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12. COOLING SYSTEM

12-0

Bet & Win 2 50

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COOLING SYSTEM

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SCHEMATIC DRAWING ---------------------------------------------- 12- 1

SERVICE INFORMATION -------------------------------------------- 12- 2

TROUBLESHOOTING ------------------------------------------------- 12- 2

COOLING SYSTEM TESTING --------------------------------------- 12- 4

RADIATOR -------------------------------------------------------------- 12- 4

WATER PUMP ---------------------------------------------------------- 12- 9

THERMOSENSOR ------------------------------------------------------ 12-15

THERMOSTAT---------------------------------------------------------- 12-16

Summary of content (18 pages)

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12. COOLING SYSTEM Bet & Win 250 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.
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12. COOLING SYSTEM Bet & Win 250 SPECIFICATIONS Radiator cap relief pressure 0.9±0.15kg/cm_ 80±2℃ 90℃ 3.5_ 4.5mm Begins to open Full-open Valve lift Thermostat temperature 825cc Total system 1165cc Radiator: Reserve tank: 340cc Coolant capacity COOLANT GRAVITY Temp. ℃ Coolant concentration 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 0 5 10 15 20 25 30 35 40 45 50 1.009 1.018 1.028 1.036 1.045 1.053 1.063 1.072 1.080 1.086 1.095 1.100 1.009 1.107 1.027 1.035 1.044 1.051 1.062 1.070 1.
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12. COOLING SYSTEM Bet & Win 250 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 Tester ＊ Apply water to the cap sealing surface before testing. Radiator Cap Relief Pressure: 0.9±0.15kg/cm_ Radiator Cap Install the radiator tester onto the radiator and apply specified pressure to it. It must hold specified pressure for at least six seconds.
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12. COOLING SYSTEM Bet & Win 250 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.
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12. COOLING SYSTEM Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. Bet & Win 250 Fan Motor Wire Coupler Thermostatic Switch Thermostatic Switch Wire Radiator Remove the two bolts and two nuts on the radiator. Nuts Bolts Fan/Shroud RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan/shroud from the radiator.
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12. COOLING SYSTEM Bet & Win 250 Battery Check fan motor by battery. Fan Motor CHECK THERMOSTATIC SWITCH When coolant temperature lower then 85~90℃ the thermostatic switch OFF. When coolant temperature over 85~90℃ the thermostatic switch ON. Thermostatic Switch Bolts Install the fan shroud on the radiator with the four bolts.
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12. COOLING SYSTEM Bet & Win 250 Radiator RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Nuts Bolts . Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire and fan motor wire couplers. Upper Hose Thermostatic Switch Wire Lower Hose Overflow Tube Connect the overflow tube and secure with the tube clamp. Fill the radiator with coolant. (!3-9) Connect the vent tube to the radiator filler.
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12. COOLING SYSTEM Bet & Win 250 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. Water Pump Outlet Hose WATER PUMP/IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose.
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12. COOLING SYSTEM Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Bet & Win 250 Bolts Water Pump Cover Impeller (Left Hand Threads) Remove the water pump impeller. ＊ The impeller has left hand threads. Inspect the mechanical (water) seal and seal washer for wear or damage. Mechanical Seal ＊ The mechanical seal and seal washer must be replace as a set.
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. COOLING SYSTEM Bet & Win 250 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the eight bolts attaching the right crankcase cover. Water Pump Assembly Remove the water pump bearing snap ring from the water pump assembly. Remove the water pump shaft and inner bearing. Water Pump Assembly Snap Ring Inner Bearing Water Pump Shaft Water Pump Assembly Remove the water pump shaft outer bearing.
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12. COOLING SYSTEM MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Bet & Win 250 Water Pump Assembly Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver. Mechanical Seal Driver ＊ Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal.
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12. COOLING SYSTEM Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Bet & Win 250 Snap Ring Water Pump Shaft Inner Bearing Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten the eight bolts to secure the right crankcase cover.
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12. COOLING SYSTEM Install the impeller onto the water pump shaft. Torque: 9.8_ 13.7N-m Bet & Win 250 Impeller (Left Hand Threads) ＊ The impeller has left hand threads. Install the two dowel pins and a new gasket. Dowel Pins Water Pump Cover Install the water pump cover and tighten the 4 bolts. Torque: 7.8_ 11.
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12. COOLING SYSTEM Bet & Win 250 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 through the sensor as the water heats up.
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12. COOLING SYSTEM THERMOSTAT Bet & Win 250 Thermostat Bolt 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. Remove the mounting bolt and the thermostat housing from the cylinder head. Water Hose Remove the two bolts and separate the thermostat housing halves.
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12. COOLING SYSTEM THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation. Technical Data Begins to open Full-open Valve lift Bet & Win 250 Thermostat Thermometer 80±2℃ 90℃ 3.5_ 4.5mm ＊ • Do not let the thermostat touch the pan O-ring as it will give a false reading. • Replace the thermostat if the valve stays open at room temperature.