifier wire coupler Check the continuity between the wire terminals
82. ermostatic switch OFF When coolant temperature over 85 90 C the thermostatic switch ON LA Install the fan shroud on the radiator with the four bolts Fan Shroud Radiator 12 7 12 COOLING SYSTEM RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire and fan motor wire couplers Connect the overflow tube and secure with the tube clamp Connect the vent tube to the radiator filler Fill the radiator with coolant 3 9 After installation check for coolant leaks KYMCO Bet amp Win 125 150 Radiator Nuts Bolts Thermostatic Switch Lower Hose Wire Overflow Tube Air Ven Tube 12 8 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Install the front upper cover Right Crankcase Cover WATER PUMP MECHANICAL SEAL WATER SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage If the mechanical seal 1s leaking remove the right crankcase cover and replace the mechanical seal amp LY di b i zi il 4 i 4 4 mim 2 PT 4 Md a lt Water Pump Telltale Hole Outlet Hose E E d E D m i WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and out
83. ery negative cable Remove the frame body cover 2 3 Disconnect the engine negative cable Disconnect all of the A C generator auto bystarter spark plug thermosensor wire couplers and connectors Disconnect the engine fuel tube Drain the coolant 3 9 Disconnect the water hose Rear Brake Caliper Starter Relay Disconnect the starter motor wire that goes to the starter relay Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump Disconnect the vacuum tube from the air cut off valve Disconnect the throttle cable from the carburetor Fuel Tube ACV Vacuum Tube Remove the brake fluid tube bolt of the rear Brake Fluid Tube Eum brake caliper b Remove the rear brake caliper bolt and the rear brake DEP Rear Brake Caliper 5 3 KYMCO 5 ENGINE REMOVAL INSTALLATION Bet amp Win 125 150 Rear Shock Absorber Upper Mount Bolts Remove the right left rear shock absorber l upper mount bolts Remove the two engine mounting bolts and pull out the engine with the engine hanger backward Engine Hanger Bolt Engine Mounting Bolt ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger Bolt Engine Hanger Inspect the engine hanger bushings and Bushings stopper rubber for wear or damage Stopper Rubber 5 4 KYMCO 5 ENGINE REMOVAL INSTALLATION Bet amp Win
84. fore connecting A S a Vr anu ct Bet amp Win 125 150 Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Engine Oil Apply grease for lubrication Transmission Gear Oil 907 Gear Oi Use special tool Special Caution V Warning KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 TORQUE VALUES STANDARD TORQUE VALUES 5mm bolt nut 5mm Screw 6mm bolt nut 6mm screw SH bolt amm bolt nut 6mm flange nut 10mm bolt nut 8mm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head cap nut alve adjusting lock nut Cam chain tensioner slipper bolt NO Double end bolt Double end bolt Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt ater pump impeller 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1 Left hand threads Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt 1 GENERAL INFORMATION
85. front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there is any looseness 3 11 4 LUBRICATION SYSTEM Bet amp Win 125 150 i LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE INFORMATION 4 2 TOW OO TIN cee 4 2 ENGINE 0 Becca ec 4 3 DIL PUMP REMO a ties 4 4 OIL PUMP DISASSEMBLY 4 4 OIL PUMP 4 5 OL PUMP AS 4 6 DIL PUMP SINS 4 6 4 0 4O KYMCO 4 LUBRICATION SYSTEM Bet amp Win 125 150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump 4 1 KYMCO 4 LUBRICATION SYSTEM Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame Drain the coolant before starting any operations Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it re
86. gged carburetor fuel inlet tube vacuum tube or fuel tube Clogged auto fuel valve Fuel reaches Fuel does not Clogged float oil passage carburetor reach carburetor 5 Clogged fuel tank cap breather hole nnd ee PME 2 Clogged fuel filter Remove spark plug and into Faulty fuel pump spark plug cap to test spark by connecting it i 4 D Faulty spark plug 2 Fouled spark plug Faulty CDI unit Spark Faulty A C generator Broken or shorted ignition coil 9 Broken or shorted exciter coil EE Faulty ignition switch to engine ground Test cylinder compression gt Starter motor idles but crankshaft does not rotate Normal Low or no compression compression 2 Valve clearance too small 3 Improper valve and seat contact 4 W orn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder 151 Seized valve Improper valve timing Start engine by follow ng normal starting procedure Faulty auto bystarter 2 Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Engine fires but Engine does not does not start fire Remove spark plug and inspect again Dry spark plug DFlooded carburetor Wet spark plug Faulty auto bystarter Throttle valve excessively open 1 18 1 GENERAL INFORMATION ENGINE LAC
87. gh side of bolts and screws Avoid the projected ends of bolts and screws KYMCO Bet amp Win 125 150 Route harnesses so they are neither pulled tight nor have excessive slack T Soo tig V IM 5 pt 4 mu Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover 15 used to protect the wire harnesses 1t shall be installed securely X ox 4 Tm j B Do not break the sheath of wire B fa wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it DM X E Me ME ea Cory m d Le zD B When installing other parts do not press or squeeze the wires Do not press Uu ior squeeze the Pee 5 1 6 1 GENERAL INFORMATION B After routing check that the wire harnesses are not twisted or kinked O Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions m aul When a testing device 15 used make sure to understand the operating methods thoroughly and operate according to the operating instructions 2 Do you understand the H h PEN LM GD B M fl When rust is found on a terminal remove the rust with sand paper or equivalent be
88. h the dipstick Do not screw in the dipstick when making this check OIL CHANGE Drain the oil while the engine is warm Remove the oil drain bolt to drain the engine oil Install the aluminum washer and tighten the oil drain bolt Torque 14 7N m Replace the aluminum washer with a Ts new one if it is deformed damaged Oil Filter Screen Cap Pour the recommended oil through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE 15W40 API SG CD Start the engine and check for oil leaks Stop the engine and recheck the oil level OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen and spring Clean the oil filter screen Install the oil filter screen spring and filter screen cap Fill the engine with recommended engine oil dC KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 Screws AIR CLEANER Remove the seven air cleaner case cover screws and the cover Remove the air cleaner element Check the element and replace it if it is excessively dirty or damaged CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas The air cleaner element has a viscous type paper element Do not clean it with compressed air Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the frame center cover Remove the spark plug ca
89. hock absorber lower mount bolt 19 6 29 4N m Rear axle nut 784 98N m ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring prelocad It is possible to adjust rear cushion in three positions A position soft B position medium C position hard When you adjust rear cushion the spring preload of rear cushions must be the same REAR SHOCK ABSORBER ie REMOVAL B Remove the rear carrier and hand rail 2 3 Remove the met in box 2 3 Remove the two air cleaner bolts Remove the rear shock absorber upper mount bolt Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers DISASSEMBLY Disassemble the right and left rear shock absorbers using the rear shock absorber remover Rear Shock Absorber Remover 15 5 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER Bet amp Win 125 150 Rubber Spring INSPECTION Inspect the damper rod for bending or damage A 8 Inspect the damper for oil leaks Av e Inspect the damper rubber for deterioration or sc V damage Damper Rod Damper Measure the front shock absorber spring free length Service Limit Right 226mm Left 226mm ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly INSTALLATION Install the rear sh
90. ht crankcase cover 15 installed fill with the recommended engine oil and coolant Then bleed air from the water Jacket Refer to page 18 4 for A C generator inspection SPECIFICATIONS Engine SAEI5W A407 API SG CD Oil capacity at change 0 8 liter Coolant distilled water coolant concentrate Coolant capacity 1165cc SPECIAL TOOLS Flywheel puller Flywheel holder SPECIFICATIONS Standard mm Service Limit mm Starter driven gear I D 20 025_ 20 045 20 15mm Starter driven gear O D 42 175 42 200 TORQUE VALUES Flywheel nut 343 44 1N m TROUBLESHOOTING Refer to page 1 27 for A C generator troubleshooting Starter motor rotates but engine does not start Faulty starter clutch Starter motor rotates reversely Weak battery 10 2 4O KYMCO 10 GENERATOR STARTER CLUTCH Bet amp Win 125 150 RIGHT CRANKCASE COVER Bolts REMOVAL TT i Disconnect the water hoses from the right crankcase cover Remove the nine bolts attaching the right crankcase cover and the cover 75 Bolts Water Inlet Hose STATOR REMOVAL A C Generator Stator Screws Remove the two pulser coil attaching screws r and the pulser coil Remove the three generator stator bolts y e and the stator Li When removing the pulser coil and stator be careful not to damage them to ree avoid shorted or broken wire fi fi 1 96 Bolts Pulser Coil FLYWHEEL REMOVAL Flywheel Holde
91. ive Face Assembly Drive Pulley Collar Driven Pulle Lay the drive belt on the driven pulley y Set the drive belt on the drive pulley collar Drive Belt 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Drive Pulley Face Install the drive pulley face washer and drive face nut Washer Drive Face Nut Universal Holder Hold the drive pulley with the universal odi holder and tighten the drive face nut Torque 49 0 58 5N m Universal Holder Do not get oil or grease on the drive belt or drive pulley faces Drive Pulley Clutch Outer CLUTCH DRIVEN PULLEY Remove the left crankcase cover 8 3 Remove the drive pulley and drive belt 8 4 Hold the clutch outer with the universal holder and remove the clutch outer nut Universal Holder Remove the clutch outer Universal Holder INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 130 5mm replace if over 8 DRIVE AND DRIVEN PULLEYS KYMCO Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Clutch Driven Pulle E r m E E CLUTCH DRIVEN PULLEY DISASSEMBLY Hold the clutch driven pulley assembly with the clutch spring compressor 3s Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor
92. ive carbon build up in combustion chamber Poor quality fuel 3 Clutch slipping Mixture too lean Ignition timing too early KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause S DFaulty CDI unit Faulty A C generator Check carburetor pilot screw adjustment pm D Mixture too rich turn screw Incorrectly adjusted out 2 Mixture too lean turn screw in Check carburetor gasket for air leaks insulator rubber 2 Carburetor not securely tightened Faulty intake manifold gasket 0 Deformed carburetor O ring Remove spark plug and install it into spark plug cap to test sss spark by connecting it ence D Faulty or fouled spark plug 2 Faulty CDI unit Faulty A C generator Faulty ignition coil Broken or shorted high tension wire Faulty ignition switch Weak or inter Good spark mittent spark Check carburetor air cut off valve D Damaged air cut off valve diaphragm 2 Damaged air cut off valve spring 1 20 1 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing gt Check fuel pump for fuel supply 4 Check carburetor jets for clogging eee Check valve spring tension ok 1 21 KYMCO Bet amp Win 125 150 Probable Cau
93. ke disk SPECIFICATIONS Item Axle shaft runout Front wheel rim runout ront shock absorber spring free length rake disk thickness rake disk runout Radial 240 6 3 rake master cylinder I D 12 70 12 74 rake master cvlinder piston O D rake caliper piston O D rake caliper cvlinder I D TORQUE VALUES Steering stem lock nut 784 117 6N m Steering top cone race 4 9 12 7N m Front shock absorber bolt 198 24 5N m Front axle nut 441 49N m Brake caliper bolt 245 34 3N m SPECIAL TOOLS Lock nut wrench Front shock absorber compressor Ball race remover Driver handle Outer driver 37x40mm Pilot 12mm Bearing remover Bearing remover head 12mm 0 2 2 23 3 0 30 2 3 14 2 14 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK 5 Wn 129 159 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls nsufficient tire pressure Steers to one side or does not track straight Uneven front shock absorbers Bent front fork Bent front axle or uneven tire Poor brake performance Worn brake pads Contaminated brake pad surface Deformed brake disk Air in brake system Deteriorated brake fluid Worn brake master cylinder piston oil seal Clogged brake fluid line Unevenly worn brake caliper 14 3 Front wheel wobbling Bent rim
94. l battery When charging check the voltage with an electric tester SPECIFICATIONS I2V8AH Fully charged 13 2V Battery 20 Undercharged 12 3V Charging current A C Generator Charging coil resistance 20 0 6 160 TESTING INSTRUMENTS TORQUE VALUES Ammeter Pulser coil bolt 4 9N m Electric tester Coil lock bolt 9 8 Tachometer Flywheel nut 34 3 44 1N m 16 2 KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 SPECIAL TOOLS Universal holder Flywheel puller TROUBLESHOOTING No power Intermittent power Dead battery Loose battery cable connection Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier 16 3 KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 Battery Cover Screw BATTERY Remove the seat and met in box 2 3 Remove the battery cover screw and the battery cover Remove the battery First disconnect the battery negative cable and then the positive cable When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The i
95. let hose Inlet Hose 12 9 dC KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Remove the four bolts and the water pump cover gasket and 2 dowel pins Impeller Left Hand Remove the water pump impeller ya The impeller has left hand threads Inspect the mechanical water seal and seal Mechanic washer for wear or damage E The mechanical seal and seal washer must be replace as a set al Seal Seal Washer Porcelain E NM JAY E Impeller 12 10 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove the 3 bolts attaching the water pump assembly Remove the water pump assembly gasket and dowel pins Water Pump Assembly Water Pump Assembly Inner Bearing Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and shaft inner bearing snap Ring Water Pump Shaft Water Pump Assembly Remove the water pump shaft outer bearing Inner Bearing 12 11 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 MECHANICAL S EAL REPLACEMENT Water Pump Assembly Drive the mechanical seal out of the water pump assembly from the inside Mechanical Seal Water Seal Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver Apply sealant to the right crankcase cover fitting su
96. logged air cleaner 13 6 13 FUEL SYSTEM CARBURETOR C KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 CARBURETOR REMOVAL Auto Bystarter Wire Auto 2 Remove the seat met in box and center cover Disconnect the fuel tube and vacuum tube at the carburetor Disconnect the auto bystarter wire Fuel Tube Intake Manifold Band Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then remove the carburetor ri Air Cleaner Connecting Tube VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Drain Screw 13 7 13 FUEL SYSTEM CARBURETOR GO KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 Screws Remove the two vacuum chamber cover screws and the cover Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston Vacuum Piston Remove needle holder spring and jet Vacuum Piston laphragm needle from the piston Be careful not to damage the vacuum piston diaphragm VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears Jet Needle Spring Needle Holder 13 8 13 FUEL SYSTEM CARBURETOR C KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 FLOAT CHAMBE
97. m m 2 a eum See 22 Mm o 2 uem ee en a ee 1 T A La s m fi E A cw 1 r E a a r T m la c oi y xs E o pn i ru TE p m ee Em L Lh m m i Bir r p v S IL LY nn a Aog a m y ir i T im Speedometer Gear Rear Wheel Beari Front Wheel Bearing ear Wheel bearing A m Crease 1 11 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 CABLE amp HARNESS ROUTING Front Brake Fluid Tube Rear Brake Fluid Tube Front Stop Switch Rear Stop Switch Throttle Cable Speedometer Cable Pressure Radiator Air Radiator Cap Vent Tube Radiator Horn 1 12 dC KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 Ignition Switch Radiator Air Vent Tube Fuel Tank Breather Tube Fuel Filler Thermostatic 4 Switch Fuel Tank Inlet Tube Water Hose Fuel Pump Water Hoses Front Brake Fluid Tube 1 13 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 Front Stop Switch Reserve Tank Cap Throttle Cable Radia
98. me its service life will be shortened Generally the capacity of a battery will decrease after itis used years A capacity decreased battery will resume its voltage after it is recharged but its voltage decreases suddenly and then increases when a load is added When a battery 1s overcharged some symptoms can be found If there is a short circuit inside the battery no voltage 1s produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life f a battery 1s not used for a long time it will discharge by itself and should be recharged every 3 months A new battery filled with electrolyte will generate voltage within a certam time and it should be recharged when the capacity 1s insufficient Recharging a new battery will prolong its service life nspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equip ment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation t is not necessary to check the MF battery electrolyte or fill with distilled water Check the load of the whole charging system Do not quick charge the battery Quick charging should only be done in an emergency Remove the battery from the motorcycle for charging When replacing the battery do not use a traditiona
99. mover Head 12mm 14 6 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FR ONT FORK Bet amp Win 125 150 Driver Handle Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the sealed end facing out Special Tools Outer driver Outer Driver Driver handl river handle Speedometer Gear Unit INSTALLATION Apply grease to the speedometer gear unit Install the speedometer gear unit by aligning its retaining pawl with the hub cutout If not aligned the retaining pawl will be deformed when the axle nut 15 tightened amp After installing the axle turn the wheel to make sure that the speedometer drive shaft rotates freely Hub Cutout TE Install the front wheel by aligning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle nut When installing the front wheel position the brake disk between the two brake pads Torque 41 49N m 1 Speedometer Gear Unit Groove 14 7 14 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet Win 125 1 59 Bolts Holder FRONT BRAKE BRAKEMASTER CYLINDER REMOVAL Remove the handlebar covers 2 6 First drain the brake fluid from the hydraulic br
100. n any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Place clean shop towel in crankcase to keep the piston pin clip from falling into the crankcase 7 3 dC KYMCO Bet amp Win 125 150 Cylinder Cam Chain Guide e Cylinder Base Bolt Dowel Pins Shop Towel Piston Rings Lam ER _ z M gun Ls _ Piston Pin Piston KYMCO 7 CYLINDER PISTON Bet amp Win 125 150 Inspect the piston piston pin and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom 9 Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 15 04mm replace if over 7 4 KYMCO 7 CYLINDER PISTON Bet amp Win 125 150 Measure the piston pin O D Service Limit 14 96mm replace if below Measure the piston O D Take measurement at 9mm from the bottom
101. n switch to check if the black wire of it 15 enough voltage 2 Put the heater controler unit in refrigerator Start engine after keeping the temperatureunder 10 4 C 3 Check if the yellow wire of heater controler unit has output voltage Start engine and if the temp erature of heater controler unit is under 10 4 C Check if the white blue wire of heater controler unit has output voltage If it has not any voltage It is damaged 19 6 19 SWITCHESHORNFUELUNITTHERMOsTAncswitar KYMCO IEMPERATUREGAUGEINSTRUMENTSILIGHTS Bet amp Win 125 150 Speedometer Cable INSTRUMENTS REMOVAL Remove the front upper cover 2 5 Disconnect the instrument wire couplers and connectors Disconnect the speedometer cable Remove the four instrument cover and leg shield screws Remove the instruments DISASSEMBLY ASSEMBLY Remove the three instrument holder nuts Remove the holder Remove the four screws to disassemble the instruments and instrument cover Assemble the instruments in the reverse order of disassembly INSTALLATION The installation sequence 1s the reverse of removal 19 7 19 SWITCHESHORNFUELUNIT THERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSILIGHIS Bet amp Win 125 150 LIGHTS HEADLIGHT BULB REPLACEMENT Remove front upper cover 2 5 Disconnect the headlight and turn signal light wire couplers Remove the rubber boot from the bulb socket Remove the bulb
102. nder head cap nuts in 2 3 times Bolts First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks 6 10 dC KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Gasket Lock Pawl Install a new cam chain tensioner gasket Release the lock pawl and push the push rod all the way in Install the cam chain tensioner and tighten the two bolts Install the tensioner spring and tighten the sealing bolt Torque 2 9 5 8N m Spring Cylinder Head Cover CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 3 6 Install a new cylinder head cover O ring and install the cylinder head cover Be sure to install the O ring into the groove properly Install and tighten the cylinder head cover bolts Torque 7 5 11 85N m 6 11 7 CYLINDER PISTON Bet amp Win 125 150 CYLINDER PISTON SCHEMATIC DRAWING 7 SERVICE INFORMATION 925 TOU SOO TING ce eee 7 2 CVEINDER BEMOWVAT 7 3 PISTON REMOVA 253 PICTON IN TALAT O _ s CYLINDER INSTALLATION 25 7 0 Bet amp Win 125 150 7 CYLINDER PISTON SCHEMATIC DRAWING KYMCO 7 CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engin
103. nstallation sequence 1s the reverse of removal First connect the positive cable and then negative cable to avoid short circuit BATTERY VOLTAGE INSPECTION OPEN CIRCUIT VOLTAGE Disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 2V Undercharged 12 3V max Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Keep flames and sparks away from a charging battery Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery Charge the battery according to the current specified on the battery During quick charging the battery temperature should not exceed Quick charging should only be done in an emergency Measure the voltage 30 minutes after the battery 1s charged Charging current Standard 0 9A Quick 4 Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open arcuit voltage 12 8V min 16 4 KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 CHARGING SYSTEM CURRENT TEST Use a fully charged battery 12 8V min to check the charging system Warm up the engine before taking readings Connect an electric tester across the battery terminals Disconnect the red wire from the fuse t
104. ock absorbers in the reverse order of removal Torque Upper Mount Bolt 39 2N m Lower Mount Bolt 19 6 29 4N m 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 BATTERY CHARGING SYSTEM CHARGING SYSTEM LAYOUT 16 1 SERVICE INFORMATION 16 2 TROUBLE HOOTIN G ee re 16 3 16 4 CHARING SYSTEM 16 5 A C GENERATOR INSPECTION 16 5 REGULATOR RECTIFIER INSPECTION 16 6 CHARGING INDICATOR INSPECTION 16 7 16 0 4O KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 CHARGING SYSTEM LAYOUT Fuse Battery Regulator Rectifier A C Generator CHARGING CIRCUIT Hattery I12V8AH Charging Indicator amp antrol EN ds R R ril Fuse E NA Ignition SW Fuse 15 Charzing lawl Indicator Light Regulator Kectilier 16 1 KYMCO 16 BATTERY CHARGING SYSTEM Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid 1s poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention The battery can be charged and discharged repeatedly If a discharged battery 1s not used for a long ti
105. ont fork Bottom Cone Race BALL RACE REPLACEMENT Drive out the ball races Ball Race Remover 14 17 I4 STEERING HANDLEBAR FRONT WHEEL FRONT AYMCO __BRAKE FRONT SHOCK ABSORBER FRONT FORK amp Win 1257150 Outer Driver Drive in new ball races Be sure to drive the ball races into place completely INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Then install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten Lock Nut Wrench it while holding the top cone race Torque 78 4_ 117 6N m Install the front wheel 14 7 Install the front brake caliper 14 12 Install the front inner fender 2 6 Install the throttle grip and the right and left handlebar switches 14 5 Install the right and left brake master cylinders 14 5 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER Bet amp Win 125 150 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SCT MATIC DRA WING 15 1 SERVICE INFORMATION 15 2 TROUBLESHOOTING
106. orber TE o o o In the interest of safety we recommend these items be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding rain or at full throttle KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 FUEL LINE FUEL FILTER Remove the center cover Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Check for dirty or clogged fuel filter and replace with a new one if it is clogged Do not smoke or allow flames or sparks in your working area THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6mm Major adjustment of the throttle grip free play 15 made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Lock Nut Adjusting Nut KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground Wait for2_ 3 minutes and check oil level wit
107. osits from the exhaust port and combustion chamber Be careful not to damage the cylinder head mating surface Exhaust Port dC KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over Feeler Gauge VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner IN EX 29 3mm replace if below Outer IN EX 32 0mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 925mm replace if below EX 4 915mm replace if below CYLINDER HEAD ASSEMBLY Install the valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Valve Spring Compressor KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters Be careful not to damage the valves Cylinder Head Gasket CYLINDER HEAD INSTALLATION Install the cam chain guide Install the dowel pins and a new cylinder head gasket
108. p and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush m d r n le Spark Plug Specified Spark Plug NGK DP7EA9 Measure the spark plug gap Spark Plug Gap 0 9mm Cracks x 4 Damage When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench Gap Torque 7 5 9 8N m ouling Deposit 3 5 KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 VALVE CLEARANCE nspect and adjust valve clearance while the engine is cold below 35 Remove the cylinder head cover Cylinder Head Cover Mark Turn the A C generator flywheel to the top dead center TDC on compression stroke so that the mark on the flywheel aligns with the index mark on the left crankcase cover Top Dead Center Inspect and adjust valve clearance Valve Clearance IN 0 1mm EX 0 lmm Loosen the lock nut and adjust by turning the adjusting nut Valve Wrench Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED The engine must be warm for accurate idle speed inspection and adjustment Lift up the seat and remove the inspection Warm up engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain
109. pect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface 1s worn check each cam lobe for wear or damage Rocker Arm Shafts Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 90mm replace if below EX 9 90mm replace if below Intake Manifold CYLINDER HEAD REMOVAL First drain the coolant from the radiator and water jacket then remove the thermostat water hose Remove the camshaft 6 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Bolt Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface Be careful not to drop any gasket material into the engine Cylinder Cam Chain Tensioner Slipper 6 6 4O KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Valve Spring Compressor Combustion Chamber Remove carbon dep
110. play to 2 6mm Fi Intake Manifold Band Air Cleaner Connecting Tube Band Fuel Tube Connect the auto bystarter wire Connect the fuel tube and vacuum tube to the carburetor Perform the following inspections and adjustments Throttle grip free play 3 3 speed 3 6 Install the seat met in box and frame center i Auto Bystarter Wire 13 17 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK Bet amp Win 125 150 Outlet Tube FUEL PUMP REMOVAL Remove the frame center cover Disconnect the fuel pump inlet outlet and vacuum tubes Remove the two fuel pump attaching bolts and the fuel pump Vacuum Tube Fuel Strainer Inlet Tube Inlet Screws FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws Vacuum Tube Outlet Disassemble the fuel pump 13 18 13 FUEL SYSTEM CARBURETOR K FUEL PUMP FUEL TANK Bet amp Win 125 150 FUEL PUMP INSPECTION Diaphragm Inspect the fuel pump diaphragms A and B for damage Inspect each gasket for damage Gaskets Outlet Relief Valve Suction Valve Inspect the suction valve outlet valve and relief valve in the fuel pump body for damage cracks or foreign matters Spring Outlet Valve Inlet Spring Dowel Pins FUEL PUMP ASSEMBLY Assemble the fuel pump 1n the reverse order of disassembly During assembly be sure to install the gaskets and diaphragms properly to avoid d
111. r Hold the flywheel with a flywheel holder and remove the flywheel nut Flywheel Nut Remove the flywheel with a flywheel puller Flywheel Puller 10 3 KYMCO 10 A C GENERATOR STARTER CLUTCH _ Bet 8 Win 125 150 Shaft Starter Idle Gear E STARTER CLUTCH REMOVAL Remove the starter idle gear and shaft Remove the starter driven gear INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits 10 20 15mm replace if over O D 41 00mm replace if below Starter Driven Gear starter Idle Gear Inspect the starter idle gear and shaft for wear or damage Shaft 10 4 KYMCO 10 A C GENERATOR STARTER CLUTCH Bet amp Win 125 150 Remove the starter one way clutch rollers plungers and springs Inspect each roller and plunger for wear or damage and check for broken or weak spring INSTALLATION Install the starter driven gear onto the crankshaft Install the starter idle gear and shaft FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Before installation check and make sure that the inside of the flywheel 15 not contaminated Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 34 3 39 2N m 10 5 Spring Roller Plunger Shaft Starter Idle Gear Starter Driven G
112. r head cover bolt 7 8 I11 8N m SPECIAL TOOLS Valve spring compressor Valve seat cutter 24 5mm 45 IN EX Valve seat cutter 25mm Plane cutter 37 5 EX Valve seat cutter 22mm Plane cutter 37 5 EX Valve seat cutter 26mm Plane cutter 63 5 IN EX Cutter clip Valve guide driver Valve guide reamer Bet amp Win 125 150 6 CYLINDER HEAD VALVES TROUBLESHOOTING KYMCO Bet amp Win 125 150 The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed Compression too low Compression too low ncorrect valve clearance adjustment Burned or bend valves ncorrect valve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plug Compression too high Excessive carbon build up in combustion chamber 6 3 White smoke from exhaust muffler Worn valve stem or valve guide Damaged valve stem oil seal Abnormal noise ncorrect valve clearance adjustment Sticking valve or broken valve spring Damaged or worn camshaft Worn cam chain tensioner Worn camshaft and rocker arm KYMCO 6 CYLINDER HEAD VALVES Bet amp Win 125 150 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the center cover 2 3 Remove the met in box 2 3 Remove the cylinder head cover four bolts and then remove the cylin
113. r shall be inserted completely B If the double connector has a lock lock it at the correct position Check if there is any loose wire nx gem C TEM _ Gus dap 2 Lu HU 72 Before connecting a terminal check for damaged terminal cover or loose negative terminal x Won mas Check the double connector cover for proper coverage and installation OA B Insert the terminal completely Check the terminal cover for proper coverage Do not make the terminal cover opening face up m m i j x 5 C Um X E Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses x 1 GENERAL INFORMATION B After clanping check each wire to make sure it is secure X not squeeze wires against the weld or its clamp 1 xm y __ O X Qu B After clamping check each harness to make sure that it 15 not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat No Contact pe yatt T Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route wire harnesses passing throu
114. rface of a new mechanical seal and then drive in the mechanical seal Outer Bearing WATER PUMP SHAFT INS TALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Water Pump Assembly 12 12 KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Install the water pump shaft and shaft inner Snap Ring Water Pump Shaft bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly m Inner Bearing Water Pump Assembly Install the dowel pins and a new gasket and N then install the water pump assembly to the right crankcase cover Tighten the 3 bolts to secure the water pump assembly When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft Bolts Mechanical Seal Seal Washer Porcelain WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Impeller 12 1 dC KYMCO 12 COOLING SYSTEM Bet amp Win 125 150 Install the impeller onto the water pump shaft Torque 9 8 13 7N m The impeller has left hand threads Impeller Left Hand Threads E Install the two dowel pins and a new gasket Gasket Install the water pump cover and tighten the 4 bolts Torque 7 5 11 85N m Bolt 12 14 4O KYMCO 12 COOLING
115. s poorly connected terminals or shorted wires 19 5 Lower 4O KYMCO Bet amp Win 125 150 Needle moves from F to E 19 SMICHESHORN FUELUNITTHERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSI IGHIS Bet amp Win 125 150 Thermostatic THERMOSTATIC SWITCH INSPECTION Remove the front covers 2 5 Start and run the engine to make the water temperature reaches 85 90 and check if cooling fan motor operates Lower the water temperature to 85 check if the fan motor stops If the fan motor does not start disconnect the wires from the thermostatic switch and then connect a jumper wire between the Wire wire harness and thermosensor wires black and green wires Turn the ignition switch ON The thermostatic switch is faulty if the cooling fan motor runs properly If it does not start check for voltage between the fan motor coupler wire terminals black green If there 15 no voltage check for the following Blown or faulty fuse Loose terminals or connectors Shorted wire in the wire harness TEMPERATURE GAUGE Disconnect the wire from the thermosensor and ground it to the engine Turn the ignition switch ON The temperature gauge needle should move all the way to H Do not leave the thermosensor wire grounded for longer than 5 seconds or the temperature gauge will be damaged HEATER CONTROLER UNIT INS PECTION l Open ignitio
116. se DFaulty CDI unit Faulty A C generator DImproperly adjusted valve clearance 2 Worn valve seat D Empty fuel tank 2 Clogged fuel tube or filter Faulty fuel pump amp Cracked fuel pump vacuum tube QClean and unclog DCam timing gear aligning marks not aligned Faulty spring 1 GENERAL INFORMATION ENGINE NOISE O Symptom Piston noise Cam chain noise Crankshaft noise Gear noise KYMCO Bet amp Win 125 150 Probable Cause Valve clearance too large Worn camshaft lobe D Worn piston rings 2 Worn piston pin and connecting rod small end Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain 4 Extended cam chain Faulty crankshaft bearing 2 Worn crank pin bearing Worn or damaged final reduction gears 2Worn final reduction gear shaft splines 1 22 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS 1 23 Engine starts but motor cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There 1s abnormal noise KYMCO Bet amp Win 125 150 Probable Cause or slipping drive belt Broken ramp plate 9 Broken drive face spring Separated clutch lining
117. socket and replace the bulb Install the bulb socket aligning the bulb socket tab with the groove Install the rubber boot Install the front cover in the reverse order of removal Wire FRONT POSITION LIGHT BULB REPLACEMENT Remove the front upper cover 2 5 Disconnect the headlight and turn signal light wire couplers Remove the bulb sockets by turning them counterclockwise Remove the bulbs and replace them with new ones Front Position Light Bulb Sockets Fixer FRONT TURN SIGNAL LIGHT BULB 1 REPLACEMENT Remove the one screw attaching the turn signal light shell and remove the light shell Remove the turn signal fixer two screws Remove the bulb protector screw Remove the bulb and replace with a new one TAILIIGHT RFAR TURN S IGNAL LIGHT BULB REPLACEMENT Remove the rear protective cover 2 3 Remove the two screws attaching the rear S light shell and remove the light shell Wr Remove the bulbs and replace with new ones a AUN 2 rm T The installation sequence 15 the reverse of o iilii a removal 19 SWITCHESHORNFUELUNIDTHERMostaTicswrrc KYMCO TEMPER ATUREGAUGEINSTRUMENTSILIGHTS Bet amp Win 125 150 HEATER WIRING DIAGRAM Lae SRM HEATER TROLER L 1 I 7 4 i 1 E P HEATER
118. spark plug referring to Section 3 Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Item Spark plug Spark plug gap Eu mark Ignition timing Full advance Primarv coil Ignition coil resistance 20 coil with plug cap Pulser coil resistance 20 Exciter coil resistance 20 Ignition coil primary side max voltage Pulser coil max voltage Exciter coil max voltage TESTING INSTRUMENT Electric tester TROUBLESHOOTING No spark at plug Faulty spark plug Poorly connected broken or shorted wire Faulty ignition switch Faulty ignition coil Faulty CDI unit Faulty A C generator Secondary without plug cap Standard NGK DP7EA9 NGK DP6EA9 DPS8EA9 0 8 1 0mm BTDC 10 1 BTDC 27 0 16 10 3 6 4 6KQ 7 0 9 6K Q 50 170 50 3500 244V 10 5V 244V Engine starts but turns poorly Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Poorly contacted ignition switch Ignition secondary circuit Faulty ignition coil Faulty spark plug Faulty high tension wire Poorly insulated plug cap Improper ignition timing Faulty A C generator Stator not installed properly Faulty CDI unit 17 2 4O KYMCO 17 IGNITION SYSTEM Bet amp Win 125 150 Ignition Coil SPARK PLUG For spark plug inspection and adjustment refer to page 3 5 IGNITION COIL INSPECTIO
119. tch wire couplers Check for continuity between the wire terminals HEADLIGHT SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals STARTER SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the starter switch wire couplers Depress the starter button and check for T Us between the wire terminals HAZARD SWITCH Remove the front upper cover 2 5 Disconnect the headlight switch wire couplers Check for continuity between the hazard switch wire terminals 19 SMICHESHORN FUELUNITTHERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSMI IGHIS Bet amp Win 125 150 FIORN BUTTON INSPECTION Remove the frame front covers 2 5 Disconnect the horn wire couplers Depress the horn button and check for continuity between the wire terminals w Light Green Brown Blue FRE 0 PUSH O 1 O TURN SIGNAL SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the turn signal switch wire couplers and turn on the turn signal switch Check for continuity between the wire terminals e CUN TM Blue Orange White 38 DIMMER SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect headlight dimmer switch wire couplers Turn on the dimmer switch and check for continuity between the wire terminals SSP ome Pa Blue ite Blue Lo O
120. ter motor cable Loose connectors Open wire harness 2 Starter motor turns or idles Inspection Adjustment Check battery circuit by turn signals signals dim remain n on or don t operate Connect starter motor directly to battery Starter motor turns normally 3 Starter motor does not stop turning Inspection Adjustment Not stopped Turn ignition switch Hard to turn Stopped Probable Cause Weak or dead battery DLoose connector or terminal 2 Poor contact in starter relay _ Faulty starter clutch OSeized cylinder Broken or shorted starter motor cable Probable Cause O Faulty starter pinion Starter relay shorted or stuck 1 24 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 closed NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Replace with a new spark plug and inspect again Faulty spark plug Good spark Check spark plug cap and high tension wire gt for looseness Check CDI unit BEEN UO coupler for looseness connected coupler Measure resistance between terminals of CDI unit coupler D Faulty ignition switch Faulty exciter coil Faulty pulser coil 4 Faulty ignition coil Broken wire harness Poorly connected coupler Check CDI unit with a CDI unit tester Check igni
121. the specified idle speed Idle Speed 1600rpm When the engine misses or run erratic adjust the pilot screw Throttle Stop Screw Pilot Screw 3 6 KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 Timing Hole Cap IGNITION TIMING The CDI unit is not adjustable f the ignition timing 15 incorrect check the ignition system Remove the timing hole cap Check the ignition timing with a timing light When the engine 15 running at the specified idle speed the ignition timing is correct if the mark on the flywheel aligns with the index mark on the crankcase cover Also use a timing light to check the advance Raise the engine speed to 4 000rpm The index mark should be between the advance marks CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 15 2 If the compression is low check for the following _Leaky valves _Valve clearance to small _Leaking cylinder head gasket _Worn pistons _Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head Compression Gauge KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 Oil Check Bolt Hole Oil Filler
122. tion coil with a CDI unit tester D Faulty ignition coil KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause E Start engine and test limit voltage of battery terminals OFaulty AC generator Normal voltage ee Faulty regulator rectifier Faulty battery Measure resistance Dowen gt coil terminals DShorted AC generator coil 2 Open circuit between AC generator 3 yellow wires Test output voltage of regulator rectifier coupler red wire DFaulty regulator rectifier Faulty AC generator Normal voltage Loose regulator rectifier coupler Limit voltage too high Overcharging Inspection Adjustment Probable Cause Measure battery limit voltage with an electric tester DFaulty battery Faulty regulator rectifier 2 Broken or poorly connected regulator rectifier black wire Check resistance between regulator rectifier terminals 1 26 1 GENERAL INFORMATION FUEL GAUGE 1 Pointer does not correctly Ignition switch ON Inspection Adjustment Check battery circuit by operating turn signals Signals operate Signals dim remam eo aioe neem don t Remove fuel unit and pe p check operation of Pointer Dy MOVING
123. tor Air Vent Tube s d gt Fuel Filler Rear Brake Fluid Speedometer Cable Tube Fuel Tank Inlet Tube Fuel Tank Breather Tube Fuel Tank Water Hose Wire Harness Throttle Cable 1 14 dC KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 Oil Vapor Recovery Tube Fuel Tube Thermostat Auto Bystarter Wire Ignition Coil Air Cut off Valve A C V Carburetor starter Motor Starter Relay Charging Indicator Regulator Rectifier Battery Cable Fuse Box Battery Cable 1 15 KYMCO Bet amp Win 125 150 1 GENERAL INFORMATION Fuel Pump Vacuum Tube Fuel Tube Throttle Cable Thermostat Air Cut off Starter Motor Valve A C V Auto Bystarter Oil Vapor Vacuum Recovery Tube Ground Wire Spark Plug Cap Ignition Coil Regulator Rectifier Starter Relay Fuel Tube Charging Indicator Fuel Pump Vacuum Tube Wire Harness Fuel Pump Eat Ignition Coil e r e wy A Vacuum Oil Vapor mM Spark Plug Cap Recovery Tube Fuel Unit Wire 1 16 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 WIRING DIAGRAM i 1 17 KYMCO 1 GENERAL INFORMATION Bet amp Win 125 150 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Check if fuel reaches carburetor by gt loosening drain screw OEmpty fuel tank 2 Clo
124. ual gasoline into a container INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump Arrow Mark Fuel EIE 13 21 I4 STEERING HANDLEBAR FRONT WHEEI FRONT ATMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet 8 Win 125 150 SIEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SCT MATIC TR VING 14 1 SERVICE INFORMATION 14 2 TROUBLESHOOTING ee rere rene ree rene eee 14 3 STEERING HANDIT DAR renean nire enne 14 4 14 5 FRONT BRAKE 14 8 FRONT SHOCK ABSORBER 14 14 14 17 14 0 B y E t kt s a m Y 1 ypa BRAKE FRONT SHOCK ABSORBER FR ONT FORK Bet amp Win 125 150 SCHEMATIC DRAWING o 14 STEERING HANDLEBAR FRONT WHFELFRONT KYMCO 14 1 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK Bet amp Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing the front wheel steering handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down During servicing keep oil or grease off the brake pads and bra
125. ue 14 7N m Pour the recommended oil through the oil filler hole OIL FILTER SCREEN Drain the engine oil Remove the oil filter screen cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and filter screen cap Torque 14 7N m Recommended Oil SAEIS5W40 API SG CD Oil Filter Screen Cap Oil Capacity At disassembly 1 1 At change 0 9 liter Start the engine and check for oil leaks Start the engine and let it idle for few minutes then recheck the oil level KYMCO 4 LUBRICATION SYSTEM Bet amp Win 125 150 Bolts OIL PUMP REMOVAL First drain the coolant Remove the right crankcase cover 10 3 Remove the A C generator starter driven gear 10 4 Remove the attaching bolt and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Circlip Oil Pump Driven Gear Oil Pump Remove the two oil separator bolts to remove the oil pump OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown dC KYMCO 4 LUBRICATION SYSTEM Bet amp Win 125 150 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 25mm replace if over Outer Rotor Inner Rotor
126. uity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay 15 normal if there 1s continuity 18 6 19 SWITCHESHORN FUELUNITTHERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSILIGHIS Bet amp Win 125 150 SWITCHES HORN FUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS ELECTRICAL EQUIPMENT LAYOUT 19 1 SERVICE INFORMATION 19 2 19 2 SABIO Sz E 19 3 HORN INSPECTION eee seers 19 5 O G UNIT 19 5 THEPMOSTATIC 2 19 6 TEMPERATURE OA Oe 19 6 IN B22 OID SIN See eee 19 7 MEIN Em 19 8 HEATER WIRING DIAGRAM 19 9 19 0 19 SWITCHESHORNFUELUNIDTHERMOsTAIcswircy LO KYMCO IEMPERATUREGAUGEINSTRUMENTSILIGHTS Bet amp Win 125 150 ELECTRICAL EQUIPMENT LAYOUT Headlight Dimmer Switch Turn Signal Switch Horn Button E 4 Headlight Switch Starter Button Instruments Auto Bystarter Ignition Switch Fuel Unit m Horn NE Thermostatic Switch
127. ve Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Faulty driven face Engine stalls or motorcycle creeps Broken clutch weight spring 8 DRIVE AND DRIVEN PULLEYS KICK STARTER LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw Remove the left crankcase cover bolts and left crankcase cover Remove the seal rubber and dowel pins INSTALLATION Install the dowel pins and the seal rubber Install the left crankcase cover Do not pull out the kick starter spindle Press in the kick starter spindle when installing the left crankcase cover Install the cable clamp to the specified location Install and tighten the left crankcase cover bolts 8 3 dC KYMCO Bet amp Win 125 150 Air Tube Band Bolts Left Crankcase Cover Kick Lever Dowel Pins Seal Rubber Left Crankcase Cover 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER Bet amp Win 125 150 Install the drive belt air tube and tighten the tube band screw Tube Band Screw Universal Holder DRIVE PULLEY 5 REMOVAL Remove the left crankcase cover Hold the drive pulley using an universal holder and remove the drive face nut and washer Remove the drive pulley face Universal Holder Drive Pulley Face Movable Driv
128. y 0 20 liter Reserve tank capacity 340cc At change 0 18 liter CHASSIS Front rear brake free play 20 30mm TIRE _ Rider 2Rides 1 75kg em_ 1 75kg em_ 2 00kg em_ 2 25kglem TIRE SPECIFICATION Front 120 70 12 56J Rear 130 70 12 59J TORQUE VALUES Front axle nut 14 8 68 6N m Rear axle nut 107 8 127 4N m KYMCO 3 INSPECTION ADJUSTMENT Bet amp Win 125 150 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary A Adjust C Clean R Replace T Tighten Whichever Regular Service Mileage km comes P P Pe mum New Engine oil Mg DORK EN ne filter Fuel filter screen DOK NEN Valve clearance clearance Eee TL 1 x Spark plug RENE Clean at every 3000km and replace 1f necessary Buessm 1 Suspenso O oo i Sepang 1 13 a Brake fluid Perform pre ride inspection daily Radiator coolant 1 _ Replace every year or at every 10000km R Radiatorcore o o SeS o Po Radiatoreap o o Po Brakelever po o Po Brakeshoewear I T Jj I Shock abs
129. y 0 2 liter Drain Bolt At change 0 18 liter Install and tighten the oil check bolt Torque 98 14 7N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level 15 low KYMCO 10 A C GENERATOR STARTER CLUTCH _ Bet 8 Win 125 150 A C GENERATOR STARTER CLUTCH SCHEMATIC DRAWING 10 1 SERVICE INFORMATION 10 2 TOU SECO 10 2 RIGHT CRANKCASE COVER REMOVAL 10 3 STATOR REMOVA ee eae 10 3 ELY WHEEL REMO V A 10 3 10 4 FLYWHEEL INSTALLATION 10 5 STATOR INSTALLATION 10 6 RIGHT CRANKCASE COVER INSTALLATION 10 6 10 0 dC KYMCO 10 GENERATOR STARTER CLUTCH Bet amp Win 125 150 SCHEMATIC DRAWING 10 1 KYMCO 10 A C GENERATOR STARTER CLUTCH _ Bet 8 Win 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS All servicing operations and inspections in this section can be made with the engine installed Drain the coolant before removing the right crankcase cover Be careful not to drain the coolant when the engine temperature 1s high Perform this operation when the engine 15 cold Drain the coolant into a clean container Drain the engine oil into a clean container before removing the right crankcase cover When the rig

1 - Free

Contents

Download Pdf Manuals

Related Search

Related Contents