KYMCO BET & WIN 50 User manual

BET &WIN 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO B&W 50.
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 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.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/CYLINDER/PISTON
6
KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
7
FINAL REDUCTION
8
A.C. GENERATOR
9
CRANKCASE/CRANKSHAFT
10
COOLING SYSTEM
11
CARBURETOR
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
INSTRUMENT/SWITCHES/LIGHTS
16
EVAPORATIVE/EXHAUST EMISSION
CONTROL SYSTEM
17
CHASSIS ELECTRICAL
EQUIPMENT
ENGINE
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
°Ø
E/M
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1. GENERAL INFORMATION
1-0
BET &WIN 50
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
ENGINE SERIAL NUMBER------------------------------------------- 1- 1
SPECIFICATIONS ------------------------------------------------------ 1- 2
SERVICE PRECAUTIONS--------------------------------------------- 1- 3
TORQUE VALUES ----------------------------------------------------- 1-13
SPECIAL TOOLS ------------------------------------------------------- 1-14
LUBRICATION POINTS----------------------------------------------- 1-15
WIRING DIAGRAM ---------------------------------------------------- 1-21
TROUBLESHOOTING ------------------------------------------------- 1-22
1
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1. GENERAL INFORMATION
1-1
BET &WIN 50
ENGINE SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
Vehicle Identification Serial Number
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1. GENERAL INFORMATION
1-2
BET &WIN 50
SPECIFICATIONS
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
Rear wheel
130/70-12 59J
Ground clearance
155mm
Perform
-
Braking distance (m)
4.4m /30km/H
ance
Min. turning radius
2300mm
Starting system
Starting motor &
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
(kg/cm_-rpm)
11.8
Max. output (kw/rpm)
3.09/6500
Max. torque (kg-m/rpm)
0.5/6000
Intake
Open
Port
(1mm)
Close
timin
g
Exhaust
Open
(1mm)
Close
Valve
Intake
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
Air cleaner type & No
Sponge wet
Gear oil capacity
0.12 liters
Fuel capacity
10 liters
Type
¢fi¢–
Piston dia.
13
Venturi dia.
14 equivalent
Type
CDI
Ignition timing
13.5°±2°/2000rpm
Spark plug
NGK
BR8HSA
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V4AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
type
Type
Two-stage reduction
Reduction
1st
ratio
2nd
Front
Caster angle
Axle
Connecting rod
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.25
Turning
Left
42.5°
angle
Right
42.5°
Brake system
Front
Disk brake
type
Rear
Drum brake
Suspension
Front
Telescope
type
Rear
Unit
Frame type
Under pipe
Tires
Engine
Fuel System
Carburetor
Electrical Power Drive System
Reduction Gear
Moving Device Damping
Device
Ignition System
System
Transmis- sion Gear
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1. GENERAL INFORMATION
1-3
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.
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.
KYMCO
KYMCO
KYMCO
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1. GENERAL INFORMATION
1-4
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.
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.
KYMCO
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1. GENERAL INFORMATION
1-5
BET &WIN 50
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.
Confirm
Capacity
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1. GENERAL INFORMATION
1-6
BET &WIN 50
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.
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.
Snapping!
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1. GENERAL INFORMATION
1-7
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.
No Contact !
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1. GENERAL INFORMATION
1-8
BET &WIN 50
Route harnesses so they are neither
pulled tight nor have excessive slack.
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
pull too
tight!
Do not press or
squeeze the wire.
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1. GENERAL INFORMATION
1-9
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.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand the
instrument? Is the
instrument set
correctly?
Remove Rust
!
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1. GENERAL INFORMATION
1-10
BET &WIN 50
Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.
:Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
:Apply grease for
lubrication.
:Transmission Gear Oil
(90#)
:Use special tool.
: Caution
:Warning
Engine Oil
Grease
Special
Gear Oil
°Ø
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1. GENERAL INFORMATION
1-11
BET &WIN 50
SERVICE INFORMATION
ENGINE
Standard (mm)
Service Limit (mm)
Item
B&W50
B&W50
Cylinder head warpage

0.10
Piston O.D.(5mmfrombottomofpiston
skirt)
38.955_38.970
38.90
Cylinder-to- piston clearance
0.10
Piston pin hole I.D.
12.002_12.008
12.03
Piston pin O.D.
11.994_12.0
11.98
Piston-to-piston pin clearance
0.002_0.014
0.03
Piston ring end gap (top/second)
0.10_0.25
0.40
Connecting rod small end I.D.
17.005_17.017
17.03
Cylinder bore
39.0_39.025
39.05
Drive belt width
18
17
Drive pulley collar O.D.
20.01_20.025
19.97
Movable drive face ID.
20.035_20.085
20.21
Weight roller O.D.
13.0
12.4
Clutch outer I.D.
107_107.2
107.5
Driven face spring free length
87.9
82.6
Driven face O.D.
33.965_33.985
33.94
Movable driven face I.D.
34.0_34.025
34.06
Connecting rod big end side clearance

0.60
Connecting rod big end radial clearance

0.04
Crankshaft runout A/B

L:0.15 R:0.10
CARBURETOR
SH10CA(SP)
SH10CA(IT)
SH10CA(GR)
Venturi dia.
14mm
Identification number
PB109_
PB103_
PB118_
Float level
8.6mm
Main jet(Unlimited/limited speed)
#75
#75
#88
Slow jet
#35
Air screw opening
1_±_
Idle speed
2000°”100rpm
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1. GENERAL INFORMATION
1-12
BET &WIN 50
Throttle grip free play
2_6mm
Jet needle clip notch
1st notch
FRAME
Standard (mm)
Service Limit (mm)
Item
B&W50
B&W50
Axle shaft runout

0.2
Radial
Front wheel rim runout
Axial
Front shock absorber spring free length
221.5
204.3
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
Rear shock absorber spring free length
214.7
197.7
ELECTRICAL EQUIPMENT
B&W50
Capacity
12V4AH
Voltage
13.0_13.2V
Charging
Standard
0.4A/5H
Battery
current
Quick
4A/0.5H
Spark plug
(NGK)
BR8HSA
Spark plug gap
0.6_0.7mm
Primary coil
0.153_0.187Ω
Secondary coil
(with plug cap)
6.99_10.21KΩ
Ignition coil resistance
Secondary coil
(without plug cap)
3.24_3.96KΩ
Pulser coil resistance (20¢J)
80_160Ω
Ignition timing
13.5°±2°BTDC/2000rpm
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1. GENERAL INFORMATION
1-13
BET &WIN 50
TORQUE VALUES
ENGINE
Item
Thread dia. (mm)
Torque (N-m)
Remarks
Cylinder head bolt
Clutch drive plate nut
Clutch outer nut
Drive face nut
Oil check bolt
Engine mounting bolt
Engine hanger bracket bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
BF7x115
10
NH10
NH12
10
BF10x95
BF10x50
NC6mm
BF8x35
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
(cold)
(cold)
FRAME
Item
Thread dia. (mm)
Torque (N-m)
Remarks
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
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
10
25.4
25.4
12
16
8
8
10
8
8
44.1_49.0
78.4_117.6
4.9_12.7
49.0_68.6
107.8_127.4
32.3
32.3
14.7_29.4
14.7_29.4
34.3_44.1
23.5_29.4
14.7_24.5
Flange bolt/U-nut
Flange U-nut
Flange U-nut
Flange bolt/U-nut
Cross head
Apply locking agent
Flange screw/U-nut
Flange nut
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt
Item
Torque (N-m)
Item
Torque (N-m)
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1. GENERAL INFORMATION
1-14
BET &WIN 50
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
4.4_5.9
7.8_11.8
17.6_24.5
29.4_39.2
49.0_58.8
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
3.43_4.9
6.86_10.8
9.8_13.7
23.5_29.4
14.7_44.1
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
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1. GENERAL INFORMATION
1-15
BET &WIN 50
LUBRICATION POINTS
ENGINE
NO.
Lubrication Points
Lubricant
Remarks
1
Crankcase sliding & movable parts
JASO-FC or API-TC
2
Cylinder movable parts
3
Transmission gear (final gear)
SAE-90#
4
Kick starter spindle bushing
Grease
5
Drive pulley movable parts
Grease
6
Starter pinion movable parts
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.
Seat Lock
Throttle Cable
Engine Oil
Grease
Speedometer Gear/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Grease
Grease
Speedometer Cable
Rear Wheel
Bearing
Engine Oil
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1. GENERAL INFORMATION
1-16
BET &WIN 50
Main Stand Pivot
Grease
Front Stop
Switch
Rear Stop
Switch
Throttle
Cable
Radiator
Brake Master
Cylinders
Speedometer
Cable
Horn
Water Hose
Reserve Cap
Engine Oil
Rear Brake
Control Cable
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1. GENERAL INFORMATION
1-17
BET &WIN 50
Front Brake Fluid Tube
Water Hose
Ignition
Switch
Fuse Tank
Resistors
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1. GENERAL INFORMATION
1-18
BET &WIN 50
Speedometer
Cable
Reserve Cap
Rear Brake
Control Cable
Water Hose
Regulator/
Rectifier
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