Download BET & WIN 50

TEXT
BET & WIN 50
A.C. GENERATOR INSTALLATION
9 -4
EXHAUST MUFFLER REMOVAL
A.C. GENERATOR REMOVAL
9 - 2
EXHAUST MUFFLER
AIR CLEANER
3 - 6
FINAL REDUCTION ASSEMBLY
8 - 5
2 - 6
17 - 2
AIR SCREW ADJUSTMENT
12 -10
FINAL REDUCTION DISASSEMBLY
8 - 2
AUTO BYSTARTER
12 - 5
FINAL REDUCTION GEAR OIL
3 - 9
BATTERY
15 - 4
FINAL REDUCTION INSPECTION
8 - 2
BRAKE CALIPER
13 -11
FLOAT CHAMBER
12 - 7
BRAKE SYSTEM
3 -11
FLOAT LEVEL INSPECTION
12 - 9
BULB REPLACEMENT
16 - 7
FRAME COVERS REMOVAL
2 - 2
CARBURETOR INSTALLATION
12 -10
FRONT BRAKE
13 - 8
CARBURETOR REMOVAL
12 - 4
FRONT FORK
13 -18
CHARGING SYSTEM
15 - 3
FRONT SHOCK ABSORBER
13 -14
13 - 5
CLUTCH/DRIVEN PULLEY
7 -11
FRONT WHEEL
COOLING SYSTEM
3 -10
FUEL LINE/FUEL FILTER
3 - 5
CRANKCASE ASSEMBLY
10 - 6
FUEL UNIT
CRANKCASE SEPARATION
10 - 2
HEADLIGHT AIM
CRANKSHAFT INSPECTION
10 - 3
IGNITION SYSTEM
15 - 7
CRANKSHAFT INSTALLATION
10 - 4
IGNITION TIMING
3 - 7
CRANKSHAFT REMOVAL
10 - 2
INSPECTION AND MAINTENANCE
CYLINDER COMPRESSION
3 - 8
SCHEDULE
CYLINDER HEAD
6 - 2
INSTRUMENT/HEADLIGHT
CYLINDER/PISTON
6 - 4
KICK STARTER
7 - 2
DRIVE BELT
7 - 6
LUBRICATION POINTS
1 -15
DRIVE BELT
3 - 9
LUBRICATION SYSTEM
3 -14
DRIVE PULLEY
7 - 8
NUTS/BOLTS/FASTENERS
3 -13
ENGINE INSTALLATION
5 - 4
OIL METER
ENGINE REMOVAL
5 - 2
OIL PUMP BLEEDING
4 - 4
ENGINE SERIAL NUMBER
1 - 1
OIL PUMP INSPECTION
4 - 2
EXHAUST EMISSION CONTROL SYSTEM17 - 1
OIL PUMP INSTALLATION
4 - 3
EXHAUST EMISSION RELATED SYSTEM
OIL PUMP REMOVAL
4 - 2
INSPECTION
OIL TANK
4 - 5
17 - 3
16 - 2
3 -10
3 - 2
16 - 8
16 - 3
TEXT
BET & WIN 50
RADIATOR
11 - 3
THERMOSENSOR
11 -11
REAR BRAKE DRUM
14 - 3
THERMOSTAT
11 -12
REAR SHOCK ABSORBER
14 - 5
THROTTLE OPERATION
REAR WHEEL
14 - 3
THROTTLE VALVE DISASSEMBLY
12 - 2
REED VALVE
12 -11
THROTTLE VALVE INSTALLATION
12 - 3
SERVICE INFORMATION
11 - 1
TORQUE VALUES
SERVICE INFORMATION
14 - 1
TROUBLESHOOTING
11 - 1
SERVICE INFORMATION
10 - 1
TROUBLESHOOTING
14 - 1
SERVICE INFORMATION
12 - 1
TROUBLESHOOTING
10 - 1
SERVICE INFORMATION
13 - 1
TROUBLESHOOTING
12 - 1
SERVICE INFORMATION
15 - 1
TROUBLESHOOTING
13 - 2
SERVICE INFORMATION
16 - 1
TROUBLESHOOTING
15 - 1
SERVICE INFORMATION
6 - 1
TROUBLESHOOTING
16 - 1
SERVICE INFORMATION
7 - 1
TROUBLESHOOTING
6 - 1
SERVICE INFORMATION
8 - 1
TROUBLESHOOTING
7 - 1
SERVICE INFORMATION
9 - 1
TROUBLESHOOTING
8 - 1
SERVICE INFORMATION
2 - 1
TROUBLESHOOTING
1 -22
SERVICE INFORMATION
3 - 1
TROUBLESHOOTING
2 - 1
SERVICE INFORMATION
4 - 1
TROUBLESHOOTING
4 - 1
SERVICE INFORMATION
5 - 1
WATER PUMP
SERVICE PRECAUTIONS
1 - 3
WHEELS/TIRES
3 -13
SPARK PLUG
3 - 7
WIRING DIAGRAM
1 -21
SPECIAL TOOLS
1 -14
SPECIFICATIONS
1 - 2
STARTER PINION
7 -10
STARTING SYSTEM
15 -11
STEERING HANDLEBAR
13 - 3
STEERING HANDLEBAR
3 -13
STOP SWITCH INSPECTION
SUSPENSION
SWITCHES
16 - 6
3 -13
16 - 4
3 - 5
1 -13
11 - 5
BET & WIN 50
PREFACE
TABLE OF CONTENTS
Section 2 is the removal/installation
procedures for the frame covers which are
subject to higher removal/installation
frequency during maintenance and
servicing operations.
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
CLUTCH/DRIVEN PULLEY
A.C. GENERATOR
CRANKCASE/CRANKSHAFT
COOLING SYSTEM
CARBURETOR
ELECTRICAL
EQUIPMENT E/M
Sections 5 through 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 is the removal/
installation of chassis. Section 15 states
the testing and measuring methods of
electrical equipment.
KICK STARTER/DRIVE PULLEY/
FINAL REDUCTION
CHASSIS
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
ENGINE
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/CYLINDER/PISTON 6
GENERAL INFORMATION
This Service Manual describes the
technical features and servicing
procedures for the KYMCO B&W 50.
7
8
9
10
11
12
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
13
REAR BRAKE/REAR BRAKE
DRUN/REAR SHOCK ABSORBER`
14
ELECTRICAL EQUIPMENT
15
16
INSTRUMENT/SWITCHES/LIGHTS
EVAPORATIVE/EXHAUST EMISSION
CONTROL SYSTEM
17
1. GENERAL INFORMATION
BET & WIN 50
1
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
ENGINE SERIAL NUMBER ---------------------------------------------SPECIFICATIONS ---------------------------------------------------------SERVICE PRECAUTIONS -----------------------------------------------TORQUE VALUES --------------------------------------------------------SPECIAL TOOLS ----------------------------------------------------------LUBRICATION POINTS -------------------------------------------------WIRING DIAGRAM-------------------------------------------------------TROUBLESHOOTING-----------------------------------------------------
1- 1
1- 2
1- 3
1-13
1-14
1-15
1-21
1-22
1-0
1. GENERAL INFORMATION
BET & WIN 50
ENGINE SERIAL NUMBER
Vehicle Identification Serial Number
Location of Engine Serial Number
1-1
Location of Frame Serial Number
1. GENERAL INFORMATION
BET & WIN 50
SPECIFICATIONS
Air cleaner type & No
Gear oil capacity
Fuel capacity
Type
Piston dia.
Venturi dia.
Carburetor
Fuel System
Ignition System
Electrical Equipment
Type
Ignition timing
Spark plug
Sponge wet
0.12 liters
10 liters
ＰＢ
13
14 equivalent
CDI
13.5°±2°/2000rpm
NGK
BR8HSA
Spark plug gap
Battery Capacity
Clutch Type
0.6～0.7mm
12V4AH
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic centrifugal
type
TransmisReduction
Gear
sion Gear
Power
Drive System
Type
Two-stage reduction
1.75
2.25
42.5°
42.5°
Disk brake
Drum brake
Telescope
Unit
Frame type
Under pipe
Damping
Device
Lubrication
System
Reduction 1st
ratio
2nd
Front Caster angle
Axle Connecting rod
Front
Tire pressure
(kg/cm²)
Rear
Turning
Left
angle
Right
Front
Brake system
type
Rear
Front
Suspension
type
Rear
Moving Device
Engine
Name & Model No.
B&W50
Overall length
1940mm
Overall width
740mm
Overall height
1173mm
Wheel base
1352mm
Engine type
Water cooled 2-stroke
Displacement
49.4cc
Fuel Used
nonleaded gasoline
Front wheel
52.5
Net weight (kg) Rear wheel
67.5
Total
120
Front wheel
79
Gross weight(kg) Rear wheel
114
Total
193
Front wheel
120/70-12 56J
Tires
Rear wheel
130/70-12 59J
Ground clearance
155mm
Perform- Braking distance (m)
4.4m /30km/H
ance
Min. turning radius
2300mm
Starting motor &
Starting system
Kick starter
Type
Gasoline,2-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Bore x stroke (mm)
39.0 x 41.4
Compression ratio
7.2:1
Compression pressure
11.8
(kg/cm²-rpm)
Max. output (kw/rpm)
3.09/6500
Max. torque (kg-m/rpm)
0.5/6000
Intake
Open
Close
Port (1mm)
timing Exhaust Open
(1mm)
Close
Intake
Valve
clearance (cold) Exhaust
Idle speed (rpm)
2000±100rpm
Lubrication type
Separate type
Oil pump type
Plunger type
Oil filter type
Full-flow filtration
Oil capacity
1.1 liters
Exchanging capacity
0.9 liters
Cooling Type
Water cooling
1-2
1. GENERAL INFORMATION
BET & WIN 50
SERVICE PRECAUTIONS
„ Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
„ When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
„ Use genuine parts and lubricants.
KYMCO
KYMCO
„ When servicing the motorcycle, be sure
to use special tools for removal and
installation.
„ After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
1-3
KYMCO
1. GENERAL INFORMATION
BET & WIN 50
„ Apply or add designated greases and
lubricants to the specified lubrication
points.
„ After reassembly, check all parts for
proper tightening and operation.
„ When two persons work together, pay
attention to the mutual working safety.
KYMCO
„ Disconnect the battery negative (-)
terminal before operation.
„ When using a spanner or other tools,
make sure not to damage the motorcycle
surface.
„ After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
„ When connecting the battery, the positive
(+) terminal must be connected first.
„ After connection, apply grease to the
battery terminals.
„ Terminal caps shall be installed securely.
1-4
1. GENERAL INFORMATION
„ If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
„ After operation, terminal caps shall be
installed securely.
„ When taking out the connector, the lock
on the connector shall be released before
operation.
„ Hold the connector body when
connecting or disconnecting it.
„ Do not pull the connector wire.
„ Check if any connector terminal is
bending, protruding or loose.
1-5
BET & WIN 50
Confirm
Capacity
1. GENERAL INFORMATION
„ The connector shall be inserted
completely.
„ If the double connector has a lock,
lock it at the correct position.
„ Check if there is any loose wire.
BET & WIN 50
Snapping!
„ Before connecting a terminal, check
for damaged terminal cover or loose
negative terminal.
„ Check the double connector cover for
proper coverage and installation.
„ Insert the terminal completely.
„ Check the terminal cover for proper
coverage.
„ Do not make the terminal cover opening
face up.
„ Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
1-6
1. GENERAL INFORMATION
BET & WIN 50
„ After clamping, check each wire to make
sure it is secure.
„ Do not squeeze wires against the weld or
its clamp.
„ After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
„ When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
„ Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and screws.
„ Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
1-7
No Contact !
1. GENERAL INFORMATION
„ Route harnesses so they are neither
pulled tight nor have excessive slack.
BET & WIN 50
Do not pull
too tight!
„ Protect wires and harnesses with
electrical tape or tube if they contact a
sharp edge or corner.
„ When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
„ Do not break the sheath of wire.
„ If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.
„ When installing other parts, do not press
or squeeze the wires.
Do not press or
squeeze the wire.
1-8
1. GENERAL INFORMATION
BET & WIN 50
„ After routing, check that the wire
harnesses are not twisted or kinked.
„ Wire harnesses routed along with
handlebar should not be pulled tight,
have excessive slack or interfere with
adjacent or surrounding parts in all
steering positions.
„ When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.
Do you understand the
instrument? Is the
instrument set
l ?
„ Be careful not to drop any parts.
„ When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
1-9
Remove Rust !
1. GENERAL INFORMATION
BET & WIN 50
„ Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.
Engine Oil
Grease
Gear Oil
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for
lubrication.
: Transmission Gear Oil
(90#)
: Use special tool.
Special
＊
: Caution
: Warning
1-10
1. GENERAL INFORMATION
BET & WIN 50
SERVICE INFORMATION
ENGINE
Item
Cylinder head warpage
Piston O.D.(5mm from bottom of piston skirt)
Cylinder-to- piston clearance
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end gap (top/second)
Connecting rod small end I.D.
Cylinder bore
Drive belt width
Drive pulley collar O.D.
Movable drive face ID.
Weight roller O.D.
Clutch outer I.D.
Driven face spring free length
Driven face O.D.
Movable driven face I.D.
Connecting rod big end side clearance
Connecting rod big end radial clearance
Crankshaft runout A/B
CARBURETOR
Standard (mm)
Service Limit (mm)
B&W50
⎯
B&W50
0.10
38.955～38.970
38.90
0.10
12.002～12.008
12.03
11.994～12.0
11.98
0.002～0.014
0.03
0.10～0.25
0.40
17.005～17.017
17.03
39.0～39.025
39.05
18
17
20.01～20.025
19.97
20.035～20.085
20.21
13.0
12.4
107～107.2
107.5
87.9
82.6
33.965～33.985
33.94
34.0～34.025
34.06
⎯
⎯
⎯
0.60
SH10CA(SP)
Venturi dia.
Identification number
Slow jet
Air screw opening
Idle speed
L:0.15
SH10CA(IT)
PB109□
PB103□
SH10CA(GR)
PB118□
8.6mm
#75
#75
#35
1¼±½
2000±100rpm
Throttle grip free play
2～6mm
Jet needle clip notch
1st notch
1-11
R:0.10
14mm
Float level
Main jet(Unlimited/limited speed)
0.04
#88
1. GENERAL INFORMATION
BET & WIN 50
FRAME
Item
Axle shaft runout
Front wheel rim runout
Standard (mm)
Service Limit (mm)
B&W50
B&W50
⎯
0.2
221.5
204.3
Radial
Axial
Front shock absorber spring free length
Rear wheel rim runout
2.0
Brake drum I.D.
Front/rear
110
111
Brake lining thickness
Front/rear
4.0/4.0
2.0/2.0
Brake disk runout
Front/rear
⎯
0.30
214.7
197.7
Rear shock absorber spring free length
ELECTRICAL EQUIPMENT
B&W50
Capacity
Voltage
Battery
Charging Standard
current
Quick
Spark plug
(NGK)
Spark plug gap
Primary coil
Secondary coil
Ignition coil resistance (with plug cap)
Secondary coil
(without plug cap)
Pulser coil resistance (20℃)
Ignition timing
12V4AH
13.0～13.2V
0.4A/5H
4A/0.5H
BR8HSA
0.6～0.7mm
0.153～0.187Ω
6.99～10.21KΩ
3.24～3.96KΩ
80～160Ω
13.5°±2°BTDC/2000rpm
1-12
1. GENERAL INFORMATION
BET & WIN 50
TORQUE VALUES
ENGINE
Item
Thread dia. (mm)
Cylinder head bolt
BF7x115
Clutch drive plate nut
10
Clutch outer nut
NH10
NH12
Drive face nut
Oil check bolt
10
Engine mounting bolt
BF10x95
Engine hanger bracket bolt
BF10x50
Exhaust muffler joint lock nut
NC6mm
BF8x35
Exhaust muffler lock bolt
Spark plug
Torque (N-m)
14.7～16.7
34.3～39.2
34.3～44.1
49.0～58.8
9.8～14.7
44.1～53.9
34.3～44.1
9.8～13.7
29.4～35.3
10.8～16.7
Remarks
(cold)
(cold)
FRAME
Item
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
Thread dia. (mm)
10
25.4
25.4
12
16
Torque (N-m)
44.1～49.0
78.4～117.6
4.9～12.7
49.0～68.6
107.8～127.4
8
32.3
32.3
14.7～29.4
14.7～29.4
Front shock absorber:
upper mount bolt
lower mount bolt
hex bolt
Front damper nut
Front pivot arm bolt
Rear shock absorber:
upper mount bolt
lower mount bolt
lower joint nut
8
Remarks
Flange bolt/U-nut
Flange U-nut
Flange U-nut
Flange bolt/U-nut
Cross head
Apply locking agent
Flange screw/U-nut
10
8
8
34.3～44.1
23.5～29.4
14.7～24.5
Flange nut
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES
Item
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
1-13
Torque (N-m)
4.4～5.9
7.8～11.8
17.6～24.5
29.4～39.2
49.0～58.8
SH bolt: 8mm
Item
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
Flange 6mm bolt
Torque (N-m)
3.43～4.9
6.86～10.8
9.8～13.7
23.5～29.4
14.7～44.1
1. GENERAL INFORMATION
BET & WIN 50
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Universal bearing puller
E030
Crankshaft bearing removal
Lock nut socket wrench
F001
Top cone race holding
Lock nut wrench,
F001
Stem lock nut tightening
Crankcase puller
E026
Crankcase disassembly
Bearing remover set, 12mm
(Spindle assy, 15mm)
(Remover weight)
E020
Drive shaft bearing removal/installation
Bearing remover set, 15mm
(Spindle assy, 15mm)
(Remover head, 15mm)
(Remover shaft, 15mm)
E018
Drive shaft bearing removal/installation
Bearing outer driver, 28x30mm
E014
Bearing installation
Clutch spring compressor
E027
Driven pulley disassembly/assembly
Crankcase assembly collar
E023
Driven shaft, crankshaft & crankcase
assembly
Crankcase assembly tool
E024
Crankshaft & crankcase assembly
Ball race remover
F005
Steering stem bearing races
Rear shock absorber compressor
F004
Rear shock absorber disassembly/assembly
Universal holder
E017
Flywheel holding
Flywheel puller
E001
Flywheel removal
Pilot, 12mm
E020
Drive shaft bearing installation
Bearing outer driver, 32x35mm
E014
Drive shaft bearing installation
Final shaft bearing installation
Bearing outer driver, 37x40mm
E014
Drive shaft bearing installation Final
shaft bearing installation Crankshaft
bearing installation
Outer driver, 24x26mm
E014
Driven pulley bearing installation
1-14
1. GENERAL INFORMATION
BET & WIN 50
LUBRICATION POINTS
ENGINE
NO.
1
2
3
4
5
6
Lubrication Points
Crankcase sliding & movable
Cylinder movable parts
Transmission gear (final gear)
Kick starter spindle bushing
Drive pulley movable parts
Starter pinion movable parts
Lubricant
JASO-FC or API-TC
Remarks
SAE-90#
Grease
Grease
Grease
FRAME
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.
Engine Oil
Throttle Cable
Engine Oil
Speedometer Cable
Grease
Seat Lock
Grease
Speedometer Gear/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Grease
Rear Wheel
Bearing
Grease
Main Stand Pivot
1-15
Engine Oil
Rear Brake
Control Cable
1. GENERAL INFORMATION
Brake Master
Cylinders
BET & WIN 50
Rear Stop
Switch
Front Stop
Switch
Throttle
Cable
Water Hose
Speedometer
Cable
Reserve Cap
Radiator
Horn
1-16
1. GENERAL INFORMATION
BET & WIN 50
Ignition
Switch
Water Hose
Resistors
Fuse Tank
1-17
Front Brake Fluid Tube
1. GENERAL INFORMATION
BET & WIN 50
Regulator/
Rectifier
Reserve Cap
Speedometer
Cable
Water Hose
Rear Brake
Control Cable
1-18
1. GENERAL INFORMATION
BET & WIN 50
Oil Meter
Fuel Pump
Fuel Pump
Vacuum Tube
Fuel Filter
Fuel Tank
Breather Tube
Thermostat
1-19
Ignition Coil
1. GENERAL INFORMATION
BET & WIN 50
Throttle Cable
Water Hose
Oil Tube
Spark Plug Cap
1-20
1. GENERAL INFORMATION
WIRING DIAGRAM
1-21
BET & WIN 50
1. GENERAL INFORMATION
BET & WIN 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment
Probable Cause
Symptom
Check if fuel reaches
carburetor by loosening
drain screw.
Fuel reaches
carburetor
Fuel does not
reach carburetor
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Spark jumps
Weak or no spark
Test cylinder
compression.
Normal
compression
Low or no
compression
Start engine by following normal starting
procedure.
Engine does not
fire
Engine fires but
does not start
Dry spark plug
Wet spark plug
Not clogged
Clogged
c Empty fuel tank
d Clogged float valve
e Clogged charcoal canister
f Clogged fuel filter
g Faulty auto fuel valve
c Faulty spark plug
d Fouled spark plug
e Faulty CDI unit
f Faulty A.C. generator
g Broken or shorted ignition coil
h Broken or shorted exciter coil
iFaulty ignition switch
c Burned or worn cylinder
piston
d Faulty reed valve
e Blown cylinder head gasket
f Leaking crankcase
g Faulty crankcase oil seal
c Incorrectly adjusted idle speed
d Air leaking through intake
pipe
e Incorrect ignition timing
Remove spark plug and
inspect again.
Wait for 30 minutes and
then remove the carburetor auto choke circuit
hose and blow the hose
with mouth.
c Flooded carburetor
d Throttle valve excessively
open
c Faulty auto bystarter
1-22
1. GENERAL INFORMATION
BET & WIN 50
ENGINE STOPS IMMEDIATELY AFTER IT STARTS
Inspection/Adjustment
Symptom
Probable Cause
Check if fuel reaches
carburetor by loosening
drain screw.
Fuel reaches
carburetor
Fuel does not
reach carburetor
c Empty fuel tank
d Clogged float valve
e Clogged charcoal canister
f Clogged fuel filter
g Faulty auto fuel valve
Plug fouled or
discolored
c Fouled spark plug
d Incorrect heat range plug
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Plug not fouled or
discolored
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Good spark
Weak or intermittent spark
Test cylinder
compression (using a
compression gauge).
c Fouled spark plug
d Faulty CDI unit
e Faulty A.C. generator
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Flaws in cylinder head
f Faulty reed valve
g Seized piston
Normal
compression
Abnormal
compression
Not Clogged
Clogged
Correct timing
Incorrect timing
c Faulty CDI unit or A.C.
generator
d A.C.G. flywheel not aligned
Correctly adjusted
Incorrectly adjusted
c Mixture too rich (turn screw
out)
d Mixture too lean (turn screw
in)
Check carburetor for
clogging.
c Clogged carburetor jets
Check ignition timing.
Check carburetor air
screw adjustment.
1-23
1. GENERAL INFORMATION
Inspection/Adjustment
BET & WIN 50
Symptom
Probable Cause
Check carburetor gasket
for air leaks.
No air leak
Air leaks
c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed or broken
carburetor O-ring
Not clogged
Clogged
c Broken cable
d Dirty auto bystarter
e Faulty auto bystarter
Clogged
Not Clogged
c Faulty auto bystarter
Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.
Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.
1-24
1. GENERAL INFORMATION
BET & WIN 50
ENGINE LACKS POWER
Inspection/Adjustment
Symptom
Probable Cause
Start engine and
accelerate lightly for
observation.
Engine speed
increases
Engine speed does
not increase
sufficiently
Correct timing
Incorrect timing
Normal
compression
Abnormal
compression
Not Clogged
Clogged
c Clogged air cleaner
d Clogged fuel filter
e Clogged exhaust muffler
f Faulty auto bystarter
g Faulty charcoal canister
Check ignition timing
(using a timing light).
c Faulty CDI unit
d Faulty A.C. generator
Test cylinder
compression (using a
compression gauge)
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Faulty reed valve
Check carburetor for
clogging
c Clogged carburetor jets
Remove spark plug and
inspect
Plug not fouled or
discolored
Plug fouled or
discolored
c Fouled spark plug
d Incorrect heat range plug
Engine overheats
c Mixture too lean
d Poor quality fuel
e Excessive carbon build-up in
combustion chamber
f Ignition timing too early
Engine knocks
c Excessive carbon build-up in
combustion chamber
d Poor quality fuel
e Clutch slipping
f Mixture too lean
Check if engine
overheats
Engine does not
overheats
Rapidly accelerate or
run at high speed
Engine does not
knock
1-25
1. GENERAL INFORMATION
BET & WIN 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing.
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
c Faulty CDI unit
d Faulty A.C. generator
Check carburetor air
screw adjustment.
c Mixture too rich (turn screw
out)
d Mixture too lean (turn screw
in)
Check carburetor gasket
for air leaks.
Air leaks
c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed carburetor O-ring
Good spark
Weak or intermittent spark
c Faulty or fouled spark plug
d Faulty CDI unit
e Faulty A.C. generator
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch
Not clogged
Clogged
Clogged
Not clogged
No air leak
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.
Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.
c Broken auto bystarter wire
d Faulty auto bystarter
1-26
1. GENERAL INFORMATION
BET & WIN 50
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing.
Correct timing
Incorrect timing
c Faulty CDI unit
dLoose A.C.G. stator
e Faulty A.C. generator
Check auto fuel valve
for fuel supply.
c Empty fuel tank
d Clogged fuel tube or filter
e Clogged charcoal canister
Fuel flows freely
Fuel flow restricted
Not clogged
Clogged
c Clean and unclog
Not clogged
Clogged
c Broken auto bystarter wire
d Faulty auto bystarter
Clogged
Not clogged
Check carburetor jets
for clogging.
Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.
Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
the hose with mouth.
1-27
c Faulty auto bystarter
1. GENERAL INFORMATION
BET & WIN 50
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Probable Cause
Engine starts but motorcycle does not move
c Worn or slipping drive belt
d Broken ramp plate
e Broken driven face spring
f Separated clutch lining
g Damaged driven pulley shaft splines
h Damaged final gear
i Seized final gear
Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)
c Broken shoe spring
d Clutch outer and clutch weight stuck
eSeized pivot
Engine lacks power at
start of a grade (poor
slope performance)
c Worn or slipping drive belt
d Worn weight rollers
e Seized drive pulley bearings
f Weak driven face spring
g Worn or seized driven pulley bearings
Engine lacks power at
high speed
c Worn or slipping drive belt
d Worn weight rollers
e Worn or seized driven pulley bearings
There is abnormal noise
or smell while running
c Oil or grease fouled drive belt
d Worn drive belt
e Weak driven face spring
f Worn or seized driven pulley bearings
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
Symptom
Probable Cause
(Front and rear tire pressures are normal)
Steering is heavy
c Steering stem nut too tight
d Broken steering steel balls
Front or rear wheel is
wobbling
c Excessive wheel bearing play
d Bent rim
e Loose axle nut
Steering handlebar pulls
to one side
c Misaligned front and rear wheels
d Bent front fork
1-28
1. GENERAL INFORMATION
BET & WIN 50
POOR SUSPENSION PERFORMANCE
Symptom
Probable Cause
(Front and rear tire pressures are normal)
Suspension is too soft
c Weak shock spring
d Excessive load
e Shock damper oil leaking
Suspension is too hard
c Bent fork tube or shock rod
d Fork slider and tube binding
Suspension is noisy
c Fork tube and spring binding
d Fork slider and tube binding
POOR BRAKE PERFORMANCE
Symptom
Probable Cause
(Adjust brake according to standards)
Index mark on brake
panel aligns with wear
indicator arrow
c Worn brake linings
d Worn brake cam contacting area on
brake shoes
e Worn brake cam
f Worn brake drum
Brake squeaks
c Worn brake linings
d Foreign matter on brake linings
e Rough brake drum contacting area
Brake performance is
poor
c Sluggish or elongated brake cables
d Brake shoes improperly contact
brake drum
e Water and mud in brake system
f Oil or grease on brake linings
Expanding
Brake
Hydraulic
Brake
1-29
c Faulty brake master cylinder
d Faulty brake caliper
e Oil or grease on brake disk
f Deformed brake disk
g Leaking brake fluid tube
1. GENERAL INFORMATION
BET & WIN 50
OIL METER
1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)
Inspection/Adjustment
Symptom
Probable Cause
Check battery circuit by
operating turn signals.
Signals operate
properly
Signals dim, remain
on or don‘t operate
c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness
Bulb lights
Bulb does not light
cBurned out bulb
Good
Faulty
c Loose wire connector
d Broken wire harness
e Incorrectly connected wire
Good
Faulty
c Faulty float
d Broken or shorted wire in
meter
Connect indicator light
bulb to battery for bulb
inspection.
Check connectors for
proper operation.
Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on
2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)
Inspection/Adjustment
Probable Cause
Symptom
Check connectors for
proper connection.
Good
Faulty
Good
Faulty
Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on
c Loose or disconnected
connector
d Broken wire harness
e Incorrectly connected wire
c Faulty float
d Broken or shorted wire in
meter
c Damaged oil tank
d Foreign matters in oil tank
1-30
1. GENERAL INFORMATION
BET & WIN 50
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Inspection/Adjustment
Probable Cause
Symptom
Check battery circuit by
operating turn signals.
Remove fuel unit and
check operation of
pointer by moving float
up and down.
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire
harness side.
Signals operate
properly
Signals dim, remain
on or don‘t operate
Pointer moves
c Faulty float
Pointer moves
c Broken or shorted fuel unit
wire
Pointer does not
move
Pointer does not
move
c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness
Check connectors for
proper connection.
c Loose or disconnected
Faulty
Good
connector
d Incorrectly connected
connector
c Broken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)
Probable Cause
Symptom
Inspection/Adjustment
Check battery circuit by
operating turn signals
and horn.
Remove fuel unit and
check operation of
pointer by moving float
up and down.
Signals operate
properly
Pointer moves
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer.
Pointer moves in
accordance with
float
Signals dim, remain
on or don‘t operate
Pointer does not
move
Pointer does not
move in accordance with float
c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness
c Poor contact in fuel unit
c Insufficient damping oil in
fuel gauge
Check connectors for
proper connection.
Good
1-31
Faulty
c Loose or disconnected
connector
c Broken or shorted wire in
1. GENERAL INFORMATION
BET & WIN 50
fuel gauge
STARTER MOTOR
1. Starter motor won‘t turn
Symptom
Inspection/Adjustment
Probable Cause
Check operation of
stop switch by
applying brake.
Stoplight does not
come on
c Burned out fuse
d Weak or dead battery
e Faulty stop switch
f Loose or disconnected
connector
g Broken or shorted ignition
switch wire
Signals operate
properly
Signals dim, remain
on or don‘t operate
c Faulty or weak battery
Relay operates
properly
Relay does not
operate
Starter motor turns
Starter does not turn
Stoplight comes on
Check battery circuit
by operating turn
signals.
Check operation of
starter relay by
depressing starter
button.
Connect starter
motor directly to
battery.
c Poor starter button connection
d Faulty starter relay
e Loose or disconnected
connector
c Faulty starter motor
c Faulty wire harness
2. Starter motor turns slowly or idles
Symptom
Inspection/Adjustment
Probable Cause
Check battery circuit
by operating turn
signals.
Signals operate
properly
Signals dim, remain
on or don‘t operate
c Weak or dead battery
Starter motor
turns slowly
Starter motor
turns normally
c Loose or disconnected
connector
d Faulty starter relay
Connect starter
motor directly to
battery.
Rotate crankshaft.
Hard to turn
Turns easily
c Seized cylinder
c Broken or shorted starter
motor cable
d Faulty starter pinion
3. Starter motor does not stop turning
Symptom
Inspection/Adjustment
Probable Cause
Turn ignition switch
OFF.
Not stopped
Stopped
c Faulty starter pinion
c Starter relay shorted or stuck
1-32
1. GENERAL INFORMATION
BET & WIN 50
closed
1-33