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13. fuel injection system

1. 8 3 CLUTCH OUTER DRIVEN PULLEY V BELT 8 3 8 DRIVE AND DRIVEN PULLEYS V BELT SCHEMATIC DRAWING Lem 3226 oe 12r em 2301A 22132 e lt KYMCO People GT 300i 11347 90201 KHE7 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i 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 Standard mm Service Limit mm Clutch lining thickness 40 1220 4 0 2 0 Clutch outer 1 0 152 1 152 2 152 2 Weight roller O D 19 92 20 08 TORQUE VALUES Drive face nut 9 5 kgf m 93 1 N m Apply oil Clutch outer nut 5 5 kgf m 54 N m Clutch drive plate nut 5 5 kgf m 54 N m SPECIAL TOOLS Universal holder E017 Clutch spring compressor E053 Fittings amp Nut Wrench 41mm E028 TROUBLESHOOTING Engine starts but motorcycle 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 Bro
2. 14 2 TROUBLESHOOTING 14 3 STEERING 14 4 a e ecd 14 5 ERONTBBAKE i he a 14 8 FRONT SHOCK ABSORBER 14 12 Tech ei 14 13 14 0 KYMCO People GT 300i 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SCHEMATIC DRAWING 95701 06016 95701 08016 Be Pya CR 90304 5 8 s oS e 2 oe 22 S CT 94050 06080 Ha 95701 06045 64315 wei 94050 06080 31 95701 08016 5071B 50306 90503 53220 S 53213 25 a S vc 65 D 53250 ues 53214 51500 e 8366 lt 83551 7 61100 9 2 96600 Le s lt 44311 46252 um gt 433583 9 44301 mn am C eR z jj mmm bd ais 0 A d i x 14 1 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO People GT 300i e Remove the motorcycle frame covers before removin
3. 2 ener 6 4 CYLINDER HEAD 6 6 CYLINDER HEAD DISASSEMBLY En 6 7 CYLINDER HEAD ASSEMBLY een 6 8 CYLINDER HEAD INSTALLATION 6 9 CAMSHAFT INSTALLATION e nennen enne nn enne nnn 6 9 CYLINDER HEAD COVER INSTALLATION 6 11 KYMCO 6 CYLINDER HEAD VALVES People GT 300i SCHEMATIC DRAWING 95701 06016 39301 90652 96001 06008 39200 T 90478 37720 Bin c 49300 19315 93500 05016 SR 1711A e 94301 08100 goo 91302 070 7 fes lt MN 4 us 162001 5 94050 06080 Aal 9 14721 14781 14761 14777 92900 eS d 96001 06025 245 2 14771 14751 90206 P ER 94301 12200 90012 90001 14453 14430 94301 12200 14452 9 96001 06025 Na ys 94050 06080 a e 12200 12209 14751 Hee 14100 44321 lt 9 90008 225 d 14777 eo ey 14771 Pu 144 e 14452 14781 90206 90012 96001 06010 gt 90008 90017 KYMCO 6 CYLINDER HEAD VALVES People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water hoses mus
4. 3 7 FINAL REDUCTION GEAR OIL 3 8 DRIVE BELT E 3 8 BRAKE SYSTEM 3 9 CLUTCH SHOE WEAR Ts ss Tg 3 10 SUSPENSION 3 10 NUTS BOLTS FASTENERS 3 11 WHEELS TIRES 3 11 STEERING HANDLEBAR 3 11 SIDE STAND een 3 12 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i SERVICE INFORMATION GENERAL e Before running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people e Gasoline 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 play 2 6 mm Spark plug NGK CR7E Spark plug gap 0 6 mm 0 7 mm Valve clearance IN 0 10 mm EX 0 10 mm Idle speed 1600 100 rpm Engine oil capacity Cylinder compression 16 2 kg cm At disassembly 1 5 Lite
5. 13 28 VEHICLE CAN NOT BE STARTED 13 40 TROUBLESHOOTING PROCEDURE BY MANUAL 13 41 DIAGNOSTIC REPORT oec ot eee 13 42 13 0 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS Scooter services can be done with the engine installed in the frame Be sure to relieve the fuel pressure before fuel pump or fuel hose removal e Bending or twisting the control cables will affect operation and could cause the cables to stick or bind resulting in loss of vehicle control Work in a fully ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion e Do not snap the throttle valve from fully open to fully close after the throttle cable has been removed it may cause incorrect idle speed e Do not loosen or tighten the painted bolts and screws of the throttle body Loosening or tighten them can cause throttle and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed e Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization e Do not take the fuel pump on the ground downward e Always replace the packing when the fuel pump is removed e The electronic fuel injection system is eq
6. 96001 06080 94050 sg 91300 79 M e 90032 ee gt lt 50504 94301 2 91307 15161 96001 06070 96001 06020 11 1 KYMCO 11 CRANKCASE CRANKSHAFT People GT 300i SERVICE INFORMATION GENERAL 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 knock the crankcase forcedly to prevent damaging the mating surfaces e When installing the crankcase do not use an iron hammer to tap it e When installing the crankcase or crankshaft must be replaced in pair e The following parts must be removed before separating the crankcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pump SPECIFICATIONS Pp Standard Service Limit mm Connecting rod big end side clearance 0 15 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 TORQUE VALUES Crankcase cover bolt 1 0 1 4 kgf m 11 8 N m Cam chain tensioner pivot 0 8 1 2 kgf m 9 8 N m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bearing play e Worn piston pin and piston pin hole 11 2 KYMCO 11 CRANKCASE CRANKSHAFT People GT 300i CRANKCASE SEPARATION Remove
7. 18 3 STARTER RELAY INSPECTION 18 4 18 0 KYMCO 18 STARTING SYSTEM People GT 300i STARTING SYSTEM LAYOUT Starter Relay Ignition Switch STARTING CIRCUIT Ignition Switch Side Stand Switch Starter al Relay 18 1 18 STARTING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO People GT 300i e The removal of starter motor can be accomplished with the engine installed 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 r em Standard mm Service Limit mm TORQUE VALUES Starter motor mounting bolt 6 7 10 8 N m Starter motor case screw 2 9 4 9 Starter clutch bolt 9 8 13 7 N m SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING Starter motor won t turn e Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter clutch e Faulty front or rear stop switch e Faulty starter relay e Poorly connected broken or shorted wire e Faulty starter motor Lack of power e Weak battery e Loosed wire or connection e Foreign matter stuck in starter motor or gear Starter motor rotates but engine does not start e Faulty starter pinion e Starter motor rotates reversely e Weak battery 18 2 KYMCO 18 STARTING SYSTEM People GT 300i STARTER MOT
8. Green Pink 5V Throttle position sensor TPS resistance at 20 C 68 F 3500 6500 Q Cable Ends REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from throttle seat Disconnect the TPS ISC and MAP sensor connectors Loosen the air cleaner connecting hose band screw Loosen the intake manifold band screw Remove the throttle body MAP sensor TPS sensor and ISC sensor as a set KYMCO People GT 300i TPS TPS Sensor 13 24 KYMCO 13 FUEL INJECTION SYSTEM People GT 3001 Screw Set Plate DISASSEMBLY F The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the throttle body MAP TPS ISC or ECU has been reinstalled Remove the screw and then remove the ISC and set plate Remove the screw and set plate Remove the MAP Remove the screw AND then remove the Screw ISC Set Plate TPS TPS ASSEMBLY The throttle position sensor TPS and idle air bypass valve ISC have to reset when the throttle body MAP TPS ISC or ECU has been reinstalled ISC TPS Apply onto a new O ring When install the TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely MAP 13 25 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i Apply oil onto a new O ring When install the MAP onto the throttle body being careful not
9. SASA 96001 06035 s NL h Ke 6x22 P 5 es r A Qe 7o 85001 06028 e 6 5 1895 0548 2 15425 ka D 7 18231 D O Oil filter Oil pump Oil pump chain 4 0 4 LUBRICATION SYSTEM People GT 3001 SERVICE INFORMATION GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks TROUBLESHOOTING Oillevel too low 1 Natural oil consumption 2 Oilleaks 3 Worn or poorly installed piston rings 4 Worn valve guide or seal Poor lubrication pressure 1 Oil level too low 2 Clogged oil filter or oil passages 3 Nouse the specified oil 4 1 O KYMCO eee Boogie ENGINE OIL OIL FILTER OIL LEVEL Place the motorcycle 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 Check the engine oil level each day before riding your scooter The level must be maintained between the upper lower level 2 marks on the oil filler
10. KYMCO People GT 300i KWANG YANG Motor Co Ltd 1st Edition March 2010 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300 LGE5 A2 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO People GT 300i Section 1 contains the precautions for all operations stated in this manual Read them carefully before any operation is started Section 2 is the removal installation procedures for the frame covers which are subject to removal installation frequency during maintenance and servicing operations Section 3 describes the inspection adjustment procedures safety rules and service information for each part starting from periodic maintenance Sections 5 to 12 give instructions for disassembly assembly and adjustment of engine parts Section 13 is the AFI system Section 14 to 15 is the removal installation of chassis Section 16 to 19 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 CO LTD QUALITY TECHNOLOGY DEPT EDUCATION SECTION
11. Clutch Spring CompressorE053 Fittings amp Nut Wrench 41mm E033 Lock Nut Wrench Clutch Driven Pulley 8 11 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft Drive Pulley Collar Movable Drive Face Assembly Put the drive belt on the driven pulley Put the drive belt on the drive pulley collar Install the clutch driven pulley and clutch outer onto the drive shaft Ss e Keep grease off the drive shaft Install washer and the clutch outer nut Clutch Outer Hold the clutch outer with the universal holder to tighten clutch outer nut Torque 54 N m Universal HolderEO17 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 93 1 N m e Do not get oil or grease on the drive belt or drive pulley faces Universal Holder 8 12 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i Install the left crankcase cover Left Crankcase Cover 8 13 KYMCO 9 FINAL REDUCTION People GT 300i FINAL REDUCTION SCHEMATIC DRAWING 9 1 SERVICE INFORMATION d eate eege 9 2 TROUBLESHOOTING Sed uu a cea et sms he 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION INSPECTION Eege 9 3 PINAL REDUCTION ASSEMBLY
12. ea QN R wes 3847 ex bet CALIPER wes 3940 35 Tam emp Wodzs 3640 ex 35 foose fA emm Ier eu e mess E Wc tW Iran 892 mz U RtEXR 605 447 en 45 8 we aras fos s ansa 1 1 S mesm Joss en wn 8 UNIT Des Jos 4552 465 UIT GE EE uz 1 22 es ul weem reem 32528 3698 55 ease en e ae e 7 ORANG ru Sii 35 Iess um J J L J a em sena Ce IN ON eat 25455 8595 03 54946 ba a RR Wiss aa aa e4 ome KYMCO 1 GENERAL INFORMATION People GT 300i SPECIAL TOOLS Flywheel Puller A120E00003 A C generator flywheel removal Tappet Adjuster A120E00012 Tappet adjustment Oil Seal amp Bearing A120E00014 Oil seal amp bearing installing Installer Flywheel Holder A120E00021 A C generator flywheel holding 41 Nut amp Fitting A120E00028 Clutch disassembly amp assembly Thread Protector 120 00029 Protecting the crankshaft s thread Valve Cotter Installer A120E00051 Valve cotter installation Clut
13. m After routing check that the wire harnesses are not twisted grisnked KYMCO 1 GENERAL INFORMATION People GT 300i m 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 Y 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 the instrument m B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting emove Rust 1 6 1 GENERAL INFORMATION Symbols The following symbols represent the servicing methods and cautions included in this service manual engine oil to specified points Use Engine Oil designated engine oil for lubrication Grease Apply grease for lubrication Transmission Gear Oil 90 Gear Oil Use special tool Caution lt EL Warning 1 7 KYMCO People GT 300i KYMCO 1 GENERAL INFORMATION People GT 300i TORQUE VALUES STANDARD TORQUE VALUES ee lem Torque 20 ltem 17 Torque 5mm bolt nut 5mm screw 6mm bolt nut 6mm screw SH bolt 8mm bolt nut 6mm flange bolt nut 10mm bolt nut 8mm flange bolt nut 12mm bolt nut 10mm flange bolt nut ENGINE messen Cylinder head stud
14. 6 9 12 15 18 1 gt 3 aaea Jm niapi EE Cas R HHHH Ecke MONTH AIR CLEANER SPARK PLUGS THROTTLE OPERATION VALVE CLEARANCE FUEL LINE CRANKCASE BREATHER ENGINE OIL ENGINE OIL SCREEN ENGINE OIL FILTER NGINE IDLE SPEED TRANSMISSION OIL DRIVE BELT CLUTCH SHOE WEAR BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH STEERING BEARINGS HEADLIGHT AIM NUTS BOLTS FASTENERS WHEELS TIRES 2242424 CES fd Et le on EBC pP Ir ez mu ee ES KS ES Q O gt Z 3 2 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6 mm Adjusting Nut Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Lock Nut Adjusting Nut KYMCO 3 INSPECTION ADJUSTMENT People GT 300i ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on the level ground Wait fo
15. 95801 10040 Q 96001 06012 amam 43156 LDB2 90302 amp 6 amp 95801 10060 95801 10060 91255 LGE5 42753 90305 43100 1 90122 amp 43353 45131 42312 42311 43109 43352 lt 45107 of 43210 4 7 E 42601 s wem 7 Kl 43105 Nor 15 1 KYMCO People GT 300i 15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 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 50 4 27 05 Rear brake disk runout _ j 00 Rear brake master cylinder 27 00 Rear brake master cylinder piston O D 26 95 26 90 TORQUE VALUES Exhaust muffler lock bolt Exhaust muffler pipe nut Rear axle nut Rear shock absorber lower mount bolt Rear shock absorber upper mount bolt Rear brake caliper holder bolt TROUBLESHOOTING Rear wheel wobbling e Bent rim e Faulty tire e Axle not tightened properly Soft rear shock absorber e Weak shock absorber spring e Damper oil leaks Rear wheel noise e Worn rear wheel axle bearings e Worn rear fork bearings e Deformed rear fork 35 N m 20 N m 140 N m 40 N m 40 N m 35 N m Poor brake performan
16. Ignition switch OFF ON 13 7 KYMCO People GT 300i If more than a damaged part has occurred the CELP begins blinking in order For example If the indicator blinks six times then shows one second illumination and two blinks so there are two failures have occurred Follow code 6 and 12 Blinks 12 12 10 11 sec KYMCO 13 FUEL INJECTION SYSTEM People GT 3001 SELF DIAGNOSIS RESET PROCEDURE 1 Put the side stand up and engine stop switch is at RUN 2 Turn the key to the ON position and wait for ten seconds 3 Fully open the throttle and wait for ten seconds 4 Release the throttle 5 The indicator will blink twice 0 5 second after five seconds quickly 6 Self diagnosis memory Is disappeared after the CELP lamp is off The self diagnosis can not be reset when has still problem inside the system Throttle opened fully KEY ON 10s 10s 95 Throttle Throttle closed closed Indicator blinks twice continuously 13 8 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i CELP FAILURE CODES LIST Blinks Failure Codes Contents Causes Symptoms 06 P0120 Faulty TPS e Faulty TPS voltage range 0 3 4 5 V e Loose or poor connection on TPS Sensor e Open or short circuit on the TPS wire e Faulty TPS itself Engine operates normally 09 P0105 Faulty MAP e Faulty MAP voltage range 1 4 2 V
17. e Loose or poor connection on MAP Sensor e Open or short circuit on MAP wire e Faulty MAP itself Engine operates normally 12 P0115 Faulty WTS water temperature e Faulty ECT range 20 C 18 8 40 1 136 Q 100 C 0 1553 e Loose or poor connection on ECT e Open or short circuit on ECT wire e Faulty ECT Engine operates normally 15 P1630 Faulty Tilt switch Roll e Faulty Tilt switch voltage range inclined angle lt 65 0 4 1 4 V Inclined angle gt 65 3 7 4 4 V Loose or poor connection on Tilt switch e Open or short circuit in Tilt switch wire e Faulty tilt switch Engine operates normally 17 P0130 Faulty O Sensor e Faulty O sensor voltage range A F below 14 7 gt 0 7V A F over 14 7 lt 0 18 V e Loose or poor connection on O sensor e Open or short circuit on O sensor wire e Faulty O sensor Engine operates normally 33 P0201 Faulty Injector Nozzle e Faulty Fuel injector Q range 9 945 13 50 Loose poor connection on injector e Open or short circuit on injector wire e Faulty fuel injector Engine fail to be operated 13 9 KYMCO 13 FUEL INJECTION SYSTEM Failure Blinks Codes Contents Causes Symptoms e Faulty Inductive ignition coil range 4 2 15 Faulty Loose or poor connection on 37 P0351 inductive inductive ignition coil
18. ignition coil amp Open or short circuit on inductive ignition coil wire e Faulty inductive ignition coil e Faulty Fuel pump range 11005330 100 3 0 Engine fail to be operated 41 P0230 Faulty Fuel e Loose or poor connection on fuel Pace mili Be Pump pump operated e Open or short circuit on fuel pump wire e Faulty fuel pump e Faulty O sensor heater Q range 6 7 0 9 50 2 Loose or poor connection on Engine starts 45 P0135 Pauly sensor heater normally but not Sensor Heater Open or short circuit on O sensor smooth heater wire Faulty sensor heater e Loose or poor contacts on ISC Faulty ISC e Open or short circuit in ISC wire Faulty ISC Engine operates normally e Loose or poor connection on CPS Engine starts Faulty CPS sensor e Open or short circuit on CPS wire 2 but not e Faulty CPS sensor 13 10 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i SPARK PLUG ANTI FLOOD When have not failure code occurs and pressing starter switch repeatedly can still not start the engine maybe the spark plug is wet by fuel perform the spark plug anti flood to purge the fuel in the engine Close the throttle turn the ignition switch to ON Test the battery voltage over 12 V Replace a fully charged battery Yes Open and hold the throttle fully pressing starter switch more than 3 seconds Yes 13 11 13 FUEL INJEC
19. oio nt centre esent 9 5 KYMCO 9 FINAL REDUCTION People GT 300i SCHEMATIC DRAWING 95701 08040 as 95701 08035 95701 08040 9 1 9 FINAL REDUCTION SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO People GT 300i e The servicing operations of this section can 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 90 Oil Capacity At disassembly 0 23 liter At change 0 21 liter TORQUE VALUES Transmission case bolt Oil check drain bolt 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 Oil level too high e Worn or damaged oil seal 0 8 1 2 kgf m 9 8 N m 1 8 2 2 kgf m 19 7 N m 9 2 KYMCO 9 FINAL REDUCTION People GT 300i FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler Remove the rear brake caliper Remove the right rear shock absorber Remove the rear fork Remove the rear wheel Remove the left crankcase cover Remove the clutch outer driven pulleys Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Transmission Case Cover Dowel Pi
20. 120 N m 95801 10035 00 Rear cushion lower upper mount bolts 4 0 kgf m 40 N m KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 300i ENGINE Thrott ied MAP Air Cleaner Connector REMOVAL INSTALLATION REMOVAL Remove the air cleaner Disconnect the connector including of ISC Throttle body TPS WTS MAP sensor and injector Disconnect the O2 sensor connector Disconnect the throttle cables Injector TPS ISC Disconnect the Regulator Rectifier connector Disconnect the starter relay wire from starter motor Disconnect the fuel hose from fuel injector Disconnect the input water hose Disconnect the air bleed hose Oil filter Water pump 5 2 KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 300i Remove the muffler Remove the rear fork mounting bolts 1 attaching to the crankcase Torque 3 5 kgf m 35 N m Remove the rear axle nut 2 Torque 12 0 kgf m 120 N m Remove two bolts 3 attaching to rear brake hose clamps Torque 3 2 kgf m 32 N m 2 Disconnect the alternator connector 5 Disconnect the ignition pulse generator connector 6 Release the rubber cap and remove terminal screw 6 to disconnect the start motor cable from the start motor Remove the bolt and engine ground cable KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 300i Remove the spark plug cap Disconnect the lower radiator hose from Radiator Hope lower ra
21. First remove the eight nuts attaching the met in box Remove the met in box Remove the four bolts attaching the rear carrier Remove the rear carrier FRAME BODY COVER REMOVAL Remove the two nuts attaching the rear protective cover Remove the rear protective cover Remove the center cover Remove the body cover KYMCO People GT 300i Center Cover KYMCO 2 EXHAUST MUFFLER FRAME COVERS People GT 300i Side Cover FLOOR FOOT REMOVAL Remove the screws attaching the right and left side covers Remove the right and left side covers by pulling them outward Screws Disconnect the battery wire Remove the battery Remove the floor mat Remove the center cover gt 2 3 Remove the four bolts attaching the floorboard Remove the floorboard The installation sequence is the reverse of removal Bolts LEG SHIELD REMOVAL Remove the met in box Remove the body cover Remove the floorboard Remove the front upper cover Remove the screws attaching the leg shield low Disconnect the leg shield low with the cowl under cover The installation sequence is the reverse of removal KYMCO 2 EXHAUST MUFFLER FRAME COVERS People GT 300i WINDSHIELD REMOVAL Remove the two bolts attaching the front z windshield 3 2 93891 Remove the windshield cover Remove the windshield Windshield HANDLEBAR COVER REMOVAL First remove the two bolts attaching the
22. Wheel base 1450 mm Engine type 4 stroke O H C Displacement 298 9 cc Fuel Used 92 nonleaded gasoline Curb weight Front wheel 66 kg Rear wheel 100 Total 166 Front wheel 97 aa Rear wheel 149 kg Total 246 Ground clearance mm 150 Braking distance m 7 9m 40 km hr Min turning radius mm R L 2250 2170 Engine part Starting system Starting motor KYMCO People GT 300i Type Gasoline 4 cycle Cylinder arrangement Single cylinder Combustion chamber type Semi sphere Valve arrangement O H C 4V Bore x stroke mm 12 1 12 Compression ratio 10 8 1 Compression pressure kg cm 2 rpm 16 570 rpm Max output ps rpm 28 7150 Max torque kg m rpm 2 7 6500 T Open 9 5 BTDC Close 37 5 BTDC Exhaust Open 40 BTDC Timing Close 10 BTDC Valve Intake 0 10 clearance Exhaust 0 10 Idle speed rpm 1600 100 rpm Cooling Type Liquid cooling ati Forced pressure amp Lubrication type wet sump Oil pump type Inner outer rotor Oil filter type Full flow filtration Oil capacit 1 5 liter Exchanging capacity 1 3 liter Fi injection system Air cleaner type amp No Paper element wet Fuel capacity 9 liters Brand Keihin Throttle Body Butterfly type Venturi diameter mm 34 Fuel pump pressure 3 0 bar Electrical system Ignition type ECU Ign
23. button and then turn to the previous page Current pTC List Previous NO Current DTC 13 31 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i Press the UP button YMCO Diagnostic ious Freeze All DIC H Press the Enter button and then turn to the previous page with red color I Press the UP button KYMCO Diagnostic Previous Clear DTC 13 32 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i J Press Enter button and then turn to the first page LGES is for ECL Jer x People GT 300i DATA mr AdJust LGES is for People GT 3001 13 33 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i DTC CLEAR PROCEDURE A Check the DTC LGES is for People GT 300i B Press the Enter button LGES is for People GT 300i Choose Load DTC Press the Down button KYMCO Diagnostic Previous Clear DTC 13 34 KYMCO 13 FUEL INJECTION SYSTEM People GT 3001 Press Enter button and the indicator is lighting KYMCO Diagnostic Prev ious Load DIC JT Clearing DTC completed if the indicator is off KYMCO Diagnostic Clearing DIC Comp leted 13 35 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i DATA ANALYSIS PROCEDURE A Press Down twice LGES is for People GT 3001 B Choose Data Analyze Press Ente
24. thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat Thermosensor Wire housing THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data Valve lift 3 5 4 5mm e Do not make the thermostat touch the pan as it will give a false reading 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 Thermometer THERMOSTAT INSTALLATION Replace the O ring with a new one and apply grease to it Fill the cooling system with the specified coolant 12 COOLING SYSTEM People GT 300i COOLANT REPLACEMENT The engine must be cool before serving the cooling system or severe scalding may result Open the radiator protector and remove the radiator cap Place a drain pan under the water pump and drain the coolant from the system by removing the drain bolt Fill the system with a 40 60 mixture of distilled water and ethylene glycol Coolant capacity Radiator and engine 1 12 liter Reserve tank 0 30 liter Total system 1 42 liter Bleed air from the system 1 Start the engine a
25. 14 13 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK People GT 300i 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 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 gt Make sure the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 63 N m Install the front wheel 215 7 Install the front brake caliper 215 12 Install the front fender cover 22 6 Install the throttle grip and the right and left handlebar switches 15 5 Install the right and left brake master cylinders 215 5 Lock Nut Socket 14 14 15 REAR BRAKE REAR FORK REAR KYMCO ___WHEEL REAR SHOCK ABSORBER 300i REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SCHEMATIC DRAI 15 1 SERVICE INFORMATION 15 2 TROUBLESHOOTING Tq 15 2 REAR BRAKE een 15 3 REAR el 15 4 REAR WHEEL E 15 5 REAR SHOCK ABSORBER 15 5 15 0 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER People GT 300i SCHEMATIC DRAWING
26. Gear Clip Install the oil separator cover properly Oil Separator Cover Fit the tab of the separator cover into the slit in the separator Bolts 10 7 10 A C GENERATOR STARTER CLUTCH Install the starter idle gear and shaft 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 make sure that the inside of the flywheel is not contaminated Install washer and nut Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 5 5 6 5 kgf m 58 8 N m Remove the flywheel nut and washer Flywheel holder E021 KYMCO People GT 300i Starter Idle Gear 7 Shaft A Key Starter Driven Gear Flywheel Flywheel Holder 10 8 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 3001 STATOR INSTALLATION Install the A C generator stator on the right Screws crankcase cover and secure it with the three bolts Install the pulsar 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 pulsar coil RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket Pulsar Coil A C Generator Stator Install the right c
27. INSPECTION Remove the bolt attaching to the Leg Shield Under Cowl 12 4 KYMCO 12 COOLING SYSTEM People GT 300i From Reserve Tank From Engine Remove the under cowl Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed air If insects are clogging the radiator wash them off Carefully straighten any bent fins To Water Pump Radiator RADIATOR REMOVAL Drain the coolant 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 Loosen the hose band and disconnect the upper hose and lower hose from the radiator Disconnect the thermostatic switch wire win coupler d p 19012 SC a 90301 37760 Thermostatic Switch 19014 To Water Pump 19013 From Thermostat 19016 To Reserve Tank 12 5 KYMCO 12 COOLING SYSTEM People GT 300i Remove two bolts nuts on the radiator 95002 KHE7 Remove the radiator 95701 06016 Bolts 94050 06060 nuts RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator 95701 06016 Check fan motor by battery 12 6 12 COOLING SYSTEM KYMCO People GT 300i THERMOSTATIC SWITCH When the coolant temperature is lower than 85 C the thermostatic switch OFF When cool
28. MUFFLER FRAME COVERS People GT 300i SCHEMATIC DRAWING 35130 E e CT r 90104 Q 53140 35150 53207 93500 r 53105 5 lt Se 93903 34360 35170 E 35200 35180 7 90652 LCA4 Y 202 7 P 90302 50 4 lt 64306 81146 90302 50 4 A 5 1 22 i 93903 34360 gt 90677 90302 GFY6 90302 LLB1 b 64316 LGES 64307 D a 64310 Km oe 2 93903 35360 81142 90652 LCA4 Y 93903 34360 8120 90652 oF 75581 90106 6 D T s0106 KuDU 93404 eee gt ee X lt lt d Ma gt 77234 LGE5 305 M1 77234 LGE5 305 M2 90302 5 6 940 IIF W 90302 5 6 940 KYMCO 2 EXHAUST MUFFLER FRAME COVERS People GT 300i 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 35 N m Exhaust muffler joint lock nut 20 TROUBLESHOOTING Noisy exhaust muffler e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power Caved exhaust muffler e Clogged exhaust muffler e Exhaust muffler air leaks 2 EXHAUST MUFFLER FRAME COVERS Nuts FRAME COVERS REMOVAL REAR CARRIER Remove the met in box
29. and left handlebar switches and tighten the screws e Adjust the throttle grip free play to the specified range of 2 6mm sP Throttle Grip Bolt Collar Install the front and rear brake master cylinders e Install the brake master cylinders by aligning the index marks FRONT WHEEL REMOVAL Disconnect the speed wire from the front right suspension unit Remove the front axle to pull out the axle Remove the front wheel INSPECTION Axle AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is of the total indicator reading Service Limit 0 2 mm replace if over Front axle 14 5 14 STEERING HANDLEBAR FRONT WHEEL FRONT WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0 mm replace if over Axial 2 0 mm replace if over Dust Seal Collar 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 6 14 STEERING HANDLEBAR FRONT WHEEL FRONT dO ___ BRAKE FRONT SHOCK ABSORBER FRONT FORK 300 Driver Handle Pack all bearing cavities with grease Drive in the left
30. bearing Install the distance collar Drive in the right bearing e Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the sealed end facing out Special Tools Oil seal amp Bearing Driver E014 INSTALLATION Insert the axle and tighten the axle nut When installing the front wheel take the brake disk among the two brake pads Torque 65 N m Axle 14 7 14 STEERING HANDLEBAR FRONT WHEEL FRONT dO EE ___BRAKE FRONT SHOCK ABSORBER FRONT FORK People 3001 FRONT BRAKE BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers 22 3 Drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove two bolts attaching the brake master cylinder Remove the brake master cylinder e When servicing the brake system use 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 brake 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 cyl
31. below Measure the piston O D Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 72 70mm replace if below Measure the piston to piston clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder 1 0 at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Service Limit 72 70 mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1 mm 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 05mm repair or replace if over Cylindricity 0 05 mm repair or replace if over 7 5 KYMCO 7 CYLINDER PISTON People GT 3001 Measure the connecting rod small Z Service Limit 15 06 mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring careful to damage the piston and piston rings during assembly eAll 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 figur
32. bolts attaching left crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase eNever use a driver to knock the crankcase mating surfaces apart Remove the engine oil screen Crankshaft Remove the crankshaft from the left crankcase 11 3 KYMCO 11 CRANKCASE CRANKSHAFT People GT 300i Oil Seal Remove the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6 mm replace if over Measure the connecting rod small end LD Service Limit 17 06 mm replace if over Measure the crankshaft bearing play Service Limits Axial 0 20 mm replace if over Radial 0 05 mm replace if over 11 4 KYMCO 11 CRANKCASE CRANKSHAFT People GT 300i Left Crankcase CRANKCASE ASSEMBLY Install a new oil seal onto the left crankcase Place the left crankcase down and install the crankshaft into the left crankcase e Avoid damaging the oil seal e Apply grease to the lip of the oil seal e Avoid damaging the crankcase mating surfaces Install the two dowel pins Crankshaft Place the right crankcase over the crankshaft and onto the left crankcase Install the right crankcase squarely and do not tap it with an iron or plastic hammer Install and tighten the right and left crankcase attaching bolts Install the engine oil screen
33. pulley Install other removed parts in the reverse order of removal Torque Transmission case bolt 0 8 1 2 kgf m 9 8 N m After installation fill the transmission case with the specified oil Transmission Case Cover e Place the scooter on its main stand on level ground e Check the oil sealing washer for wear or damage Specified Gear SAE90 Oil Capacity At disassembly 0 23 liter At change 0 21 liter Install and tighten the oil check bolt Torque Oil filler drain bolt 1 8 2 2 kgf m 19 7 N m 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 9 5 Drain Bolt under Oil filler Bolt KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i A C GENERATOR STARTER CLUTCH SCHEMATIC DRAWING 10 1 SERVICE INFORMATION 10 2 TROUBLESHOOTING Y YY 10 2 RIGHT CRANKCASE COVER REMOVAL 10 3 STATOR REMOVAL F J T NS E 10 3 FLYWHEEL REMOVAL Ns T vF Es S T s 10 4 STARTER CLUTCH Y TYT YYTTYT 10 4 FLYWHEEL INSTALLATION 10 8 STATOR INSTALLATION qsm C ss T
34. step Press the Down button to enter page 06 519 05 1624 rem LE H Down page 06 The measure figures including of ISC motor state Press the Down button to enter page 07 I Down page 07 The measure figures including of Cut Out voltage Diagnosis 11 ON J Press the UP to the previous page 13 39 KYMCO 5 FUEL INJECTION SYSTEM People GT 300i Vehicle can not be started Handling method Steps Preliminary Checking 6 basic inspection 1 Is the battery with voltage 12 V or higher 2 Key On and listen for any action with Fuel Pump Fuel Pump Relay It will turn off automatically in 5 10 seconds 3 Key On to check for any failure lamp light up on dashboard 4 Is the Idle screw of Throttle Valve being changed or loose 5 Has the vehicle under regular service Is the gas station a good one 6 Is the spark plug the correct model of specified by the vehicle builder Vehicle can not be started Check for any Failure code Failure Lamp on How to tell the Failure code Turn on power to see if the engine inspection failure lamp off If it flashes continuously or light up for long time the vehicle is at failure read the Failure Code Methods Reading DTC from speedometer if PDA or diagnosis tool is not available 2 Reading DTC from Diagnosis tool if it is available 13 40 5 FUEL INJECTION SYSTEM 75 Manual Trouble Shooting Pro
35. to damage the O ring T Always replace an O ring with a new one S Install the set plate and tighten the screw securely Apply oil onto a new O ring When install the ISC and set plate onto the throttle body being careful not to damage the O ring Screw ISC Set Plate DIAGNOSTIC TOOL CONNECTOR INSPECTION Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure the voltage between the following terminals of the diagnostic tool connector with PDA tester Terminal Normal Black Green Battery voltage Diagnostic Connector Battery voltage White Yellow Green 1 13 26 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00 13 27 28 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i FI DIAGNOSTIC TOOL This tool is developed by KYMCO and for KYMCO vehicle only Please refer to the specification when serving this vehicle This tool is without battery inside The power is provided from vehicle This software can be updated with computer for new model through the USB cable The power required of tool is connected with 12V battery For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch The side stand must be upward when serving the diagnostic procedure The function inclu
36. windshield Remove the two screws and four bolts attaching the handlebar rear cover Remove the handlebar rear cover The installation sequence is the reverse of removal Remove the two screws attaching the handlebar cover Remove the handlebar cover The installation sequence is the reverse of removal BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom cover Remove the bottom cover Bottom Cover Bolts KYMCO 2 EXHAUST MUFFLER FRAME COVERS People GT 300i EXHAUST MUFFLER REMOVAL Remove three 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 packing collar The installation sequence is the reverse of removal Torque Exhaust muffler lock bolt 35 N m Exhaust muffler joint lock nut 20 N m Lock Bolts KYMCO 3 INSPECTION ADJUSTMENT People GT 300i INSPECTION ADJUSTMENT SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 THROTTLE OPERATION ee enne enne enn 3 3 ENGINE OIL 3 4 RESERVE TANK 3 5 AIR CLEANER eessen 3 6 SPARK PLUG 3 6 VALVE CLEARANCE I 3 7 CYLINDER COMPRESSION
37. worn KYMCO 3 INSPECTION ADJUSTMENT People GT 300i CLUTCH SHOE WEAR Start engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine stop check the clutch shoes for wear and replace if necessary SUSPENSION FRONT Check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Each shock absorber 4 on your scooter has 5 spring preload adjustment positions for different load or riding conditions Use a pin spanner 5 to adjust the rear shock spring preload Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooter is heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions 3 10 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i 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 Check the tires for cuts imbedded nails or other damages Check the tire pressure e Tire pressure should be checked when tires are cold Tire Pressure 1 Rider 1 Rider with passenger 1 75 kg cm 2 00 kg cm gt F Axl t Tire Size Front 110 70 16 Rear 140 70 16 Chec
38. your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Besure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that requires proper battery voltage A continuity test can be made with the switches installed on the scooter Route the wires and cables properly after servicing each component TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON correctly e Burned bulb e Faulty temperature gauge e Faulty switch e Faulty thermosensor e Poorly connected broken or shorted wire e Broken or shorted wire between the temperature gauge and thermosensor Fuel gauge does not work or wrong show figures e Faulty fuel gauge e Faulty fuel unit e Poorly connected wire between fuel gauge and fuel unit e Fuse burned out SPECIFICATIONS Fuse 10A 15A 30A Headlight bulb 12V 60W 55W Turn signal light bulb 12V10W 2W LED Stoplight taillight 12 21 5W 19 2 KYMCO 19 LIGHTS SWITCHES FUEL PUMP People GT 300i BULB REPLACEMENT LICENECE LIGHT Disconnect the license bulb socket Remove the bulb and replace with a new one HEADLIGHT A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF Be sure to let it cool down before servicing REMOVAL Remove the handle cover Disconnect the headlight conne
39. 0 9 0 15 kg cm Begins to open Thermostat temperature Valve lift 3 5 4 5 mm Radiator 820 cc Coolant capacity Total 1120 Reserve tank 300 cc 12 2 KYMCO 12 COOLING SYSTEM People GT 300i COOLANT GRAVITY CHART Temp EL EEE Epee concentration COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS e Use coolant of specified mixing rate 40 60 The mixing rate of 448cc KYMCO SIGMA coolant concentrate 672cc distilled water e Do not mix coolant concentrate of different brands Do not drink the coolant which is poisonous The freezing point of coolant mixture shall be 5 lower than the freezing point of the riding area 12 3 KYMCO 12 COOLING SYSTEM People GT 300i COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester 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 sealing cap surface before testing Radiator Cap Relief Pressure 0 9 0 15 kg cm 2 Radiator Cap Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six _ Radiator seconds Check the water hoses and connectors for leaks test pressure should not exceed 1 05 kg cm Excessive pressure damage the radiator and its hose connectors RADIATOR RADIATOR
40. 0km Check the mesh filter for clogging or damage and replace if necessary Install the mesh filter and a new gasket 4 3 KYMCO e PUMP REMOVAL Remove twelve bolts attaching the right crankcase cover Remove the A C generator flywheel with special tool Flywheel puller E003 Universal Holder E021 Remove the gasket and dowel pins Remove the starter idle gear and starter clutch Remove the two bolts and oil separator cover Remove the oil pump driven gear clip to remove the oil pump driven gear and drive chain Starter idle gear Dowel Pins Oil separator cover Oil pump drive chain 4 4 KYMCO EE Mark UP Remove two oil pump mounting bolts and the oil pump INSTALLATION Install the oil pump into the crankcase Install the oil pump with the arrow on the pump body facing up and fill the oil pump with engine oil before installation After the oil pump is installed tighten the two mounting bolts Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft Install and tighten the pump driven gear bolts Install the oil separator cover and tighten the bolts Oil separator cover Starter idle gear Install the starter idle gear and starter clutch Install the gasket and dowel pins Install the right crankcase cover and tighten the twelve bolts Torque 1 2 kg m i Diag
41. 1 Stud bolt Inlet pipe side 2 Stud bolt EX pipe side Cylinder head stud nut Right crankcase cover bolt Left crankcase cover bolt Bolt B stud 10 180 Valve adjusting lock nut Cam sprocket bolt Transmission oil check drain bolt Engine oil drain bolt Clutch outer nut Starter motor mounting bolt Mission case bolt Drive face nut Drive plate comp Cam chain tensioner bolt Cam chain tensioner pivot Oneway clutch bolt ACG flywheel nut Spark plug Water pump impeller Double end bolt Double end bolt 1 1 Apply oil to thread Apply oil to thread Apply oil to thread Apply thread lock et mh ck RA NJ M3 06 4e Left thread KYMCO 1 GENERAL INFORMATION People GT 300i TORQUE VALUES FRAME ITEM TORQUE THREAD DWG Kof m Nm Clem ANOLE mer 4950 854 M5 sees Term boer eem 87 seW rk e 60565 845 63 Wc WAP wi Iess es EE uc EE e Sher 1 1 1 1 T RAE 545 545 WAREN wens UN BEE ce AE SE E SUSPENSION h Ct 13 HRFEK BOLT eu mees RR CS UP was 345 45 9509 0250 jw W Lwe 3545 es 42 ex EE ium BRAKE
42. 14 10 When installing the brake fluid tube be sure to install the two copper sealing washers REAR FORK REMOVAL Remove the exhaust muffler 22 10 Remove the rear brake caliper gt 16 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 15 REAR BRAKE REAR FORK REAR C KYMCO WHEEL REAR SHOCK ABSORBER PEOPLES 300i Rear Brake Disk REAR WHEEL REMOVAL Remove the exhaust muffler 22 10 Remove the rear brake caliper 16 3 Remove the rear fork 16 6 Remove the rear axle collar Remove the rear wheel 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 40 N m Rear axle nut 140 N m REAR SHOCK ABSORBER REMOVAL Remove met in box and carrier gt 2 6 Remove the body cover center cover and rear fender A together 22 6 Remove the right left rear shock absorber upper and lower mount bolts Remove the righ
43. 2 96001 06028 19229 5 90428 94510 91303 LEA7 0d 19232 D 12 1 KYMCO 12 COOLING SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS e The water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame e The 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 with a cooling system tester TORQUE VALUES Water pump impeller 1 0 1 4 kgf m 11 8 N m Water pump cover bolt 1 0 1 4 kgf m 11 8 N 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 shows the wrong temperature e Faulty temperature gauge or thermosensor e Faulty thermostat SPECIFICATIONS Radiator cap relief pressure
44. 234 5 4 a N d V 96001 06025 7 1 KYMCO 7 CYLINDER PISTON People GT 300i 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 Service Limit mm SPECIFICATIONS Standard mm Cylinder D _ 72705 72715 0015 0055 049 clearance 0 015 0 055 om 0 10 0 25 Piston 0 10 0 25 piston ring Oil side rail 0 2 0 7 Piston 0 0 72 67 72 69 72 6 Piston O D measuring position 9mm from bottom of skirt 0 010 0 040 15 002 15 008 14 994 15 000 0 002 0 014 15016 15034 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 Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and pisto
45. EMOVAL INSTALLATION Remove the side body cover Disconnect the regulator rectifier connectors Remove the two bolts regulator rectifier Installation is in the reverse order of removal Connectors 16 7 17 IGNITION SYSTEM KYMCO People GT 300i IGNITION SYSTEM IGNITION SYSTEM LAYOUT SERVICE INFORMATION TROUBLESHOOTING SPARK IGNITION COIL INSPECTION A C GENERATOR INSPECTION TILT SWITCH INSPECTION 17 0 KYMCO 17 IGNITION SYSTEM People GT 300i IGNITION SYSTEM LAYOUT Tilt switch Ignition Switch IGNITION CIRCUIT 1 ee ENG Stop Ignition Switch Switch Tilt switch Side Stand Switch ECU Relay TPS Y G O Y B sas 55 amp SES SS SW e o O YIG 4 00909 Agi ACG Pulser Coil Ignition Coil 17 1 KYMCO 17 IGNITION SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS e Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is and current is present e When servicing the ignition sy
46. Failure to follow this precaution can damage tester electrical Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make absolutely certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000 rpm Standard Battery charging voltage 14 15V 16 5 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i REGULATOR RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator rectifier connectors Check the connectors for loose contacts of corroded terminals BATTERY WIRE Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all times GROUND WIRE Check the continuity between the Green wire terminal and ground There should be continuity at all times 16 6 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals Standard 0 4 0 6 Q 20 C 68 F Disconnect the regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity Regulator Rectifier R
47. GT 300i a FRESHAIR mb EXHAUST GAS ABBREVIATIONS Electronic control unit ECU Tilt switch Angle detect sensor ROLL Fuel pump Fuel level unit FP Water temperature sensor WTS sensor Crank position sensor Pulser CPS Oxygen Oxygen heater sensor O7 O Heat sensor Inductive ignition coil IG Fuel injector Nozzle INJ Intake pressure sensor MAP sensor Idle air bypass valve ISC Throttle position sensor TPS KYMCO 13 FUEL INJECTION SYSTEM People GT 300i PARTS LOCATION Winker Relay Tilt Switch Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay MAP Sensor Throttle Body ISC Injector 13 4 13 FUEL INJECTION SYSTEM TROUBLESHOOTING Engine fail to start e Intake manifold air leak e Fuel contaminated deteriorated e Pinched or clogged fuel hose e Faulty fuel pump e Clogged fuel filter throttle body e Sticking fuel injector needle e Faulty fuel pump operating system e Carbon deposit stayed on the fuel injector e Spark plug dirty e Fuel pressure incorrect Engine stall hard to start rough idling e Intake air leak e Fuel contaminated deteriorated e Pinched or clogged fuel hose e Idle speed fail to adjust Fail to perform PTS ISC reset 13 5 KYMCO People GT 300i Backfiring or misfiring during acceleration e Ignition system malfunction Poor performanc
48. ION ADJUSTMENT People GT 300i FINAL REDUCTION GEAR OIL e Place the scooter on its main stand on level ground Remove the transmission fluid drain bolt Remove the transmission fluid filler bolt then slowly rotate the rear wheel to drain the fluid Fill the transmission with the recommend fluid to the capacity listed below Oil Drain Bolt Transmission fluid type SAE 90 Transmission fluid capacity 0 23 L Transmission fluid exchanging capacity 0 21 L Install the transmission filler bolt and tighten it to the specified torque DRIVE BELT Remove the left 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 Drive Belt 3 8 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i BRAKE SYSTEM BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk runout is within the specified service limit Check if the brake pad wear exceeds the wear indicator line Keep grease or oil off the brake disk to avoid brake failure lt Front Brake gt lt Rear Brake gt BRAKE FLUID Turn the steering handlebar upright and check if both brake fluid levels is at the upper limit If the brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 brake fluid level will decrease if the brake pads are
49. KYMCO 1 GENERAL INFORMATION People GT 3001 Fuel Pump Ignition Coil Regulator Rectifier 1 15 1 GENERAL INFORMATION People GT 300i Test cylinder compression KYMCO TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Possible cause Check for operation of the fuel pump Abnormal e Faulty fuel pump Normal Inspect the fuel flow Abnormal e Faulty pressure regulator Normal Inspect the fuel injector Abnormal Faulty injector Normal Perform spark test Weak or no spark e Faulty spark plug e Fouled spark plug e Faulty ECU Good spark e Broken or shorted spark plug wire e Faulty ignition switch e Faulty ignition pulse generator e Loose or disconnected spark plug wire Low compression s e Valve stuck open e Worn cylinder and piston ring e Damaged cylinder head gasket Compression normal e Seized valve e Improper valve timing Starting following normal procedure Engine start e Intake pipe leaking but stops e Improper ignition timing Faulty ignition coil or ignition pulse generator Engine does not start e Fuel contaminated Remove and inspect spark plug Wet plug e Throttle valve open e Clogged air cleaner 1 16 KYMCO 1 GENERAL INFORMATION People GT 300i ENGINE LACKS POWER Possibl
50. OR REMOVAL 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 make sure the starter motor can t operate securely Remove the seat met in box and carrier Starter Motor Cable Remove the body cover center cover and rear fender together Remove the nut goes to the starter relay and relax cable band to disconnect the starter motor cable Remove two start motor mounting bolts and the motor 18 3 KYMCO 18 STARTING SYSTEM People GT 300i Starter Motor Cable 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 Yellow Red Wire And Green Yellow Wire STARTER RELAY INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire green yellow wire 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 OPERATION TEST Connect the electric meter to the starter relay 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 star
51. RAKE 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 INSTALLATION Install the two brake pads Install the two brake pad dowel pin and tighten them When installing the brake caliper be sure to position the brake disk between the two brake pads Washers Brake Fluid Tube Install the brake caliper to the shock absorber and tighten the two bolts Torque 35 N 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 35 N 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 5 lt dg p gt sure to install the two sealing washers M M m Bolts 14 11 14 STEERING HANDLEBAR FRONT WHEEL FRONT ___BRAKE FRONT SHOCK ABSORBER FRONTFORK GT 300i FRONT SHOCK ABSORBER Upper Mount Bolts REMOVAL Remove the front cover gt 2 5 Remove the front wheel 215 5 Remove the front brake caliper 15 11 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers ras m INSTALLATION Lower Mount Bolts Install the front shock absorbers onto the front fork Install and tighten the front shock ab
52. SISSVHO INAWNdINOA TvOId1O9313 KYMCO People GT 300i TABLE OF CONTENTS GENERAL INFORMATION EXHAUST MUFFLER FRAME COVERS ENGINE REMOVALISTALLATON DRIVE AND DRIVEN PULLEYS V BELT FINAL REDUCTION A C GENERATOR STARTER CLUTCH CRANKCASE CRANKSHAFT 1 COOLING SYSTEM FUEL INJECTION SYSTEM STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER FUEL zue al le e mle e e v KYMCO 1 GENERAL INFORMATION People GT 300i GENERAL INFORMATION SERIAL 1 1 SPECIFICATION s TTSqqYq 1 2 SERVICE 6 1 5 TORQUE 1 9 SPECIAL 86 1 10 LUBRICATION POINTS eet 1 11 CABLE amp HARNESS 1 13 TROUBLESHOOTING T 1 14 KYMCO 1 GENERAL INFORMATION People GT 300i SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number 1 1 1 GENERAL INFORMATION SPECIFICATIONS Name People GT 3001 Model No BF60AA Overall length 2130 mm Overall width 750 mm Overall height 1280 mm
53. SSEMBLY Remove the clips and retainer plate to disassemble the clutch e Keep grease off the clutch linings Clutch Lining 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i CLUTCH ASSEMBLY Install the damper rubbers on the drive plate pins Install the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the clips 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 10 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i Install the movable driven face onto the driven face Grooves Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Install the seal collar Remove any excessive grease sure to clean the driven face off any grease Set the driven pulley assembly driven face I spring and clutch assembly onto the clutch Guide Pins spring compressor e 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 Clutch Spring Compressor Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 75 N m pe sure to use a clutch spring compressor to avoid spring damage
54. TION SYSTEM TPS ISC RESET e If close or open the throttle grip randomly the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled It can cause hard to start engine or idling speed is not smooth when engine installation 15 has a motor inside which controls ISC valve to obtain smooth idling speed The ECU may record the incorrect ISC position during the engine speed isn t working when the ECU or the throttle body has been reinstalled It can cause engine stop hard to start engine or rough idling speed The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body MAP TPS ISC or ECU has been reinstalled TPS ISC RESET PROCEDURE 1 Put the side stand up and engine stop switch is at RUN Turn the key to the OFF position Fully open the throttle Turn the key to the ON position nA BW N Release the throttle after waiting for eight seconds Turn the key to the OFF position Turn the key to the ON position 8 TPS and ISC have been reset successfully If fail to reset repeat the steps from 1 to 8 KYMCO People GT 300i 13 12 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i FUEL PUMP Connector INSPECTIION Put the side stand up and the engine stop switch is at RUN Disconnect the fuel pump fuel unit connector Connect the multimeter probe to the Red Black termin
55. To install the crankshaft or crankcase must be replaced in pair Crankcase Crankcase mark Bearing Crankshaft Crankshaft mark A black green green Red B green green Red 11 5 KYMCO 12 COOLING SYSTEM People GT 300i COOLING SYSTEM SCHEMATIC DRAWING 12 1 SERVICE INFORMATION 12 2 TROUBLESHOOTING 12 2 COOLING SYSTEM TESTING 12 4 RADIATOR Tq 12 4 WATER PUMP T S JT 12 8 THERMOSENSOR qc 12 11 THERMOSTAT ee 12 12 12 0 KYMCO 12 COOLING SYSTEM People GT 300i SCHEMATIC DRAWING 19105 4 90914 19111 5 Su amp 19012 e 90301 ws 95002 KHE7 19104 SE 93404 Up ACA HS 95002 70000 95002 KHE7 KE m 19102 90656 19505 amp 19016 qo 50 06060 PL 940 97 SS A er B oar ets 19014 cv JJ 95701 06016 SOL 95701 06016 96001 06022 96001 06035 1565A Gea 2 2 90084 SE 330 L a Cu 96001 06028 19014 96001 06022 19505 LBA
56. aJs 10 9 RIGHT CRANKCASE COVER INSTALLATION 10 9 10 0 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 3001 SCHEMATIC DRAWING 96001 06022 96001 06035 E e C 96001 06022 1565 _ Kg py 90084 A 96001 06028 19014 9008A Z O 19505 LBA2 SA 96001 06028 19229 91302 6001 0601 90478 5 11394 19221 54557 25 Jee 94301 08140 19215 d 90428 19231 Gei 19232 31210 28110 15100 93600 32410 10 1 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS e All operations and inspections in this section can be made with the engine installed e Should 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 Remember to bleed air from the water hose SPECIFICATIONS Engine oil SAE 5W 50 API SJ above Oil capacity at change 1 5 Liter Coolant capacity Radiator capacity 0 766 liter Hose with cool coolant 0 169 liter Hose with hot coolant 0 194 liter Upper limit for reser
57. ail to start the engine or in trouble in case of riding KYMCO 13 FUEL INJECTION SYSTEM People GT 300i Battery FUEL CUT OFF RELAY INSPECTION Remove the fuel cut off relay Connect the ohmmeter to the fuel cut off relay connector terminals Connection Black Red Black Connect 12 V battery with the fuel cut off Fuel Cut Off Relay relay connector Connection Blue Black Black There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is connected replace a fuel cut off relay REMOVAL Disconnect the fuel cut off relay connector and remove it from frame 13 15 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i TILT SWITCH INSPECTION Support the scooter level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to OFF Remove the screws washers and tilt switch gt Do not disconnect the tilt switch connector during inspection Place the tilt switch vertical as shown and turn the ignition switch to ON Measure the voltage between the following terminals of the tilt switch connector with the connector connected Terminal Normal Violet Red Green Pink 5 252 Black Blue Green Pink 0 4 1 4 V Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage be
58. al and the multi meter probe to the Green terminal Turn the ignition switch to ON and measure the voltage between the terminals Fuel Hose It should be shown the current battery voltage for a few seconds If there is still battery voltage replace the fuel pump If there is not any battery voltage inspect the following Fuse 10 A Fuel cut off relay ECU Measure resistance between Red Black and Green terminals of the fuel pump side connector Standard at 20 C 68 F 1 940 3 Fuel level sensor inspection Measure the resistance between Yellow White and Green terminals of the fuel pump side connector Standard at 20 C 68 F Float at full position 100 3 Float at empty position 1100433 13 13 KYMCO REMOVAL Fuel Pump Disconnect the connector and fuel band from the fuel pump Remove the six screws onto the fuel pump Remove the fuel pump and O ring INSTALLATION Replace a new O ring on the fuel tank Don t damage the fuel pump wire and ensure the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 Ibf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose from the fuel injector Connect the fuel pressure gauge Turn the key to the ON position Check the fuel pressure Standard 3 0 Bar If the fuel output pressure is less than 3 0 bar may f
59. ankcase cover Tighten 12 bolts to secure the right crankcase cover When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft WATER PUMP IMPELLER Mechanical Water Seal INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Install the impeller onto the water pump shaft Torque 1 0 1 4 kgf m 11 8 N m The impeller has left hand threads Install two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 1 0 1 4 kgf m 11 8 N m 12 10 KYMCO 12 COOLING SYSTEM People GT 300i Thermosensor Wire 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 THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of Thermosensor water over a burner and measure the resistance through the sensor as the water heats up Tempersture C 60 80 100 120 154 12 11 KYMCO 12 COOLING SYSTEM People GT 300i THERMOSTAT THERMOSTAT 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 from the thermosensor Disconnect the water hose the
60. ant temperature is over 90 the thermostatic switch ON 37760 Thermostatic Switch RADIATOR INSTALLATION Install the fan rubber on the radiator with three bolts Install the radiator on the radiator bracket with three bolts nuts Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire Connect the fan motor wire couplers Connect the overflow tube and secure with the tube clamp Fill the radiator with coolant Connect the vent tube to the radiator filler After installation check for coolant leaks Connect the outlet tube of the reservoir and secure with the tube clamp 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 Start the engine filled in the coolant till the coolant flowed out from the air vent tube 12 7 95002 KHE7 S 19102 ui ec 7 9 50 06060 SS From Engine From Reserve Tank To Water Pump Radiator KYMCO 12 COOLING SYSTEM People GT 300i WATER PUMP 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 Telltale Water Pump Cover WATER PUMP IMPELLER REMOVAL Impeller Washer Porcelain Re
61. ar from the cam chain Diagonally loosen the cylinder head cap nuts in 2 or 3 times Remove the set plate located beside the rocker arm shaft Set Plate KYMCO 6 CYLINDER HEAD VALVES People GT 3001 Rocker Arm Remove the rocker arm with bolt as shown CAMSHAFT INSPECTION Check each cam lobe for wear or damage 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 Rocker Arm If the surface of rocker arm is worn check each cam lobe for wear or damage Camshaft CYLINDER HEAD REMOVAL Remove the muffler Remove the throttle body Drain the coolant from the radiator and water hose then remove the thermostat water hose Remove the camshaft Remove the Temp Map Sensor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Thermostat 6 6 KYMCO 6 CYLINDER HEAD VALVES People GT 300i Remove two nuts attaching to the upper lower side of cylinder head Remove two bolts attaching to the cylinder head Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface Be careful not to drop any gasket Cynder maad Ge Dowel pins material into the engine E NN CYLINDER HEAD DISASSEMBLY Remove the valve
62. cap dipstick OIL CHANGE The engine oil will drain more easily while the engine 15 warm Remove the oil filter screen cap located on the bottom of the engine to drain the engine oil thoroughly Clean the oil filter screen Install the oil filter screen filter Oil Filter Screen screen cap Fill the engine with recommended engine oil Engine oil recommendation Use a fully synthetic quality 4 stroke engine oil to ensure longer service life of your scooter Only use oils that have a SJ rating above per the API service classification Engine oil viscosity SAE 5W 50 If these viscosities are not available select an alternative engine oil according to the chart shown below ENGINE OIL VISCOSITIES ES a ee 20W 40 20W 50 mm 15W 40 15W 50 aS Sa reem 10 0 10 20 30 40 0 20 40 60 80 100 F Engine oil capacity 1 5 L 4 2 KYMCO 4 LUBRICATION SYSTEM People GT 300i OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right under crankcase cover The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is good condition Install a new oil filter T Make sure the rubber seal on the oil filter facing the left crankcase MESH FILTER REPLACEMENT Drain the engine oil Remove the right crankcase cover Clean the mesh filter at every 1000
63. ce e Air in brake system e Deteriorated brake fluid e Contaminated brake pad surface e Worn brake pads e Clogged brake fluid line e Deformed brake disk e Unequal worn brake caliper 15 2 15 REAR BRAKE REAR FORK REAR KYMCO ___WHEEL REAR SHOCK ABSORBER People GT 290 Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler 52 10 Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove 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 coated surfaces to avoid damage INSPECTION Inspect the brake pads and brake disk Measure the brake disk thickness Service Limit 4 0 mm replace if below Visually check the brake pad thickness and it should not exceed the wear indicator mark DISASSEMBLY Remove two brake pads dowel pins and three bolts from the brake caliper Remove the brake pads Brake Pads 15 3 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER FFOPIFS300 INSTALLATION Fluid Tube Bolt Install the brake caliper to the rear fork and tighten the two bolts Torque 35 N 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 2
64. cedure How to read DTC from speedometer New Phase 5 Fuel Injection Engine Vehicle DTC Reading Automatic indication ECU upgrade version with Oxygen sensor Reading DTC from speedometer directly KYMCO People GT 300i Key On light off in 2 seconds When the engine inspection lamp is light up again it starts to deliver failure code If no show there is without any failure Note 1 The CELP denotes the failure codes When the indicator lights for 1 second it is equivalent 10 blinks For example a 1 second illumination and two blinks 0 5 second x 2 of the indicator equals 12 blinks Refer to DTC 12 2 If more than one failure occurs the CELP shows the blinks in the occurred order For example if the indicator blinks 6 times then shows one second illumination and two blinks two failures have occurred Refer to DTC 6 and DTC 12 Put the side stand up and engine stop switch is at RUN 2sec ON CELP mE OFF Blin 111 Blinks 12 10 11 3 sec 5sec Ignition switch ON After excluding trouble how the DTC can be cleared Confirm the failure is excluded Turn on power but maintain not stated and keep the engine inspection lamp light up for 4 cycles If it is off automatically it means the historical DTC is cleared automatically Use PDA
65. ch Spring A120E00053 Clutch disassembly amp assembly Compressor Shaft Collar Puller 120 00088 Bearing crankcase removal Shaft Collar Driver A120E00091 Bearing crankcase removal Shaft Collar Installer A120E00092 Bearing crankcase installation Bearing Puller A120E00093 Bearing removal Lock Nut Socket Wrench A120F00002 Steering stem removal installation Electric Repair Kit A120F00032 Fuel injection system diagnosis KYMCO 1 GENERAL INFORMATION People GT 300i LUBRICATION POINTS FRAME The following is the lubrication points for the frame Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorcycle n Sg Grease Sg Grease WE Grease Side stand pivot Rear wheel axle amp nut Front wheel axle amp nut amp Main stand pivot 1 11 KYMCO 1 GENERAL INFORMATION People GT 3001 CABLE amp HARNESS ROUTING Tilt Switch Winker Relay Tilt Switch a Y Horn e m L d Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay 1 12 KYMCO 1 GENERAL INFORMATION People GT 3001 Oil Controller Front Brake Hose _ Tilt Switch 1 13 KYMCO 1 GENERAL INFORMATION People GT 3001 MAP Sensor Throttle Body We Zoe WW M Injector 1 14
66. cker arm shaft any grease before installation Gasket Cam chain guide Install the cylinder head Nut Cylinder Head Install the camshaft Install the intake valve rocker arm and the rocker arm shafts CAMSHAFT INSTALLATION Install the set plate to prevent the rocker arm Bolt Fix plate shaft from pull out Torque 1 2 kgf m 8 9 N m KYMCO 6 CYLINDER HEAD VALVES People GT 300i CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket Install the cam chain guide e Clean the intake valve rocker arm shaft grease before installation Gasket Cam chain guide Nut N Cylinder Head ei VW Install the cylinder head Install the camshaft Install the intake valve rocker arm and the rocker arm shafts A s Bolts CAMSHAFT INSTALLATION Install the set plate to prevent the rocker arm Bolt Fix plate shaft from pull out Torque 1 2 kgf m 8 9 N m 6 10 KYMCO 6 CYLINDER HEAD VALVES People GT 300i Tighten the four cylinder head nuts and the Nuts four bolts between the cylinder head and cylinder Torque Cylinder head nuts 3 6 kgf m 35 3 N m Turn the A C generator flywheel so that the Camshaft Gear Round hole T 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 two bolts on the camshaft gear w
67. continuity between each pins 8 9 and 24 of the ECU side connector There should be continuity at all times Check for continuity between pin 24 and 36 of the ECU side connector There should be no continuity at all times ECU PIN FUNCTION FUNCTION KYMCO People GT 300i 18 PIN 36 PIN FUNCTION Ignition power Roll sensor Tilt switch Battery Crank pulse sensor Multi indicator lamp ECLP Water temperature sensor Throttle position sensor ECT Manifold pressure sensor Intake pressure sensor Sensor ground HEGO HEGO sensor O2 sensor LG Logic ground CRK M Crank pulse sensor ground K LINE _ Diagnostic tool FLPR Fuel pump relay Sensor power output Idle speed control ISC ISCBP w speed control ISC Idle speed control ISC ISCAP control ISC Meter INJ Injection HEGO HT HEGO HT sensor O2 HT sensor Power ground IG Ignition coil Power ground 13 18 KYMCO 13 FUEL INJECTION SYSTEM People GT 3001 FUEL INJECTOR INSPECTION Disconnect the fuel injector connector Measure the resistance between 2 pins of the fuel injector connector Standard 11 7 0 6 Q at 20 C 68 F REMOVAL Disconnect the connector from the fuel injector Remove the bolt of the fuel injector Take out of the fuel pipe and fuel injector
68. ctor from the headlight bulb INSTALLATION Install a new bulb into the headlight case Install the headlight and connect the headlight connector Headlight Bulb 19 3 KYMCO 19 LIGHTS METERS SWITCHES People GT 300i FRONT TURN SIGNAL LIGHT Remove the front cover Turn the bulb socket and then remove the front turn signal light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal Socket TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL LIGHT Remove the seat and met in Remove the body covers Remove the taillight bulb socket Taillight Bulb REAR TURN SIGNAL LIGHT Turn the bulb counterclockwise to remove it P ri then replace with a new one 4 Installation is in the reverse order of removal Rear Turn Signal Light 19 4 KYMCO 19 LIGHTS METERS SWITCHES People GT 300i BRAKE LIGHT SWITCH Remove the handlebar cover Disconnect front or rear brake light switch connectors and check for continuity between the switch terminals There should be continuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front cover Disconnect the ignition switch connector and check the ignition switch for continuity at the switch side connector terminals Continuity should exist between the co
69. des ECU version model name data analysis and reset ECU version includes model name ECU number identifications number and software version Failure codes DTC reading DTC clearing and troubleshooting Data analysis For ECU s software inspection Reset For the setting function adjustment Model No ECU Version DTC Inspect Down Button Power indicator Enter or Exit DTC indicator 13 28 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power LGES is for ET People GT 300i maluze OO A ECU version Including of model name ECU number identifications number and software version Press Enter button Hoda lt LGES is for e name LFG People 3001 im 46 LATALA pate 81 ware 1 13 29 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i B Press the Down button and then turn to the first page LGES is for People GT 300i DTC Leppert DATA fmsluze HCO Adjust C Press the Enter button to check the DTC failure code LGES is for People GT 300i 13 30 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i D Press the Enter button KYMCO Diagnostic Previous ia A Clear DTC E Press the Enter button F Display what s DTC number on this DTC List Press the Enter
70. diator pipe Remove the right and left rear cushion lower mount bolts Torque 4 0 kgf m 40N m Mount Bolt 5 4 KYMCO 5 ENGINE REMOVAL INSTALLA TION People GT 300i Remove the engine mount nut and pull it out Remove the engine from the frame At removing the engine be careful not to catch your hand or finger between the engine hanger and crankcase Torque 6 5 kgf m 65 N m INSTALLATION Mount Nut Installation is in the reverse order of removal After installation inspect and adjust the following e Throttle grip free play e Fill the cooling system with coolant and start the engine to bleed air from the system API ABV Reset Refer to chapter14 page 17 KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 300i Mount Nut ENGINE HANGER REMOVAL Remove the engine mount nut and pull it out Be careful to put the engine down Remove the left right engine hanger mount bolt Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts to the specified torque Torque 6 5 kgf m 65 N m KYMCO 6 CYLINDER HEAD VALVES People GT 300i CYLINDER HEAD VALVES SCHEMATIC 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING enee 6 3 CYLINDER HEAD COVER REMOVAL 6 4 CAMSHAFT
71. e drive ability and poor fuel economy e Pinched or clogged fuel hose e Faulty injector KYMCO 13 FUEL INJECTION SYSTEM People GT 300i SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL RUN SELF DIAGNOSTIC PROCEDURES It can be performed without diagnostics program Place the scooter on its main stand Put the side stand up and the engine stop switch is at RUN e Turn key to On position The CELP will be lighting for two seconds and then off e If the engine has problem the CELP will blink to show the failure codes Upward side e There re 11 failure codes for the KEHIN stand system If the vehicle gets more failure codes the CELP will be blinking from a lower number then show the higher number after three seconds All failure codes would be appeared repeatedly No matter when CELP illuminated while riding condition should find out the cause of the problem as soon as YY u Fi indicator 13 6 13 FUEL INJECTION SYSTEM EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES The CELP denotes the failure codes When the indicator lights for one second that is equal to ten For example one longer blink illumination and two shorter blinks 0 5 second x 2 of the indicator is equal to 12 blinks Follow code 12 Put the side stand up and engine stop switch is at RUN 1111 5 sec 3 sec 1 DL
72. e shown KYMCO 7 CYLINDER PISTON People GT 300i 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 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 Ge The piston must be changed in pair with cylinder 2 12 1 10 00 0 010 0 030 HE g pira 0 010 0 030 PISTON O D CYLINDER BORE CLEARANCE 7 7 KYMCO 7 CYLINDER PISTON People GT 300i Install the cam chain guide Gasket Dowel Pin X e Insert the tab on the cam chain guide into the cylinder groove Install the cylinder head gasket and dowel pins Connect the water hose to the cylinder Install the cylinder head Tighten the cylinder base bolt 8 DRIVE AND DRIVEN PULLEYS KYMCO L MSBEDE CL DRIVE AND DRIVEN PULLEYS V BELT SCHEMATIC DRAWING 8 1 SERVICE INFORMATION 8 2 TROUBLESHOOTING q m m 8 2 LEFT CRANKCASE COVER 8 3 DRIVE PULLEY
73. e battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive 4 terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps be installed securely E f the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity 1 GENERAL INFORMATION After operation terminal caps shall be installed securely x Confirm B When taking out the connector the lock the connector shall_be released before operation B Hold the connector body when connecting or disconnecting it B Do not pull the connector wire B Check if any connector terminal is bending protruding or loose BRN Be B connector shall inserted completely B f the double connector has a lock lock it at the correct position m Check if there is any loose wire CR KYMCO People GT 300i m Before connecting a terminal check for damaged terminal cover or loose negative terminal Q X m Check the double connector cover for proper coverage and installation cto n E Insert the terminal completely m Check the terminal cover for proper coverage Do n
74. e cause 1 Raise wheel off the ground Wheels do not e Brake dragging and spin by hand spin freely e Worn or damaged wheel bearing Wheel spins freely 2 Check tire pressure Pressure low OR e Faulty tire valve e Punctured tire Pressure normal 3 Accelerate lightly Engine speed does cleaner dirty not increase e Restricted fuel flow e Clogged muffler Engine speed increase e Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU e Faulty ignition pulse generator Correct 5 Test cylinder compression Incorrect e Valve stuck open e Worn cylinder and piston rings e Leaking head gasket Normal e Improper valve timing 6 Inspect fuel flow Abnormal e Faulty pressure regulator Normal 7 Inspect the fuel injector Abnormal n_ e Faulty injector Normal 8 Remove spark plug Fouled or discolored e Faulty spark plug Not fouled or discolored 1 17 KYMCO 1 GENERAL INFORMATION People GT 300i Possible cause 9 Check oil level and condition Incorrect e Oil level too high e Oil level too low e Contaminated oil Correct 10 Remove cylinder head cover Valve train not Clogged oil and inspect lubrication lubricated p
75. e the terminal leads Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Remove the battery from the battery box BATTERY INSTALLATION Install in the reverse order of the removal When install the battery first connect the positive cable and then negative cable to avoid short circuit VOLTAGE INSPECTION Remove the battery cover Measure the battery voltage by using a commercially available digital multimeter Voltage 20 C 68 F Fully charged 13 0 13 2 V Insufficient charged lt 12 3 V Terminal KYMCO People GT 300i Terminal 16 4 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i BATTERY BATTERY CHARGING Remove the battery Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Turn the power ON OFF at the charger not at the battery terminals CHARGING CURRENT Standard 1 2A 5 10 Hours For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test Do not disconnect the battery or cable in the charging system without first switching off the ignition switch
76. f battery must be fully charged Place the tilt switch vertical as shown at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the tilt switch 65 10 degrees to the left or right at the ignition switch Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue m Green Pink 3 7 4 4 V If repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON KYMCO People GT 300i Crank Position Sensor Wire Coupler Tilt Switch P UP Mark Connector 17 4 KYMCO 17 IGNITION SYSTEM People GT 300i REMOVAL INSTALLATION Disconnect the connector and remove two screws then remove tilt switch Installation is in the reverse order of removal Install the tilt switch with its up mark facing up Tighten the mounting screws securely 17 5 KYMCO 18 STARTING SYSTEM People GT 300i STARTING SYSTEM STARTING SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 TROUBLESHODOTING Y erer 18 2 STARTER MOTOR
77. from the Inlet pipe Remove the fuel injector from the fuel pipe Ensure the fuel pipe without any pressure then remove the fuel injector STEP 1 Disconnect the fuel pump relay or fuel pump connector STEP 2 Turn the key to the ON position Starting the engine till the engine stop working O ring Fuel Iniector 13 19 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i Groove INSTALLATION Apply the engine oil to a new O ring Install the fuel injector into the fuel pipe Ensure the tab of the fuel injector inserted into the groove of the fuel pipe Install the fuel pipe into the intake manifold by aligning the dowel pin Be careful not to damage the O ring Tighten the fuel pipe mounting bolt FUEL INJECTOR CLEANING PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard lt 1 6ms ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container Connect the battery as picture The injector cleaner with the flash relay Container Keeping the fuel Injector operation Waiting for 20 30 minutes Cleaning the carbons completely Flash Relay 13 20 O Q KYMCO 13 FUEL INJECTION SYSTEM People GT 3001 WTS SENSOR Water Sensor Throttle Body Temperature Sensor REMOVAL INSTALLATION Dra
78. g 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 It is not necessary to check the MF battery electrolyte or fill with distilled water e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done in an emergency 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 Battery 20 C Insufficient charged lt 12 3V Charging current 1 2A 5 10H 16 2 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i TROUBLESHOOTING No power e Dead battery e Disconnected battery cable e Fuse burned out e Faulty ignition switch Low power Weak battery Loose battery connection e Charging system failure e Faulty regulator rectifier 16 3 Intermittent power Loose battery cable connection e Loose charging system connection e Loose connection or short circuit in ignition system Charging system failure Loose broken or shorted wire or connector e Faulty regulator rectifier e Faulty A C generator 16 BATTERY CHARGING SYSTEM BATTERY REMOVAL The battery is under the floorboard Remove the two screws attaching the battery cover Pull battery out to expos
79. g 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 Standard mm 0 2 Radia 2 Aid IL 20 Axle shaft runout Front wheel rim runout Brake disk runout Brake caliper cylinder I D Brake master cylinder O D TORQUE VALUES Steering Handle Post Bolt Steering Stem Lock Steering Head Race Nut Rear Suspension Bolt Front Axle Nut Brake caliper holder bolt SPECIAL TOOLS Lock Nut Wrench Oil seal amp Bearing Driver 002 014 Brake caliper piston O D 25 33 25 36 25 4 25 45 25 45 13 95 13 98 13 95 Brake master cylinder 1 0 14 0 14 04 14 05 45 N m 63 20 N m 27 N m 120 N m 35 N m 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 bra
80. h Clutch Driven Pulley Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Remove the oil seal from the movable driven face ASSEMBLY 23200 R 23225 i 910 23226 Movable Driven Face esd d SE L d ES P 23220 S MAVAS 91351 23225 91351 23237 42 Guide Roller 23233 0 23238 O ring 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i INSPECTION Measure the driven face spring free length Service Limit 136 mm replace if below Outer Bearing 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 eDiscard the removed bearing replace with a new one Remove the snap ring and drive the outer bearing out of the driven face eDiscard the removed bearing 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 Grooves Seat the snap ring in its groove Apply grease to the driven face bore areas Guide Pins 8 8 8 DRIVE AND DRIVEN PULLEYS KYMCO E Press a new needle bearing into the driven face CLUTCH DISA
81. he pulley face clutch outer driven pulley and belt Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i INSPECTION Check each weight roller for wear or damage Check the movable drive face bushing wear or damage or ASSEMBLY 90201 KHR8 OG 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i 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 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 Service Limit 153 5 mm replace if over Measure the clutch lining thickness Check the clutch shoes for wear or damage 22300 Service Limit 2 0 mm replace if below Clutch Lining 8 6 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i Clutch Spring Compressor CLUTCH DRIVEN PULLEY DISASSEMBLY Hold the clutch driven pulley assembly with the clutch spring compressor Set the tool in a vise and remove the clutch drive plate nut eBe sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor E053 Fittings amp Nut Wrench 41mm E033 Lock Nut Wrenc
82. in the coolant from the cooling system Disconnect the WTS sensor connector from the sensor Remove the WTS sensor and O ring Injector Install a new O ring and WTS sensor i Always replace an O ring with a new one Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 N m 8 6 Ibf ft Connect the WTS sensor connector the cooling system with the recommended coolant O ring INSPECTION Measure the resistance at the WTS sensor terminals STANDARD C 20 40 100 18 8 1 136 0 1553 13 21 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i SENSOR The O sensor issues signal to ECU when the temperature is over 350 C during the engine is working The temperature is up to 350 C earlier than the muffler for heater sensor So the sensor begins performance The function of sensor only controls the fuel injector operation INSPECTION Disconnect sensor connector Measure the resistance between each White wire terminals of the sensor side connector Standard 7 7 1 2 Q at 20 C 68 F REMOVAL INSTALLATION Disconnect the sensor connector and then remove it from exhaust muffler Installation is in the reverse order of removal Apply anti seize compound on the surface of thread area before sensor installation Tighten the O sensor to specified torque Torque 2 5 kgf m 25 N
83. inder and brake reservoir with brake fluid 4 Snap Ring Rubber Cover 14 8 14 STEERING HANDLEBAR FRONT WHEEL FRONT INSPECTION Measure the brake master cylinder Inspect the master cylinder for scratches or cracks Service Limit 14 05 mm Measure the brake master cylinder piston O D Service Limit 13 94 mm Before assembly inspect the 1st and 2nd E rubber cups for wear Master Cylinder Spring Main Piston ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup e During assembly the main piston and spring must be installed as a unit without exchange e 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 EE Place the brake master cylinder on the handlebar and install the holder with the up UP Mark 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 12 N 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 c
84. ion If the coolant level is below the LOWER level mark remove the left floor mat remove the lid screw the reserve tank lid and then the reserve tank cap to add coolant mixture until it reaches the er level mark RPE x Reserve Tank Add coolant to the reserve tank only Do not attempt to add coolant by removing the radiator cap Coolant in the radiator is under pressure and is very hot and can cause serious burns 3 5 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i AIR CLEANER AIR FILTER REPLACEMENT Remove the body cover Remove seven screws attaching to the air cleaner cover Remove six screws attaching to the filter Check the filter and replace it if it is excessively dirty or damaged Air Cleaner Cover CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas e The air cleaner element has viscous type paper element Do not clean it with compressed air eBe sure to install the air cleaner element and cover securely SPARK PLUG 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 NGK CR7E Measure the spark plug gap Spark Plug Gap 0 6 0 7 mm Spark Plug e When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench 4 Crack
85. ion test or by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler e 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 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 Leaking 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 3 KYMCO 6 CYLINDER HEAD VALVES People GT 300i CYLINDER HEAD COVER REMOVAL Remove the met in box Remove the body cover and center cover Disconnect the breather hose to air cleaner Remove the cylinder head cover four bolts Remove the cylinder head cover Cylinder Head Cover CAMSHAFT REMOVAL Remove the injector and inlet pipe Th inim Remove two screws attaching the thermostat 55 Inlet pipe Turn the chain tensioner screw clockwise to tighten it Cam Chain Tensioner Torque 1 0 kgf m 9 8 N m KYMCO 6 CYLINDER HEAD VALVES People 300i Remove four nuts attaching to the cylinder head Remove two bolts attaching to the camshaft gear Remove the camshaft ge
86. ith the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear e Apply engine oil to the threads of the cylinder head cap nuts eDiagonally tighten the cylinder head cap nuts 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 Install the thermostat bolt Torque 1 2 kgf m 11 8 N m Turn the cam chain tension screw counter clockwise to release it 6 11 6 CYLINDER HEAD VALVES CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 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 the inlet pipe Install the injector Install and tighten the cylinder head cover bolts KYMCO People GT 300i Thermostat Injector Inlet pipe 6 12 KYMCO 7 CYLINDER PISTON People GT 300i CYLINDER PISTON 7 SCHEMATIC DRAWING 25 SERVICE INFORMATION u estate tedesca 72 TBOUBUESHOOTHNO ee eel a 7 2 CYLINDER REMOVAL LU 7 3 Selfie LE 7 3 TON IVS WALLIN sec CYLINDER INSTALLATION 77 KYMCO 7 CYLINDER PISTON People GT 300i SCHEMATIC DRAWING 90005 pee 01206 145
87. ition timing ECU control Spark plug CR7E NGK Spark plug gap 0 6 0 7mm Battery Capacity 12V12AH Transmission system Clutch type Dry multi disc Transmission type CVT Operation type Auto centrifugal Reduction gear type Two stage reduction Reduction ratio Primary Final 7 222 Moving device Tire type Tubeless Front wheel 110 70 16 Tire spec Rear wheel 140 70 16 Front wheel 1 75 Tire Ee Rear wheel 2 25 with kg cm passenger Wheel material Aluminium Left 45 5 Turning angle Right 45 45 Front Disk brake SE Ape Rear Disk brake Damping Device Suspension Front Telescope type Rear Swing arm Shock absorber Front 110 mm stroke Rear 100 mm 1 2 1 GENERAL INFORMATION SERVICE PRECAUTIONS m Make sure to install new gaskets O rings circlips cotter pins etc when reassembling 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 e B When the motorcycle be sure to use special tools for removal and installation B After disasse ean removed parts Lubricate sliding surfaces with engine oil before reassembly 1 3 KYMCO People GT 300i B Apply or add designated greases and lubricants to the specified lubrication points B When two persons work together pay attention to the mutual working safety B Disconnect th
88. k the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the specified torques Torque Front axle nut 20 N m Rear axle nut 120 N m Rear Axle Nut 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 3 11 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i SIDE STAND Your scooter s side stand is not only necessary when you park but it contains an important safety feature This feature cuts off the ignition if you try to ride the scooter when the side stand is down Perform the following side stand inspection INTERLOCK FUNCTION CHECK Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower the side stand The engine should stop as you put the side stand down If the side stand system does operate as described see your KYMCO dealer for service 3 12 4 KYMCO USOS SERVICE INFORMATION 41 OIL FILTER REPLACEMENT 4 3 TROUBLESHOOTING 4 1 OQILPUMP uQ ege 4 4 ENGINE OIL OIL FILTER aasan 4 2 A e Dipstick 94001 04013 X e 96001 0502 e Wa aA
89. ke fluid line e Unevenly worn brake caliper 14 3 KYMCO People GT 300i Front wheel wobbling e Bent rim e Loose front axle e Bent spoke plate e Faulty tire e 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 dO ___BRAKE FRONT SHOCK ABSORBER FRONTFORK GT 3001 Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers 22 3 Remove the front and rear brake master cylinder attaching bolts Throttle Cable 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 Remove the handlebar lock nut then take out the bolt and collar Remove the handlebar Lock Nut Bolt Collar INSTALLATION X Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the handle post bolt to the specified torque Torque 45 N m 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO BRAKE ERONT SHOCK ABSORBER FRONT FORK People GT 300i 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
90. ken clutch weight spring 8 2 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i LEFT CRANKCASE COVER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the protector cover of left crankcase cover Remove the bolts attaching to the left Left Crankcase Cover crankcase cover Remove the gasket and dowel pins INSPECTION Check the bearing for wear or damage Replace the bearing with a new one if the bearing is noisy or have excessive play DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Bearing Remove the left crankcase cover Drive Pulley Face Hold the drive pulley using a universal holder and remove the drive face nut and washer Remove the drive pulley face Universal Holder E017 CLUTCH OUTER DRIVEN PULLEY V BELT REMOVAL Remove the drive pulley face Universal Holder Hold the clutch outer with the universal holder Bushin Nut and remove the clutch outer nut bushing and usung washer Universal Holder E017 Remove the clutch outer driven pulley and belt together Remove the drive belt from the movable drive face Movable Drive Face 8 3 8 DRIVE AND DRIVEN PULLEYS KYMCO V BELT People GT 300i INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Replace a new belt at every 20 000km eUse specified genuine parts for replacement MOVABLE DRIVE FACE ASSEMBLY Remove t
91. l with a flywheel puller Flywheel puller E003 Flywheel Puller Starter Idle Gear Shaft e e Wi A STARTER CLUTCH REMOVAL Remove the starter driven gear Remove the starter idle gear and shaft Starter Driven Gear 10 4 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i Oil Separator Cover OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover Bolts Spread the clip off and remove the oil pump OIF ump Drive chain Cam Chain driven gear then remove the oil pump drive chain Remove the cam chain Oil Pump Driven Gear Clip Bolts Remove the two oil pump bolts to remove the oil pump Oil pump 10 5 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear 1 0 and O D Service Limits 1 0 22 15mm replace if over O D 41 50mm replace if below 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 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i INSTALLATION Arrow Mark Bolts Chain Install oil pump and tighten two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install cam chain Install the pump drive chain and driven gear then set the clip securely on the pump shaft Oil Pump Driven
92. lor code wires as follows COMB SW Ignition Switch 19 5 KYMCO 19 LIGHTS METERS SWITCHES People GT 300i RIGHT HANDLEBAR SWITCH Engine Stop Switch INSPECTION Remove the handle cover Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Lighting Switch Starter Switch LIGHTING SW JBA3 PO TL HL DT Dt E E E 19 6 19 LIGHTS METERS SWITCHES LEFT HANDLEBAR SWITCH INSPECTION Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows WINKER SW DIMMER SW PASSING SW AUXILIARY OUTLET INSPECTION Open the luggage box Disconnect the auxiliary outlet connector and check for continuity between the switch terminals There should be no continuity with the luggage box light switch pushed and there should be continuity with the luggage box light switch is released 19 7 KYMCO People GT 300i Dimmer Switch Horn Switch Turn Signal light Switch Passing Switch Auxiliary Outlet KYMCO 19 LIGHTS METERS SWITCHES People GT 300i FUEL PUMP Connector REMOVAL Remove the seat and met in Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel p
93. m 18 Ibf ft 13 22 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i THROTTLE BODY MAP ISC TPS e Turn off the ignition switch while TPS Isc MAP replacement e Check and confirm if the voltage is over 12V by a voltmeter after replacement e Check and confirm if the other connectors are installed correctly after replacement Do not damage the throttle body it may cause the throttle and idle valve isn t synchronization e The throttle body is preset in KYMCO factory do not disassemble it by a wrong way e Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchronization failure e TPS and ISC have to be reset after the throttle body MAP TPS ISC or ECU has been reinstalled MAP INSPECTION Support the scooter on a level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON position Measure if the ECU voltage outputs to the MAP between the following terminals of the MAP connector Terminal Normal Violet Red Green Pink 5V 13 23 13 FUEL INJECTION SYSTEM TPS INSPECTION Support the scooter on a level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector Terminal Normal Violet Red
94. move the coolant inlet hose and outlet hose Remove four bolts and the water pump cover gasket and 2 dowel pins 4 Remove the water pump impeller d The impeller has left hand threads Ka Mechanical Water Seal Inspect the mechanical water seal and seal washer if wear or damage mechanical seal and seal washer must be replace as a set 12 8 KYMCO 12 COOLING SYSTEM People GT 300i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove bolts attaching the right crankcase cover Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and inner bearing Remove the water pump shaft outer bearing Snap Ring MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside Apply sealant to the right crankcase cover of anew mechanical seal and then drive in the mechanical seal Water Pump Shaft WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Install the water pump shaft and shaft inner bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly Mechanical Seal 12 9 KYMCO 12 COOLING SYSTEM People GT 300i Install the dowel pins and a new gasket and WE Seal Washer Porcelain then install the water pump assembly to the right cr
95. n Remove the gasket and dowel pins Remove the final shaft Remove the final gear and countershaft Final Shaft Final Gear FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft 9 3 9 FINAL REDUCTION KYMCO People GT 300i 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 remove the transmission case cover except for necessary part replacement When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing Drive Shaft Drive Shaft Bearing Countershaft Bearing Drive Shaft Bearing Drive Shaft 9 4 KYMCO 9 FINAL REDUCTION People GT 300i FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Dowel Pin Put the final gear on the left crankcase Install the countershaft and gear into the left crankcase Install the final shaft into the final gear and transmission case Install the dowel pins and a new gasket Gm Final Gear Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch outer driven
96. n pin e Incorrectly installed piston 7 2 7 CYLINDER PISTON CYLINDER REMOVAL Remove the cylinder head 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 towel in the crankcase to keep the piston pin clip from falling into the crankcase KYMCO People GT 300i Cylinder Dowel Pins Water Hose Cam Chain Guide Gasket Dowel Pins Piston Piston Pin Piston Rings KYMCO 7 CYLINDER PISTON People GT 300i Inspect the piston piston pin and piston rings Remove the piston rings 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 09 mm replace if over 2nd 0 09 mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the hole of piston pin Service Limit 15 04 mm replace if over KYMCO 7 CYLINDER PISTON People GT 300i Measure the piston pin O D Service Limit 16 994 mm replace if
97. nd allow it to run until there are no air bubbles in the coolant and the level stabilizes 2 Open the air vent tube to see the hot coolant flow out 3 Stop the engine and add coolant up to the proper level if necessary 4 Reinstall the radiator cap 5 Check the level of coolant in the reserve tank and fill to the correct level if the level is low 6 Close the radiator protector Air Vent Tube 12 5 13 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM SERVICE INFORMATION uuu 13 1 SPECIFICATION 13 2 INJECTION SYSTEM DIAGRAM 13 3 PARTS LOCATION renes 13 4 TROUBLESHOOTING 13 6 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC EE 327 EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES ee 13 8 SELF DIAGNOSIS RESET PROCEDURE 13 9 CELP FAILURE CODES LIS Tse ee 13 10 IPSIS CRESET eegen eeh 13 13 EIERE 13 14 FUEL CUT OFF RELAY eebe 13 16 TESNO A 13 17 ELECTRONIC CONTROL UNIT ECU 13 18 FUE INJEC TOR ee 13 20 WETS SENSOR Sa Sa eei 13 22 O SENSOR ee 13 23 THROTTLE BODY MAP ISC TPS 13 24 DIAGNOSTIC TOOL CONNECTOR 13 27 DIAGNOSTIC TOOL OPERATION INSTRUCTIONS
98. nition control module e Faulty crank position sensor e Faulty ignition control module Peak voltage is normal but no spark jumps at the plug e Faulty spark plug or leaking ignition coil secondary current e Faulty ignition coil 17 2 KYMCO 17 IGNITION SYSTEM People GT 300i SPARK PLUG For spark plug inspection and adjustment refer to page 3 5 IGNITION COIL INSPECTION Remove the seat and met in box gt 2 6 Remove the ignition coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil This is a general test Accurate ignition coil test must be performed with an ignition unit tester Measure the ignition coil resistances at 20 C 3 57 4 830 15 19KQ 10 14 KQ 17 3 17 IGNITION SYSTEM A C GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION This test is performed with the stator installed in the engine Remove the seat and met in box Disconnect the Crank Position Sensor Wire Coupler Measure the resistance between the blue white and green white wire terminals Blue Yellow Green White 11150 150 TILT SWITCH INSPECTION Support the scooter level surface Put the side stand up and engine stop switch is at RUN Turn the ignition switch to OFF Remove the screws washers and tilt switch Do not disconnect the tilt switch connector during inspection The capacity o
99. nition timing Incorrect e Faulty ECU Correct 2 Inspect the fuel flow Y Abnormal e Faulty pressure regulator Normal 3 Inspect the fuel injector Abnormal e Faulty injector Normal 4 Check valve timing Incorrect e Camshaft not installed properly Correct 5 Check valve spring Weak e Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy e Steering stem adjusting nut too tight e Damaged steering head bearings 2 If either wheel is wobbling e Excessive wheel bearing play e Bent rim e Improper installed wheel hub e Swing arm pivot bearing excessively worn e Bent frame 3 If the motorcycle pulled to one side ______________ _ e Faulty the shock absorber e Front and rear wheel not aligned e Bent fork e Bent swing arm e Bent axle 1 20 KYMCO 2 EXHAUST MUFFLER FRAME COVERS People GT 300i EXHAUST MUFFLER FRAME COVERS SCHEMATIC DRAWI G at as 2 1 SERVICE INFORMATION eeneg 2 2 TROUBLESHOOTING l 2 2 FRAME COVERS REMOVAL en 2 3 EXHAUST MUFFLER REMOVAL nnn 2 6 KYMCO 2 EXHAUST
100. onally tighten the bolts in 2 3 times Dowel Pins 4 5 KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 3001 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION 5 1 ENGINE REMOVAL INSTALLATION 5 2 ENGINE HANGER E 5 6 5 0 KYMCO 5 ENGINE REMOVAL INSTALLATION People GT 300i 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 scooter body cables and wires during engine removal e Use shop towels to protect the scooter 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 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 5 L At change 1 3 L Coolant capacity Radiator 766 cc Hose with cool coolant 169 cc Hose with hot coolant 194 cc Reserve tank 590 cc Total capacity 1719 cc TORQUE VALUES 90304 GHE8 0040 Engine hanger Engine side 5 0 kgf m 50 N m 90305 LBD4 9000 Engine hanger Frame side 6 5 kgf m 65 N m 95801 10060 Rear fork mount bolts 3 5 kgf m 35 N m 90305 KFW6 9120 M1 Rear axle nut 12 0 kgf m
101. or diagnosis tool clear Historical Failure code Check again to confirm DTC is excluded Turn on power again When there is no residual historical failure cod Start the engine and if no failure lamp is on or flashing it is Okay 13 41 5 FUEL INJECTION SYSTEM KYMCO DiagnosticReport Customer Service Date Production Date KYMCO People GT 300i LGES Eng No Mileage gt 5 a E maintenance NOW dojgoulsuy 1000 Ay eursug N 8 5 T 9 lt e amp c 5 2 09 gt P e lt S ECU Hardware oftware Ver Calibration Ver Model Name Active Occurred History DTC Number Throttle Position Throttle Position Voltage V Engine Temp C Atom Pressure Kpa Roll Sensor State als 8 ELM lt Se EJS AE lt 3 n park plug Type CO Set Engine speed rpm ntake Pressure Kpa Engine Temp C uel Inject Interval ms gnition Timing Battery Voltage V Engine speed target rpm SC Step step DLE CO CO Set Engine speed rpm E 1009 manum uv Cer Kod ER EEN Engine speedo 1952199 intake Pressure Kpa Engine Tem
102. ot make the terminal cover opening face up aL es B Secure wire harnesses to the frame with their respective wire bands the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses m After clamping check each wire to make sure it is secure X AE 1 4 1 GENERAL INFORMATION Do not squeeze wires against the weld or its clamp io p too tight m After clamping check each harness to make sure that it is not interfering with any moving or sliding parts O X B When fixing the wire harnesses do make it contact the parts that will generate high heat o B 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 m Route harnesses so they are neither pulled tight nor have excessive slack KYMCO People GT 300i B Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner m When rubber protector cover is used to protect the wire harnesses it shall be installed securely m Do not break the sheath of wire B f a 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
103. overs 22 3 BRAKE FLUID REFILLING Bolts Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add DOT 4 brake fluid to the brake reservoir Stop Switch Wire Connector 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 Washer the specified brake fluid to the upper limit gt e Do not allow dust or water to enter the brake system during refilling e When servicing the brake system use 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 Bleed Valve Brake fluid spiled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk 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 B
104. p Fuel Inject Ignition Timing 2 4 Battery VolagetY pv 71 02 Sensor 7 005 090 V Engine speed target apm 1620 pm Sep ep 1 93 4 ERE ECUS at ks 2 14 05 00 160 93 19 4 Ka Engine Temp C uel Inject Interval ms gnition Timing Battery Voltage V Engine speed target rpm SC Step step IDLE CO CO Set Repair description Report ID breakdown Full Throttle gt 93 Full Throttle Voltage gt 3 78V When the height goes up at an elevation of 1000 meters the lt 1 00 0 50 0 1 V 101 3 3 kPa 212 5 0 1 V ON stand CR7E 0 1620 100 rpm 34 0 41 0 kpa 1 60 2 50ms 12 14 BTDC 212 0 05 0 90 1620 rpm 0 15 0 3 1 5 Before muffler 0 Suggestion Value 5 5 1620x100rpm Following data Engine Temp gt 80 C Befor atmosphere pressure goes down 12kpa 34 0 41 0 kpa C 1 60 2 50ms 12 14 BTDC gt 12 0 05 0 90 V 1620 rpm 90 15 0 3 1 5 Suggestion Value 5 5 Repair Process Report Version 2011 1 17 13 42 14 STEERING HANDLEBAR FRONT WHEEL FRONT EE STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK ie Ela Eng ent ER SERVICE
105. ple GT 300i CHARGING SYSTEM LAYOUT Battery AC Generator Regulator Rectifier 16 1 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention e The battery can be charged and discharged repeatedly If 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 A 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 If a battery is not used for a long time it will discharge by itself and should be recharged every 3 months e A 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 Troubleshootin
106. r button to enter page 01 LGES is for People GT 300i C Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Down button to enter page 02 KYMCO Diagnosis H1 Speed 164d5rm 12 6 U 13 36 KYMCO 5 FUEL INJECTION SYSTEM People GT 300i DATA ANALYSIS PROCEDURE A Press Down twice LGES is for People GT 3001 B Choose Data Analyze Press Enter button to enter page 01 LGES is for People GT 300i C Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Down button to enter page 02 KYMCO Diagnosis H1 Speed 164d5rm 12 6 U 5 37 KYMCO 5 FUELINJECTION SYSTEM People GT 300i D Down page 02 The measure figures including of TPS position Intake pressure and Intake air temperature Press the Down button to enter page 03 E Down page 03 The measure figures including of Atmosphere pressure Fuel Injector interval and Ignition advance timing Press the Down button to enter page 04 KYMCO Diagnosis 83 1 75 ms F Down page 04 The measure figures including of Engine temperature O2 sensor voltage and O2 heater activation Press the Down button to enter page 05 13 38 KYMCO 5 FUEL INJECTION SYSTEM People GT 300i G Down page 05 The measure figures including of ISC target ISC step and ISC learn
107. r 2 3 minutes and check the oil level with the dipstick Do not screw in the dipstick when checking the oil level OIL CHANGE Remove the oil drain bolt to drain the engine EN oil Dipstick Install the aluminum washer and tighten the oil drain bolt Torque 2 5 kg m e Replace the aluminum washer with new one if it is deformed or damaged Pour the recommended oil through the oil filler hole OIL CAPACITY Oil Drain Bolt Engine oil capacity 1 5L Engine oil exchanging capacity 1 3 L Engine Oil Viscosity SAE 5W50 OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen attaching the left under crankcase Clean the oil filter screen Install the oil filter screen and filter screen cap Fill the engine with recommended engine oil OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right under crankcase cover Oil Filter Cap KYMCO 3 INSPECTION ADJUSTMENT People GT 300i The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new oil filter Make sure the rubber seal on the oil filter facing the left crankcase RESERVE TANK COOLANT LEVEL INSPECTION The reserve tank is under left floorboard Check the coolant level through the inspection window at the left side skirt white the engine is at the normal operating temperature with the scooter In an upright posit
108. r Ignition timing ECU At change 1 3 Liter Coolant type Water Cooling Gear oil capacity At disassembly 0 23 Liter At change 0 21 Liter TIRE j TIRE SPECIFICATION Front 110 70 16 Rear 140 70 16 TORQUE VALUES Front axle nut 20 N m Rear axle nut 120 N m SPECIAL TOOL Tappet Adjuster E012 3 1 KYMCO 3 INSPECTION ADJUSTMENT People GT 300i Maintenance schedule Perform the pre ride inspection see page 21 at each scheduled maintenance period This interval should be judged by odometer reading or months whichever comes first Maintenance schedule legend I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE The maintenance schedule on the flowing two pages specifies the maintenance required to keep your DOWNTOWN 300i scooter in peak operating condition Maintenance work should be performed in accordance with KYMCO standards and specifications by properly trained and equipped technicians YourKYMCO dealer meets all of these requirements Should be serviced by your KYMCO dealer unless you have the proper tools service data and are technically qualified In the interest of safety we recommend these items be serviced only by your KYMCO dealer KYMCO recommends that your KYMCO dealer road test your scooter after each periodic maintenance service is completed WHICHEVER COMES FIRST ODOMETER READING X 1000 km i oe
109. rankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Dowel Pins Right Crankcase Cover Tighten 12 bolts attaching to right crankcase cover Connect the water hoses to the right crankcase cover and water pump cover Add the recommended engine oil Fill the cooling system with the specified coolant gt Water Pump Shaft Water Hose e Be sure to bleed air from the water hose after filling the coolant 10 9 KYMCO 11 CRANKCASE CRANKSHAFT People GT 300i CRANKCASE CRANKSHAFT SCHEMATIC DRAWING m T 11 1 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASE 11 3 CRANKSHAFT INSPECTION Tq q 11 4 CRANKGASE ASSEMBLY s ease cece eee nee 11 5 11 0 KYMCO 11 CRANKCASE CRANKSHAFT People GT 3001 SCHEMATIC DRAWING 1122A 11103 P 19613 1110A 95002 Ce Ion net 91552 13314 LEA7 E0A 95701 91301 o 90701 13314 LEA7 E0B 2 LO 14 SH 11203 15200 E We s1009 91255 Y 94301 96100 63020 S 90701 91005 4 11340 90032 2 91552 67 95701 gt 91201 lt 96001 06080 32105 een 87
110. roperly e Clogged oil control orifice Valve train lubricated properly 11 Check for engine overheating Overheating e Fan motor not working e Excessive carbon build up in combustion chamber e Use of poor quality fuel Not overheating e Wrong type of fuel e Drive and driven pulleys clutch slipping 12 Accelerate or run at high Engine knocks e Worn piston and cylinder speed e Worn type of fuel e Excessive carbon build up in combustion chamber e Ignition timing to advanced faulty ECU Engine does not knock e Lean fuel mixture 1 18 KYMCO 1 GENERAL INFORMATION People GT 300i POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check ignition timing Correct 2 Inspect the fuel flow Normal 3 Inspect the fuel injector Normal 4 Check for leaks in the intake pipe No leak 5 Perform spark test Good spark 1 19 Possible cause Incorrect e Improper ignition timing Abnormal e Faulty pressure regulator Abnormal e Faulty injector Leaking Loose insulator clamp e Damage insulator Weak or intermittent spark e Faulty the spark plug e Faulty carbon or wet fouled spark plug e Faulty ECU e Faulty ignition coil e Faulty ignition pulse generator e Faulty ignition switch e Loose or disconnected spark plug wires KYMCO 1 GENERAL INFORMATION People GT 300i POOR PERFORMANCE AT HIGH SPEED Possible cause 1 Check ig
111. s Damage 4 Gap Deformation Torque 17 2 N m Wear Fouling 1 0 6 0 7 mm Deposits KYMCO 3 INSPECTION ADJUSTMENT People 300i VALVE CLEARANCE Cylinder Head Cover e Inspect and adjust valve clearance while the engine is cold below 35 Remove the seat assy and luggage box Remove the four bolts and then cylinder head cover Turn the A C generator flywheel to the top dead center TDC on the compression stroke so that the mark on the flywheel aligns with the index mark on the left crankcase cover Bolts Top Dead Center Mark Inspect and adjust valve clearance Valve Clearance IN 0 10 mm EX 0 10 mm Loosen the lock nut and adjust by turning the adjusting nut Valve Adjuster E012 Feeler Gauge e Check the valve clearance again after the lock nut is tightened CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and luggage box Remove the spark plug Insert a compression gauge Open the throttle fully and push the starter button to test the compression Max Compression 16 2 kg cm 570 rpm If the compression is low check for the following e Leaky valves Valve clearance too small e Leaking cylinder head gasket Worn piston rings Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head 3 7 KYMCO 3 INSPECT
112. sorber upper mount bolts Tighten the lower mount bolts Torque 27 N m Align the hole of upper mount bolt with the groove on the front fork Install the front wheel 215 7 Standard oil capacity 177 1cc lt 96600 c Front Shock Absorber 14 12 14 STEERING HANDLEBAR FRONT WHEEL FRONT qO KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK People GT 300i FRONT FORK REMOVAL 3 1 v Lock Nut Wrench gt Remove the handlebar covers 22 3 Remove the steering handlebar gt 15 4 Remove the front cover gt 2 5 Remove the front fender cover 52 6 Remove the front wheel 15 5 Remove the front brake caliper 15 11 Remove the front shock absorbers Hold the steering stem top cone race and remove 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 Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering Top Ball Race stem and front fork gt 50306 90503 53220 Ss 53213 53240 Bottom Ball Race BALL RACE REPLACEMENT Drive out the ball races Drive in new ball races gt Be sure to drive the ball races into place completely
113. spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor sure to compress the valve springs with a valve spring compressor Cam Chain Guide e Mark all disassembled parts to ensure correct reassembly Valve spring compressor E040 Remove carbon deposits from the exhaust port and combustion chamber Valve Spring Compressor 6 7 KYMCO 6 CYLINDER HEAD VALVES People GT 300i VALVE STEM INSPECTION Inspect each valve for bending burning or abnormal stem wear Intake valve Exhaust valve Remove carbon deposits from the Valves combustion chamber Clean off any gasket remnants from the cylinder head contact surface Be careful not to damage the cylinder head mating surface CYLINDER HEAD ASSEMBLY Install the valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Install the valve spring Valve spring compressor E040 the valve stems gently with plastic hammer for 2 3 times to firmly seat the cotters e Be careful not to damage the valves Valve spring compressor 6 8 KYMCO 6 CYLINDER HEAD VALVES People GT 300i Dowel Pins CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket Install the cam chain guide eClean the intake valve ro
114. stem always follow the steps in the troubleshooting on page 17 2 e The ignition timing cannot be adjusted since the ignition control module is already adjusted in factory e The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn off the ignition switch before servicing e A faulty ignition system is often related to poor connections Check those connections before proceeding e Make sure the battery is adequately charged Using the starter motor with weak battery results in a slower engine cranking speed as well as no spark at the spark plug e Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS o Hem 1 Standard Inductive Ignition Coil Ge coil without plug 10 42 14 49 Throttle Position Sensor 3500 6500 Q Fuel Pump 1 9 Q about Fuel Injector 11 7 0 60 Water Temperature Sensor 2 076KQ 1 0 25 C Oxygen Sensor engine warming condition 6 705950 Crank Position Sensor 11503150 0 4V 1 4V normal Tilt Switch 3 7V 4 4V fall down TROUBLESHOOTING No peak voltage e Short circuit in engine stop switch or ignition switch wire e Faulty engine stop switch or ignition switch e Loose or poorly connected ignition control module connectors e Open circuit or poor connection in ground wire of the ig
115. t and left rear shock absorbers Lower Mount Bolts 15 5 15 REAR BRAKE REAR FORK REAR KYMCO ___ WHEEL REAR SHOCK ABSORBER PEOPLES 3001 INSTALLATION Install the rear shock absorbers in the reverse order of removal Torque Upper Mount Bolt 40 N m Lower Mount Bolt 40 N m ADJUSTABLE REAR CUSHION To suit scooter comfortable 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 position medium C position hard When adjusting rear cushion the spring preload of rear cushions must be the same Standard spring preload position People GT 125i 1st People GT 300i 2nd A cushion adjust wrench is provided with new scooter Wrench The rear right cushion can be adjusted directly with the wrench tool Disconnect the breather hose from air cleaner and keep air cleaner up to adjust rear left cushion with wrench tool Air Cleaner 15 6 KYMCO 16 BATTERY CHARGING SYSTEM People GT 300i BATTERY CHARGING SYSTEM CHARGING SYSTEM LAYOUT CHARGING CIRCUL u SER VICE INFORMATION TROUBLESHOOTING set ote a BATTERY CHARGING CHARGING SYS BEGUEATOR BECTIEIER ee 16 0 KYMCO 16 BATTERY CHARGING SYSTEM Peo
116. t be drained 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 The valve rocker arms are lubricated by engine oil through the 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 eure Cylinder head compression pressure 16 kg cm 34 2987 Camshaft cam height 34 1721 IN 10 00 10 015 Valve rocker 1 0 10 00 10 015 Valve rocker arm shaft IN 9 972 9 987 O D 9 972 9 987 IN 12 WN 4 990 4 975 Valve stem O D 4 970 4 955 Valve stem to guide IN 0 010 0 037 clearance 0 030 0 057 TORQUE VALUES Tread size Torque Cylinder head stud bolt 1 Stud bolt Inlet pipe side Double end bolt 2 Stud bolt EX pipe side Double end bolt Bolt B stud 10 180 Apply oil to thread Valve adjusting lock nut Apply oil to thread Cam sprocket bolt SPECIAL TOOL Valve spring compressor E063 6 2 KYMCO 6 CYLINDER HEAD VALVES People GT 300i TROUBLESHOOTING e The poor cylinder head operation can be diagnosed by a compress
117. ter relay Starter Relay test chart large terminals The relay is normal if there is continuity and hear sounds 18 4 19 LIGHTS SWITCHES FUEL PUMP KYMCO People GT 300i LIGHTS METERS SWITCHES SERVICE INFORMA TION 19 1 BULB REPLACEMENT Stoo ee 19 3 BRAKE WIGHT SWITCH 19 5 Sus 19 5 RIGHT HANDLEBAR SWITCH 19 6 LEFT HANDLEBAR SWITCH 19 7 AUXILIARY OUTE ua 19 7 Mia ae 19 8 SIDE STAND SWITCH Ee 19 10 19 0 KYMCO 19 LIGHTS SWITCHES FUEL PUMP People GT 300i ELECTRICAL EQUIPMENT LAYOUT Oil Controller Winker Relay Winker Relay Tilt Switch ET Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay 19 1 KYMCO 19 LIGHTS SWITCHES FUEL PUMP People GT 300i SERVICE INFORMATION GENERAL A halogen head light bulb becomes very hot while the head light is on and remains for a while after it is turned off Be sure to let it cool down before servicing Note the following when replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put finger prints on the headlight bulb as they may create hot spots on the bulb and cause it to fail If you touch the bulb with
118. tween the following terminals of the tilt switch connector with the connector connected Terminal Normal Violet Red Green Pink 5V S Black Blue Green Pink 2 3 7 4 4 V If repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON REMOVAL INSTALLATION Disconnect the connector and remove two screws Remove the Tilt switch Installation is in the reverse order of removal Install the tilt switch with its UP mark facing up Tighten the mounting screws securely 13 16 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i ELECTRIC CONTROL UNIT ECU REMOVAL INSTALLATION e Do not disconnect or connect the ECU connector during the ignition switch ON it may cause the ECU damaged e The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body MAP TPS ISC or ECU has been reinstalled Disconnect the ECU connector and remove the ECU from the frame Installation is in the reverse order of the removal Winker Relay Tilt Switch a em 9 e Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay ECU Fuel Pump Relay 13 17 13 FUEL INJECTION SYSTEM INSPECTION Disconnect and remove the ECU from the frame Check for continuity between pin 35 and 36 of the ECU side connector There should be continuity at all times Check for
119. uipped with the self diagnostic system If the Check Engine Lamp CELP illuminate while riding follow the self diagnostic procedures to solve the problem e A faulty AFI problem is often related to poorly connected or corroded connectors Check those connections before proceeding e When disassembling the fuel injection parts note the location of the O rings Replace them with new ones upon reassembly Do not disconnect the battery negative or positive cable while engine is running it may cause ECU damage e Do not disconnect or connect the ECU connector during the ignition switch ON it may cause the ECU damage 13 1 KYMCO 13 FUEL INJECTION SYSTEM People GT 300i SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number LGES Idle speed 1600x100 rpm Throttle grip free pla 7 6 mm 1 16 1 4 in 2 11 70 60 at 20 C 68 F 0 1553KO At 100 C 212 F 0 1553 KO 13 332 kPa 0 13332 cm 1 89 psi 4 2 V 119 99 kPa 1 1999 kgf 17 04 psi il AT ATA Primary 3 57 4 83 2 Throttle position sensor TPS resistance at Crank position sensor voltage at 200 rpm 100 1300 O heater sensor resistance at 20 C 68 F 6 7 9 5 Q engine warming condition Tilt switch voltage Standard 0 414 V Over 65 fall down 3 7 4 4 V 13 2 13 FUEL INJECTION SYSTEM INJECTION SYSTEM DIAGRAM 13 3 FULL NAME KYMCO People
120. ump or fuel hose Remove the six nuts and fuel unit connectors then remove the fuel hose Fuel Hose Check the fuel pump O ring If was damage replace a new one 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 19 8 KYMCO 19 LIGHTS METERS SWITCHES People GT 300i Measure the resistance between the Red Black and Green wire of the fuel unit connector Standard at 20 C 68 F FULL Float at full position About 1100 Q Float at empty position About 100 Q EMPTY 19 9 19 LIGHTS METERS SWITCHES SIDE STAND SWITCH INSPECTION Remove the luggage box The side stand switch is located on the side stand Disconnect the side stand switch connector There should be continuity between Yellow Green and Green with the side stand is up There should be continuity between Yellow Black and Green with the side stand is down 95014 72204 KYMCO People GT 300i Side Stand Switch 50505 KEBE C 90108 NC 9 93404 DOWN 19 10
121. ve tank capacity 0 590 liter Lower limit for reserve tank capacity 0 370 liter 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 5 5 6 5 kgf m 58 8 N m TROUBLESHOOTING Refer to chapter 1 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 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 3001 RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover Disconnect the water hoses from the right crankcase cover Remove 12 bolts attaching the right crankcase cover and the cover Water Hose Oil filter Remove the bolt between water pump cover and oil filter Remove right crankcase cover STATOR REMOVAL Remove two screws attaching the pulsar coil Remove three A C generator stator bolts and the stator When removing the pulsar coil and stator be careful not to damage them to avoid short circuit or broken wire Pulsar Coil A C Generator Stator 10 3 KYMCO 10 A C GENERATOR STARTER CLUTCH People GT 300i FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer Flywheel holder E021 Remove the flywhee

13. fuel injection system

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