Bad Boy 1500 - Troubleshooting

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Tools Requirement:
Special tools
• Water pump bearing driver (6901): TGB-440640
• Water pump oil seal driver (Inner): TGB-440641
• Water pump mechanical seal driver: TGB-440642
• Inner bearing puller: TGB-440645
Troubleshooting:
The engine temperature is too high IF:
• Insufficient coolant.
• The water hose and jacket are clogged.
• Fan motor malfunction.
• Filler malfunction.
• Loose cylinder bolts or nuts
Coolant is leaking:
• The water pump mechanical seal does not
function properly.
• The O ring is deteriorated.
• The water hose is broken or aged.
The temperature indicated is too high:
• Stop and wait for the engine is completely cooled
down, open cap to check the capacity of coolant in
radiator.
• Refill the radiator with coolant then check for any
leakage.
If the temperature indicated is too high:
WARNING
• Allow engine to cool before proceeding!
A: Open radiator cap and softly throttle, inspect to
see if coolant has circulated.
B: Stop engine and remove water pump cover, start
the motor to inspect pumps proper rotation.
If not:
• Water pump needs repair
• Water hose is clogged
C: Keep eng. 3000~4000 rpm and inspect cooling fan
operation.
• Connect cooling fan terminals with battery (12V)
directly to inspect its operation. Replace cooling
fan if malfunctioning.
• To bleed the air bubbles completely, open radiator
cap and start engine while engine is cool. Press
water hose softly by hand bleed. Press the throttle
repeatedly until the coolant surface becomes
stable.