KYMCO Bet & Win 125/150, BW 125 150 COMPLETE OFFICIAL FACTORY Service / Repair / Full Workshop Manual

12. COOLING SYSTEM 12-0 Bet & Win 125/150 12 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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

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

12. COOLING SYSTEM 12-2 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. • Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces. Wash off any spilled coolant with fresh water as soon as possible. • After servicing the system, check for leaks with a cooling system tester. SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9.8_ 13.7N-m Water pump cover bolt 7.8_ 11.8N-m TROUBLESHOOTING Engine temperature too high Coolant leaks • Faulty temperature gauge or thermosensor • Faulty pump mechanical (water) seal • Faulty radiator cap • Deteriorated O-rings • Faulty thermostat • Damaged or deteriorated water hoses • Insufficient coolant • Passages blocked in hoses or water jacket • Clogged radiator fins • Passages blocked in radiator • Faulty water pump Temperature gauge pointer does not register the correct coolant temperature • Faulty temperature gauge or thermosensor • Faulty thermostat

12. COOLING SYSTEM 12-3 Bet & Win 125/150 SPECIFICATIONS Radiator cap relief pressure 0.9±0.15kg/cm_ Begins to open 80±2℃ Thermostat temperature Full-open 90℃ Valve lift 3.5_ 4.5mm Coolant capacity Total system 1165cc Radiator: 825cc Reserve tank: 340cc COOLANT GRAVITY Temp. ℃ Coolant concentration 0 5 10 15 20 25 30 35 40 45 50 5% 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.009 0.997 10% 1.018 1.107 1.017 1.016 1.015 1.014 0.013 1.011 1.009 1.007 1.005 15% 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012 20% 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019 25% 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025 30% 1.053 1.051 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032 35% 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040 40% 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047 45% 1.080 1.078 1.076 1.074 1.072 1.069 1.056 1.063 1.062 1.057 1.054 50% 1.086 1.084 1.082 1.080 1.077 1.074 1.071 1.068 1.065 1.062 1.059 55% 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 60% 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 -9℃ 20% -15℃ 30% 360cc 825cc -25℃ 40% -37℃ 50% -44.5℃ 55% Cautions for Using Coolant: • Use coolant of specified mixing rate. (The mixing rate of 360cc KYMCO SIGMA coolant concentrate + 825cc distilled water is 30%.) • Do not mix coolant concentrate of different brands. • Do not drink the coolant which is poisonous. • The freezing point of coolant mixture shall be 5℃ lower than the freezing point of the riding area.

12. COOLING SYSTEM 12-4 Bet & Win 125/150 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. Radiator Cap Relief Pressure: 0.9±0.15kg/cm_ Install the radiator tester onto the radiator and apply specified pressure to it. It must hold specified pressure for at least six seconds. Check the water hoses and connectors for leaks. RADIATOR RADIATOR INSPECTION Remove the front upper cover. (  2-5) Remove the front lower cover. (  2-5) Radiator Cap Radiator Tester The test pressure should not exceed 1.05 kg/cm_. Excessive pressure can damage the radiator and its hose connectors. ＊ Apply water to the cap sealing surface before testing. ＊

12. COOLING SYSTEM 12-5 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. RADIATOR REMOVAL Drain the coolant. (  3-9) Disconnect the air vent tube from the radiator filler. Remove the overflow tube clamp and disconnect the overflow tube. Loosen the hose band and disconnect the upper hose and lower hose from the radiator. Air Vent Tube Radiator Upper Hose Overflow Tube

12. COOLING SYSTEM 12-6 Bet & Win 125/150 Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. Remove the two bolts and two nuts on the radiator. RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan/shroud from the radiator. Fan/Shroud Radiator Bolts Thermostatic Switch Wire Fan Motor Wire Coupler Bolts Thermostatic Switch Nuts

12. COOLING SYSTEM 12-7 Bet & Win 125/150 Check fan motor by battery. CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85~90℃ the thermostatic switch OFF. When coolant temperature over 85~90℃ the thermostatic switch ON. Install the fan shroud on the radiator with the four bolts. Radiator Thermostatic Switch Bolts Fan Motor Battery Fan Shroud

12. COOLING SYSTEM 12-8 Bet & Win 125/150 RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire and fan motor wire couplers. Connect the overflow tube and secure with the tube clamp. Connect the vent tube to the radiator filler. Fill the radiator with coolant. (  3-9) After installation, check for coolant leaks. . Air Vent Tube Radiator Upper Hose Overflow Tube Lower Hose Bolts Thermostatic Switch Wire Nuts

12. COOLING SYSTEM 12-9 Bet & Win 125/150 Install the front upper 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. WATER PUMP/IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose. Right Crankcase Cover Telltale Hole Water Pump Outlet Hose Inlet Hose

KYMCO Bet & Win 125/150, BW 125 150 COMPLETE OFFICIAL FACTORY Service / Repair / Full Workshop Manual

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