Home

Kymco People 250 Service Manual

Contents

1. 4 5 OIL PUMP ASSEMBLY 4 5 OIL PUMP 4 6 4 0 dO KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE S 250 LUBRICATION SYSTEM Rocker Arm Shaft 4 1 GQ KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed in the frame e Drain the coolant before starting any operations e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line e Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After the oil pump is installed check each part for oil leaks SPECIFICATIONS OIL PUMP Standard mm Service Limit mm Outer rotor to pump body clearance 0 15 0 20 Rotor end to pump body clearance 0 04 0 09 ENGINE OIL Engine Oil Capacity At disassembly 1 1 liter change 0 9 liter Recommended Oil SAE15W40 API SJ TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption e Oil level too low e Oil leaks e Clogged oil filter or oil passage e Worn piston rings e Faulty oil pump e Worn valve guide e Worn valve guide seal
2. 14 1 SERVICE INFORMATION 14 2 TROUBLESHOOTING F 14 3 STEERING HANDLE BAR 14 4 FRONT 14 5 FRONT BRAKE 14 8 FRONT SHOCK ABSORBER 14 14 FRONT FORK eme 14 15 14 0 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE ERONT SHOCK ABSORBER FRONTFORK PEOPLEIPEOPLE 5 250 SCHEMATIC DRAWING 14 1 KYMCC 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e Remove the motorcycle frame covers before removing the front wheel steering handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Axle shaft runout ee Frontwheelrimmunou Ba Front wheel runout Axa _ 20 Brake disk runout 030 TORQUE VALUES Steering stem lock nut 40 50N m Steeri
3. eee LERNEN III MILL lun Z Lu Sd Pilot Screw Tcp L Main Jet Bypass Jet Slow Jet Low amp Middle Speed Supplementary Fuel Inlets 13 3 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FUEL PUMP CONSTRUCTION The fuel pump adopted for this model is a fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve FUEL PUMP CONSTRUCTION Lower Cover Big Spring Outlet Valve Spring Washer Comp Valve opring 1 d Upper Cover 13 4 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e When working with gasoline keep away from sparks and flames e Note the locations of O rings when disassembling and replace them with new ones during assembly e Before float chamber disassembly drain the residual gasoline from the float chamber e Do not try to disassemble the auto bystarter e When assembling the vacuum chamber and air cut off valve be careful not to damage the diaphragms e All cables fuel lines and wires must be routed and secured at correct lo
4. 19 6 l l ll l ia 19 7 19 8 SIDE STAND SWIT 19 8 HEATER WIRING DIAGRAM qq 19 9 19 0 19 SWTCHES HORNFUEL UNIT THERMOSTATIC SWITCH dO KYMCO TEMPERATURE GAUGEANS TRUMENTS LIGHTS PEOPLE PEOPLE S 250 ELECTRICAL EQUIPMENT LAYOUT Starter Button Engine Stop Switch Headlight Switch Stop Switches Ed Ignition Switch Dimmer Switch Turn Signal Switch Horn Button Thermostati Fuel Unit Heater Control Unit 19 1 19 SWTCHESHORNFUEL UNIT THERMOSTATIC SWITCH QC KYMCO TEMPERATURE GAUGE NSTRUMENTSILIGHTS PEOPLE PEOPLE 5 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e After installation of each switch a continuity check must be performed continuity check can usually be made without removing the part from the motorcycle TESTING INSTRUMENT Electric tester TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON correctly e Burned bulb e Faulty switch e Faulty temperature gauge e Faulty thermosensor e Poorly connected broken or shorted wire e Broken or shorted wire between temperature gauge and thermosensor Fuel gauge pointer does not move or register correctly e Faulty fuel gauge e Faulty fuel unit e Poorly connected wire between fuel gauge and fuel unit e Fuse burned out SPECIFICATIONS Fuse Headlight bulb Turn signal l
5. S 250 Handlebar Rear Cover HANDLEBAR REAR COVER REMOVAL Remove handlebar front cover 22 3 Remove front cover 22 4 Remove the bolt on the handlebar rear cover Remove the two screws attaching frame i 7 Screw Screw Disconnect all of the wire connectors Speed Wire couplers and the speedometer cable Remove the handlebar rear cover i un kv L NI m 1 1 a 4 Wire Connectors Wire Connectors FRONT COVER REMOVAL Remove the bolt on the front of the front Cover Remove the six screws attaching the leg shield Screws 2 5 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS S 250 Remove the four screws attaching the front under cover Disconnect the front cover from leg shield and front under cover Screws Disconnect all of the wire couplers Wire Couplers Remove the front cover w Bolts Bolts mr N P i a LH L m m j i FRONT FENDER REMOVAL Remove the two screws that combine front fender A with the front fender B Remove the two screws under the front fender A Remover the front fender A Remover the bolt under front fender B that combine front fender B with frame Remover the front fender B dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 RIGHT LEFT SIDE COVER REMOVAL
6. m QC KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE S 250 STARTER CLUTCH INSPECTION Refer to pages 10 4 and 10 5 for the starter clutch removal inspection and installation STARTER RELAY INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire terminal and ground There should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire N Yellow Red Wire Starter Relay OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal if there is continuity 18 6 19 SWITCHESHORNFUELUNITTHERMOsTATICSWwicH QO KYMCO TEMPERATURE GAUGEINSTRUMENTSILIGHTS PEOPLE PEOPLE S 250 SWITCHES HORN FUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGE INSTRUMENTSILIGHTS ELECTRICAL EQUIPMENT LAYOUT 19 1 SERVICETNEORIMA TION ec 19 2 TROUBLESHOOTING 19 2 SWITCHES MU 19 3 N PESTS u eee pe ieu DUE 19 5 FN 19 5 THERMOSTATIC SW CH cic 19 6 TEMPERATURE METER
7. 12V 10AH BATTERY l STARTER MOTOR RH RR WINKER 12V 10W Gr S G BR RF TAIL ST OF LIGHT 12V S 21 LICENCE LIGHT 12V SW a LH RR WINKER 12V 10V LR FRAME EARTH GIL PRESSURE SW 1 20 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 WIRING DIAGRAM PEOPLE S 250 HOH 15 ORIS GIC a3 AIO HIA MAA F E r H 2 r mz Hee ete EEE L I II I j LLI I c lt il H HH gt L III IT 3 fae 5 RH ga 8 84 m c gf 2 5 A 2 An ds 2 B 031 1 21 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment justment Symptom carburetor by Check if fuel reaches drain screw Fuel reaches carburetor Probable Cause fuel tank Clogged carburetor fuel inlet tube vacuum tube or fuel tube GClogged auto fuel valve Clogged float oil passage GClogged fuel tank cap breather hole Clogged fuel strainer Clogged fuel filter Faulty fuel pump Fuel does not reach c
8. When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft Water Pump Assembly 12 12 12 COOLING SYSTEM PEOPLE PEOPLE S 250 Impeller Mechanical Seal WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Seal Washer Porcelain Impeller Left Hand Threads Install the impeller onto the water pump shaft Torque 9 8 13 7 The impeller has left hand threads P wy ao K 6 2 Dowel Pins M Cw vt lt aN uum Install the two dowel pins and new gasket TER Install the water pump cover and tighten the 4 bolts Torque 7 8 11 8 B l P E Water Pump Cover 12 13 12 COOLING SYSTEM THERMOSENSOR THERMOSENSOR REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender cover A 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 C 50 80 100 120 154 THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads and install it into the thermostat housing Connect the thermosensor wire
9. e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done an emergency e Remove the battery from the motorcycle for charging e When replacing the battery do not use a traditional battery e When charging check the voltage with an electric tester SPECIFICATIONS Voltage Battery 20 C 1 62 50 Regulator Rectifier Limit voltage 14 5 0 5V TESTING INSTRUMENTS TORQUE VALUES Ammeter Pulser coil bolt 4 9N m Electric tester YF 3501 Coil lock bolt 8 8N m Tachometer Flywheel nut 08 8N m 16 2 dO KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 250 SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING No power Intermittent power e Dead battery e oose battery cable connection e Disconnected battery cable e Loose charging system connection e Fuse burned out e oose connection or short circuit in e Faulty ignition switch ignition system Low power Charging system failure e Weak battery Loose broken or shorted wire or connector e oose battery connection e Faulty regulator rectifier e Charging system failure e Faulty A C generator e Faulty regulator rectifier 16 3 dO KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 250 Screw BATTERY Remove the seat and met in box 22 3 Remove the battery cover screw and the battery cover Remove the battery First disconnect the battery negative cabl
10. 14 12 Install the front fender cover A and B 22 6 Install the throttle grip and the right and left handlebar switches c 14 5 Install the right and left brake master cylinders 14 5 14 16 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER F FOPFLE FEOFLE 5 250 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SCHEMATIC DRAWING 15 1 SERVICE INFORMATION m roii iretur 15 2 TROUBLESHOOTING l e UE 15 2 REAR DRAKE u LIE I eee 15 3 HEAR FORK _____ _ __ ___ _ __ __ 15 6 REAR 15 7 REAR SHOCK ABSORBER 15 7 15 0 QC KYMCO PEOPLE PEOPLE S 250 15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SCHEMATIC DRAWING 15 1 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER F FOPFLE FEOFLE 5 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Standard mm Rear wheel rim runout Rear brake disk thickness 485 36 Rear brake disk runout o j 030 2 Rear brake master cylinder 1 0 27 00 27 05 Rear brake master cylinder piston O D 26 95 26 90 TORQUE V
11. 5 1 ENGINE REMOVAL 5 2 ENGINE INSTALLATION 5 5 ENGINE HANGER REMOVAL 5 4 5 0 QC KYMCO 5 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e A floor jack or other adjustable support is required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal e Use shop towels to protect the motorcycle body during engine removal e Drain the coolant before removing the engine e After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks e Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil capacity at disassembly 1 1 liter TORQUE VALUES Rear shock absorber upper mount bolt 35 45N m Rear shock absorber lower mount bolt 35 45N m Rear axle nut 110 130N m Engine hanger bolt frame side 45 55N m Engine hanger bolt ENG side 45 55N m Rear caliper holder bolt 29 35N m Exhaust muffler pipe nut 18 22N m Exhaust muffler bolt 32 38N m Rear fork bolt 29 35N m KYMCO 5 ENGINE REMOVAL INSTALLATION PE
12. Oil contamination e Oil not changed often enough e Faulty cylinder head gasket Loose cylinder head bolts dO KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE S 250 Oil Dipstick ENGINE OIL OIL FILTER lt q e Place the scooter upright on level ground for engine oil level check Run the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level is near the lower level fill to the upper level with the recommended engine oil OIL CHANGE X e he engine oil will drain more easily while the engine is warm E Remove the oil drain bolt located at the left side of the engine to drain the engine oil After the oil has been completely drained install the aluminum washer and tighten the oil drain bolt Torque 14 7 Pour the recommended oil through the oil filler hole OIL FILTER SCREEN Drain the engine oil Remove the oil filter screen cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and filter screen cap Torque 12 7 Recommended Oil SAE15W40 SJ Filter Screen Cap Oil Capacity Sprin At disassembly 1 1 liter WD s k At change 0 9 liter w p
13. PEOPLE PEOPLE S 250 By KWANG YANG Motor Co Ltd First Edition Jan 2006 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 LLJ3 LDH1 S00 This Service Manual describes the technical features and servicing procedures for the KYMCO People People s 250 oection 1 contains the precautions for all operations stated in this manual Read them carefully before any operation 15 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 oections 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 The information and contents included in this manual may be different from the motorcycle in case specifications are changed KWANG YANG MOTOR LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION GQ KYMCO
14. r 4 S gt Location of Engine Serial Number 1 1 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 SPECIFICATIONS Paper element wet 8 5 liters Overall width Wheel base 1 Displacement 251 249 1cc Fuel Used 92 nonleaded gasoline Contact breaker Non contact point type MEA 9 park plug gap 0 2 person 110kg Front wheel Battery Capacity 12V10AH 1 person 55kg Front wheel 86 weight kg jueuudinb3 6e21129 3 uoniuD weight kg Rear wheel 175 Clutch Type Dry multi disc clutch Type Non stage transmission Tires Front wheel 110 70 16 52P Rear wheel 140 70 16 65P Jeoc uols SILUSUBL Perform Braking distance m 4 0m 30km hr ance Min turning radius 2350mm Two stage reduction Starting system starting motor ype Gasoline 4 stroke JeMog 1895 uononpeM Operation Automat rifugal ype Reduction 1st 0 83 2 2 ratio F Cylinder arrangement Single cylinder Combustion chamber type Tire pressure Valve arrangement 29 Bore x stroke mm 72 7 x 60 ic cent T ear Telescope o gt c 2 Q 216 S rme 10 3 1 mr Compression pressure w kg cm Brake system ron type Max output ps rpm 18 3 7000 Max torque kg m rpm 2 0 5500 Suspension ron type ear Double swing 8 Front
15. 20 EXHAUST EMISSION CONTROL KYMCO SYSTEM PEOPLE PEOPLE S 250 EXHAUST EMISSION CONTROL SYSTEM SCHEMA TIC DRAWING uniones 18 1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION 18 1 TROUBLESHOO TING ciis pERSSSNSMISCEA uuu 18 2 SERVICE INFORMATION 18 2 SECONDARY AIR CLEANER NAM 18 3 AIR INJECTION CUT OFF VALVE A I C V 18 3 iil 18 4 20 0 20 EXHAUST EMISSION CONTROL KYMCO SYSTEM SCHEMATIC DRAWING PEOPLE PEOPLE S 250 Air Injection Vacuum Cut off Valve Secondary Secondary Air Air Cleaner Cleaner Into Hole EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re combustion by means of exhaust pulsation so as to minimize the exhaust emission FUNCTION Secondary Air Cleaner Air Injection Cut off Valve Reed Valve Filter secondary air Prevent exhaust muffler noise and backfiring at sudden deceleration Control the secondary air inlet to reduce CO Function It filters the fresh
16. Double swing 1 1 BID 2 2 O gt Q oO o D m FP lt D AJ D Q ATDC Frame type Valve Intake 0 clearance cold Exhaust Wet sump Full flow filtration 1 1 liters Cooling Type Water cooling i Type 7 Fulltransistor igniter Engine type Type Full transistor igniter Ignition timing Repeatedly uoneouq 1 GENERAL INFORMATION SPECIFICATIONS gine yp OHC engine Displacement 251 249 1cc gasoline 1 person 55kg Frontwheel 96 weight kg weight kg Rear wheel 175 Front wheel Rear wheel Perform Braking distance m 4 0m 30km hr ance Min turning radius 2350mm 2 person 110kg Front wheel 10 3 Compression pressure Max output ps rpm 20 1 7500 Max torque kg m rpm 2 1 6500 clearance cold Exhaust Wet sump timing 8 0 2 Exhaust _ 1 1 uoneouqn QC KYMCO PEOPLE PEOPLE S 250 Fuel capacity 10 0 liters eid 9 Spark plug gap 0 7mm Battery Capacity 12V10AH Clutch Type Dry multi disc clutch Type Non stage transmission Automat rifugal ulejs S jen 1 jueuudinb3 e21129 3 uoniuD Jeoc uols SIUJSUEJ Two stage reduction JeMog Jeoc uononpeM ic cent T 1st ront SU ear ear OU Eon a ear Shock absorber Front type Double swi
17. Dowel Pins Right Crankcase Cover SR A 1 mcm L o Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Connect the water hoses to the right crankcase cover and water pump cover Add the recommended engine oil 254 3 Fill the cooling system with the specified coolant 23 9 e Be sure to bleed air from the water jacket after filling the coolant 10 9 QC KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE S 250 CRANKCASE CRANKSHAFT SCHEMATIC 11 1 SERVICE 11 2 TROUBLESHOOTING 11 2 CRANKCASE 11 3 CRANKSHAFT INSPECTION 11 4 CRANKCASE ASSEMBLY pel US ee 11 5 11 0 dO KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE 5 250 SCHEMATIC DRAWING A 92 1 2 9 gt E P N je DDR Ep E s MM NES SS Kad a ge B 11 1 dO KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE S 250 SERVICE INFORMATION G
18. E T Pu lt gt Breather Hose Cylinder Head Cover rk Plug Cap am Remove the screw attaching rear fender C Remove the three bolts on the air cleaner r Fi Bolts Remove the air cleaner and disconnect breather hose from transmission case cover Remove the right left rear shock absorber upper mount bolts Remove the left rear shock absorber lower mount bolts Rear Shock Absorber Y Upper Mount Bolts A Breather Hose Lower Mount Bolts 5 3 KYMCO 5 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 Remove the left rear shock absorber Remove the right rear shock absorber lower mount bolts Remove the right rear shock absorber Remove the rear wheel nut Disconnect the rear brake fluid tube from the guide Remove the four bolts on the rear fork to remove rear brake caliper and rear fork Remove the bolt to disconnect the engine negative cable Remove the engine mounting nut i 1 3 J L i F 1 A J es 4 d 4 a Y k 4 Engine Mounting Nut Remove the two nuts of the right and left step bar Remove the right and left step bar Step Bar 5 4 lt Step Bar GQ KYMCO 5 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 Remove the engine mounting bolt and pull out the engine ENGINE INSTALLATION
19. Fill the radiator with coolant 43 9 Install the center cover met in box and seat 22 3 Be sure to bleed air from the cooling system KYMCO PEOPLE PEOPLE S 250 Thermosensor T 1 Je m a Ex t e V A n 8 Thermosensor Thermos ensor al 7 if 4 7 2 yn _ 1 ia e Thermosensor Wire 12 14 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 THERMOSTAT Water Hose Thermostat __ Bolt THERMOSTAT REMOVAL 25 4 Remove the met in box carrier Remove the body cover center cover and rear fender cover A 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 gt thermostat housing Air Vent Tube Remove the mounting bolt and the thermostat housing from the cylinder head Thermosensor Wire Bolts Remove the two bolts and separate the thermostat housing halves Thermostat Thermostat Remove the thermostat from the thermostat housing 12 15 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 80 2 C Full open 90 C Valve lift 3 5 4 5mm e Do not let the thermostat touch the pan as it will give a false rea
20. Overflow Tube Fan Moto Upper Hose Thermostatic Switch r Wire Coupler Loosen the hose band and disconnect the upper hose and lower hose from the radiator Disconnect the thermostatic switch wire coupler Thermostatic Switch Wire Lower Hose 12 5 dO KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE 5 250 Radiator Remove the two bolts and two nuts on the radiator Remove the radiator erer RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan shroud from the radiator Check fan motor by battery Fan Motor 12 6 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 88 92 C the thermostatic switch OFF When coolant temperature over 88 92 the thermostatic switch ON Radiator Install the fan shroud on the radiator with p the three bolts 12 7 QC KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 Nuts Radiator RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts Bolts Upper Hose Thermostatic Switch Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire Thermostatic Switch Wire Lower Hose Connect the fan motor wire couplers Air Vent Tube Connect the overflow tube and secure with the tube clamp Fill the radiat
21. PEOPLE PEOPLE S 250 TABLE OF CONTENTS GENERAL INFORMATION 1 Fa CYLINDER WEADNALVES DRIVE AND DRIVEN PULLEYS V BELT FINAL REDUCTION A C GENERATOR STARTER 1 CLUTCH CRANKCASE CRANKSHAFT COOLING SYSTEM FUEL SYSTEM CARBURETOR FUEL 4 PUMP FUEL TANK STEERING HANDLEBAR FRONT T WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK m 2 m I gt o REAR BRAKE REAR FORK REAR 15 WHEEL REAR SHOCK ABSORBER mm BATTERY CHARGING SYSTEM QU IGNITION SYSTEM STARTING SYSTEM ISWITCHES HORN FUEL UNIT THERMO STATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 GENERAL INFORMATION SERIAL NUMBER uuu llu Dee 1 1 SPECIFICATION 1 2 SERVICE PRECADTIONS E 1 4 VALUE 1 8 SPECIAL TOOLS 25 2 nae 1 9 1 10 CABLE amp HARNESS ROUTING 1 12 WIRING AA ct TROUBLE SHOOTIN 1 22 QC KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 SERIAL NUMBER j 1 1 2 r j 2 ES E B 1 LA i F j gt a
22. Remove the front cover Remove the four screws attaching the leg shield low Disconnect the leg shield low with the cowl under cover The installation sequence is the reverse of removal Screws FLOOR FOOT REMOVE Remove the met in box Remove the body cover Remove the front cover Remove the leg shield cover and cowl under cover Remove the four bolts attaching the floor foot The installation sequence is the reverse of remove Blots Windshield WINDSHIELD REMOVAL Remove the three bolts attaching the front windshield out cover Remove the windshield out cover Remove the windshield 2 15 KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 Bolt HANDLEBAR COVER REMOVAL First remove the windshield Remove the four screws and two bolts attaching the handlebar rear cover Remove the handlebar rear cover The installation sequence is the reverse of removal NC ur Screws Remove the three nuts attaching the handlebar cover Remove the handlebar cover The installation sequence is the reverse of removal Handlebar Cover i Bolts AN BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom COVer Remove the bottom cover Bottom Cover EXHAUST MUFFLER REMOVAL Remove two lock nuts from joint in the exhaust muffler Remove the exhaust muffler two lock bolts to remove the exhaust muffler Remove the exhaust muffler joint pa
23. Remove the screw combine right left side cover with front under cover Remove the screw combine right left side cover with the floor board Remove the right left side cover Screws Bolts MET IN BOX AND REAR CARRIER REMOVAL Open the seat with key Remove two bolts and two nuts on the met in box Disconnect all of the wire couplers Remove met in box Remove three bolts and remove the rear carrier BODY COVER CENTER COVER REAR FENDER A REMOVAL Remove six screws on air cleaner cover Loosen band to remove air cleaner cover and disconnect air duct hose Band Air Duct Hose 2 7 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS __ PEOPLE PEOPLE S 250 Remove the met in box and rear carrier gt 2 6 Remove the four screws attaching the floor board Remove the two screws on the rear fender A Disconnect all of the wire couplers Remove the body cover center cover and rear fender A together FLOOR BOARD REMOVAL Remove the met in box and rear carrier gt 2 6 Remove the body cover center cover and rear fender A together 22 6 Remove right and left side cover 42 6 Remove the four bolts on the floor board Remove the floor board dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 FRONT UNDER COVER REMOVAL Screw Screw Remove the front cover 22 8 y P 4 Remove the right and left side cover 22 6 Remove the two screws that combine the front under cover w
24. Reverse the REMOVAL procedures Apply grease onto the O rings oil seals and bush ENGINE HANGER REMOVAL Remove met in box and carrier 22 6 Remove the body cover center cover and rear fender A together 22 6 Remove air cleaner 5 3 Remove the two nuts of the right and left step bar Remove the right and left step bar E Engine Mounting Bolt Remove the engine mounting nut and engine hanger bolt left side I i f T pr s T 3 ne z L i i I gill 4 T L 4 4 k P ie Ax Iw w lt f P i e i s E ey d X Engine Mounting Nut Remove the engine mounting bolt and engine hanger bolt right side Remove the starter motor 218 3 Remove the engine hanger f j m 1 lt P P E i E k o 1 20 Engine Mounting Bolt 5 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 Inspect the engine hanger bushings and stopper Bushing rubber for wear or damage INSTALLATION Reverse the REMOVAL procedures x Apply grease onto the bush 5 6 GQ KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE 5 250 CYLINDER HEAD VALVES SCHEMATIC DRAWING 6 SERVICE INFORMATION 6 2 TROUBLESHOOTING euer tiec 6 3 CYLINDER HEAD COVER 6 4 CAMSHA
25. e he freezing point of coolant mixture shall be 5 Clower than the freezing point of the riding area 12 3 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE 5 250 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 Apply water to the cap sealing surface before testing Radiator Cap Relief Pressure 0 9 0 15kg cm 2 Radiator Tester 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 Check the water hoses and connectors for leaks The test pressure should not exceed 1 05 kg cm Excessive pressure can damage the radiator and its hose connectors RADIATOR RADIATOR INSPECTION Remove the front cover 22 5 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 Radiator Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed air lf insects etc are clogging the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain the coolant 23 9 Disconnect the outlet tube of the reserve tank Remove the overflow tube clamp and disconnect the overflow tube Disconnect the air vent tube from the radiator filler Disconnect the fan motor wire coupler
26. 15 WINKER FR RR METER STARTER POSITION PHONE FUSE C 104 IGNITION IGN COIL AUTO B S FUSE D 10A FAN MOTOR FUSE E 15A HEAD LIGHT LUGGAGE BOX RH FR WINKER 12V FUSE ASS Y COMB Sw LUGGAGE 12V 1 7W LUGGAGE BOX LIGHT SW IGNITION UNIT GG V Y w bn w Ww orbs o SIDE STAND SW THROTTLE DC 12V POSITION POWER SENSOR FUEL AUTO ges UNIT BS p i G ty L v B Fa k w f 8 K ILLUMI 12V 1 7WW ILLUMI 12V 1 7W ILLUMI 12 1 7 FUEL METER TURN R 12V 3 TURM L 12v 24V HIGH BEAM 12V 1 7 MET IN 12V 1 GIL FILOT 12V 1 7 Re Ws BRIL DS Yn 28021 om eon cL BR GER W w 6 LG L 2 ig By L LO BEAM RELAY HI BEAM RELAY STOP SW HORN WINKER DIM PASSING SW HORN CONTROLER OIL LIGHT EL LH RR WINKER L EEN 12V DW THERMO UNIT MOTOR MAIN SW WIRING DIAGRAM PEOPLE 250 ror oto EE jen 5 Vy SSS ai c An GERO wN Y Y un ER G v W a 8 5 2 HEATER RESISTOR CONTROL HEATER 19 20 8W E CARBURETION PULSER 58 REG ASSY ACG LIGHTING SW SW START SW NEG Fus Oto TUBE SLACK ci FILLER CAP
27. 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 250 A C GENERATOR REMOVAL generator removal 210 3 generator installation 210 6 REGULATOR RECTIFIER INSPECTION Remove the met in box 22 6 Remove the regulator rectifier wire coupler Check the continuity between the wire terminals Normal Direction Continuity Probe Probe Probe Probe VOLTAGE REGULATION TEST Connect a voltmeter across the battery terminals Start the engine and gradually increase the engine speed The battery terminal voltage should be within 14 0 15 0V A C Generator Stator Pulser Coil Bolts Normal Direction Reverse Direction 16 6 GQ KYMCO 17 IGNITION SYSTEM PEOPLE PEOPLE S 250 IGNITION SYSTEM IGNITION SVSTENIEAY OUT 17 1 SERVICE INFORMATION uuu 17 2 TROUBLESHOOTING x 17 2 SPARK PLUC _ 17 3 IGNITION COIL INSPEC TON Eee 17 3 GENERATOPIINSPEGTION 17 4 IGNITION UNIT RESISTANCE INSPECTION 17 4 17 0 KYMCO 17 IGNITION SYSTEM PEOPLE PEOPLE 5 250 IGNITION SYSTEM LAYOUT Ignition Switch gt Ignition Unit ignition A C Generator Pulser Coil IGNITION CIRCUIT IGNITION UNIT 2 1 17 1 QC KYMCO 17 IGNITION SYSTEM PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e Check the i
28. 3 FRAME COVERS REMOVAL 2 4 12 EXHAUST MUFFLER REMOVAL 2 10 16 2 0 GQ KYMCO PEOPLE PEOPLE 5 250 2 EXHAUST MUFFLER FRAME COVERS SCHEMATIC DRAWING 2 1 O KYMCO PEOPLE PEOPLE S 250 2 EXHAUST MUFFLER FRAME COVERS PEOPLE S 250 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use care not to pull them by force because the cover joint claws may be damaged e Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler lock bolt 32 38N m Exhaust muffler joint lock nut 18 22N m TROUBLESHOOTING Noisy exhaust muffler e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power e Caved exhaust muffler e Clogged exhaust muffler e Exhaust muffler air leaks dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 FRAME COVERS REMOVAL RIGHT AND LEFT BACK MIRROR REMOVAL E Loosen the nut on the back mirror Remove the back mirror N Nuts HANDLEBAR FRONT COVER REMOVAL Remove one bolt on the handlebar front cover Remove the four screws attaching handlebar rear cover to separate from handlebar rear Cover Disconnect all of the wire connectors couplers Remove handlebar front cover dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS
29. A o Air Cleaner Noe23 R J R Sparkplug Clean at every 3000km and replace if necessary Brake system i piebet FE NEN NEN NEN Brake fluid Perform pre ride inspection daily Radiator coolant Replace every year or at every 10000km R Radiatorcore Radiatorcap Brakelever Brake shoe wear 0 Shock absorber e the interest of safety we recommend these items be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle GQ KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 Fuel Filter FUEL LINE FUEL FILTER Remove the right side cover Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Check for dirty or clogged fuel filter and replace with a new one if it is clogged e Do not smoke or allow flames or sparks in your working area THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6mm Remove the met in box Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and turning t
30. DRIVE AND DRIVEN PULLEYS V BELT PEOPLE PEOPLE S 250 Ramp Plate Install the ramp plate Insert the drive pulley collar into the movable drive face INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer 1 0 Service Limit 153 5mm replace if over 8 7 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Clutch Lining Clutch Driven Pulley CLUTCH DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Lock Nut Wrench Hold the clutch driven pulley assembly with the clutch spring compressor X e Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor E034 Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar 8 DRIVE AND DRIVEN PULLEYS V BELT PEOPLE PEOPLE S 250 Movable Driven Face Guide Roller Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Guide Roller Pin O ring Remove the oil seal from the movable driven Oil Seal face INSPECTION Measure the driven face spring free length Service Limit 130 5mm replace if below Check the driven face assembly for wea
31. FUEL METER INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel meter for correct indication by moving the fuel unit float up and down Float Position Display Upper Much Full Less Empty Display From Much to Less Apply From Less to Much The fuel meter is normal if it operates as above indicated If not check for loosely tightened nuts poorly connected terminals or J shorted wires Lower Fuel Empty 19 5 19 SWTCHESHORNFUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGEANSTRUMENTS LIGHTS PEOPLE PEOPLE 5 250 THERMOSTATIC SWITCH INSPECTION Remove the front covers 2 5 Start and run the engine to make the water temperature reaches 85 C 90 C and check if the cooling fan motor operates Lower the water temperature to 85 and check if the fan motor stops If the fan motor does not start disconnect the wires from the thermostatic switch and then connect a jumper wire between the wire harness and thermosensor wires black and green wires Turn the ignition switch ON The thermostatic switch is faulty if the cooling fan motor runs properly If it does not start check for voltage between the fan motor coupler wire terminals black green If there is no voltage check for the following e Blown or faul
32. Hard brake lever Hard to brake Poor brake performance Brake squeaks Probable Cause Front and rear tire pressures are normal Steering stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim QGLoose axle nut Misaligned front and rear wheels Bent front fork Probable Cause Front and rear tire pressures are normal Weak shock spring OQ Excessive load Shock damper oil leaking Bent fork tube or shock rod Fork tube and slider binding QFork spring and slider binding Damaged shock stopper rubber Loose steering stem nut Probable Cause Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings QForeign matter on brake linings GRough brake drum contacting area Worn brake linings Worn brake cam contacting area on Worn brake linings Foreign matter on brake linings Sluggish or elongated brake cables Brake shoes improperly contact Water and mud in brake system Oil or grease on brake linings 1 32 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 EXHAUST MUFFLER FRAME COVERS SCHEMATIC 2 1 SERVICE 2 2 TROUBLESHOOTING 2
33. Inspection Adjustment D Faulty ignition unit 2 Faulty A C generator Incorrect timing errr rr rrrry Olmproperly adjusted valve clearance Worn valve seat Incorrectly adjusted x Check fuel pump for x fuel supply x Empty fuel tank 2 Clogged fuel tube or filter Fuel flows freely Fuel flow restricted GFaulty fuel pump Cracked fuel pump vacuum Check carburetor jets for clogging Not clogged Clogged Clean and unclog nananannanannnnanannannhnnnnnkannannaanannknaannannaananaanaahnahannahahannaahaanannanannaaahnannnanaannnnannannhannanahaq Incorrect Cam timing gear aligning marks not aligned Weak spring spring Check valve spring tension Not weakened 1 25 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Piston noise Worn piston pin and connecting rod small end Excessive carbon build up in combustion chamber Damaged cam chain tensioner Damn Worn cam gear teeth Worn or damaged cam chain Extended cam chain Q Faulty crankshaft bearing Crankshaft noise Worn crank pin bearing Worn or damaged final reduction gears Gear noise Worn final reduction gear shaft splines 1 26 1 GENERAL INFOR
34. P 9 6 ON RA 7 uo 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER 5 250 REAR WHEEL REMOVAL Remove the exhaust muffler 52 10 Remove the rear brake caliper 215 3 Remove the rear fork 215 6 Remove the rear axle collar Remove the rear wheel Y gt Rear Axle Collar Disk INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 35 45N m Rear axle nut 110 130N m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier 42 6 Remove the body cover center cover and rear fender A together 2 6 Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers Lower Mount Bolts 15 7 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER 5 250 INSTALLATION Install the rear shock absorbers in the reverse order of removal Torque Upper Mount Bolt 35 45N m Lower Mount Bolt 35 45N m ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring preload It is possible to adjust rear cushion in three positions A position soft B
35. PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS servicing operations of this section be made with the engine installed e When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil SAE 902 Oil Capacity At disassembly 0 20 liter At change 0 18 liter TORQUE VALUES Transmission case cover bolt 17 7 21 6N m Oil check bolt 7 8 11 8N m SPECIAL TOOLS Bearing puller E037 TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks e Oil level too high e Worn or damaged oil seal dO KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler 52 10 Remove the rear brake caliper 15 3 Remove the right rear shock absorber gt 15 7 Remove the rear fork 215 6 Remove the rear wheel gt 15 7 Remove the left crankcase cover 8 3 Remove the clutch outer driven pulleys 28 4 Drain the transmission gear oil into a clean container Transmission Case Cover Remove the transmission case cover attaching bolts Remove the transmission case cover Dowel Pin Remove the gasket and dowel pins Gasket Drive Shaft Final Shaft Remove the final shaft Remove the final gear and countershaft Countershaft Fina
36. Pin DISASSEMBLY Remove the two brake pads dowel pins and three bolts from the brake caliper Remove the brake pads 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER F FOPFLE FEOFLE 5 250 Compressed Air Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid X Be careful not to damage the piston surface Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 26 90mm Check the caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 27 05mm 15 4 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER 5 250 ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 5mm beyond the brake caliper opring Plate Install the two spring plate into the groove of the caliper Make sure th
37. RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring e Be careful not to damage the piston and piston rings during assembly e All rings should be installed with the markings facing up e After installing the rings they should rotate freely without sticking e Stagger the ring end gaps as the figure shown oide Rail Oil Ring oide Rail Second 7 6 7 CYLINDER PISTON GQ KYMCO PEOPLE PEOPLE S 250 PISTON INSTALLATION Remove any gasket material from the crankcase surface e Be careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip e Position the piston IN mark on the intake valve side e Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings e Be careful not to damage or break the piston rings e he piston ring end gaps should not be parallel with or at 90 to the piston pin Pi ston Pin Clip Piston Pin Gasket 7 CYLINDER PISTON PEOPLE PEOPLE S 250 Install the cam chain guide e Insert the tab on
38. Start the engine and check for oil leaks Start the engine and let it idle for few minutes then recheck the oil level Oil Filter Screen QC KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE S 250 OIL PUMP REMOVAL First drain the coolant Remove the right crankcase cover 10 3 Remove the A C generator starter driven gear 10 3 Remove the attaching bolt and oil separator cover Oil Separator Cover Oil Pry the circlip off and remove the oil pump driven gear then remove the pump drive e a J chain Oil Pump Drive chain Bolts Remove the two oil pump bolts to remove the oil pump OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown 4 4 GQ KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE 5 250 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 25mm replace if over Outer Rotor Measure the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Inner Rotor Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over Pump Body Rotor End OIL PUMP ASSEMBLY Dowel Pin Pump Body Install the outer rotor inner rotor and pump shaft into the pump body X Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin There i
39. Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and piston pin e Incorrectly installed piston 7 CYLINDER PISTON GQ KYMCO PEOPLE PEOPLE S 250 CYLINDER REMOVAL Remove the cylinder head cchapter 6 Remove the dowel pins and cylinder head gasket Remove the water hose from the cylinder Remove the cam chain guide Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Cylinder Dowel Pins Cylinder Head Gasket 81 _ i r Water Hose Gasket Dowel Pins Shop Towel Piston Rings Piston Pin ae Piston 7 CYLINDER PISTON PEOPLE PEOPLE S 250 Inspect the piston piston pin and piston rings Remove the piston rings e Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom X Use the piston head to push each pis
40. a suitable stand under the back of engine Remove the bolt between water pump cover and oil filter screen cap Remove right crankcase cover Support the machine securely so there is no danger of it falling over STATOR REMOVAL Remove the two pulser coil attaching screws and the pulser coil Remove the three generator stator bolts and the stator When removing the pulser coil and stator be careful not to damage them to avoid shorted or broken wire 10 3 KYMCO PEOPLE PEOPLE S 250 Water Pump Cover Bolt Water Pump Cover ni U W TR a L 1 D RJ D ad 2 4 Oil Filter Screen Cap A C Generator Stator Screws or 7 Toa 7 4 4 T AM 1 p 7 7 N 1 2 ay ow E ge _ Bolts Pulser Coil i wp f 4 f O 62 RR a 4 i ex B MLL 2 E T C 10 A C GENERATOR STARTER CLUTCH PEOPLE PEOPLE S 250 opring Oil Through Remove the oil through and spring FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer Flywheel holder E021 Remove the flywheel with a flywheel puller Flywheel puller E003 STARTER CLUTCH REMOVAL Remove the starter driven gear Starter Dri
41. bolts Remove the four screws attaching the right and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Screw Throttle Grip Lock Nut Remove the handlebar lock nut then take out the bolt and collar Remove the handlebar INSTALLATION Bolt Collar Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 40 50N m 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONTSHOCK ABSORBER FRONTFORK FFOFLE FFOPLE 5 250 Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip Connect the throttle cable to the throttle grip Install the right and left handlebar switches and tighten the screws X e Adjust the throttle grip free play to the specified range of 2 6mm Throttle Grip Brake Master Cylinder Install the front and rear brake master cylinders e Install the brake master cylinders by aligning the index marks FRONT WHEEL REMOVAL Remove the two bolts from the left front absorber Remove the screw from the speedometer gear unit then disconnect the speed wire from the speedometer gear unit Remove the front axle to pull out the axle Remove the front wheel and the speedometer gear unit INSPECTION AXLE RUNOUT Set the axle in V blocks and measure t
42. from the water jacket SPECIFICATIONS Engine oil SAE15W 40 API SJ Oil capacity at change 0 9 liter Coolant distilled water coolant concentrate SPECIAL TOOLS Flywheel puller E003 Flywheel holder E021 SPECIFICATIONS Standard mm Service Limit mm Starter driven gear 22 026 22 045 22 15mm Starter driven gear O D 42 195 42 208 TORQUE VALUES Flywheel nut 53 9 63 7N m TROUBLESHOOTING Refer to page 1 19 for A C generator troubleshooting Starter motor rotates but engine does not start e Faulty starter clutch e Starter motor rotates reversely e Weak battery 10 2 10 GENERATOR STARTER CLUTCH RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover c chapter 5 Disconnect the water hoses from the right crankcase cover Remove the nine bolts attaching the right crankcase cover and the cover Remove right crankcase cover RIGHT CRANKCASE COVER REMOVAL ENGINE INSTALLED Remove met in box and frame body cover 22 6 Disconnect the water hoses from the water pump cover c chapter 5 Disconnect the water hoses from the right crankcase cover chapter 5 Disconnect A C generator wire coupler and oil pressure switch wire 2 chapter 5 Remove the eight bolts attaching the right crankcase cover and the cover Remove the left and right rear shock absorber lower mount bolts 2 chapter 5 Elevate the back of engine as possible by placing
43. holder with the mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 10 14N m Install the brake fluid tube with the attaching bolt and two sealing washers then tighten the fluid tube bolt Connect the front stop switch wire connector Install the handlebar covers 22 3 Bolts Fluid Tube Bolt Washer BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add DOT 4 brake fluid to the brake reservoir X e When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e When using a brake bleeder follow the manufacturer s instructions e Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system BRAKE FLUID BLEEDING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add the specified brake fluid to the upper limit e Do not allow dust or water to enter the brake system during refilling e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk
44. position medium C position hard When you adjust rear cushion the spring preload of rear cushions must be the same A cushion adjust wrench is provided with PEOPLE 250 The rear right cushion can be adjusted directly with the wrench Bolts Remove the four bolts from air cleaner before rear left cushion to be adjusted 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER 5 250 Disconnect the breather hose from air cleaner and keep air cleaner up to adjust rear left cushion with wrench o M y Air Cleaner Breather Hose 15 0 dO KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 250 BATTERY CHARGING SYSTEM CHARGING SYSTEM LAYOUT 16 1 SERVICE INFORMATION L ul ll lll l lll l ii i iii i i ii a 16 2 TROUBLESHOOTING 16 3 BATTE N eee 16 4 CHARGING SA Tc 16 5 AG GENERATOR INSPECTION catch u Lu u u uu 16 5 REGULATOR RECTIFIER INSPECTION 16 6 16 0 GQ KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE 5 250 CHARGING SYSTEM LAYOUT Fuse Battery ravi lt q lig 47 Generator CHARGING CIRCUIT MIA MAIN SW o 12V IOAH 16 1 dO KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid is poisonous and may seriously damage t
45. the cam chain guide into the cylinder groove y s Cam Chain Guide Dowel Pin Gasket Install the cylinder head gasket and dowel p m t arr pins Connect the water hose to the cylinder Water Hose Install the cylinder head chapter 6 Tighten the cylinder base bolt 7 8 8 DRIVE AND DRIVEN PULLEYS KYMCO HELD DRIVE AND DRIVEN PULLEYS V BELT SCHEMATIC DRAWIN G 8 1 SERVICE INFORMATION 8 2 TROUBLESHOOTING x 8 2 LEFT CRANKCASE 8 3 DRIVE pp y 8 4 CLUTCH OUTER DRIVEN PULLEY V BELT 8 4 8 0 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 SCHEMATIC DRAWING 6 1 8 DRIVE AND DRIVEN PULLEYS O KYMCO V BELT PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed e Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS TORQUE VALUES Drive face nut 88 2 98N m Clutch outer nut 49 0 58 8N m Clutch drive plate nut 49 0 58 8N m SPECIAL TOOLS Universal holder E017 Clutch spring compressor E034 TROUBLESHOOTING Engine starts but motorcycl
46. the heater has to be changed Heater Air Cleaner Connecting Tube Band CARBURETOR INSTALLATION EC EN 74 Tighten the drain screw 4 A Install the carburetor onto the intake manifold 44 tighten the band Install the air cleaner connecting tube and tighten the band Connect the throttle cable to the carburetor Connect the heater carburetion wire coupler Intake Manifold Band A After connecting the throttle cable adjust the throttle grip free play to 2 6mm Throttle Cable Wire Coupler T P S Auto Bystarter Fuel Tube Connect the auto bystarter wire Connect the fuel tube and vacuum tube to the W carburetor i A See Connect the throttle position sensor wire Y Lf y 022 V Perform the following inspections and MT i 74 adjustments eThrottle grip free play 23 3 eldle speed 3 6 Install the seat met in box and frame body cover AAP 13 17 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 Vacuum Tube FUEL PUMP REMOVAL Remove met in box and carrier Remove the body cover center cover and rear fender cover A Disconnect the fuel pump inlet outlet and vacuum tubes Remove the two fuel pump attaching nuts and the fuel pump Nuts Inlet Tube Inlet Screws FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws Vacuum Tube Outlet Disassemble the fuel pump 13
47. to the right and the coolant will drain more easily Drain the coolant in the reserve tank Reinstall the drain bolt Fill the radiator coolant e coolant freezing point should be 5 C lower than the temperature of the riding area Start the engine and check if there are no bubbles in the coolant and the coolant level is stable Reinstall the radiator cap If there are bubbles in the coolant bleed air from the system Fill the reserve tank with the recommended coolant up to the upper line BRAKE SYSTEM BRAKE FLUID Rear Brake Reservoir Front Brake Reservoir Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit Ifthe brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 e he brake fluid level will decrease if the brake pads are worn BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk rubout is within the specified service limit Check if the brake pad wear exceeds the wear indicator line X Keep grease or oil off the brake disk to avoid brake failure Wear Indicator Line 3 10 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found WHEELS TIRES Pressure Gauge Check
48. with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9 8 13 7N m Water pump cover bolt 7 8 11 8N m TROUBLESHOOTING Engine temperature too high Coolant leaks e Faulty temperature gauge or thermosensor e Faulty pump mechanical water seal e Faulty radiator cap e Deteriorated O rings e Faulty thermostat e Damaged or deteriorated water hoses e Insufficient coolant e Passages blocked in hoses or water jacket e Clogged radiator fins e Passages blocked in radiator e Faulty water pump Temperature gauge pointer does not register the correct coolant temperature e Faulty temperature gauge or thermosensor e Faulty thermostat 12 2 QC KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 SPECIFICATIONS Radiator cap relief pressure 0 9 0 15kg cm www Begins to open 80 26 Thermostat temperature Full open Valve lift NENNEN 1000 20cc Coolant capacity Total system 1400 20 Reserve tank 400420cc COOLANT GRAVITY Temp gt s concentration COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS 955 22 406 cC 59 0 450 5 040 Cautions for Using Coolant e Use coolant of specified mixing rate The mixing rate of 425cc KYMCO SIGMA coolant concentrate 975cc distilled water is 30 e Do not mix coolant concentrate of different brands e Do not drink the coolant which is poisonous
49. 18 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage Inspect each gasket for damage gt Gaskets Outlet Relief Valve Suction Valve Inspect the suction valve outlet valve and relief valve in the fuel pump body for damage cracks or foreign matters Spring Outlet Valve Inlet Spring Dowel Pins FUEL PUMP ASSEMBLY Assemble the fuel pump in the reverse order of disassembly During assembly be sure to install the gaskets and diaphragms properly to avoid damage e Do not allow any foreign matter to enter the fuel pump during assembly Fuel Pump Body Dowel Pin Holes 13 19 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 Outlet Tube Vacuum Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two nuts Connect the fuel pump inlet outlet and vacuum tubes Install the met in box and carrier Install the body cover center cover and rear fender A ECC FONS 77 w Nuts Inlet Tube Outlet Tube Measure the fuel pump output Start the engine and disconnect the fuel outlet tube and place a clean container under the tube to check the fuel output Output 33cc 1800rpm 10 seconds FUEL TANK REMOVAL Remove the floor board 22 7 Remove four nuts at
50. 50 Red Wire CHARGING SYSTEM Use a fully charged battery 12 8V min to check the charging system Warm up the engine before taking readings Connect an electric tester across the battery terminals Disconnect the red wire from the fuse terminal and connect ammeter between the red wire lead and the fuse terminal i Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 14 15V 0 5A max 5000rpm max If the limit voltage is not within the specified range check the regulator rectifier PERFORMANCE TEST Engine Speed 2000rpm 5000rpm ator Connector 25 Charging Current 10 5A min A C Gener X When measuring the charging current disconnect the black wire from the regulator rectifier wire coupler If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION X This test can be made without removing the stator from the engine Disconnect the yellow wire from the auto bystarter Remove the met in box Disconnect the A C generator connector Check the continuity between the yellow wires and ground There should be continuity between the yellow wires and no continuity between each yellow wire and ground Resistance Yellow Yellow 1 6 2 50 Electric tester YF 3501 16 5
51. ALUES Exhaust muffler lock bolt 32 38N m Exhaust muffler pipe nut 18 22N m Rear axle nut 110 130N m Rear shock absorber lower mount bolt 35 45N m Rear shock absorber upper mount bolt 35 45N m Rear brake caliper holder bolt 29 35N m TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Air in brake system e Faulty tire e Deteriorated brake fluid e Axle not tightened properly e Contaminated brake pad surface e Worn brake pads Soft rear shock absorber e Clogged brake fluid line e Weak shock absorber spring e Deformed brake disk e Damper oil leaks e Unevenly worn brake caliper Rear wheel noise e Worn rear wheel axle bearings e Worn rear fork bearings e Deformed rear fork 15 2 15 REAR BRAKE REAR FORK REAR O KYMCO WHEEL REAR SHOCK ABSORBER 5 250 REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler 222 10 Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove the two bolts attaching the rear brake caliper Remove the rear brake caliper When removing the brake fluid tube use shop towels to cover plastic parts and Brake Caliper coated surfaces to avoid damage Inspect the brake pads and brake disk Measure the brake disk thickness Service Limit 3 0mm replace if below Visually check the brake pad thickness and it should not exceed the wear indicator mark Dowel
52. Brake Fluid Tube Fuel Tank Breather Tube Fuel Hose between the Fuel Tank and Fuel Filler 1 13 KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 Winker Horn DIM Wire Start Light ENG Stop Passing Wire Radiator Air Ventilated Tube to Raciator Throttle Cable Front Brake Fluid Tube Radiator Air Ventilated Tube Ignition Switch Water Inlet Hose Fan Motor Wire Fuel Tank Cap Rear Brake Fluid pe Tube Fuel Tank Eus ack Breather Tube Cap Open Cable opeedometer Cable Fuel Tank Inlet Tube Wire Harness dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 Secondary Air Vacuum Tube Fuel Tank Inlet Tube Thermostat Wire Harness Thermosensor Wire Fuel Pump Vacuum Tube Starter Motor wire Heater Wire Starter Relay Air Inlet Hose V belt Chamber Ai Ignition Coil Fuse Box A C G Starter Ignition Unit Relay Wire 4 Battery Cable Battery Seat Open Cable Wire Harness 1 15 KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 Starter Relay Carburetor Fuel Pump Ignition Coil Oil Vapor Recovery Tube Secondary Air Inlet Tube opark Cap Side Stand Switch Fuel Unit Wire Harness 1 16 KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 Battery Fuse Box Ignition Coil Starter Motor Wire Carburetor Regulator Rectifier Fuel Unit Seconda
53. CATIONS Air injection cut off valve actuating pressure 250mm Hg 30 liter min Reed valve stopper clearance 4 6mm 20 2 20 EXHAUST EMISSION CONTROL QC KYMCO SYSTEM PEOPLE PEOPLE S 250 SECONDARY AIR CLEANER AIR INJECTION CUT OFF VALVE A I C V REMOVAL Remove the seat 22 4 Remove the body cover Disconnect the secondary air cleaner A 1 C V connecting tube Secondary Air Cleaner A I C V x Vacuum Tube Air Outlet Tube INSPECTION Inspect the air injection cut off valve flow Air Outlet Tube using a vacuum pump If the flow is not within the specified values replace with a new one The flow should be at least 30 liter min when a vacuum of 250mm Hg is applied The flow should be at least 1 6 liter min when a vacuum of 320mm Hg is applied Check each connecting tube for cracks or damage and replace if necessary INSTALLATION The installation sequence is the reverse of removal Air Inlet Tube Vacuum Tube e he secondary air cleaner must be assembled and installed properly to avoid dust entering the air cleaner e When installing be careful not to bend or twist the tubes and check for proper installation e tube length is very important to its performance use the tube of same specification for replacement 20 3 20 EXHAUST EMISSION CONTROL O KYMCO SYSTEM PEOPLE PEOPLE S 250 REED VALVE Reed Valve Cover Cylinder Head Cover Py REMOVAL B
54. EL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FLOAT CHAMBER ASSEMBLY Slow Jet Main Jet Install the main jet Install the slow jet Install the pilot screw e sure to record the rotating turns when it is removed Pilot Screw Float Install the float valve float and float pin Float Valve Float Pin 13 15 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet just contacting the float valve Float Level 18 5 1 0mm 18 1 0mm PEOPLE S 250 Replace the float if the level is incorrect Check the operation of the float and then reinstall the float chamber Vacuum Piston VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Needle Holder Jet Needle Vacuum Piston Install the vacuum piston into the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws e Be careful not to let the diaphragm slip e If the diaphragm cannot be positioned correctly because of expansion dry the diaphragm before installation Spring Diaphragm 13 16 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 Check the heater with battery If the heater is getting hot means the heater without problem otherwise
55. ENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e When separating the crankcase never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces e When installing the crankcase do not use an iron hammer to tap it The following parts must be removed before separating the crankcase Cylinder head gt 6 Cylinder piston gt 7 Right crankcase cover drive and driven pulley chapter 8 generator starter clutch c chapter 10 Rear wheel rear shock absorber chapter 15 Starter motor chapter 18 Oil pump gt 4 SPECIFICATIONS Lo tem Standard Service Limit mm Connecting rod big end side clearance 0 15 0 35 06 Crankshaft Connecting rod big end radial clearance 0 0 008 Rn d 1 TORQUE VALUES Crankcase bolt 7 8 10 8 Cam chain tensioner slipper bolt 7 8 11 8N m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bearing play e Worn piston pin and piston pin hole 11 2 GQ KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE 5 250 Bolt CRANKCASE SEPARATION Remove the three right crankcase attaching bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase X e Never use a driver to pry the c
56. ET REMOVAL ceu Ee UL UE 6 4 CYLINDER ED T 6 6 CYLINDER HEAD DISASSEMBLY T 6 7 CYLINDER HEAD ASSEMBLY Tq 6 8 CYLINDER HEAD INSTALLATION Tq 6 9 CAMSHAFT INSTALLATION lll uuu 6 10 CYLINDER HEAD COVER INSTALLATION 6 11 dO KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 SCHEMATIC DRAWING 6 1 GQ KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE 5 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water jacket must be drained first e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication e valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head e After disassembly clean the removed parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Standard mm PEOPLE PEOPLE S PEOPLE PEOPLE E Cylinder head compression pressure 15ka cm ECCE Cylinder head warpage m 005 Camshaft cam height aod 5 00 10 Valve rocker arm 1 0 STD Ta 22 19 Val
57. FLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the three exhaust muffler lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt next to exhaust pipe 32 38 Exhaust muffler lock bolt 59N m Exhaust muffler joint lock nut 18 22N m Be sure to install new exhaust muffler packing collar 2 11 Rear Fender Cover C Air Clean Case Crews Joint Lock Nuts Lock Bolts Packing Collar dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 FRAME COVERS REMOVAL REAR CARRIER Remove the met in box First remove the four bolts attaching the met in box Remove the met in box Remove the three bolts attaching the rear carrier Remove the rear carrier Bolts FRAME BODY COVER REMOVAL Remove the two nuts and screws attaching the rear protective cover Remove the rear protective cover Screws Body Cover Remove the two screws on the bottom of the side center cover Remove the side center cover Remove the body cover Center Cover 2 12 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 Side Cover SIDE COVER REMOVAL Remove the screws attaching the right and left side covers Remove the right and left side covers
58. Faulty or weak battery starter relay by x x depressing starter x button eter TELLAN PE EE E E properly operate Open or shorted starter relay Loose or disconnected Connect starter x 2 connectors x motor directly to gt battery x Worn brushes M Starter m Starter doas not turh or shorted wires or rotor GOpen starter motor cable Loose connectors Open wire harness 2 Starter motor turns idles Inspaction Adjustment Symptom Probable Cause Q Check operation of stop switch by applying brake Burned out fuse Weak or dead battery GFaulty stop switch Check battery circuit x by operating turn x M Cee signals Signals operate Signals dim remain 2 2 j 2 don t operate Weak or dead battery Connect starter x motor directly to gt battery Loose connector or terminal Poor contact in starter relay GFaulty starter clutch Starter motor turns normally Hard to turn QSeized cylinder OBroken or shorted starter motor cable 3 Starter motor does not stop turning Inspection Adjustment symptom Probable Cause Turn ignition switch x M gt OFF x Vive vu Not stopped Faulty starter pinion Stopped Starter relay shor
59. G HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK FRONT SHOCK ABSORBER REMOVAL Remove the front cover 2 5 Remove the front fender cover and B 22 9 Remove the front wheel 14 5 Remove the front brake caliper 14 11 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers INSTALLATION Install the front shock absorbers onto the front fork Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Torque 29 35N m Align the upper mount bolt hole with the groove on the front fork Install the front wheel 214 7 GQ KYMCO PEOPLE PEOPLE S 250 Mount Bolts apt bri A i TT QAI DU TE 10 M TUM T TU Front Fork Lower Mount Bolts Front Shock Absorber 14 14 KYMCt 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 5 250 Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers 22 3 Remove the steering handlebar gt 14 4 Remove the front cover 22 5 Remove the front leg shield 22 8 Remove the front fender cover and B 2 6 Remove the front wheel 14 5 Remove the front brake caliper 14 11 Remove the front shock absorbers Hold the steering stem top cone race and remove
60. MATION CLUTCH DRIVE AND DRIVEN PULLEYS 1 27 Symptom Engine starts but motor cycle does not Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There is abnormal noise GQ KYMCO PEOPLE PEOPLE 5 250 Probable Cause Worn or slipping drive belt Broken ramp plate GBroken drive face spring Separated clutch lining driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring QClutch outer and clutch weight stuck Seized pivot Worn or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 STARTER MOTOR 1 Starter motor won t turn nspection Adjustment UN Probable Cause E Loose Or disconnected Stoplight comes on Stoplight does not come on Check battery circuit by operating turn GBroken or shorted ignition signals x switch wire Signals operate Signals dim remain Check operation of properly on or don t operate
61. NT PEOPLE PEOPLE S 250 AIR CLEANER Remove the six air cleaner case cover screws and the cover Remove the air cleaner element Check the element and replace it if it is excessively dirty or damaged CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas X e The air cleaner element has a viscous type paper element Do not clean it with compressed air e Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the met in box and center cover Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug DPR7EA9 Measure the spark plug gap Spark Plug Gap 0 7mm Cracks Damage X When installing first screw in the spark plug by hand and then tighten it with a 4 Deformation spark plug wrench Gap Torque 14 7 19 6N m Wear Fouling 0 9mm Deposits 3 5 GQ KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE 5 250 VALVE CLEARANCE e Inspect and adjust valve clearance while the engine is cold below 35 Remove the met in box and center cover Disconnect oil vapor recovery tube and secondary air cleaner fresh air outlet hose from cylinder head cover Remove two lower bolts and two nuts on the cylinder head cover Place the scooter on its side stand and load a person on the r
62. OPLE PEOPLE S 250 AUTO BYSTARTER INSPECTION REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 14 200 10 minutes minimum after stopping the engine If the reading is not within the limit replace the auto bystarter with a new one Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter is normal Hose AUTO BYSTARTER REMOVAL Auto Bystarter Screws Remove the one set plate screw and set plate and then remove the auto bystarter from the carburetor body Set Plate 13 11 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part is found replace the auto bystarter with a new one Bystarter Needle Bystarter Valve AIR CUT OFF VALVE A C V Air Cut off Valve Cover A C V REMOVAL Remove the two screws and the air cut off valve cover Screws Diaphragm Remove the spring diaphragm and O rings Inspect the di
63. OPLE PEOPLE S 250 ENGINE REMOVAL Drain the coolant 23 9 Remove the met in box carrier 22 6 Remove the frame body cover center cover and rear fender A together 2 6 Remove the exhaust muffler 22 10 Disconnect all of the A C generator Remove the nut to disconnect the starter motor wire that goes to the starter relay Disconnect the secondary air vacuum tube and fuel pump vacuum tube from inlet pipe Disconnect the air inlet hose v belt chamber from frame Loosen the intake manifold band air cleaner tube and inlet pipe Disconnect the radiator air ventilated tube and thermosensor wire coupler from thermostat Nut Starter Motor Wire Starter Relay secondary Air __ Air Inlet Hose Vacuum Tube Inlet Pipe V belt Chamber r j j Fuel Pump Vacuum Tube Intake Manitold Radiator Air Band Thermostat Ventilated Tube 4 k Thermosensor Wire Coupler KYMCO 9 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 Engine Oil Pressure Water Hoses Switch Wire Water Ducts Disconnect the engine oil pressure switch E 1 Ees lt wire Loosen the water hose bands to disconnect water hoses from the water ducts Disconnect the secondary air tube from the secondary air inlet tube aee Disconnect the breather hose air cleaner from cylinder head cover Disconnect the spark plug cap from cylinder head 7 bs
64. Remove the frame body cover ge Remove the floor foot cover Disconnect the secondary air inlet tube connector Remove the reed valve cover three bolts and two secondary air outlet tube bolts Remove the three bolts attaching the reed valve cover and the reed valve Reed Valve INSPECTION Check the reed valve for cracks damage big clearance or weak reeds Replace if necessary Check the gasket and O ring for damage or deterioration and replace if necessary Reed valve stopper clearance 4 6mm INSTALLATION Install the reed valve in the reverse order of removal e When installing be careful not to bend or twist the tubes and check for proper installation Reed Stopper 20 4
65. TARTER CLUTCH SCHEMATIC SERVICE INFORMATION TRO SOO INC erect ee eee RIGHT CRANKCASE COVER REMOVAL STATOR REMOVAL FLYWHEEL REMOVAL STARTER CLUTCH FLYWHEEL INSTALLATION STATOR INSTALLATION rient ere RIGHT CRANKCASE COVER INSTALLATION QC KYMCO PEOPLE PEOPLE S 250 10 0 GQ KYMCO PEOPLE PEOPLE 5 250 10 A C GENERATOR STARTER CLUTCH SCHEMATIC DRAWING 10 1 10 GENERATOR STARTER CLUTCH PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e All servicing operations and inspections in this section can be made with the engine installed e Drain the coolant before removing the right crankcase cover e Be careful not to drain the coolant when the engine temperature is high Perform this operation when the engine is cold e Drain the coolant into a clean container e Drain the engine oil into a clean container before removing the right crankcase cover e When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air
66. UUM CHAMBER ASSEN BIYsuuu eese 13 16 CARBURETOR INSTALLATION 13 17 FUEL PUMP REMOVAL DISASSEMBLY 13 18 FUEL PUMP INSPECTION Tq 13 19 13 19 FUEL PUMP INSTALLATION en 13 20 FUEL TANK REMOVAL menea 13 20 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FUEL SYSTEM 13 1 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 SCHEMATIC DRAWING fj RN ff A K 13 2 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 OPERATION OF CARBURETOR JETS 1 LOW SPEED X Air Venturi slightly opened throttle valve Bleed gt Mixture Low Speed Air Inlet Fuel in Float Chamber Slow Jet Low Speed Small Jet Holes 2 MIDDLE SPEED X Air l Venturi halfway opened throttle valve Bleed Holes Mixture High Speed Air Jet X Fuel in Float Chamber Main Jet Main Jet The slow jet also works Low amp Middle Speed Supplementary Device Vacuum Tube Low Speed Air Jet qu rl FN d Y Kok T ML x WE Vacuum Diaphragm y j TM lt Air 7 P
67. air drawn for re burning to prevent dirt or dust from affecting the operation of the air injection cut off valve The air injection cut off valve usually opens to lead air into the exhaust muffler in which air is re burned to reduce CO When the throttle valve closes suddenly the air injection cut off valve is actuated by vacuum to close and cut off secondary air in order to prevent exhaust muffler backfiring due to air in the exhaust system When the motorcycle speed is less than 50km per hour the reed valve operates to draw secondary air into the exhaust system for re combustion 20 1 20 EXHAUST EMISSION CONTROL KYMCO SYSTEM PEOPLE PEOPLE S 250 TROUBLESHOOTING High CO at idle speed 1 Damaged or clogged reed valve 2 Damaged or clogged air injection cut off valve 3 Clogged air cleaner Backfiring at sudden deceleration 1 Damaged reed valve malfunction 2 Faulty air injection cut off valve unable to close 3 Carburetor incorrectly adjusted 4 Faulty air cut off valve 5 Leaking vacuum tube Exhaust muffler noise 1 Faulty air injection cut off valve 2 Broken vacuum tube 3 Faulty reed valve SERVICE INFORMATION GENERAL INSTRUCTIONS e During operation be careful to avoid scalding caused by the exhaust muffler e Note the locations of tubes for proper installation e Replace any damaged tube with a new one e Make sure to tighten the connector of each tube securely TOOLS e Vacuum pump SPECIFI
68. and belt together Remove the drive belt from the movable drive face INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 22 0mm replace if below X e Use specified genuine parts for replacement dO KYMCO PEOPLE PEOPLE S 250 Air Tube Drive Pulley Face Universal Holder Y Drive Belt 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face clutch outer driven E pulley and belt 2 8 4 Remove the movable drive face assembly Remove the drive pulley collar Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate Remove the weight rollers Weight Roller INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 22 00mm replace if below 8 DRIVE AND DRIVEN PULLEYS O KYMCO V BELT PEOPLE PEOPLE S 250 Measure the movable drive face bushing assembly I D Service Limit 27 13mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 26 90mm replace if below ASSEMBLY Install the weight rollers into the movable drive face e The direction of all weight rolls is same The color side is towards to clockwise Weight Roller 8 6 8
69. and nuts Torque 7 8 11 8 6 11 dO KYMCO 7 CYLINDER PISTON PEOPLE PEOPLE S 250 CYLINDER PISTON SCHEMATIC DRAWING 7 1 SERVICE INFORMATION issue 7 2 TROUBLESHOOTING 7 2 DER PEMOVA sc niece 7 3 PE OPE O AD u L 7 3 PI TONING TEA TON u l a 7 7 CYLINDER INSTALLATION 7 7 7 0 QC KYMCO 7 CYLINDER PISTON PEOPLE PEOPLE S 250 SCHEMATIC DRAWING 7 1 dO KYMCO 7 CYLINDER PISTON PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder and piston can be serviced with the engine installed in the frame e When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed e After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS Standard mm Service Limit mm I Chou o TROUBLESHOOTING e When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler e Worn or damaged cylinder and piston rings e Worn or damaged piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high Abnormal noisy piston e Excessive carbon build up in combustion e
70. aphragm and spring for wear or damage Cover opring 13 12 13 FUEL SYSTEM CARBURETOR dC KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body e Make sure that no fuel jet is clogged O ring Install the O ring onto the air cut off valve body securely X e Install the O ring with the flat face toward the valve body side Install the diaphragm spring and cover Cover Spring Diaphragm Install and tighten the two screws attaching the air cut off valve cover Connect the hose Screws 13 13 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 S ACCELERATING PUMP Crews DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover Remove the spring and accelerating pump diaphragm INSPECTION 26 Inspect the accelerating pump diaphragm for cracks damage or deterioration Replace if necessary Assemble the accelerating pump in the reverse order of disassembly O ring Spring Auto Bystarter Screws AUTO BYSTARTER INSTALLATION Install the auto bystarter and set plate Install and tighten the two screws e Insert the auto bystarter into the carburetor body until it bottoms and position the set plate into the upper groove in the bystarter e Install the set plate with its round face facing down 13 14 13 FU
71. arburetor TC TCTS Remove spark plug and install it into spark plug cap to test spark by x connecting it to engine x ground QFaulty spark plug Fouled spark plug GFaulty ignition unit Spark jumps Weak or no spark Faulty A C generator GBroken or shorted ignition coil amp Broken or shorted exciter coil OFaulty ignition switch Test cylinder compression Y Starter motor idles but crankshaft does not rotate Valve clearance too small Improper valve and seat contact amp Worn cylinder and piston rings compression amp Blown cylinder head gasket Flaws in cylinder head Seized valve amp Improper valve timing ing normal starting procedure Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Remove spark plug and inspect again RUN pO Dry spark plug QFlooded carburetor Faulty auto bystarter Throttle valve excessively open Wet spark plug 1 22 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation n oymptom Engine speed increases Correct timing Engine speed does not increase sufficiently using a timing light Incorrect timi
72. bulb and replace with a new one Screws REAR TURN SIGNAL LIGHT BULB Screw REPLACEMENT fA Remove the one screw attaching the turn signal light shell and remove the screw bulb shell Remove the bulb and replace with a new one 19 7 19 SWITCHESHORNFUELUNITTHERMOSTATICSwrcH KYMCO TEMPERATURE GAUGE INSTRUMENTSILIGHTS PEOPLE PEOPLE S 250 Rubber Boot FRONT POSITION LIGHT HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover 22 3 Remove the position bulb socket by turning them counterclockwise Remove the bulb and replace with new one Disconnect the headlight wire couplers Remove the rubber boot from the bulb socket Relax the lock clip to remove the bulb and replace with new one Install the bulb aligning the bulb socket tab with the groove and set the lock clip Install the rubber boot Install the handlebar front cover in the reverse order of removal TAILLIGHT LIGHT BULB EPLACEMENT Front Position Light Bulb Sockets Remove the two screws attaching the rear light shell and remove the light shell Remove the bulb and replace with new ones The installation sequence is the reverse of removal Screws SIDE STAND SWITCH Side Stand Switch Side Stand Switch 19 8 19 SWTCHESHORNFUELUNTITHERVOSTATCSwrcH KYMCO ITEMPERATUREGAUGEINSTRUMENTSLIGHTS PEOPLE PEOPLE S 250 HEATER WIRING DIAGRAM COMB SW 12V10AH BATTERY HEATER W Y G HEATER CARBURETION 19 9
73. by pulling them outward Disconnect the tow screws attaching the center cover Remove the center cover FRONT COVER REMOVE Remove the screws attaching the right and left side covers air outlet Disconnect the right and left side cover air outlet 1 Side Cover Air Outlet Screws Front Cover Remove the two screws on the both sides of front cover Remove the two screws on the back of front cover Remove the two screws on the skirt of front cover Remove the bolt and two adjusting screws on the front of front cover Disconnect the signal light wire connector Remove the front cover The installation sequence is the reverse of remove 2 13 Screw Bolt dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 Remove the front cover of decoration cover Decoration Cover the decoration covers by the little tool push the decoration of a back claw Remove the bolt on the front cover Bolt Install the decoration cover onto the front cover with the claw aligned with the front cove hole Hole Claw 2 14 dO KYMCO 2 EXHAUST MUFFLER FRAME COVERS PEOPLE PEOPLE S 250 LEG SHIELD COVER REMOVE Remove the ignition switch decoration ring Remove the bolt on the leg shield cover Remove the two screws on the back of under position Disconnect the leg shield cover The installation sequence is the reverse of removal COWL UNDER REMOVE
74. case cover Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and inner bearing KYMCO PEOPLE PEOPLE S 250 Impeller Mechanical Seal Seal Washer Porcelain AN Og 2 N X LT 5 Water Pump Assembly _ M SAW Inner Bearing Snap Ring Water Pump Shaft 12 10 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 Water Pump Assembly Remove the water pump shaft outer bearing Inner Bearing Water Pump Assembly MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside Mechanical Seal Water Seal Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal 12 11 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Outer Bearina E Install the water pump shaft and shaft inner bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly 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
75. cations e When removing the fuel tank keep sparks and flames away from the working area e When removing the fuel tank the remaining fuel in the tank must be lower than gt of the fuel tank capacity to avoid gasoline overflowing e Fuel tank capacity 8 0 liters PEOPLE 250 PEOPLE S 250 SPECIFICATIONS Size of bore mm Main jet NO 1082 104 Pilot screw opening SPECIAL TOOLS Float level gauge Fuel unit remover 13 5 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK TROUBLESHOOTING Engine does not start e No fuel in tank e Restricted fuel line e oo much fuel getting to cylinder e Clogged air cleaner e Contaminated fuel e Faulty fuel pump Throttle does not open fully so engine stalls e Damaged vacuum piston diaphragm e Clogged diaphragm hole Lean mixture e Clogged fuel jets e Clogged fuel tank cap breather hole e Clogged fuel filter e Bent kinked or restricted fuel line e Faulty float valve e Float level too low e Faulty fuel pump or insufficient output Engine is hard to start e No fuel in tank e Restricted fuel line e Clogged fuel strainer e Faulty fuel pump e Broken or clogged vacuum tube e Faulty or clogged charcoal canister Lean mixture e Clogged charcoal canister e Bent kinked or restricted fuel line e Clogged fuel strainer e Float level too low QC KYMCO PEOPLE PEOPLE S 250 Engine idles roughly stalls or runs poorly e Incorrect idle speed e Rich mixt
76. cking collar The installation sequence is the reverse of removal Torque Exhaust muffler joint lock nut 2 2kg m Exhaust muffler lock bolt 3 3kg m Lock Bolts Sek NR 2 16 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 INSPECTION ADJUSTMENT SERVICE INFORMATION Se 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE FUEL 3 3 THROTTLE OPERATION Y 3 3 ENGINE 3 4 NIR CLEANER E 3 5 SPABICPEUS a 3 5 VALVE CLC i saa 3 6 CARBURETOR IDLE SPEED T 3 6 CYLINDER COMPRESSION 3 7 FUEL TANK CAP CABLE WIRE SEAT CABLE WIRE 3 7 FINAL REDUCTION GEAR OM 3 8 DRIVE DELT 3 9 HEADLIGHT AIN 3 9 CLUTCH SHOE WEAR u ull lll l l uuu 3 9 GOO a 3 9 s 3 10 NUT BOLT FASTENER lll l l l ll A 3 11 WHEELS TIRES lll 3 11 STEERING HANDLEBAR SUSPENSION 3 11 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL eBefore running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust
77. contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free 2 6mm Spark plug NGK DPR7EA9 Spark plug gap 0 7mm Valve clearance IN 0 4mm EX 0 1mm Idle speed 1700 100rpm 1600 100rpm people s 250 Engine oil capacity Cylinder compression 15 2kg cm At disassembly 1 1 liter Ignition timing repeatedly At change 0 9 liter Coolant type water cooling Gear oil capacity At disassembly 0 20 liter At change 0 18 liter TIRE T 38e 2845 TIRE SPECIFICATION Front 110 70 16 52P Rear 140 70 16 65P TORQUE VALUES Front axle 29 35N m Front axle nut 60 70N m people s 250 Rear axle nut 110 130N m 3 1 GQ KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period l Inspect and Clean Adjust Lubricate or Replace if necessary A Adjust C Clean R Replace T Tighten Whichever Regular Service Mileage km comes first 4000 6000 8000 10000 R scooter 300km o T 1 C C Engine oil filter screen Fuel filter NEM Replace at every 6000km Gear oil m I ES 11 11 scooter 300km Vavedearance
78. ding e Replace the thermostat if the valve stays open at room temperature e Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 C THERMOSTAT INSTALLATION The installation sequence is the reverse of removal Replace the O ring with a new one and apply grease to it Fill the cooling system with the specified coolant 23 9 QC KYMCO PEOPLE PEOPLE S 250 Thermostat f Thermometer O ring Thermosensor me a a i SS CON EU o s F w d Da NUS 4 rhs 12 16 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL 13 1 SCHEMATIC DRAWING 13 2 OPERATION OF CARBURETOR JETS 13 3 SERVICE INFORMATION 13 5 CARBURETOR RENOVA eee 13 7 VACUUM CHAMBER DISASSEMBLY 13 7 FLOAT CHAMBER DISASSEMBLY 13 9 AUTO BYSTARTER 13 11 13 12 AUTO BVSTARTER INSTALLATION te 13 14 FLOAT CHAMBER ASSEMBLY aee p 13 15 FLOAT LEVEL INSPECTION nq 13 16 VAC
79. e and then the positive cable Battery Cover When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence is the reverse of removal First connect the positive cable and then negative cable to avoid short circuit BATTERY VOLTAGE INSPECTION OPEN CIRCUIT VOLTAGE Disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 2V Undercharged 12 3V max X Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal e Keep flames and sparks away from charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery e Charge the battery according to the current specified on the battery e During quick charging the battery temperature should not exceed 45 e Quick charging should only be done in an emergency e Measure the voltage 60 minutes after the battery is charged Charging current Standard 1 2A Quick 5 Charging time Standard 5 10 hours Quick 60 minutes After charging Open circuit voltage 12 8 min 16 4 dO KYMCO 16 BATTERY CHARGING SYSTEM PEOPLE PEOPLE S 2
80. e instrument x Do B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting QC KYMCO PEOPLE PEOPLE S 250 Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the B specified points Use Engine Oil designated engine oil for lubrication a Grease Apply grease for lubrication Transmission Gear Oil 908 Gear Oi Use special tool gt Caution Warning 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 TORQUE VALUES STANDARD TORQUE VALUES Torque N m Torque N m 5mm bolt nut I 5mm screw 6mm bolt nut 6mm screw SH bolt amm bolt nut 6mm flange bolt nut 10mm bolt nut amm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Cylinder head bolt A Double end bolt Cylinder head bolt B Double end bolt Oil filter screen cap Cylinder head cap nut Valve adjusting lock nut Cam chain tensioner slipper Clutch outer nut Clutch drive plate nut Cylinder head cover bolt Spark plug Cam chain tensioner bolt Water pump impeller Drive face nut Transmission case cover bolt 2 2 1 4 2 1 1 1 1 1 2 4 1 1 1 1 9 1 Gear oil check bolt dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 FRAME Steering stem lock nut Front axle nut Rear axle
81. e spring plate next to the brake pad dowel pin orientation Install the two brake pads and brake pad dowel pin x 4 Bu Pads 15 5 15 WHEEL REAR SHOCK ABSORBER INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts Torque 29 35N m Connect the brake fluid tube to the brake caliper and install fluid tube bolt copper washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 214 10 When installing the brake fluid tube be sure to install the two copper sealing washers REAR FORK REMOVAL Remove the exhaust muffler 52 10 Remove the rear brake caliper 215 3 Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork The installation sequence is the reverse of removal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub QC KYMCO PEOPLE PEOPLE 5 250 Fluid Tube Bolt Rear Axle Nut y J S 3 A b lt i 2 lt
82. e won t move Lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Broken driven face spring e Faulty driven face Engine stalls or motorcycle creeps e Broken clutch weight spring 8 DRIVE AND DRIVEN PULLEYS O KYMCO V BELT PEOPLE PEOPLE S 250 Air Tube LEFT CRANKCASE COVER REMOVAL Remove the met in box and carrier 22 6 Remove the body cover center cover and rear fender A together 22 6 Disconnect the belt air tube from the frame Remove the left crankcase cover bolts and left crankcase covers Remove the seal rubber and dowel pins Left Crankcase Cover Dowel Pins INSTALLATION Install the dowel pins and the seal rubber Install the left crankcase cover Install and tighten the left crankcase cover bolts Left Crankcase Cover 8 DRIVE AND DRIVEN PULLEYS V BELT Connect the drive belt air tube to frame DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover 8 3 Hold the drive pulley using a universal holder and remove the drive face nut and washer Remove the drive pulley face Universal HolderE01 7 CLUTCH OUTER DRIVEN PULLEY V BELT REMOVAL Remove the left crankcase cover 28 3 Remove the drive pulley face 28 4 Hold the clutch outer with the universal holder and remove the clutch outer nut and washer Universal HolderE017 Remove the clutch outer driven pulley
83. ear carrier for remove the two upper bolts on the cylinder head cover and remove cylinder head cover Turn the A C generator flywheel to the top dead center TDC on the compression stroke so that the T mark on the flywheel aligns with the index mark on the left crankcase Cover Inspect and adjust valve clearance Valve Clearance IN 0 1mm EX 0 1mm Loosen the lock nut and adjust by turning the adjusting nut Valve Adjuster E036 X Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED X e The engine must be warm for accurate idle speed inspection and adjustment Lift up the seat and remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700x100rpm When the engine misses or run erratic adjust the pilot screw Cylinder Head Cover Upper Bolts Lower Bolts Nuts Index Mark Top Dead Center Mark Feeler Gauge EM F Tow g TN p Pilot Screw GQ KYMCO INSPEC TION ADJUSTMENT PEOPLE PEOPLE 5 250 CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valves fully and pushes the starter button to test the compression Compression 15 2kg cm If the co
84. enerator coil Q Open circuit between generator 3 yellow wires x Test output voltage of AMETE _regulator rectifier coupler red wire Q Faulty regulator rectifier Faulty AC generator Normal voltage No voltage GLoose regulator rectifier coupler Limit voltage too high Overcharging Inspection Adjustment oymptom Probable Cause O Measure battery limit 0 voltage with an electric x tester QFaulty battery Faulty regulator rectifier Broken or poorly connected regulator rectifier black wire Check resistance 2 between regulator x ass rectifier terminals Normal Limit voltage too high 1 30 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 FUEL GAUGE 1 Pointer does not correctly switch ON Inspection Adjustment a Probable Cause x Check battery circuit by operating turn signals Signals operate properly Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connectors GBroken wire harness Remove fuel unit and check operation of pointer by moving float up and down Float up Full Float down Empty Pointer moves o Faulty float Check operation of pointer by opening and shorting fuel unit terminal wire harness Signals dim remain on or don t operate lo Broken or s
85. ents and the armature shaft There should be no continuity STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush Replace if necessary Wire Terminal Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity replace with new ones 18 STARTING SYSTEM Check if the needle bearing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage ASSEMBLY Apply grease to the dust seal in the front Cover Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shalt Insert the commutator into the front cover Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws INSTALLATION Connect the starter motor cable Check the O ring for wear or damage and replace if necessary Apply grease to the O ring and install it to the starter motor Tighten the two mounting bolts 18 5 QC KYMCO PEOPLE PEOPLE S 250 Bushing Dust Seal Motor Case Mark O ring Motor Case Starter Motor Cable
86. ft crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule 3 INSPECTION ADJUSTMENT HEADLIGHT AIM Turn the ignition switch ON Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary COOLING SYSTEM COOLANT LEVEL INSPECTION Place the scooter on its main stand on level ground Check the coolant level of the reserve tank and the level should be between the upper and lower level lines If necessary remove the screw and reserve tank cover to fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 3096 e The coolant level does not change matter the engine is warm or cold Fill to the F upper line COOLANT REPLACEMENT X Perform this operation when the engine is cold Reserve Tank Cover KYMCO PEOPLE PEOPLE S 250 Lower Line dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 Radiator Cap Remove the front cover Remove the radiator cap Remove the drain bolt to drain the coolant and tilt the scooter
87. ft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear Install the dowel pins Install the camshaft holder washers and nuts on the camshaft holder Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder Torque Cylinder head cap nut 24 5N m Cylinder amp cylinder head bolt 7 8 11 8N m e Apply engine oil to the threads of the cylinder head cap nuts e Diagonally tighten the cylinder head cap nuts in 2 3 times e First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks Camshaft Gear Cam Chain x N aqa 1 13 E Camshaft Gear Dowel Pins Punch Marks Cam Chain NE k 4 44 wii j DEN Camshaft Cap Nuts Camshaft Holder 6 10 dO KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 Tensioner Screw Turn the cam chain tension screw counter clockwise to release it Apply engine oil to a new O ring and install it Tighten the cam chain tension cap screw X Be sure to install the gasket into the groove properly CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 23 6 Install a new cylinder head cover O ring and install the cylinder head cover Be sure to install the O ring into the groove properly Install and tighten the cylinder head cover bolts
88. g and vacuum piston Vacuum Piston Remove the needle holder spring and jet Diaphragm Vacuum Piston needle from the piston X e Be careful not to damage the vacuum piston diaphragm VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears Needle Holder Jet Needle 13 8 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE 5 250 Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber Screws Remove the float pin float and float valve Float Valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Valve Seat 13 9 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 JETS SCREWS REMOVAL e Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record the rotating turns Do not force the pilot screw against its seat to avoid seat damage Pilot Screw P S Main Jet Remove the main jet needle jet holder and needle jet Remove the slow jet Slow Jet Needle Jet Slow Jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil e Be sure to use clean detergent oil Pilot Screw Needle Jet Holder Main Jet 13 10 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PE
89. gnition system according to the sequence specified in the Troubleshooting 21 28 e The ignition system adopts ignition unit and the ignition timing cannot be adjusted e f the timing is incorrect inspect the ignition unit and A C generator and replace any faulty parts Inspect the ignition unit with a ignition unit tester Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation e Use of spark plug with improper heat range is the main cause of poor engine performance e inspections in this section are focused on maximum voltage The inspection of ignition coil resistance is also described in this section Inspect the ignition switch according to the continuity table specified in page 19 3 e Inspect the spark plug referring to Section 3 e Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Spark plug opark plug gap Ignition timing Standard type F mark Full advance Standard NGK DPR7EA9 repeatedly 3 6 4 10 Ignition coil resistance 20 Secondary without plug cap 14KO C coil Pulser coil resistance 20 C Exciter coil resistance 20 C Ignition coil primary side max voltage Pulser coil max voltage Exciter coil max voltage TESTING INSTRUMENT Electric tester YF 3501 TROUBLESHOOTING No spark at plug e Faulty spark plug e Poorly connected broken or shorted wire e Faulty ig
90. he runout using a dial gauge The actual runout is of the total indicator reading Service Limit 0 2mm replace if over 14 5 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONTFORK TOP PEOPLE 5 250 WHEEL Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub BEARING REPLACEMENT Remove the front wheel bearings and distance collar 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing e Do not allow the bearings to tilt while driving them in e Drive in the bearing squarely with the sealed end facing out Special Tools Oil seal amp bearing installer E014 INSTALLATION Apply grease to the speedometer gear unit Install the speedometer gear unit by aligning its retaining pawl with the hub cutout e f not aligned the retaining pawl will be deformed when the axle nut is tightened e After installing the axle turn the wheel to make
91. he adjusting nut A Lock Nut Minor adjustment is made with the adjusting Bock Nut nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Rubber Cover dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 Cil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on level ground Wait for 2 3 minutes and check the oil level with the dipstick Do not screw in the dipstick when making this check OIL CHANGE e Drain the oil while the engine is warm Remove the oil drain bolt to drain the engine oil Install the aluminum washer and tighten the oil drain bolt Torque 14 7 e Replace the aluminum washer with a new one if it is deformed or damaged Pour the recommended oil through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE 15W40 SJ Start the engine and check for oil leaks Stop the engine and recheck the oil level Oil Filter Screen Cap opring OIL FILTER SCREEN INSPECTION HR EE 7 Drain the engine oil aa Remove the oil filter screen and spring Clean the oil filter screen Install the oil filter screen spring and filter screen cap Fill the engine with recommended engine oil A Oil Filter Screen dO KYMCO 3 INSPECTION ADJUSTME
92. he caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 45mm ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 5mm beyond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the two brake pads Install the two brake pad dowel pin and tighten them When installing the brake be sure to position the brake disk between a N 3 4 the two brake pads p Brake Pads 14 12 KYMCt 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 5 250 Bolts Install the brake caliper to the shock absorber and tighten the two bolts Torque 29 35N m Connect the brake fluid tube with the attaching bolt and two sealing washers to the brake caliper and tighten the fluid tube bolt Torque 24 30N m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 214 10 When installing the brake fluid tube be sure to install the two sealing washers 14 STEERIN
93. he skin and eyes Avoid contact with skin eyes or clothing case of contact flush with water get prompt medical attention e The battery can be charged and discharged repeatedly f a discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after it is used for 2 3 years capacity decreased battery will resume its voltage after it is recharged but its voltage decreases suddenly and then increases when a load is added e When a battery is overcharged some symptoms can be found If there is a short circuit inside the battery no voltage is produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life e f a battery is not used for a long time it will discharge by itself and should be recharged every 3 months e new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life e Inspect the charging system according to the sequence specified in the Troubleshooting e Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation e t is not necessary to check the MF battery electrolyte or fill with distilled water
94. horted fuel unit wire Check connectors for proper connection U Y ODisconnected connector Incorrectly connected connector Broken or shorted wire in fuel gauge 2 Pointer fluctuates or Ignition switch ON Inspection Adjustment _ Symptom Probable Cause O Check battery circuit by x operating turn signals and horn x Burned out fuse i QWeak Or dead battery Signals operate signals dim remain GFaulty ignition switch x properly on don t operate Loose or disconnected check operation of pointer by moving float gt GBroken wire harness and down x Pointer does not Poor contact in fuel unit mM OUS Move float up and down rapidly 1 round seC eee CCC E to check the operation of pointer x accordance with move in accord Olnsufficient damping oil in float ance with float fuel gauge Check connectors for x proper connection HH connector Broken or shorted wire in fuel gauge 1 31 1 GENERAL INFORMATION GQ KYMCO PEOPLE PEOPLE S 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT oymptom Steering is heavy Front or rear wheel is wobbling Steering handlebar pulls to one side POOR SUSPENSION PERFORMANCE oymptom Suspension is too soft Suspension is too hard POOR BRAKE PERFORMANCE oymptom Soft brake lever
95. i dO KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE 5 250 STARTING SYSTEM STARTING SYSTEM LAYOUPu ili il l iii l i s 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 2 STARTER MOI OR 18 3 STARTER CLUTCH INSPECTION 18 6 STARTER RELAY T 18 6 18 0 GQ KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE S 250 STARTING SYSTEM LAYOUT Stop Switch Starter Button M s Starter Relay ti Starter Motor STARTING CIRCUIT MAIN SW B 3 R STOP SW STOP SW zz ud STARTER SW m G Y at 12V10AH Iia 18 1 dO KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed e For the starter clutch removal refer to page 10 3 e After the starter clutch is installed be sure to add the engine oil and coolant and then bleed air from the cooling system SPECIFICATIONS Standard mm Service Limit mm TORQUE VALUES Starter motor mounting bolt 6 7 10 8N m Starter motor case screw 2 9 4 9N m Starter clutch bolt 9 8 13 7N m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter motor won t turn Lack of power e Fuse burned out e Weak battery e Weak battery e Loose wire or connection e Faulty ignition switch e Foreign matter stuck in s
96. ight bulb Stoplight taillight License plate light Position light Turn signal indicator light 10A 15A 30A 12V 35W 35W 12V 10W 12V 21 5W 12V 5W 12V 5W 12V 3W 19 2 19 SWTCHES HORNFUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGEANS TRUMENTS LIGHTS PEOPLE PEOPLE S 250 SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers 22 5 Disconnect the ignition switch wire couplers Check for continuity between the wire terminals HEADLIGHT SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals BR W STARTER SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the starter switch wire couplers Depress the starter button and check for continuity between the wire terminals FREE PUSH O T O O ENGINE STOP SWITCH Remove the handlebar front cover 22 3 Disconnect the wire couplers Checks for continuity between the engine stop switch wire terminals 19 SWTCHESHORNFUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGEANSTRUMENTS LIGHTS HORN BUTTON INSPECTION Remove the handlebar front covers 2 3 Disconnect the horn wire couplers Depress the horn button and check for continuity between the wire terminals use Light Green Brown Blue FREE o PUSH O O TURN SIGNAL SWITCH INSPECTION Remove the handlebar front covers 92 39 Disconnect the tur
97. ing movable part O ring face Oil seal lip Starter idle gear Friction spring movable part shaft movable part High temperature resistant grease Shaft movable grooved part Starter spindle movable part Starter one way clutch threads Thread locking agent A C generator connector Transmission case breather tubee 1 10 QC KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 FRAME The following is the lubrication points for the frame Use general purpose grease for parts not listed 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 Hn Engine Oil Speedometer Cable Grease Throttle Cable Front Brake Lever Pivot aa Grease Seat Lock Speedometer Gear Rear Fork Bearing Front Wheel Bearing _ Grease Grease 1 11 PEOPLE PEOPLE S 250 1 GENERAL INFORMATION CABLE amp HARNESS ROUTING Winker Horn DIM Wire Front Brake Master Cylinder Rear Brake Master Cylinder Speedometer Cable Throttle Cable Rear Brake Fluid Tube Horn twee UT NET t Tt e Tt s 7 1 9 55555755 mft tee eet teere e HUHA 5 252122122 2 22 2 2222 UJ 4 k ia w fil 9 MOA ee E
98. it is not interfering with any moving or sliding parts B 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 B Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws B Route harnesses so they are neither pulled tight nor have excessive slack pull gt too tight fe d 9 LL Protect wires harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Am B Do not break the sheath of wire B f wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires O press er 1 GENERAL INFORMATION B After routing check that the wire harnesses are not twisted or kinked O X 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 B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Do you understand th
99. ith the leg shield Remove the front under cover LEG SHIELD REMOVAL Remove the front cover 22 4 Remove the side cover 22 6 Remover the met in box and carrier 22 6 Remove the body cover center cover and rear fender A together 22 6 Remove the floor board 2 7 Remove the front under cover 22 7 Remove the key molding and fuel tank cap molding o P ES Remove the bolt on the leg shield E Fuel Tank Cap Molding Key Molding Remove the screw on the frame that combining the frame with the leg shield Remove the three screws that combine the reserve water tank with the leg shield Remove the leg shield CENTER UNDER COVER REMOVAL Remove the right and left side cover 22 6 Remove the four bolts on the center under cover Bolts 2 EXHAUST MUFFLER FRAME COVERS Remove the center under cover REAR FENDER COVER B C REMOVAL Remove the met in box 22 6 Remove the body cover center cover and rear fender A together 22 6 Remove the four screws on the rear fender B Remove the rear fender B Remove the two bolts on the rear fender C KYMCO PEOPLE PEOPLE S 250 Bolts A VAS k ib Under Cover Screws Rear Fender Cover B TE B 2 EXHAUST MUFFLER FRAME COVERS dO KYMCO PEOPLE PEOPLE S 250 Remove the screw attaching the air cleaner case Remove the rear fender C EXHAUST MUF
100. l Gear FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft 9 FINAL REDUCTION QC KYMCO PEOPLE PEOPLE S 250 Inspect the final gear and final shaft for wear damage or seizure Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Inspect the drive shaft and gear for wear or damage Check the transmission case covers bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing Drive Shaft and Gear f _ m i F G g Q Countershaft Bearing Final Shaft Bearing Final Shaft Drive Shaft Bearing GQ KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 Drive Shaft Bearing BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Bearing Remover Drive new bearings into the transmission case cover Drive Shaft BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover dO KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 Drive ne
101. l not to drop any gasket material into the engine Cylinder ax Cam Chain Guide Cylinder Head Gasket Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor e sure to compress the valve springs with a valve spring compressor e Mark all disassembled parts to ensure correct reassembly Valve spring compressor E040 Valve Spring Compressor Combustion Chamber Remove carbon deposits from the exhaust port and combustion chamber Be careful not to damage the cylinder head mating surface 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 Straight Edge INSPECTION qe CYLINDER HEAD Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if Over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner IN EX 29 5mm replace if below Outer IN EX 39 5mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 925mm replace if below EX 4 915mm replace if below CYLINDER HEAD ASSEMBLY Install the valve spring seats and stem seals Lubricate each valve s
102. ml 4 Ly yy yy 212020227221 T 222444 tix WYANT ee ss we Sat 292 7 Radiator Air Ventilated Tube _ to Radiator II NISN Ttt VAS VAR the beer re m IILI a tt 4 bk WAWA TL rr UY s T EL w ar gt 22241444 arre E E E I Atttttttrt2t ir rto T t9t3 r 1 2 2 4 4112441221 211113 T tttttees toT MA CANA 77656794422 tt LC WAV 8 LLC GG Fuel Tank Radiator Open Cable 1 12 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 Start Light ENG Stop Passing Wire Winker Horn DIM Wire ZW Radiator Air Ventilated Tube to Radiator Water Duct Radiator Fuel Tank Cap Radiator Air Thermostatic Switch Ventilated Tube Water Inlet Hose Fuel Tank Inlet Hose Front Brake Fluid Tube Fuel Pump Vacuum Tube Fuel Pump Outlet Tube Fuel Pump 1 Mw Front Brake Caliper i Rear
103. mpression is low check for the following Leaky valves e Valve clearance to small e Leaking cylinder head gasket Worn pistons Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head FUEL TANK CAP CABLE WIRE Look Nut Pull Please remove the front cover to inspect the N fuel tank cap cable wire slack when operate the fuel tank cap hardly SEAT CABLE WIRE Please remove the front cover to inspect the seat cable wire when operate the seat hardly elax Pull dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE PEOPLE S 250 FINAL REDUCTION GEAR OIL e Place the scooter on its main stand on level ground Stop the engine and remove the oil checks bolt The oil level shall be at the oil check blowhole If the oil level is low add the recommended oil SAE90 to the proper level Install the oil check bolt Oil Drain Bolt Sealing Washer e Make sure that the sealing washer is in good condition GEAR OIL CHANGE Remove the oil check bolt Removes the oil drains bolt and drain the oil thoroughly Install the oil drain bolt Torque 9 8N m e Make sure that the sealing washer is good condition Fill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 230cc At change 180cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the le
104. n signal switch wire couplers and turn on the turn signal switch Check for continuity between the wire terminals o r o DIMMER SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the headlight dimmer switch wire couplers Turn on the dimmer switch and check for continuity between the wire terminals STOP SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the front rear stop switch wire couplers Check for continuity between the wire terminals when the front brake lever is applied Brown Blue Green Yellow KYMCO m M wx 22 pu d Button 7 Turn Signal Switch Dimmer Switch Stop Switch Stop Switch 19 4 PEOPLE PEOPLE S 250 19 SMTCHESHORNFUEL UNITITHERMOSTATIC SWITCH KYMCO TEMPERATURE GAUGEINSTRUMENTSILIGHTS S 250 Horn HORN INSPECTION Remove the front cover 2 5 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals FUEL UNIT FUEL UNIT INSPECTION Remove the fuel unit Disconnect the fuel unit wire connectors Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions YAN G 9 1 9 30 95 960 Electric tester YF 3501 Fuel Unit Fuel Full
105. ng Test cylinder compression Incorrect Check carburetor for clogging Not Clogged Remove spark plug and inspect Clogged Remove oil dipstick and i check oil level and condition Remove cylinder head oil pipe bolt and inspect Valve train Valve train not lubricated properly lubricated properly Check if engine overheats Engine does not Engine overheats overheats Rapidly accelerate or run at high speed Engine does not knock Engine knocks 1 23 QC KYMCO PEOPLE PEOPLE S 250 Probable Cause DClogged air cleaner Restricted fuel flow GClogged fuel line between fuel tank and carburetor Clogged exhaust muffler GFaulty auto bystarter Split carburetor vacuum piston diaphragm OFaulty unit Faulty A C generator Improper valve clearance adjustment Worn valve seat valve stem too protruding QImproper valve and seat contact Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head Gimproper valve timing Clogged carburetor jets Fouled spark plug Q Incorrect heat range plug level too high Oil level too low not changed Clogged oil pipe Fau fy oil pump I nsufficient coolant Faulty thermostat Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber lgnition timing
106. ng Frame type gt D o m e H D Q s 1 GENERAL INFORMATION QC KYMCO PEOPLE PEOPLE S 250 SERVICE PRECAUTIONS B Make sure to install new gaskets O rings circlips cotter pins etc when reassembling O o B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally B Use genuine parts and lubricants Qr B When servicing the motorcycle be sure to use special tools for removal and installation B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly 2 m Apply add designated greases lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first m After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 GENERAL INFORMATION B f the fuse i
107. ng top cone race 4 9 12 7N m Front shock absorber bolt 29 35N m Front axle 29 35N m Brake caliper holder bolt 29 35N m SPECIAL TOOLS Lock nut wrench 002 Oil seal amp bearing installer E014 14 2 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e Bent front fork e Bent front axle or uneven tire Poor brake performance e Worn brake pads e Contaminated brake pad surface e Deformed brake disk e Air in brake system e Deteriorated brake fluid e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Unevenly worn brake caliper 14 3 KYMCO PEOPLE PEOPLE S 250 Front wheel wobbling e Bent rim e Loose front axle e Bent spoke plate e Faulty tire Improperly tightened axle nut Soft front shock absorber e Weak shock springs e Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK PEOPLE PEOPLE S 250 Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers 52 3 Remove the front and rear brake master cylinder attaching
108. nition switch e Faulty ignition coil e Faulty ignition unit e Faulty A C generator Engine starts but turns poorly e Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Poorly contacted ignition switch e Ignition secondary circuit Faulty ignition coil Faulty spark plug Faulty high tension wire Poorly insulated plug cap e Improper ignition timing Faulty A C generator Stator not installed properly Faulty ignition unit 17 2 17 IGNITION SYSTEM GQ KYMCO PEOPLE PEOPLE S 250 SPARK PLUG For spark plug inspection and adjustment refer to page 3 5 IGNITION COIL INSPECTION Remove the seat and met in box 22 6 Remove the ignition coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil This is general test Accurate ignition coil test must be performed with a ignition unit tester Measure the ignition coil resistances at 20 Primary coil Secondary coil without plug cap Secondary coil with plug cap Electric tester YF 3501 17 3 Ignition Coil Ignition Coil Ignition Coil Secondary Coil gt C 17 IGNITION SYSTEM A C GENERATOR INSPECTION EXCITER COIL PULSER COIL INSPECTION This test is performed with the stator Installed in the engine Remove the seat and met in box gt 2 6 Disconnect the A C generator connector Measu
109. nut Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt frame side Engine hanger bolt ENG side Front caliper holder bolt Rear caliper holder bolt Master cylinder holder bolt Exhaust muffler pipe nut Exhaust muffler bolt Rear fork bolt N OONA NNa NANN SPECIAL TOOLS Clutch spring compressor Clutch disassembly Bearing puller 10 12 15 18mm Bearing removal Valve spring compressor Valve removal Oil seal amp bearing installer Oil seal amp bearing install Tappet adjuster Tappet adjustment Flywheel puller A C generator flywheel removal Universal holder Holding clutch for removal Flywheel holder A C generator flywheel holding Lock nut socket wrench Steering stem removal or install Float level gauge Carburetor fuel level check dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAE15W 40 Camshaft protruding surface SE SF or SG Egnine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft Cranksahft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bear
110. or with coolant 23 9 Connect the vent tube to the radiator filler After installation check for coolant leaks If you want to refill the coolant the following procedure must be checked 1 Please make the radiator filler and the air vent tube to be separated 2 Then start the engine filled in the coolant till the coolant flowed out from Outlet Tube of Reserve the air vent tube lg Put the air vent tube on Overflow Tube Fan Motor Wire Coupler Connect the outlet tube of the reserve tank and secure with the tube clamp GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 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 WATER PUMP IMPELLER REMOVAL Inlet Hose Remove the coolant inlet hose and outlet hose Remove the four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller The impeller has left hand threads 12 9 12 COOLING SYSTEM Inspect the mechanical water seal and seal washer for wear or damage The mechanical seal and seal washer must be replace as a set WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove the eight bolts attaching the right crank
111. r A 2 6 Disconnect the secondary air inlet tube connector and breather hose air cleaner 55 2 Remove the cylinder head cover four bolts and two nuts attaching the secondary air inlet duct Remove the cylinder head cover CAMSHAFT REMOVAL Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the right crankcase cover Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the cam chain tensioner cap bolt Turn the cam chain tensioner screw clockwise to tighten it Remove the two bolts attaching cam chain tensioner and the tensioner First remove the two bolts between the cylinder head and cylinder Then remove the four cap nuts and washers on the camshaft holder Diagonally loosen the cylinder head cap nuts in 2 or 3 times KYMCO PEOPLE PEOPLE S 250 Bolts ii a Ee 4 PI UL d dem now 1 i i m W T YR L z a Ai Lt 1 gt T3 4 Cylinder Head er Bolt Bolts Camshaft Holder 6 4 dO KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 Remove the camshaft holder Dowel Pins Remove the dowel pins Remove the camshaft gear from the cam chain to remove the camshaft CAMSHAFT INSPECTION Check each cam lobe for wear o
112. r damage Measure the cam lobe height Service Limits IN 34 14mm replace if below EX 34 02mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 CAMSHAFT HOLDER DISASSEMBLY Valve Rocker Arms Remove the valve rocker arms Rocker Arm Shafts Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface is worn check each cam lobe for wear or damage Measure the 1 0 of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits 9 90mm replace if below EX 9 90mm replace if below CYLINDER HEAD REMOVAL Bolt First drain the coolant from the radiator and water jacket then remove the thermostat water hose Remove the camshaft 26 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Thermostat 6 6 GQ KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE 5 250 Dowel Pins Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface Be carefu
113. r or damage Measure the driven face O D Service Limit 39 85mm replace if below 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 Check the movable driven face for wear or damage Measure the movable driven face Service Limit 40 06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play Drive the inner needle bearing out of the driven pulley face e Discard the removed bearing replace with a new one Remove the snap ring and drive the outer bearing out of the driven face e Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Inner Bearing Snap Ring Outer Bearing Seat the snap ring in its groove Apply grease to the driven face bore areas gt Pack all bearing cavities with 9 9 5g grease 8 10 8 DRIVE AND DRIVEN PULLEYS V BELT PEOPLE PEOPLE S 250 Press a new needle bearing into the driven face CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch e Keep grease off the clutch linings Clutch Lining Retainer Plate 8 11 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 CLUTCH ASSEMBLY Install the damper rubbers on the drive plate Circlips pins Install the cl
114. rake master cylinder Snap Ring Pliers Close Master Cylinder Spring Main Piston Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid onap Ring Rubber Cover 14 8 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO BRAKE FRONTSHOCKABSORBER FRONTFORK PF EPF F 5 250 INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 64mm Before assembly inspect the Ist and 2nd E rubber cups for wear ASSEMBLY Master Cylinder Spring Main Piston Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber During assembly the main piston spring must be installed as a unit without exchange When assembling the piston soak the cups in brake fluid for a while e Install the cups with the cup lips facing Snap Ring Rubber Cover the correct direction Install the main piston spring and snap ring Install the rubber cover Install the brake lever 14 9 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO CO ___BRAKE FRONT SHOCK ABSORBER ERONTFORK Stop Switch UP Mark Wire Connector M Place the brake master cylinder on the handlebar and install the
115. rankcase mating surfaces apart Remove the gasket and dowel pins Right Crankcase Remove the crankshaft from the left Crankshaft crankcase Left Crankcase A Left Crankcase Remove the oil seal from the left crankcase Oil Seal HEN 11 3 dO KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE S 250 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end 1 0 Service Limit 17 06mm replace if over 11 4 dO KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE S 250 Measure the crankshaft runout Service Limit 0 10mm replace if over Measure the crankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces e Avoid damaging the crankcase mating surfaces Left Crankcase Install a new oil seal into the left crankcase Oil Seal E 11 5 KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE PEOPLE S 250 Place the left crankcase down and install the crankshaft into the left crankcase X Avoid damaging the oil seal Apply grease to the lip of the oil seal Install the two dowel pins and a new gasket Place the right crankcase over the crankshaft and onto the left crankcase e Install the right crankcase squarely and do not tap it with an iron or pla
116. re the exciter coil resistance between the black white wire terminal and ground Black white Ground 8 1MQ Measure the resistance in the XO range Electric tester YF 3501 For generator removal installation refer to pages 10 3 and 10 6 Disconnect the pulser coil wire coupler Measure the pulser coil resistance between the blue white and green white wire terminals Blue Yellow Green White 105 110Q Electric tester YF 3501 IGNITION UNIT RESISTANCE INSPECTION Measure the resistance between the terminals Replace the ignition unit if the readings are not within the specifications in the table below dO KYMCO PEOPLE PEOPLE S 250 29 Pulser Coil Wire Coupler Ignition 17 4 GQ KYMCO 17 IGNITION SYSTEM PEOPLE PEOPLE 5 250 e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e n this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the condenser is discharged BAW G G GR VR VIG Unit Q lt A 5 ve pee ve e em pes mee pere on Electric tester YF 3501 17 5 18 d
117. ry Air Cleaner Fresh Air Inlet Hose Secondary Air Cleaner Fuel Pump Secondary Air Cleaner Fresh Air Outlet Hose Fuel Tube Between Fuel Pump and Fuel Filler 1 17 QC KYMCO 1 GENERAL INFORMATION PEOPLEPEOPLE S 250 Battery Cable Battery Battery Cable Fuse Box Ignition Unit Seat Open Cable Ignition Coil Throttle Cable Wire Harness Rear Brake Fluid Tube Carburetor k Auto Bystarter Thermostat WE gt n P RA s Radiator Air Ventilated Tube Thermosensor Spark Plug Cap 1 18 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE 5 250 People s 250 model Fuse Box Ignition Coil Starter Motor Wire Carburetor Regulator Rectifier Fuel Cap Fuel Pump Fuel Tube Between Fuel Pump and Fuel Filler Secondary Air Cleaner Fresh Air Outlet Hose Starter Relay C D I Unit Fuel Pump Ignition Coil Oil Vapor Recovery Tube Wire Harness Carburetor Spark Cap 1 19 2 gt lt PEOPLE PEOPLE S 250 1 GENERAL INFORMATION L wen HEAD LIGHT 12V 35Wr38VV FR POSITION 12V SW SPEEDOMETER FR LIGHTING SW amp Lar 1 ki CELL PHONE 12V CELL PHONE TEMP METER ENGINE STOP STARTER FUELLEVEL INDICATOR BR SER Y We Ww E ER G BRAY L FUSE 30A CHARGING FUSE B
118. s burned out find the cause and repair it Replace it with a new one according to the specified capacity 11 24 Capacity B After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation B Hold the connector body when connecting or disconnecting it Do not pull the connector wire DE BRO B Check if any connector terminal is bending protruding or loose KYMCO PEOPLE PEOPLE S 250 B Ihe connector shall be inserted completely B f the double connector has a lock lock it at the correct position B Check if there is any loose wire B Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation B insert the terminal completely Check the terminal cover for proper coverage B 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 O x 1 GENERAL INFORMATION KYMCO PEOPLE PEOPLE S 250 B After clamping check each wire to make sure it is secure O x Do not squeeze wires against the weld or its clamp X B After clamping check each harness to make sure that
119. s one mark on the surface of the inner rotor and outer rotor The mark is upside Outer Rotor Inner Rotor Pump Shaft 4 5 4 LUBRICATION SYSTEM GQ KYMCO PEOPLE PEOPLE S 250 Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding OIL PUMP INSTALLATION Install the oil pump and oil separator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and driven gear then set the circlip securely on the pump shaft Install the oil separator cover properly Fit the tab of the separator cover into the slit in the separator Install the A C generator starter driven gear gt 10 8 Screw a Dowel Pin _ Mark Pump Shaft i n ur imt T e HW i A 5 iy E p 2 L A P m p 5 f E i s dim 1 Es E Bolts Oil Pump Oil Pump Driven Gear Circlip 5 Ev Be m al J k gt 3 x olf Separator Cover dO KYMCO 5 ENGINE REMOVAL INSTALLATION PEOPLE PEOPLE S 250 ENGINE REMOVAL INSTALLATION SERVICE
120. stic hammer Install and tighten the right and left crankcase attaching bolts Torque 7 8 10 8 Left Crankcase Crankshaft Gasket Dowel Pins Left Crankcase Right Crankcase D a a Es e ml F t 11 6 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE 5 250 COOLING SYSTEM SCHEMATIC 12 1 SERVICE INFORMATION seed uu 12 2 TROUBLESHOOTING 12 2 COOLING SYSTEM TES TIN Cac 12 4 u 12 4 WATER PUMP eere ee EE EE 12 9 12 14 12 15 12 0 GQ KYMCO PEOPLE PEOPLE 5 250 12 COOLING SYSTEM SCHEMATIC DRAWING 12 1 GQ KYMCO 12 COOLING SYSTEM PEOPLE PEOPLE S 250 SERVICE INFORMATION GENERAL INSTRUCTIONS e water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame e engine must be cool before servicing the cooling system When the coolant temperature is over 100 C never remove the radiator cap to release the pressure because the boiling coolant may cause danger e 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 e After servicing the system check for leaks
121. sure that the speedometer drive shaft rotates freely Install the front wheel by aligning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle When installing the front wheel position the brake disk between the two brake pads Torque 29 35N m Install and tighten the two bolts Torque 29 35N m 14 7 QC KYMCO PEOPLE PEOPLE S 250 Driver Handle VS Outer Driver Pawl Speedometer Gear Unit Hub Cutout Axle _ Tab Speedometer Gear Unit Groove 14 STEERING HANDLEBAR FRONT WHEEL FRONT dO BRAKE RONTSHOCKABSORBER FRONTFORK Sta Bolts Holder FRONT BRAKE BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers 22 3 First drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt FU Remove the two bolts attaching the brake 1 master cylinder otop Switch Wire Connector Remove the brake master cylinder e When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage Snap Ring DISASSEMBLY Remove the brake lever bolt and the brake lever Remove the piston rubber cover and snap ring from the b
122. t Pump Drive Chain Oil Separator Cover Install the oil separator cover properly vo MAS Lam Fit the tab of the separator cover into the x ah slit in the separator 10 7 GQ KYMCO 10 GENERATOR STARTER CLUTCH PEOPLE PEOPLE S 250 Shaft Starter Idle Gear Install the starter idle gear and shaft ues Install the starter driven gear onto the crankshaft FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel e Before installation check and make sure that the inside of the flywheel is not contaminated Key Groove Install washer and nut Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 53 9 63 7 remove the flywheel nut and washer Flywheel holder E021 dO KYMCO 10 GENERATOR STARTER CLUTCH X PEOPLE PEOPLE S 250 Screws Screws STATOR INSTALLATION Install the A C generator stator on the right crankcase cover and secure it with the three bolts Install the pulser coil on the right crankcase cover and secure it with the two screws Install the wire grommet in the groove in the right crankcase cover securely Be sure to route the stator wire under the pulser coil Generator Stator Pulser Coil Gasket RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket
123. tarter motor e Faulty starter clutch or gear e Faulty front or rear stop switch e Faulty starter relay Starter motor rotates but engine does e Poorly connected broken or shorted wire not start e Faulty starter motor e Faulty starter pinion e Starter motor rotates reversely e Weak battery 18 2 QC KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE S 250 STARTER MOTOR REMOVAL e Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly Remove the seat met in box and carrier 52 6 Remove the body cover center cover and rear fender A together 2 6 Remove the nut goes to the starter relay and relax cable band to disconnect the starter motor cable Remove the two starter motor mounting bolts and the motor Motor Case Rear Cover DISASSEMBLY Remove the two starter motor case screws front cover rear cover motor case and other parts Front Cover Case Screws Commutator INSPECTION Inspect the removed parts for wear damage or discoloration Replace if necessary Clean the commutator if there is metal powder between the segments 18 3 dO KYMCO 18 STARTING SYSTEM PEOPLE PEOPLE S 250 Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segm
124. ted or stuck closed 1 29 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 NO SPARK AT SPARK PLUG Replace with a new spark plug and inspect again T and high tension wire looseness Check ignition unit coupler for looseness Measure resistance between terminals of Check ignition unit with a ignition unit tester Inspection Adjustment Symptom Probable Cause Q Ll Faulty spark plug Faulty spark plug ignition unit coupler QFaulty ignition switch Faulty exciter coil Faulty pulser coil Faulty ignition coil Normal Abnormal QBroken wire harness Poorly connected coupler Check ignition coil with ignition unit tester Faulty ignition coil dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment oymptom Probable Cause 9 Start engine and test limit voltage of battery terminals x Faulty AC generator Faulty regulator rectifier Faulty battery Measure resistance between AC generator coil terminals QShorted AC g
125. tem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Valve spring compressor E040 Valve Spring Compressor 6 8 6 CYLINDER HEAD VALVES dC KYMCO PEOPLE PEOPLE S 250 Tap the valve stems gently with a plastic hammer to firmly seat the cotters Be careful not to damage the valves CYLINDER HEAD INSTALLATION Install the cam chain guide Install the dowel pins and a new cylinder head gasket Install the cylinder head and take out the cam chain Assemble the camshaft holder First install the intake and exhaust valve rocker arms then install the rocker arm shafts gt e Install the exhaust valve rocker arm shaft on the EX side of the camshaft holder and the exhaust rocker arm shaft is shorter e Clean the intake valve rocker arm shaft off any grease before installation e Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder Plastic Hammer Cylinder Head Cylinder Dowel Pins Cam Ch 1 ain Guide Cam Chain Valve Rocker Arms P Xe Camshaft Holder 6 CYLINDER HEAD VALVES QC KYMCO PEOPLE PEOPLE S 250 CAMSHAFT INSTALLATION Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the right crankcase cover Keep the round hole on the camshaft gear facing up and align the punch marks on the camsha
126. the steering stem lock nut Remove the top cone race and remove the front fork Be careful not to lose the steel balls 26 on top race and 19 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Bottom Cone Race Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and front fork BALL RACE REPLACEMENT Drive out the ball races Drive in new ball races sure to drive the ball races into place completely A NOSE Top Ball Race 14 15 14 STEERING HANDLEBAR FRONT WHEEL FRONT dO BRAKE FRONTSHOCKABSORBER FRONTFORK TOPET OPT Sta INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Then install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 80 120N m Install the front wheel 214 7 Install the front brake caliper
127. the tank shield and remove the tank shield 13 20 13 FUEL SYSTEM CARBURETOR dC KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 E Fuel Unit Wire Connector Tube to Fuel Filler Disconnect the fuel unit wire connector Remove the fuel tube between the fuel tank and the fuel filler Disconnect the fuel vapor tube Disconnect the fuel tube between the fuel tank and fuel strainer Vapor Tube PU Dx 3 22 ks Tube to Fuel Strainer Fuel Bolts Remove the four bolts on the fuel tank JB 2775 ms Remove the fuel tank Bolts j The installation sequence is the reverse of removal 13 21 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 FUEL STRAINER REMOVAL Remove the right side cover Remove the fuel strainer from the fuel line Fuel Strainer INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air X When removing the fuel strainer do not allow flames or sparks near the working area and drain the residual gasoline into a container INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump Fuel Strainer 13 22 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO BRAKE RONTSHOCK ABSORBER FRONTFORK F STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SCHEMATIC DRAWING
128. the tires for cuts imbedded nails or other damages Check the tire pressure X pressure should be checked when tires are cold Tire Pressure 1 75kg cm 2 1 75kg cm 2 ram 20kglom STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheels off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there is any looseness 3 11 GQ KYMCO 4 LUBRICATION SYSTEM PEOPLE PEOPLE 5 250 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE 4 2 TROUBLESHOOTING 4 2 ENGINE OIL OIL FILTER 4 3 OIL PUMP 4 4 OIL PUMP DISASSEMBLY 4 4 OIL PUMP
129. ton ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole 1 0 Service Limit 17 04mm replace if over 7 CYLINDER PISTON PEOPLE PEOPLE S 250 Measure the piston pin O D Service Limit 16 96mm replace if below Measure the piston O D X Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 72 60mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Service Limit 72 80mm repair or replace if Over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if Over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels is subject to the maximum value calculated Service Limits True Roundness 0 09mm repair or replace if over Cylindricity 0 09mm repair or replace if over 7 5 7 CYLINDER PISTON QC KYMCO PEOPLE PEOPLE S 250 Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if over Measure the connecting rod small end 1 0 Service Limit 17 06mm replace if over PISTON
130. too early amp Air in cooling system Excessive carbon build up in combustion chamber 2 Poor quality fuel Clutch slipping amp Mixture too lean Ignition timing too early dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE 5 250 POOR PERFORMANCE ESPECIALLY IDLE AND LOW SPEEDS Inspection Adjustment Symptom Probable Cause Faulty ignition unit Faulty A C generator Correct timing Incorrect timing Check carburetor pilot screw adjustment Mixture too rich turn screw Incorrectly adjusted out Correctly adjusted Mixture too lean turn screw in RE EER REE EOS x Check carburetor gasket for air leaks n Damaged insulator rubber i M GFaulty intake manifold gasket Deformed carburetor O ring Remove spark plug and install it into spark plug to test spark by gt connecting it to engine ground oos Faulty or fouled spark plug Weak or inter Faulty ignition unit mittent spark GFaulty A C generator Faulty ignition coil GBroken or shorted high tension wire Faulty ignition switch x Check carburetor air cut off valve ODamaged air cut off valve diaphragm Damaged air cut off valve spring 1 24 dO KYMCO 1 GENERAL INFORMATION PEOPLE PEOPLE S 250 POOR PERFORMANCE AT HIGH SPEED Symptom x Check ignition timing x qaqaq Probable Cause
131. ty fuse e oose terminals or connectors e Shorted wire in the wire harness TEMPERATURE METER Disconnect the wire from the thermosensor and ground it to the engine Turn the ignition switch ON The temperature gauge needle should move all the way to H Do not leave the thermosensor wire grounded for longer than 5 seconds or the temperature gauge will be damaged HEATER CONTROLER UNIT INSPECTION 1 Open ignition switch to check if the brown blue wire of it is enough voltage 2 Put the heater controller unit in refrigerator Start engine after keeping the temperature under 10 4C 3 Check if the yellow wire of heater controller unit has output voltage otart engine and if the temperature of heater controller unit is under 10 4C Check if the white yellow wire of heater controller unit has output voltage If it has not any voltage It is damaged 19 6 19 SWTCHES HORNFUEL UNIT THERMOSTATIC SWITCH dO KYMCO TEMPERATURE GAUGEANS TRUMENTS LIGHTS PEOPLE PEOPLE S 250 THROTTLE POSTTION SENSOR Unit KO INSTRUMENTS REMOVAL Remove the handlebar rear cover 22 4 Remove the three screws under instruments Remove the instruments from the handlebar rear cover INSTALLATION The installation sequence is the reverse of removal FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the two screws attaching the turn signal light shell and remove the screw attaching bulb shell Remove the
132. ure e ean mixture e Clogged air cleaner e Intake air leak e Contaminated fuel e Faulty air cut off valve e Damaged vacuum tube and connectors e Damaged carburetor insulator Rich mixture e Auto bystarter valve opens excessively e Faulty float valve e Float level too high e Clogged air jets e Auto bystarter valve set plate installed in the wrong groove eClogged air cleaner 13 6 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 CARBURETOR REMOVAL oe Fuel Tube Remove the met in box y Disconnect the fuel tube at the carburetor ve Disconnect the auto bystarter wire VS X Disconnect the throttle position sensor wire MNT 5 y m Air Cleaner Connecting Tube Band ho Intake Manifold Band Disconnect the heater carburetion wire coupler Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then remove the carburetor Heater Carburetion Wire Coupler VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Drain Screw 13 7 13 FUEL SYSTEM CARBURETOR O KYMCO FUEL PUMP FUEL TANK PEOPLE PEOPLE S 250 Screws Remove the two vacuum chamber cover screws and the cover Vacuum Chamber Cover opring Remove the compression sprin
133. utch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips Drive Plate Movable Driven Face CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease from them Apply grease to the O rings and install them onto the moveable driven face 8 12 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 Guide Roller Guide Roller Pin Install the movable driven face onto the driven face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Driven Face Movable Driven Face Seal Collar Install the seal collar Remove any excessive grease e Be sure to clean the driven face off any grease Set the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor X Align the flat surface of the driven face with the flat on the clutch drive plate Compress the tool and install the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 49 0 58 8N m X e Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor E034 Lock Nut Wrench 8 13 8 DRIVE AND DRIVEN PULLEYS V BELT INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft Lay the drive belt on the driven pulley Set the dri
134. ve belt on the drive pulley collar Install the clutch driven pulley and clutch outer onto the drive shaft e Keep grease off the drive shaft Install washer and the clutch outer nut Hold the clutch outer with the universal holder to tighten clutch outer nut Torque 49 0 58 8kg m Universal HolderE01 7 Install the drive pulley face washer and drive face nut Hold the drive pulley with the universal holder and tighten the drive face nut Torque 88 2 98N m Universal HolderE01 7 X e Do not get oil or grease on the drive belt or drive pulley faces QC KYMCO PEOPLE PEOPLE S 250 Drive Collar BAL Movable Drive Face Assembly Drive Pulley Collar Driven Pulley and Out Drive Belt Clutch 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT PEOPLE PEOPLE S 250 Install the left crankcase cover 8 3 8 15 dO KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 FINAL REDUCTION SCHEMATIC 9 1 SERVICE INFORMATION u ullu 9 2 TROUBLESHOOTING eurer 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION INSPECTION d 9 3 FINAL REDUCTION ASSEMBLY 9 6 9 0 QC KYMCO PEOPLE PEOPLE S 250 9 FINAL REDUCTION SCHEMATIC DRAWING 9 1 dO KYMCO 9 FINAL REDUCTION
135. ve rocker arm shaft 9 972 9 987 99 J O D 9 5 987 2 8 1990 4975 Valve OLD 4 970 4 955 4 915 N 5 00 5 012 Val I D Valve oade 0 010 0 037 clearance 0 030 0 057 TORQUE VALUES Cylinder head cap nut 24 5N m Apply engine oil to threads Valve clearance adjusting nut 8 8 Apply engine oil to threads Cylinder head cover bolt 7 8 11 8 SPECIAL TOOL Valve spring compressor E040 dO KYMCO 6 CYLINDER HEAD VALVES PEOPLE PEOPLE S 250 TROUBLESHOOTING The poor cylinder head operation be diagnosed by a compression test by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler Compression too low e Worn valve stem or valve guide e Damaged valve stem oil seal Compression too low e Incorrect valve clearance adjustment Abnormal noise e Burned or bend valves e Incorrect valve clearance adjustment e Incorrect valve timing e Sticking valve or broken valve spring e Broken valve spring e Damaged or worn camshaft e Poor valve and seat contact e Worn cam chain tensioner e eaking cylinder head gasket e Worn camshaft and rocker arm e Warped or cracked cylinder head e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber 6 CYLINDER HEAD VALVES CYLINDER HEAD COVER REMOVAL Remove the met in box carrier 22 6 Remove the body cover center cover and rear fende
136. ven Gear dO KYMCO 10 GENERATOR STARTER CLUTCH X PEoPLE PEOPLE S 250 Shaft Starter Idle Gear F J 1 57 K 4 z d La Remove the starter idle gear and shaft OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover Oil Separator Cover Oil Pump Driven Gear Circlip j x n P eres ALP T x EN Pi d 4 Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the cam chain 10 5 10 GENERATOR STARTER CLUTCH PEOPLE PEOPLE S 250 Remove the two oil pump bolts to remove the oil pump INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear 1 0 and O D Service Limits ID 22 15mm replace if over 41 50mm replace if below Starter Driven Gear Starter Idle Gear shaft Inspect the starter idle gear and shaft for wear or damage Inspect the starter one way clutch for wear or damage Starter One way Clutch 10 6 dO KYMCO 10 GENERATOR STARTER CLUTCH X PEoPLE PEOPLE S 250 Arrow Mark Oil Pump INSTALLATION Install oil pump and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Cam Chain Install cam chain i P Install the pump drive chain and driven gear Circlip then set the circlip securely on the pump shaf
137. w bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive Shaft Put the final gear on the left crankcase Drive Shaft Final Gear 9 6 GQ KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 Countershaft Install the countershaft and gear into the left crankcase Final Shaft Install the final shaft into the final gear and transmission case Final Gear Gasket Install the dowel pins and a new gasket Dowel Pins 9 7 dO KYMCO 9 FINAL REDUCTION PEOPLE PEOPLE S 250 Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch outer driven pulley Install other removed parts in the reverse order of removal Transmission Case Cover Oil Check Bolt Hole Filler After installation fill the transmission case mh with the specified oil e Place the scooter on its main stand on level ground e Check the oil sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity At disassembly 0 20 liter At change 0 18 liter Drain Bolt Install and tighten the oil check bolt Torque 7 8 11 8 Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low 10 GENERATOR STARTER CLUTCH GENERATOR S
138. with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air 14 10 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system Remove the brake fluid tube bolt Remove the two bolts attaching the brake caliper Remove the brake caliper DISASSEMBLY Remove the two brake pad dowel pins from the brake caliper Remove the brake pads Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid T Be careful not to damage the piston surface 14 11 QC KYMCO PEOPLE PEOPLE S 250 Bolts Piston Oil Seal IO 14 STEERING HANDLEBAR FRONT WHEEL FRONT ___BRAKE FRONT SHOCK ABSORBER ERONTFORK TOP PEOPLE 5 250 Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 25 30mm Check t

Download Pdf Manuals

Related Search

Related Contents

  Series 5 Miscellaneous Invoicing- User Help  Maxiflo 100 N  User Manual - ADFWeb.com  User Guide DT690 and DT692 for MX  PIANO ANTINCENDIO BOSCHIVO 2013  A Control System for BEPC Storage Ring Injection Power Supplies  Manual - Petri Konferenztechnik  Management Software RFID & BIOMETRICS  Service Manual 06/2004  

Copyright © All rights reserved. Failed to retrieve file