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KYMCO Bet & Win 150 User Manual

KYMCO Bet & Win 150
225 pages
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Bet & Win 1 25/150
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Bet & Win
125/150.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is 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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL SYSTEM/CARBURETOR/FUEL
PUMP FUEL TANK
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT/
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
EQUIPMENT
ENGINE

Table of Contents

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KYMCO Bet & Win 150 Specifications

General IconGeneral
Fuel SystemCarburetor
Seat Height780 mm
Brakes (Front)Disc
Brakes (Rear)Drum
Tires (Front)120/70-12
Tires (Rear)130/70-12
Starting SystemElectric
Front SuspensionTelescopic fork
Engine Type4-stroke
TransmissionCVT

Summary

Preface

Manual Scope and Structure

Describes the service manual's content and organization, including section breakdowns.

Section 1: Precautions

General safety and operational precautions for all maintenance procedures.

Section 2: Frame Covers

Procedures for removal and installation of frequently serviced frame covers.

Section 3: Inspection & Adjustment

Details on inspection, adjustment, safety rules, and service info for periodic maintenance.

Engine and Chassis Procedures

Covers disassembly, assembly, and adjustment of engine and chassis parts.

Electrical Equipment Testing

Methods for testing and measuring electrical equipment.

1. General Information

Serial Number Identification

Locates and identifies vehicle serial numbers for reference.

Motorcycle Specifications

Detailed technical specifications of the KYMCO Bet & Win 125/150.

Service Precautions

Important safety and procedural guidelines for maintenance operations.

Torque Values

Standard and specific torque settings for critical fasteners.

Special Tools

List of specialized tools required for performing service procedures.

Lubrication Points

Guide to lubrication points and recommended lubricants for the engine.

Cable and Harness Routing

Diagrams showing proper routing of wires and cables for maintenance.

Wiring Diagram

Complete electrical system wiring schematic for troubleshooting.

Troubleshooting

Common problems and diagnostic flowcharts for engine-related issues.

2. Exhaust Muffler/Frame Covers

Schematic Drawing

Exploded view of exhaust and frame cover components for identification.

Service Information

General instructions, torque values, and troubleshooting for exhaust and covers.

Frame Cover Removal

Step-by-step instructions for removing various frame covers.

Exhaust Muffler Removal

Procedure for removing and reinstalling the exhaust muffler.

3. Inspection/Adjustment

Service Information and Specifications

General warnings, engine/chassis specs, and torque values for maintenance.

Maintenance Schedule

Recommended periodic maintenance tasks and intervals.

Engine Oil and Filter Maintenance

Procedures for checking and changing engine oil and oil filter.

Air Cleaner and Spark Plug Service

Inspection and maintenance of the air cleaner element and spark plug.

Valve Clearance and Carburetor Adjustment

Procedures for adjusting valve clearance and carburetor idle speed.

Ignition Timing and Compression Test

Methods for checking ignition timing and cylinder compression.

Cooling System Maintenance

Inspection and replacement of coolant and related components.

Brake System Inspection

Checks for brake levers, fluid level, disks, and pads.

Wheels, Tires, Steering, and Suspension Checks

Inspection of tires, steering head bearing, and suspension systems.

4. Lubrication System

Lubrication System Diagram

Schematic illustration of the engine's oil flow and components.

Service Information and Troubleshooting

General instructions, oil pump specifications, and common lubrication issues.

Engine Oil and Oil Filter Procedures

Detailed steps for checking and changing engine oil and oil filter.

Oil Pump Removal and Disassembly

Steps for removing and taking apart the oil pump assembly.

Oil Pump Inspection and Assembly

Procedures for checking clearances and reassembling the oil pump.

Oil Pump Installation

Steps for installing the oil pump assembly back into the engine.

5. Engine Removal/Installation

Schematic Drawing

Exploded view illustrating engine mounting points and related parts.

Service Information

General instructions, specifications, and torque values for engine removal/installation.

Engine Removal Procedure

Step-by-step guide to safely remove the engine from the motorcycle.

Engine Installation Procedure

Step-by-step guide to safely install the engine onto the motorcycle.

6. Cylinder Head/Valves

Schematic Drawing

Exploded view of the cylinder head and valve train components.

Service Information and Specifications

General guidelines, specifications, and torque values for cylinder head service.

Troubleshooting Cylinder Head Issues

Common problems and solutions related to the cylinder head and valves.

Cylinder Head Cover and Camshaft Removal

Procedures for removing the cylinder head cover and camshaft.

Cylinder Head Removal and Disassembly

Steps for removing and disassembling the cylinder head.

Cylinder Head Assembly and Installation

Procedures for reassembling and installing the cylinder head.

Camshaft Installation and Cylinder Head Cover Installation

Final steps for camshaft and cylinder head cover installation.

7. Cylinder/Piston

Schematic Drawing

Exploded view of the cylinder and piston assembly.

Service Information and Troubleshooting

General instructions, specifications, and common cylinder/piston issues.

Cylinder and Piston Removal

Step-by-step instructions for removing the cylinder and piston.

Piston Ring and Cylinder Inspection

Procedures for inspecting piston rings and cylinder bore for wear.

Piston and Cylinder Installation

Steps for installing the piston and cylinder assembly.

8. Drive and Driven Pulleys/Kick Starter

Schematic Drawing

Exploded view of the drive/driven pulleys and kick starter components.

Service Information and Troubleshooting

General instructions, specifications, and common pulley/kick starter issues.

Left Crankcase Cover Service

Procedures for removing and installing the left crankcase cover.

Drive Pulley Maintenance

Inspection and removal of the drive pulley and its components.

Clutch/Driven Pulley Service

Inspection and disassembly procedures for the clutch and driven pulley.

Kick Starter Service

Removal, inspection, and installation of the kick starter mechanism.

9. Final Reduction

Schematic Drawing

Exploded view of the final reduction gear assembly.

Service Information and Troubleshooting

General instructions, specifications, and common final reduction issues.

Final Reduction Disassembly and Inspection

Steps for dismantling and checking the final reduction gears and bearings.

Bearing Replacement

Procedures for replacing bearings in the transmission case and crankcase.

Final Reduction Assembly

Steps for reassembling the final reduction unit.

10. A.C. Generator/Starter Clutch

Schematic Drawing

Exploded view of the A.C. generator and starter clutch components.

Service Information and Troubleshooting

General instructions, specifications, and common generator/clutch issues.

Right Crankcase Cover and Stator Removal

Procedures for removing the right crankcase cover and stator.

Flywheel and Starter Clutch Service

Removal, inspection, and installation of flywheel and starter clutch.

Stator and Right Crankcase Cover Installation

Steps for installing the stator and the right crankcase cover.

11. Crankcase/Crankshaft

Schematic Drawing

Exploded view of crankcase and crankshaft components.

Service Information and Troubleshooting

General instructions, specifications, and common crankcase/crankshaft issues.

Crankcase Separation Procedure

Step-by-step guide to safely separate the crankcase halves.

Crankshaft Inspection

Procedures for measuring crankshaft runout and bearing play.

Crankcase Assembly Procedure

Steps for cleaning and assembling the crankcase.

12. Cooling System

Schematic Drawing

Diagram illustrating the cooling system layout and components.

Service Information and Troubleshooting

General instructions, troubleshooting, and specifications for the cooling system.

Cooling System Testing

Procedures for testing the radiator cap and overall system integrity.

Radiator Service

Inspection, removal, and disassembly of the radiator.

Water Pump Service

Inspection, removal, and replacement of water pump components.

Thermosensor and Thermostat Service

Inspection and installation procedures for the thermosensor and thermostat.

13. Fuel System/Carburetor/Fuel Pump/Fuel Tank

Schematic Drawing

Exploded view of the carburetor and associated fuel system parts.

Carburetor Jet Operation and Service

Explanation of carburetor jet functions and disassembly/assembly.

Fuel Pump Construction and Service

Description and maintenance procedures for the vacuum-type fuel pump.

Service Information and Troubleshooting

General instructions, specifications, and common fuel system issues.

Carburetor Removal and Disassembly

Steps for removing and disassembling the carburetor.

Float Chamber and Vacuum Chamber Service

Procedures for float chamber and vacuum chamber maintenance.

Auto Bystarter and Air Cut-off Valve Service

Inspection and installation of the auto bystarter and air cut-off valve.

Fuel Pump Removal and Installation

Steps for removing, disassembling, inspecting, and installing the fuel pump.

Fuel Tank Removal

Procedure for safely removing the fuel tank.

Fuel Strainer Service

Removal, inspection, and installation of the fuel strainer.

14. Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

Schematic Drawing

Exploded view of the front end components.

Service Information and Specifications

General instructions, specifications, and torque values for front end service.

Troubleshooting Front End Issues

Common problems related to steering, wheels, brakes, and front suspension.

Steering Handlebar Service

Procedures for removing and installing the handlebar assembly.

Front Wheel Service

Removal, inspection, and bearing replacement for the front wheel.

Front Brake System Service

Disassembly, assembly, and fluid refilling of the front brake system.

Front Shock Absorber Service

Removal, disassembly, and assembly of front shock absorbers.

Front Fork Service

Procedures for front fork ball and cone race replacement.

15. Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

Schematic Drawing

Exploded view of rear end components.

Service Information and Specifications

General instructions, specifications, and torque values for rear end service.

Troubleshooting Rear End Issues

Common problems related to the rear wheel, brake, and shock absorber.

Rear Brake Caliper Service

Removal, inspection, and installation of the rear brake caliper.

Rear Fork and Rear Wheel Service

Removal and inspection of the rear fork and rear wheel.

Rear Shock Absorber Service

Removal, disassembly, and installation of rear shock absorbers.

16. Battery/Charging System

Charging System Layout and Circuit

Diagrams of charging system components and wiring.

Service Information and Specifications

General instructions, battery/generator specs, and torque values.

Troubleshooting Battery and Charging

Common issues with the battery and charging system.

Battery Service

Battery removal, voltage inspection, and charging procedures.

Charging System Performance Tests

Procedures for testing charging system current and performance.

A.C. Generator Inspection

Inspection of the A.C. generator and its coils.

Regulator/Rectifier Inspection

Checking continuity and voltage regulation of the regulator/rectifier.

Charging Indicator Inspection

Testing the charging indicator lamp and its circuit.

17. Ignition System

Ignition System Layout and Circuit

Diagrams of ignition system components and wiring.

Service Information and Troubleshooting

General instructions, specifications, and common ignition system issues.

Spark Plug Service

Reference to spark plug inspection and adjustment procedures.

Ignition Coil Inspection

Procedures for inspecting the ignition coil's continuity.

A.C. Generator and Exciter/Pulser Coil Inspection

Inspection of the A.C. generator's exciter and pulser coils.

CDI Unit Resistance Inspection

Measuring the resistance of the CDI unit for testing.

18. Starting System

Starting System Layout and Circuit

Diagrams of starting system components and wiring.

Service Information and Troubleshooting

General instructions, specifications, and common starting system issues.

Starter Motor Service

Removal, disassembly, inspection, and assembly of the starter motor.

Starter Clutch Inspection

Procedure for inspecting the starter clutch for wear and damage.

Starter Relay Inspection

Procedures for inspecting and testing the starter relay.

19. Switches/Horn/Fuel Unit/Thermostatic Switch/Temperature Gauge/Instruments/Lights

Electrical Equipment Layout and Wiring Diagram

Overview of electrical components and their wiring.

Service Information and Troubleshooting

General instructions, testing instruments, and common electrical issues.

Switch Inspections

Procedures for inspecting various switches like Ignition, Headlight, Starter.

Horn, Fuel Unit, and Gauge Service

Inspection procedures for the horn, fuel unit, and fuel gauge.

Thermostatic Switch and Temperature Gauge Service

Inspection procedures for the thermostatic switch and temperature gauge.

Instrument and Light Bulb Replacement

Procedures for removing instruments and replacing light bulbs.

Heater Wiring Diagram

Wiring schematic for the heater system.

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