KYMCO People Manuale utente

PEOPLE/PEOPLE S 250

By KWANG YANG Motor Co., Ltd.

First Edition, Jan 2006

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

4122-LLJ3/LDH1-S00

PEOPLE/PEOPLE S 250

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO

People/People s 250.

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 13 give

instructions for disassembly, assembly

and adjustment of engine parts.

Section 14 is the removal/ installation

of chassis. Section 16 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

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS/V-

BELT

FINAL REDUCTION

A.C. GENERATOR/STARTER

CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL SYSTEM/CARBURETOR/FUEL

PUMP FUEL TANK

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT/

THERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

The information and contents included

in this manual may be different from the

motorcycle in case specifications are

changed.

CHASSIS

ELECTRICAL

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

PEOPLE/PEOPLE S 250

________________________________________________________________________________

GENERAL INFORMATION

________________________________________________________________________________

SERIAL NUMBER------------------------------------------------------------------------------------1-1

SPECIFICATION -------------------------------------------------------------------------------------1-2

SERVICE PRECAUTIONS-------------------------------------------------------------------------1-4

TORQUE VALUES-----------------------------------------------------------------------------------1-8

SPECIAL TOOLS-------------------------------------------------------------------------------------1-9

LUBRICATION POINTS -------------------------------------------------------------------------- 1-10

CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-12

WIRING DIAGRAM--------------------------------------------------------------------------------------------- 1-20

TROUBLESHOOTING ---------------------------------------------------------------------------- 1-22

1. GENERAL INFORMATION

1-1

PEOPLE/PEOPLE S 250

SERIAL NUMBER

Location of Engine Serial Numbe

Location of Frame Serial Numbe

1. GENERAL INFORMATION

1-2

PEOPLE/PEOPLE S 250

SPECIFICATIONS

Name & Model No. BC50AA

Motorcycle Name & Type PEOPLE 250

Overall length 2130mm

Overall width 750mm

Overall height 1170mm

Wheel base 1430mm

Engine type Water cooled 4-stroke,

OHC engine

Displacement 251/249.1cc

Fuel Used 92# nonleaded

gasoline

1 person (55kg) Front wheel 86

weight (kg) Rear wheel 127

Total 213

2 person (110kg) Front wheel 93

weight(kg) Rear wheel 175

Total 268

Front wheel 110/70-16 52P

Rear wheel 140/70-16 65P

Ground clearance 140mm

Perform- Braking distance (m) 4.0m/30km/hr

ance Min. turning radius 2350mm

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustionchambertype Semi-sphere

Valve arrangement O.H.C.

Bore x stroke (mm) 72.7 x 60

Compression ratio 10.3:1

Compression pressure

(kg/cm²)15±2

Max. output (ps/rpm) 18.3/7000

Max. torque (kg.m/rpm) 2.0/5500

BTDC -8°

Port Intake ABDC 42°

timing BBDC 33°

Exhaust ATDC 1°

Valve Intake 0.1

clearance (cold) Exhaust 0.1

Idle speed (rpm) 1700±100rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wet

Fuel capacity 8.5 liters

Type CVK

Piston dia. 30

Venturi dia. 30 equivalent

Throttle type Butterfly type

Type Full transistor igniter

Ignition timing Repeatedly

Contact breaker Non-contact point type

Spark plug NGK

DPR7EA-9

Spark plug gap 0.7mm

Battery Capacity 12V10AH

Clutch Type Dry multi-disc clutch

Type Non-stage

transmission

Operation Automatic centrifugal

Type

Type Two-stage reduction

Reduction 1st 0.83~2.2

ratio Fina

l8.72

Front 1.75

Tire pressure

(kgf/cm²)Rear 2.0

Turning Left 45°

angle Right 45°

Front Disk brake

Brake system

type Rear Disk brake

Sus

ension Front Telescope

type Rear Double swing

Shock absorber Front Telescope

type Rear Double swing

Frame type Under bone

Tires

ine

Lubrication

stem

Fuel S

stem

Carburetor

Electrical Equipment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving

Device Damping

Device

1. GENERAL INFORMATION

1-3

PEOPLE/PEOPLE S 250

SPECIFICATIONS

Name & Model No. BA50AA

Motorcycle Name & Type PEOPLE S 250

Overall length 2140mm

Overall width 750mm

Overall height 1370mm

Wheel base 1480mm

Engine type Water cooled 4-stroke,

OHC engine

Displacement 251/249.1cc

Fuel Used 92# nonleaded

gasoline

1 person (55kg) Front wheel 86

weight (kg) Rear wheel 127

Total 213

2 person (110kg) Front wheel 93

weight(kg) Rear wheel 175

Total 268

Front wheel 110/70-16 52P

Rear wheel 140/70-16 65P

Ground clearance 145mm

Perform- Braking distance (m) 4.0m/30km/hr

ance Min. turning radius 2350mm

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustionchambertype Semi-sphere

Valve arrangement O.H.C.

Bore x stroke (mm) 72.9 x 60/72.7 x 60

Compression ratio 10.3:1

Compression pressure

(kg/cm²)15±2

Max. output (ps/rpm) 20.1/7500

Max. torque (kg.m/rpm) 2.1/6500

BTDC 9°

Port Intake ABDC 40°

timing BBDC 42°

Exhaust ATDC 7°

Valve Intake 0.1

clearance (cold) Exhaust 0.1

Idle speed (rpm) 1600±100rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wet

Fuel capacity 10.0 liters

Type CVK

Piston dia. 30

Venturi dia. 30 equivalent

Throttle type Butterfly type

Type Full transistor igniter

Ignition timing Repeatedly

Contact breaker Non-contact point type

Spark plug NGK

DPR7EA-9

Spark plug gap 0.7mm

Battery Capacity 12V10AH

Clutch Type Dry multi-disc clutch

Type Non-stage

transmission

Operation Automatic centrifugal

Type

Type Two-stage reduction

Reduction 1st 0.83~2.2

ratio Fina

l8.72

Front 1.75

Tire pressure

(kgf/cm²)Rear 2.0

Turning Left 45°

angle Right 45°

Front Disk brake

Brake system

type Rear Disk brake

Sus

ension Front Telescope

type Rear Double swing

Shock absorber Front Telescope

type Rear Double swing

Frame type Under bone

Tires

ine

Lubrication

stem

Fuel S

stem

Carburetor

Electrical Equipment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving

Device Damping

Device

1. GENERAL INFORMATION

1-4

PEOPLE/PEOPLE S 250

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.

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.

1. GENERAL INFORMATION

1-5

PEOPLE/PEOPLE S 250

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.

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.

Confirm

Capacity

1. GENERAL INFORMATION

1-6

PEOPLE/PEOPLE S 250

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.

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！

No Contact

Do not press or

squeeze the wire

1. GENERAL INFORMATION

1-7

PEOPLE/PEOPLE S 250

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.

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

Special

Engine Oil

Grease

Gear Oil

＊

Do you understand

the instrument？

Remove Rust！

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