Kymco MO Super 950 Service Manual - chap 11 (raffreddamento)

11. COOLING SYSTEM

11-0

SUPER 9 50

11

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COOLING SYSTEM

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SERVICE INFORMATION -------------------------------------------- 11- 1
TROUBLESHOOTING ------------------------------------------------- 11- 1
RADIATOR -------------------------------------------------------------- 11- 3
WATER PUMP ---------------------------------------------------------- 11- 6
THERMOSENSOR ------------------------------------------------------ 11-12
THERMOSTAT---------------------------------------------------------- 11-13

11

11. COOLING SYSTEM

11-1

SUPER 9 50

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_ 13.72N-m
Water pump cover bolt 7.84_ 11.76N-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

11. COOLING SYSTEM

11-2

SUPER 9 50

SPECIFICATIONS

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

05101520253035404550

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.

11. COOLING SYSTEM

11-3

SUPER 9 50

RADIATOR

RADIATOR INSPECTION

Remove the front upper cover. (!2-3)
Remove the front lower cover. (!2-3)

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. (!3-10)
Loosen the hose band and disconnect the
upper and lower hose from connect the
radiator and reserve tank.

Upper Hose

Reserve Tank

Front Upper Cover

Front Lower Cover
Radiator

Lower Hose

11. COOLING SYSTEM

11-4

SUPER 9 50

Loosen the hose band and disconnect the
upper hose from the radiator.

Loosen the hose band and disconnect the
lower hose from the radiator.

Remove the two bolts and the radiator.

Radiator

Upper Hose

Lower Hose

Radiator

Bolts

11. COOLING SYSTEM

11-5

SUPER 9 50

RADIATOR BRACKET REMOVAL/
INSTALLATION

Remove the two nuts to remove the radiator
bracket.
The installation sequence is the reverse of
removal.

RADIATOR INSTALLATION

Install the radiator on the radiator bracket
with the two bolts.

Connect the upper and lower hoses and
secure them with hose bands.

Nuts

Radiator

Radiator Bracket

Lower Hoses

Bolts

Upper Hoses

11. COOLING SYSTEM

11-6

SUPER 9 50

Reinstall the upper and lower hoses, make
sure the bands are secured.

Fill the reserve tank with coolant. (!3-10)
Check for coolant leaks.
Install the front upper and lower 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.

.

Air Duct

Right Crankcase Cover

Upper Hose

Telltale Hole

Water Pump

Lower Hose

Reserve Tank
Reserve Tank

11. COOLING SYSTEM

11-7

SUPER 9 50

WATER PUMP/IMPELLER REMOVAL

Remove the engine from the frame. (!5-2)

Remove the three bolts and the water pump
cover, gasket and two dowel pins.

Remove the water pump impeller.

Impeller
Water Pump Cover

Bolts

The impeller has left hand threads.

＊

11. COOLING SYSTEM

11-8

SUPER 9 50

Bolts

Water Pump Assembly

Water Hose
Bolts

Water Pump Assembly

Inspect the mechanical (water) seal and seal
washer for wear or damage.

WATER PUMP SHAFT REMOVAL

Disconnect the water hose from the right
crankcase cover.
Remove the two timing cap bolts and the
timing cap.
Remove the three bolts attaching the water
pump assembly.
Remove the water pump assembly and
dowel pins.

Remove the water pump shaft from the
water pump assembly.

Mechanical Seal

Water Pump Shaft
Impeller

Seal Washer (Porcelain)

The mechanical seal and seal washer
must be replace as a set.

＊

11. COOLING SYSTEM

11-9

SUPER 9 50

Water Pump Assembly

WATER PUMP BEARING/
MECHANICAL SEAL REMOVAL

Remove the water pump shaft inside
bearing.

Drive the mechanical seal out of the water
pump assembly from the outer.

Remove the water pump shaft outer
bearing.

Water Pump Assembly

Mechanical Seal (Water Seal)

Outer Bearing

Inside Bearing

11. COOLING SYSTEM

11-10

SUPER 9 50

WATER PUMP BEARING/
MECHANICAL SEAL INS TALLATION

Drive a new water pump shaft

outer bearing
into the water pump assembly from the
inside.

Drive a new water pump shaft

inside
bearing into the water pump assembly from
the inside.

Drive in a new mechanical seal using a
mechanical seal driver.

Install the water pump shaft into the water
pump assembly.

Water Pump Assembly

Water Pump Shaft

Inside Bearing

Mechanical Seal

Apply sealant to the right crankcase
cover fitting surface of a new mechanical
seal and then drive in the mechanical seal.

＊

Outer Bearing

11. COOLING SYSTEM

11-11

SUPER 9 50

Install the dowel pins and then install the
water pump assembly to the right
crankcase.
Tighten the three bolts to secure the water
pump assembly.
Install the two timing cap bolts and the
timing cap.

WATER PUMP/IMPELLER
INSTALLATION

When the mechanical seal is replaced, a new
seal washer must be installed to the
impeller.
Install the impeller onto the water pump
shaft.

Torque: 9.8_ 13.72N-m

Install the two dowel pins and a new
gasket.

Install the water pump cover and tighten
the three bolts.
Torque: 7.84_ 11.76N-m

Water Pump Assembly

Water Pump Cover

Bolts

Mechanical Seal

Dowel Pins

Seal Washer (Porcelain)

The impeller has left hand threads.

＊

When installing the water pump
assembly, aligning the tab on the water
pump shaft with the groove on the A.C.
generator nut.

＊

Impeller

Bolts

11. COOLING SYSTEM

11-12

SUPER 9 50

Thermosenso

Thermomete

THERMOSENSOR

THERMOSENSOR REMOVAL

Remove the seat, met-in box and frame
body cover.
Drain the coolant.
Disconnect the thermosensor wire.
Remove the thermosensor.

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.

Temperature(
℃ )

5080100

120

Resistance(W)

1545227

16

THERMOSENSOR INSTALLATION

Apply 3-BOND No. 1212 sealant or
equivalent to the cylinder head threads and
install it into the thermostat housing.
Connect the thermosensor wire.
Fill the reserve tank with coolant. (!3-10)
Install the frame body cover, met-in box and
seat. (!2-3)

Thermosensor

Thermosensor Wire
Thermosensor

Be sure to bleed air from the cooling
system.

＊

11. COOLING SYSTEM

11-13

SUPER 9 50

THERMOSTAT

THERMOSTAT REMOVAL

Remove the seat, met-in box and frame
body cover.
Drain the coolant.
Disconnect the water hose from the
thermostat housing.

Remove the two screws and separate the
thermostat housing cover .

Remove the thermostat from the thermostat
housing.

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

80±2℃

Full-open

90℃

Valve lift

3.5_ 4.5mm

Thermostat Housing

Water Hose
Thermostat

Screws

Thermostat

Thermometer

• Do not let the thermostat touch the pan

as it will give a false reading.

• Replace the thermostat if the valve

stays open at room temperature.

•Test the thermostat after it is opened

for about 5 minutes and holds the
temperature at 70℃ .

＊

11. COOLING SYSTEM

11-14

SUPER 9 50

THERMOSTAT INSTALLATION

The installation sequence is the reverse of
removal.

Fill the cooling system with the specified
coolant. (!3-10)

Thermostat Housing