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KYMCO Bet & Win 125 User Manual

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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.
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
Bet & Win 125/150

TABLE OF CONTENTS

SHOCK ABSORBER/FRONT FORK
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

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Summary of Contents for KYMCO Bet & Win 125

  • Page 1: Table Of Contents

    TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing EXHAUST MUFFLER/FRAME COVERS procedures for the KYMCO Bet & Win 125/150. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual.
  • Page 2 . GENERAL INFORMATION Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER--------------------------------------------- 1-1 SPECIFICATION---------------------------------------------------------- 1-2 SERVICE PRECAUTIONS----------------------------------------------- 1-4 TORQUE VALUES ------------------------------------------------------- 1-8 TOOLS --------------------------------------------------------------------- 1-9 LUBRICATION POINTS------------------------------------------------1-10 CABLE & HARNESS ROUTING-----------------------------------------1-12 WIRING DIAGRAM-------------------------------------------------------------------1-17 TROUBLESHOOTING --------------------------------------------------1-18...

  • Page 3: General Information

    . GENERAL INFORMATION Bet & Win 125/150 SERIAL NUMBER Vehicle Identification Serial Number Location of Frame Serial Number Location of Engine Serial Number...

  • Page 4: Bet & Win 125/150

    . GENERAL INFORMATION Bet & Win 125/150 SPECIFICATIONS Cooling Type Water cooling Name & Model No. SH25CA Motorcycle Name & Type Overall length 1940mm Overall width 750mm Air cleaner type & No Paper element, wet Overall height 1145mm Fuel capacity 10.6 liters Wheel base 1390mm...
  • Page 5 . GENERAL INFORMATION Bet & Win 125/150 SPECIFICATIONS Cooling Type Water cooling Name & Model No. SH30CA Motorcycle Name & Type Overall length 1940mm Air cleaner type & No Paper element, wet Overall width 750mm Fuel capacity 10.6 liters Overall height 1145mm Type Wheel base...

  • Page 6: General Information

    . GENERAL INFORMATION Bet & Win 125/150 n Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n After reassembly, check all parts for proper tightening and operation.
  • Page 7 . GENERAL INFORMATION Bet & Win 125/150 n If the fuse is burned out, find the cause and n The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. n If the double connector has a lock, lock it at the correct position.
  • Page 8 . GENERAL INFORMATION Bet & Win 125/150 n After clamping, check each wire to make n Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight n Do not squeeze wires against the weld or its clamp.
  • Page 9 . GENERAL INFORMATION Bet & Win 125/150 n After routing, check that the wire harnesses n Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points.

  • Page 10: Torque Values

    . GENERAL INFORMATION Bet & Win 125/150 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 5mm screw 6mm bolt, nut 6mm screw, SH bolt 8mm bolt, nut 21.6 6mm flange bolt, nut 11.8 10mm bolt, nut 34.3 8mm flange bolt, nut 26.5...

  • Page 11: Special Tools

    . GENERAL INFORMATION Bet & Win 125/150 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Valve guide driver Valve guide removal/installation Valve guide reamer Valve guide grinding Valve spring compressor Valve removal Lock nut wrench, 39mm E027 Clutch disassembly Bearing driver Bearing removal Bearing remover, 12mm...

  • Page 12: Lubrication Points

    . GENERAL INFORMATION Bet & Win 125/150 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE15W-40) Camshaft protruding surface •API 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...
  • Page 13 . GENERAL INFORMATION Bet & Win 125/150 FRAME The following is 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.

  • Page 14: Cable & Harness Routing

    . GENERAL INFORMATION Bet & Win 125/150 CABLE & HARNESS ROUTING Front Brake Fluid Tube Rear Brake Fluid Tube Front Stop Switch Rear Stop Switch Throttle Cable Speedometer Cable Pressure Type Radiator Air Radiator Cap Vent Tube Radiator Horn 1-12...
  • Page 15 . GENERAL INFORMATION Bet & Win 125/150 Ignition Switch Radiator Air Fuel Tank Vent Tube Breather Tube Fuel Filler Thermostatic Switch Fuel Tank Inlet Tube Water Hose Fuel Pump Front Brake Fluid Tube Water Hoses 1-13...
  • Page 16 . GENERAL INFORMATION Bet & Win 125/150 Front Stop Switch Reserve Tank Cap Throttle Cable Radiator Air Fuel Filler Vent Tube Rear Brake Fluid Speedometer Cable Tube Fuel Tank Inlet Tube Fuel Tank Breather Tube Fuel Tank Water Hose Wire Harness Throttle Cable 1-14...
  • Page 17 . GENERAL INFORMATION Bet & 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...
  • Page 18 . GENERAL INFORMATION Bet & Win 125/150 Fuel Tube Fuel Pump Vacuum 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...

  • Page 19: Wiring Diagram

    . GENERAL INFORMATION Bet & Win 125/150 WIRING DIAGRAM 1-17...

  • Page 20: Troubleshooting

    . GENERAL INFORMATION Bet & Win 125/150 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by ÅEmpty fuel tank loosening drain screw ÇClogged carburetor fuel inlet tube, vacuum tube or fuel tube ÉClogged auto fuel valve Fuel reaches Fuel does not...
  • Page 21 . GENERAL INFORMATION Bet & Win 125/150 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate ÅClogged air cleaner lightly for observation ÇRestricted fuel flow ÉClogged fuel line between fuel tank and carburetor Engine speed Engine speed does ÑClogged exhaust muffler increases not increase...
  • Page 22 . GENERAL INFORMATION Bet & Win 125/150 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check carburetor pilot screw adjustment ÅMixture too rich (turn screw Incorrectly adjusted Correctly adjusted out)
  • Page 23 . GENERAL INFORMATION Bet & Win 125/150 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check valve clearance ÅImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance ÇWorn valve seat Check fuel pump for fuel supply...
  • Page 24 . GENERAL INFORMATION Bet & Win 125/150 ENGINE NOISE Symptom Probable Cause ÅValve clearance too large Valve noise ÇWorn camshaft lobe ÅWorn piston rings ÇWorn piston pin and connecting rod Piston noise small end ÉExcessive carbon build-up in combustion chamber ÅDamaged cam chain tensioner ÇWorn cam gear teeth Cam chain noise...
  • Page 25 . GENERAL INFORMATION Bet & Win 125/150 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause ÅWorn or slipping drive belt ÇBroken ramp plate ÉBroken drive face spring Engine starts but ÑSeparated clutch lining motor-cycle does not move ÖDamaged driven pulley shaft splines ÜDamaged final gear áSeized final gear ÅBroken shoe spring...
  • Page 26 . GENERAL INFORMATION Bet & Win 125/150 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by ÅBurned out fuse applying brake ÇWeak or dead battery Stoplight does not ÉFaulty stop switch Stoplight comes come on ÑLoose or disconnected Check battery...
  • Page 27 . GENERAL INFORMATION Bet & Win 125/150 closed NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark ÅFaulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose...
  • Page 28 . GENERAL INFORMATION Bet & Win 125/150 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals ÅFaulty AC generator Voltage does not Normal voltage ÇFaulty regulator/rectifier increase ÉFaulty battery Measure resistance between AC generator coil terminals...
  • Page 29 . GENERAL INFORMATION Bet & Win 125/150 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn ÅBurned out fuse signals ÇWeak or dead battery Signals operate Signals dim, remain ÉFaulty ignition switch properly on or don‘t...
  • Page 30 . GENERAL INFORMATION Bet & Win 125/150 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) ÅSteering stem nut too tight Steering is heavy ÇBroken steering steel balls ÅExcessive wheel bearing play Front or rear wheel is ÇBent rim wobbling ÉLoose axle nut...

  • Page 31: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6...

  • Page 32: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 SCHEMATIC DRAWING...

  • Page 33: Service Information

    . EXHAUST MUFFLER/FRAME COVERS Bet & 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 & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 34.3N-m...

  • Page 34: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 Bolts/Nuts FRAME COVERS REMOVAL REAR CARRIER & HAND RAIL REMOVAL 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.
  • Page 35 . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 Remove the midst screw attaching the right and left side covers. Screws 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.
  • Page 36 . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 FRONT UPPER COVER REMOVAL Remove the four screws on the front upper cover. Remove the four screws on the back of the front upper cover. Remove the front upper cover. The installation sequence is the reverse of removal.

  • Page 37: Exhaust Muffler Removal

    . EXHAUST MUFFLER/FRAME COVERS Bet & Win 125/150 HANDLEBAR COVER REMOVAL First remove the seven screws attaching the handlebar back cover. Remove the handlebar back cover. Screws Bolts BOTTOM COVER REMOVAL Remove the side stand. Remove the four bolts attaching the bottom cover.

  • Page 38: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3 THROTTLE OPERATION --------------------------------------------- 3- 3 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5 SPARK PLUG ----------------------------------------------------------- 3- 5 VALVE CLEARANCE ------------------------------------------------- 3- 6 CARBURETOR IDLE SPEED ----------------------------------------- 3- 6...

  • Page 39: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 SERVICE INFORMATION GENERAL WARNING •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. •Gasoline is extremely flammable and is explosive under some conditions.

  • Page 40: Maintenance Schedule

    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.

  • Page 41: Fuel Line/Fuel Filter

    . INSPECTION/ADJUSTMENT Bet & 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. •...

  • Page 42: Engine Oil

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground. Wait for 2 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.

  • Page 43: Air Cleaner

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Screws AIR CLEANER Remove the seven air cleaner case cover screws and the cover. Air Cleaner Case Cover Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.

  • Page 44: Valve Clearance

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Bolts VALVE CLEARANCE • Inspect and adjust valve clearance while the engine is cold (below 35 Remove the cylinder head cover. Cylinder Head Cover “T” Mark Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...

  • Page 45: Ignition Timing

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Timing Hole Cap IGNITION TIMING • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system, Remove the timing hole cap. “F” Mark Check the ignition timing with a timing light. When the engine is running at the specified idle speed, the ignition timing is correct if the “F”...

  • Page 46: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL • Place the motorcycle on 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 is low, add the recommended oil SAE90# to the proper level.

  • Page 47: Headlight Aim

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.

  • Page 48: Brake System

    . INSPECTION/ADJUSTMENT Bet & Win 125/150 Coolant capacity : 1165cc Radiator capacity : 825cc Reserve tank capacity :340cc Start the engine and check if there is no bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap. If there are bubbles in the coolant, bleed air from the system.

  • Page 49: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT Bet & 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. Pressure Gauge •...

  • Page 50: Lubrication System

    . LUBRICATION SYSTEM Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY ------------------------------------------- 4-4 OIL PUMP INSPECTION ---------------------------------------------- 4-5 OIL PUMP ASSEMBLY------------------------------------------------ 4-6 OIL PUMP INSTALLATION------------------------------------------ 4-6...

  • Page 51: Lubrication System Diagram

    . LUBRICATION SYSTEM Bet & Win 125/150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 52: Service Information

    . LUBRICATION SYSTEM Bet & 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.

  • Page 53: Lubrication System

    . LUBRICATION SYSTEM Bet & Win 125/150 ENGINE OIL/OIL FILTER Place the motorcycle upright on • level ground for engine oil level check. Run the engine for 2 • minutes and check the oil level after the engine is stopped for 2 3 minutes.

  • Page 54: Oil Pump Removal

    . LUBRICATION SYSTEM Bet & 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. Oil Separator Cover Pry the circlip off and remove the oil pump driven gear, then remove the oil pump drive chain.

  • Page 55: Oil Pump Inspection

    . LUBRICATION SYSTEM Bet & 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 Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Measure the rotor end-to-pump body clearance.

  • Page 56: Oil Pump Installation

    . LUBRICATION SYSTEM Bet & Win 125/150 Pump Hole Screw Cover 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.
  • Page 57 . ENGINE REMOVAL/INSTALLATION Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 5-1 SERVICE INFORMATION -------------------------------------------- 5-2 ENGINE REMOVAL --------------------------------------------------- 5-3 ENGINE INSTALLATION -------------------------------------------- 5-5...

  • Page 58: Schematic Drawing

    5. ENGINE REMOVAL/INSTALLATION Bet & Win 125/150 SCHEMATIC DRAWING...

  • Page 59: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION Bet & 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. •...

  • Page 60: Engine Removal

    5. ENGINE REMOVAL/INSTALLATION Bet & Win 125/150 Wire Connectors ENGINE REMOVAL Disconnect the battery 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.
  • Page 61 . ENGINE REMOVAL/INSTALLATION Bet & Win 125/150 Rear Shock Absorber Upper Mount Bolts Remove the right/left rear shock absorber 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...

  • Page 62: Engine Installation

    5. ENGINE REMOVAL/INSTALLATION Bet & Win 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 Rear Shock Absorber Upper Mount Bolts bolts.

  • Page 63: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 6- 1 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- 8...

  • Page 64: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES Bet & Win 125/150 SCHEMATIC DRAWING...

  • Page 65: Service Information

    . CYLINDER HEAD/VALVES Bet & Win 125/150 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.

  • Page 66: Troubleshooting

    . CYLINDER HEAD/VALVES Bet & Win 125/150 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low •...

  • Page 67: Cylinder Head Cover Removal

    . CYLINDER HEAD/VALVES Bet & 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 cylinder head cover. Bolt CAMSHAFT REMOVAL Turn the A.C.
  • Page 68 . CYLINDER HEAD/VALVES Bet & Win 125/150 Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. 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 Camshaft Bearings...

  • Page 69: Cylinder Head Removal

    . CYLINDER HEAD/VALVES Bet & Win 125/150 Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

  • Page 70: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES Bet & 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 •...

  • Page 71: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES Bet & 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...

  • Page 72: Cylinder Head Installation

    . CYLINDER HEAD/VALVES Bet & 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.

  • Page 73: Camshaft Installation

    . CYLINDER HEAD/VALVES Bet & Win 125/150 Punch Marks CAMSHAFT INSTALLATION Turn the A.C. generator flywheel so that the “T” 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...

  • Page 74: Cylinder Head Cover Installation

    . CYLINDER HEAD/VALVES Bet & Win 125/150 Lock Pawl Gasket Install a new cam chain tensioner gasket. Release the lock pawl and push the push rod all the way in. Cam Chain Tensioner Push Rod Sealing Bolt Cam Chain Tensioner Install the cam chain tensioner and tighten the two bolts.

  • Page 75: Cylinder/Piston

    . CYLINDER/PISTON Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL ---------------------------------------------------- 7-3 PISTON INSTALLATION --------------------------------------------- 7-7 CYLINDER INSTALLATION----------------------------------------- 7-7...

  • Page 76: Cylinder/Piston

    . CYLINDER/PISTON Bet & Win 125/150 SCHEMATIC DRAWING...

  • Page 77: Service Information

    . CYLINDER/PISTON Bet & Win 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 78: Cylinder Removal

    . CYLINDER/PISTON Bet & Win 125/150 Cylinder Cam Chain Guide CYLINDER REMOVAL Remove the cylinder head. ( 6-7) Remove the water hose from the cylinder. Remove the cylinder base bolt. Cylinder Base Bolt Water Hose Remove the cam chain guide. Remove the cylinder.
  • Page 79 . CYLINDER/PISTON Bet & 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.
  • Page 80 . CYLINDER/PISTON Bet & 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 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.
  • Page 81 . CYLINDER/PISTON Bet & Win 125/150 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if 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.

  • Page 82: Piston Installation

    . CYLINDER/PISTON Bet & Win 125/150 PISTON INSTALLATION Remove any gasket material from the crankcase surface. • Be careful not to drop foreign matters into the crankcase. Piston Install the piston, piston pin and a new piston pin clip. Position the piston “IN” mark •...
  • Page 83 . CYLINDER/PISTON Bet & Win 125/150 Cylinder Base Bolt 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.
  • Page 84 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/ KICK STARTER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3 DRIVE PULLEY -------------------------------------------------------- 8- 4 CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8 KICK STARTER -------------------------------------------------------- 8-15...

  • Page 85: Drive And Driven Pulleys/Kick

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER SCHEMATIC DRAWING...

  • Page 86: Service Information

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER 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.

  • Page 87: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Bolts Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Kick Lever Left Crankcase Cover Dowel Pins...

  • Page 88: Drive Pulley

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Install the drive belt air tube and tighten the tube band screw. Tube Band Screw Universal Holder DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer.
  • Page 89 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Drive Pulley Collar Remove the movable drive face assembly. Remove the 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.
  • Page 90 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER 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.
  • Page 91 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER 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 Drive Face Assembly Drive Pulley Collar Driven Pulley Lay the drive belt on the driven pulley.

  • Page 92: Drive Pulley

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Drive Pulley Face Install the drive pulley face, washer and drive face nut. Drive Face Nut Washer Universal Holder Hold the drive pulley with the universal holder and tighten the drive face nut. Torque: 49.0 58.5N-m Special...
  • Page 93 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.

  • Page 94: Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Guide Roller Guide Roller Pin Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. O-ring Movable Driven Face Remove the oil seal from the movable driven Oil Seal face.
  • Page 95 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER 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.
  • Page 96 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Press a new needle bearing into the driven face. Special Bearing Driver Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch •...
  • Page 97 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER CLUTCH ASS EMBLY Circlips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
  • Page 98 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Guide Roller Pin Guide Roller 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.
  • Page 99 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 49.0 58.8kg-m Special Universal Holder Install the drive belt. ( 8-7) Install the left crankcase cover.
  • Page 100 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER Spindle Plastic Bushing INSPECTION 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.
  • Page 101 . DRIVE AND DRIVEN PULLEYS/ Bet & Win 125/150 KICK STARTER 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. Left Crankcase Cover 8-17...
  • Page 102 . FINAL REDUCTION Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 9-1 SERVICE INFORMATION -------------------------------------------- 9-2 TROUBLESHOOTING ------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY------------------------------- 9-3 FINAL REDUCTION INSPECTION---------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ----------------------------------- 9-6...

  • Page 103: Schematic Drawing

    . FINAL REDUCTION Bet & Win 125/150 SCHEMATIC DRAWING...

  • Page 104: Final Reduction

    . FINAL REDUCTION Bet & 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 Oil: SAE 90# Oil Capacity:...

  • Page 105: Final Reduction Disassembly

    . FINAL REDUCTION Bet & Win 125/150 Bolts FINAL REDUCTION DISASSEMBLY 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.
  • Page 106 . FINAL REDUCTION Bet & Win 125/150 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Final Shaft Bearing Inspect the drive shaft and gear for wear or...
  • Page 107 . FINAL REDUCTION Bet & Win 125/150 Bearing Remover, 12mm BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Drive Shaft Bearing Pilot, 12mm Drive new bearings into the transmission case cover.

  • Page 108: Final Reduction Assembly

    . FINAL REDUCTION Bet & Win 125/150 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot, 15mm FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the left crankcase.
  • Page 109 . FINAL REDUCTION Bet & Win 125/150 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. Countershaft Washer Install the transmission case cover. Transmission Case Cover Bolts Install and tighten the transmission case cover bolts.
  • Page 110 . FINAL REDUCTION Bet & Win 125/150 Oil Check Bolt Hole/Oil Filler After installation, fill the transmission case with the specified oil. • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage.

  • Page 111: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 10-1 SERVICE INFORMATION -------------------------------------------- 10-2 TROUBLESHOOTING ------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3 STATOR REMOVAL --------------------------------------------------- 10-3 FLYWHEEL REMOVAL----------------------------------------------- 10-3 STARTER CLUTCH ---------------------------------------------------- 10-4 FLYWHEEL INSTALLATION---------------------------------------- 10-5 STATOR INSTALLATION -------------------------------------------- 10-6...

  • Page 112: . A.c. Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 SCHEMATIC DRAWING 10-1...

  • Page 113: Service Information

    . A.C. GENERATOR/STARTER CLUTCH Bet & 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 is high. (Perform this operation when the engine is cold.) •...

  • Page 114: Right Crankcase Cover Removal

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 RIGHT CRANKCASE COVER Bolts Water Outlet Hose REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover. Bolts Water Inlet Hose STATOR REMOVAL A.C.

  • Page 115: Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter idle gear and shaft. Starter Driven Gear Starter Driven Gear Remove the starter driven gear. INSPECTION Inspect the starter driven gear for wear or damage.

  • Page 116: Flywheel Installation

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 Spring Roller 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. Plunger Shaft Starter Idle Gear INSTALLATION Install the starter driven gear onto the crankshaft.

  • Page 117: Stator Installation

    . A.C. GENERATOR/STARTER CLUTCH Bet & Win 125/150 A.C. Generator Stator Screws STATOR INSTALLATION 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.

  • Page 118: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT ---------------------------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5 11-0...

  • Page 119: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT Bet & Win 125/150 SCHEMATIC DRAWING 11-1...

  • Page 120: Service Information

    . CRANKCASE/CRANKSHAFT Bet & 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.

  • Page 121: Crankcase Separation

    . CRANKCASE/CRANKSHAFT Bet & Win 125/150 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. Bolt Cam Chain Bolts Remove the five left crankcase bolts. Left Crankcase Right Crankcase Place the crankcase with the left crankcase...
  • Page 122 . CRANKCASE/CRANKSHAFT Bet & Win 125/150 Oil Seal Remove the oil seal from the left crankcase. 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...

  • Page 123: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT Bet & Win 125/150 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
  • Page 124 . CRANKCASE/CRANKSHAFT Bet & Win 125/150 Place the left crankcase down and install the crankshaft into the left crankcase. Avoid damaging the oil seal. • Apply grease to the lip of the oil • seal. Dowel Pins Install the two dowel pins and a new gasket. Gasket Right Crankcase Place the right crankcase over the crankshaft...
  • Page 125 . CRANKCASE/CRANKSHAFT Bet & 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: 7.8 11.8N-m Bolt 11-7...

  • Page 126: Cooling System

    . COOLING SYSTEM Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------- 12- 2 TROUBLESHOOTING ------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------- 12- 4 RADIATOR -------------------------------------------------------------- 12- 4 WATER PUMP ---------------------------------------------------------- 12-10 THERMOSENSOR ------------------------------------------------------ 12-16 THERMOSTAT---------------------------------------------------------- 12-17 12-0...

  • Page 127: Cooling System

    . COOLING SYSTEM Bet & Win 125/150 SCHEMATIC DRAWING Left Hand Threads Torque: 9.8 13.7N-m 12-1...

  • Page 128: Service Information

    . COOLING SYSTEM Bet & 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 the pressure because the boiling coolant may cause danger.
  • Page 129 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water 360cc 825cc -44.5 Cautions for Using Coolant: •...

  • Page 130: Cooling System Testing

    . COOLING SYSTEM Bet & 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.
  • Page 131 . COOLING SYSTEM Bet & Win 125/150 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. Overflow Tube RADIATOR REMOVAL Drain the coolant.
  • Page 132 . COOLING SYSTEM Bet & 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...
  • Page 133 . COOLING SYSTEM Bet & Win 125/150 Battery Check fan motor by battery. Fan Motor Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85~90 the thermostatic switch OFF. When coolant temperature over 85~90 the thermostatic switch ON. Bolts Install the fan shroud on the radiator with the four bolts.
  • Page 134 . COOLING SYSTEM Bet & Win 125/150 Radiator RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Bolts Nuts Upper Hose Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire and fan motor wire couplers.

  • Page 135: Water Pump

    . COOLING SYSTEM Bet & 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 is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 136 . COOLING SYSTEM Bet & Win 125/150 Bolts Water Pump Cover Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. The impeller has left hand threads. Mechanical Seal Seal Washer (Porcelain) Inspect the mechanical (water) seal and seal...
  • Page 137 . COOLING SYSTEM Bet & Win 125/150 Bolts 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...
  • Page 138 . COOLING SYSTEM Bet & Win 125/150 Water Pump Assembly MECHANICAL S EAL REPLACEMENT 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.
  • Page 139 . COOLING SYSTEM Bet & Win 125/150 Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.
  • Page 140 . COOLING SYSTEM Bet & Win 125/150 Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 9.8 13.7N-m The impeller has left hand threads. Dowel Pins Install the two dowel pins and a new gasket. Gasket Water Pump Cover Install the water pump cover and tighten the 4 bolts.

  • Page 141: Thermosensor

    . COOLING SYSTEM Bet & Win 125/150 THERMOSENSOR Thermosensor THERMOSENSOR REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire 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.

  • Page 142: Thermostat

    . COOLING SYSTEM Bet & Win 125/150 Thermostat Housing Bolt 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.
  • Page 143 . COOLING SYSTEM Bet & Win 125/150 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80±2 Full-open Valve lift 4.5mm O-ring •...
  • Page 144 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM --------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ---------------------------------------------- 13- 2 OPERATION OF CARBURETOR JETS------------------------------ 13- 3 SERVICE INFORMATION -------------------------------------------- 13- 5 CARBURETOR REMOVAL ------------------------------------------- 13- 7 VACUUM CHAMBER DISASSEMBLY------------------------------ 13- 7 FLOAT CHAMBER DISASSEMBLY--------------------------------- 13- 9...

  • Page 145: Fuel System/Carburetor/Fuel Pump

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 FUEL SYSTEM 13-1...

  • Page 146: Schematic Drawing

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 SCHEMATIC DRAWING 13-2...

  • Page 147: Operation Of Carburetor Jets

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 OPERATION OF CARBURETOR JETS LOW SPEED Venturi (slightly opened throttle valve) Air Bleed Holes‡ Mixture……. Low Speed Air Inlet Fuel in Float Chamber‡ Slow Jet -------------------- Low Speed Small Jet Holes 2.MIDDLE SPEED Venturi (halfway opened throttle valve) Air Bleed Holes‡...

  • Page 148: Fuel Pump

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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.

  • Page 149: Service Information

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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.
  • Page 150 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly • No fuel in tank • Incorrect idle speed • Restricted fuel line • Rich mixture • Too much fuel getting to cylinder •...

  • Page 151: Carburetor Removal

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Auto Bystarter Wire Auto Bystarter CARBURETOR REMOVAL 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...
  • Page 152 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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 Vacuum Piston Diaphragm Remove the needle holder, spring and jet needle from the piston.

  • Page 153: Float Chamber Disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Float Chamber FLOAT CHAMBER 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...
  • Page 154 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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.

  • Page 155: Fuel System/Carburetor/Fuel Pump Fuel Tank

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10W (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.

  • Page 156: Air Cut-Off Valve (A.c.v.)

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle Bystarter Valve Air Cut-off Valve Cover...
  • Page 157 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Air Cut-off Valve Body Hose Disconnect the hose at the valve seat. 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.

  • Page 158: Auto Bystarter Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Diaphragm O-ring Install the O-ring onto the air-cut-off valve 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...

  • Page 159: Float Chamber Assembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Main Jet Slow Jet FLOAT CHAMBER ASSEMBLY Install the main jet. Install the slow jet. Install the pilot screw. • Be sure to record the rotating turns when it is removed. Pilot Screw Float Install the float valve, float and float pin.

  • Page 160: Float Level Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 FLOAT LEVEL 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 is incorrect. Check the operation of the float and then reinstall the float chamber.

  • Page 161: Carburetor Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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.

  • Page 162: Fuel Pump Removal/Disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & 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...

  • Page 163: Fuel Pump Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Relief Valve Outlet Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.

  • Page 164: Fuel Pump Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 Outlet Tube Fuel Pump Inlet Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts. Connect the fuel pump inlet, outlet and vacuum tubes. Install the seat, met-in box and frame center cover.
  • Page 165 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK Bet & Win 125/150 FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank. INSPECTION Inspect if the fuel strainer is 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 residual gasoline into a container.

  • Page 166: Steering Handlebar/Front Wheel/Front Brake/Front

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 14- 1 SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 STEERING HANDLEBAR--------------------------------------------- 14- 4 FRONT WHEEL--------------------------------------------------------- 14- 5 FRONT BRAKE --------------------------------------------------------- 14- 8 FRONT SHOCK ABSORBER------------------------------------------ 14-14...

  • Page 167: Schematic Drawing

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...
  • Page 168 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.

  • Page 169: Troubleshooting

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate •...

  • Page 170: Steering Handlebar

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.

  • Page 171: Front Wheel

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Grip Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
  • Page 172 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
  • Page 173 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 •...

  • Page 174: Front Brake

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder Bolts FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. ( 2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
  • Page 175 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 lst and 2nd rubber cups for wear.
  • Page 176 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Connect the front stop switch wire connector. Install the handlebar covers. ( 2-6) BRAKE FLUID REFILLING Stop Switch Wire Connector Keep the handlebar upright and remove the brake reservoir cover and diaphragm. Add DOT-3 brake fluid to the brake reservoir.
  • Page 177 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bleed Valve 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.
  • Page 178 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
  • Page 179 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Fluid Tube Connect the brake fluid tube to the 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.

  • Page 180: Front Shock Absorber

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover. ( 2-5) Remove the front lower cover. ( 2-5) Remove the front wheel. ( 14-5) Remove the front brake caliper. ( 14-11) Remove the front shock absorber upper mount bolts.
  • Page 181 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 •Damper and damper rod bending •Oil seal damage or wear Measure the front shock absorber spring free length.
  • Page 182 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.

  • Page 183: Front Fork

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
  • Page 184 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT Bet & Win 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Outer Driver Drive in new ball races. Be sure to drive the ball races into place completely. Bottom Ball Race 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.

  • Page 185: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 REAR BRAKE ----------------------------------------------------------- 15-3 REAR FORK ------------------------------------------------------------- 15-4 REAR WHEEL ---------------------------------------------------------- 15-4 REAR SHOCK ABSORBER-------------------------------------------- 15-5 15-0...
  • Page 186 . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...
  • Page 187 . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER 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 Item Standard (mm)

  • Page 188: Rear Brake

    . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt 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.

  • Page 189: Rear Wheel

    . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER 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.

  • Page 190: Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER Shock Absorber Lower Mount Bolt INSTALLATION The installation sequence is the reverse of removal. Torque: Rear shock absorber lower mount bolt: 19.6 29.4N-m Rear axle nut: 78.4 98N-m Brake Caliper Bolts Axle Nut ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition...
  • Page 191 . REAR BRAKE/REAR FORK/REAR Bet & Win 125/150 WHEEL/REAR SHOCK ABSORBER Spring Rubber INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Damper Rod Measure the front shock absorber spring free length.
  • Page 192 . BATTERY/CHARGING SYSTEM Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6 CHARGING INDICATOR INSPECTION ---------------------------- 16-7 16-0...

  • Page 193: Charging System Layout

    . BATTERY/CHARGING SYSTEM Bet & Win 125/150 CHARGING SYSTEM LAYOUT Fuse Battery A.C. Generator Regulator/Rectifier CHARGING CIRCUIT 16-1...

  • Page 194: Service Information

    . BATTERY/CHARGING SYSTEM Bet & Win 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is 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 •...

  • Page 195: Troubleshooting

    . BATTERY/CHARGING SYSTEM Bet & 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 ignition system •...

  • Page 196: Battery/Charging System

    . BATTERY/CHARGING SYSTEM Bet & 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;...

  • Page 197: Charging System

    . BATTERY/CHARGING SYSTEM Bet & 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 terminal and connect an ammeter between the red wire lead and the fuse terminal.

  • Page 198: Regulator/Rectifier Inspection

    . BATTERY/CHARGING SYSTEM Bet & 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) Right Crankcase Cover Bolts REGULATOR/RECTIFIER INSPECTION Remove the frame front cover. ( 2-5) Remove the regulator/rectifier wire coupler. Check the continuity between the wire terminals.

  • Page 199: Charging Indicator Inspection

    . BATTERY/CHARGING SYSTEM Bet & Win 125/150 CHARGING INDICATOR INSPECTION Use Sanwa electric tester for testing. Take readings in XKW range. Unit: KW Red/ Black Brown/Blue Probe (+) Red/ Red Brown Red/ Probe Green Black /Blue Blue Red/ 45~55 35~55 20~40 Black Brown/...

  • Page 200: Ignition System

    . IGNITION SYSTEM Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4 CDI UNIT RESISTANCE INSPECTION----------------------------- 17-5 17-0...

  • Page 201: Ignition System

    . IGNITION SYSTEM Bet & Win 125/150 IGNITION SYSTEM LAYOUT CDI Unit Ignition Coil Ignition Switch Pulser Coil A.C. Generator IGNITION CIRCUIT 17-1...

  • Page 202: Troubleshooting

    . IGNITION SYSTEM Bet & Win 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • 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. •...

  • Page 203: Spark Plug

    . IGNITION SYSTEM Bet & Win 125/150 Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION 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.

  • Page 204: A .C. Generator Inspection

    . IGNITION SYSTEM Bet & Win 125/150 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.

  • Page 205: Cdi Unit Resistance Inspection

    . IGNITION SYSTEM Bet & Win 125/150 (Black/Red) (Black/Yellow (Black/White) CDI UNIT 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.

  • Page 206: Starting System

    . STARTING SYSTEM Bet & Win 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION----------------------------------- 18-5 STARTER RELAY INSPECTION ------------------------------------ 18-6 18-0...

  • Page 207: Starting System

    . STARTING SYSTEM Bet & Win 125/150 STARTING SYSTEM LAYOUT Stop Switches Starter Relay Starter Button Starter Motor STARTING CIRCUIT 18-1...

  • Page 208: Service Information

    . STARTING SYSTEM Bet & 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.

  • Page 209: Starter Motor

    . STARTING SYSTEM Bet & 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 if the starter motor operates properly.
  • Page 210 . STARTING SYSTEM Bet & Win 125/150 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is 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.

  • Page 211: Starter Clutch Inspection

    . STARTING SYSTEM Bet & 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 Groove O-ring...

  • Page 212: Starter Relay Inspection

    . STARTING SYSTEM Bet & 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 is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.

  • Page 213: Switches/Horn/Fuel Unit/Thermostatic

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5 THERMOSTATIC SWITCH ------------------------------------------- 19-6 TEMPERATURE GAUGE --------------------------------------------- 19-6 INSTRUMENTS--------------------------------------------------------- 19-7...

  • Page 214: Electrical Equipment Layout

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Headlight Stop Switches Dimmer Switch Instruments Turn Signal Switch Horn Button Auto Bystarter Headlight Ignition Switch Switch Starter Button Horn Fuel Unit Thermostatic Switch Thermosensor 19-1...

  • Page 215: Service Information

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS 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...

  • Page 216: Switches

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. ( 2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/Wh Green Black Position PARK LOCK HEADLIGHT SWITCH INSPECTION Remove the frame front covers.
  • Page 217 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN 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. Color Light Green Brown/Blue Position FREE...

  • Page 218: Horn Inspection

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS 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 is connected across the horn wire terminals.

  • Page 219: Thermostatic Switch

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Thermostatic Switch THERMOSTATIC SWITCH INSPECTION Remove the front covers. ( 2-5) Start and run the engine to make the water temperature reaches 85 and check if the cooling fan motor operates. Lower the water temperature to 85 check if the fan motor stops.

  • Page 220: Instruments

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Speedometer Cable INSTRUMENTS REMOVAL Remove the front upper cover. ( 2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. Wire Couplers Remove the four instrument cover and leg shield screws.

  • Page 221: Lights

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Wire LIGHTS HEADLIGHT BULB REPLACEMENT Remove the 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 socket and replace the bulb. Install the bulb socket, aligning the bulb socket tab with the groove.

  • Page 222: Heater Wiring Diagram

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH Bet & Win 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HEATER WIRING DIAGRAM 19-9...
  • Page 223 TEXT Bet & Win 125/150 A.C. GENERATOR INSPECTION 16 - 5 CYLINDER INSTALLATION 7 - 7 A.C. GENERATOR INSPECTION 17 - 4 CYLINDER REMOVAL 7 - 3 AIR CLEANER 3 - 5 DRIVE BELT 3 - 8 AIR CUT-OFF VALVE (A.C.V.) 13 - 12 DRIVE PULLEY 8 - 4...
  • Page 224 TEXT Bet & Win 125/150 FUEL UNIT 19 - 5 SCHEMATIC DRAWING 11 - 1 HEADLIGHT AIM 3 - 9 SCHEMATIC DRAWING 12 - 1 HEATER WIRING DIAGRAM 19 - 9 SCHEMATIC DRAWING 13 - 2 HORN INSPECTION 19 - 5 SCHEMATIC DRAWING 14 - 1 IGNITION COIL INSPECTION...
  • Page 225 TEXT Bet & Win 125/150 SPECIFICATION 1 - 2 TROUBLESHOOTING 7 - 2 STARTER CLUTCH INSPECTION 18 - 5 TROUBLESHOOTING 8 - 2 STARTER CLUTCH 10 - 4 TROUBLESHOOTING 9 - 2 STARTER MOTOR 18 - 3 VACUUM CHAMBER ASSEMBLY 13 - 16 STARTER RELAY INSPECTION 18 - 6...

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