Kymco People 125 & 150 Workshop Manual 2004-2007

1. GENERAL INFORMATION 1-1 PEOPLE 125/150 1 GENERAL INFORMATION ENGINE FRAME VIN SERIAL NUMBER ................................... 1-2 SPECIFICATIONS (125 CC) ....................................................... 1-3 SPECIFICATIONS (150 CC) ....................................................... 1-4 SERVICE PRECAUTIONS .......................................................... 1-5 TORQUE VALUES...................................................................... 1-7 TOOLS........................................................................................ 1-8 LUBRICATION POINTS ............................................................. 1-9 CABLE & HARNESS ROUTING ............................................... 1-11 WIRING DIAGRAM (125 CC) ................................................... 1-16 WIRING DIAGRAM (150 CC) ................................................... 1-17 TROUBLESHOOTING .............................................................. 1-18 1

1. GENERAL INFORMATION 1-2 PEOPLE 125/150 Location of Engine Serial Number Vehicle Identification Serial Number Location of Frame Serial Number ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER

1. GENERAL INFORMATION 1-3 PEOPLE 125/150 SPECIFICATIONS Name & Model No. PEOPLE 125 Overall length (mm) 1950 Overall width (mm) 690 Overall height (mm) 1075 Wheel base (mm) 1335 Engine type O.H.C. Displacement (cc) 125 Fuel Used 92# nonleaded gasoline Front wheel 41 Net weight (kg) Rear wheel 70 Total 111 Front wheel 65 Gross weight(kg) Rear wheel 116 Total 181 Front wheel 80/80-16 45P Rear wheel 100/80-16 56P Ground clearance (mm) 160 Perform - Braking distance (m) 4.4 (30km/h) ance Min. turning radius (m) 2 Starting system Starting motor & kick starter Type OHC air cooled 4-cycle Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive Bore x stroke (mm) 52.4 x 57.8 Compression ratio 9.6:1 Compression pressure (kg/cm_) 13 Max. output (ps/rpm) 9.6/7500 Max. torque (kg m/rpm) 1.0/6500 Intake Open 7.3 Valve (mm) Close 0 timin g Exhaust Open 6.9 (mm) Close 0 Valve clearance Intake 0.10 (cold) (mm) Exhaust 0.10 Idle speed (rpm) 1700rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 0.91 liter Exchanging capacity 0.81 liter Cooling Type Forced air cooling Air cleaner type & No Paper element Fuel capacity 6.8 liters Type VE Piston dia. (mm) 24 Venturi dia.(mm) 22.1 equivalent Throttle type Butterfly type Type CDI Ignition timing 15°~28°BTDC/1700r Contact breaker Non-contact point type Spark plug NGK C7HSA Spark plug gap 0.6_ 0.7mm Battery Capacity 12V6AH Clutch Type Dry multi-disc clutch Type Non-stage transmission Operation Automatic centrifugal type Type Two-stage reduction Reduction 1st 0.86~2.64 ratio 2nd 10.98 Front Caster angle 25° Axle Trail length Tire pressure Front 1.75 (kg/cm_) Rear 2.00 (2.25) Turning Left 45° angle Right 45° Brake system Front Disk brake type Rear Drum brake Suspension Front Telescope type Rear Swing arm Shock absorber Front Telescope type Rear Swing arm Frame type Steel pipe Tires Engine System Fuel System Carburetor Electrical Ignition System Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device

1. GENERAL INFORMATION 1-4 PEOPLE 125/150 SPECIFICATIONS Name & Model No. PEOPLE 150 Overall length (mm) 1950 Overall width (mm) 690 Overall height (mm) 1075 Wheel base (mm) 1335 Engine type O.H.C. Displacement (cc) 150 Fuel Used 92# nonleaded gasoline Front wheel 41 Net weight (kg) Rear wheel 70 Total 111 Front wheel 65 Gross weight(kg) Rear wheel 116 Total 181 Front wheel 80/80-16 45P Rear wheel 100/80-16 56P Ground clearance (mm) 160 Perform - Braking distance (m) 4.4 (30km/h) ance Min. turning radius (m) 2 Starting system Starting motor & kick starter Type OHC air cooled 4-cycle Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C., chain drive Bore x stroke (mm) 57.4 x 57.8 Compression ratio 9.2:1 Compression pressure (kg/cm_) 15 Max. output (ps/rpm) 10.5/7500 Max. torque (kg m/rpm) 1.1/5500 Intake Open 7.3 Valve (mm) Close 0 timin g Exhaust Open 6.9 (mm) Close 0 Valve clearance Intake 0.10 (cold) (mm) Exhaust 0.10 Idle speed (rpm) 1700rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 0.91 liter Exchanging capacity 0.81 liter Cooling Type Forced air cooling Air cleaner type & No Paper element Fuel capacity 6.8 liters Type VE Piston dia. (mm) 24 Venturi dia.(mm) 22.1 equivalent Throttle type Butterfly type Type CDI Ignition timing 15°~28°BTDC/1700r Contact breaker Non-contact point type Spark plug NGK C7HSA Spark plug gap 0.6_ 0.7mm Battery Capacity 12V6AH Clutch Type Dry multi-disc clutch Type Non-stage transmission Operation Automatic centrifugal Type Type Two-stage reduction Reduction 1st 0.86~2.64 ratio 2nd 10.98 Front Caster angle 25° Axle Trail length Tire pressure Front 1.75 (kg/cm_) Rear 2.00 (2.25) Turning Left 45° angle Right 45° Brake system Front Disk brake type Rear Drum brake Suspension Front Telescope type Rear Swing arm Shock absorber Front Telescope type Rear Swing arm Frame type Steel pipe Tires Engine System Fuel System Carburetor Electrical Ignition System Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device

1. GENERAL INFORMATION 1-5 PEOPLE 125/150 SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. n Use genuine parts and lubricants. n When servicing the motorcycle, be sure to use special tools for removal and installation. n After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly. n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When two persons work together, pay attention to the mutual working safety. n Disconnect the battery negative (-) terminal before operation. n When using a spanner or other tools, make sure not to damage the motorcycle surface. n After operation, check all connecting points, fasteners, and lines for proper connection and installation. n When connecting the battery, the positive (+) terminal must be connected first. n After connection, apply grease to the battery terminals. n Terminal caps shall be installed securely. n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. n After operation, terminal caps shall be installed securely. n When taking out the connector, the lock on the connector shall be released before operation. n Hold the connector body when connecting or disconnecting it. n Do not pull the connector wire. n Check if any connector terminal is bending, protruding or loose. n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire. n Before connecting a terminal, check for damaged terminal cover or loose negative terminal. n Check the double connector cover for proper coverage and installation. n Insert the terminal completely. n Check the terminal cover for proper coverage. n Do not make the terminal cover opening face up. n Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. n After clamping, check each wire to make sure it is secure. n Do not squeeze wires against the weld or its clamp. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. n When fixing the wire harnesses, do not make it contact the parts which will generate high heat. n Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. n Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws.

1. GENERAL INFORMATION 1-6 PEOPLE 125/150 n Route harnesses so they are neither pulled tight nor have excessive slack. n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. n When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. n Do not break the sheath of wire. n If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it. n When installing other parts, do not press or squeeze the wires. n After routing, check that the wire harnesses are not twisted or kinked. n 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. n When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. n Be careful not to drop any parts. n When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. n Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. n Symbols: The following symbols represent the servicing methods and cautions included in this service manual. :Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) : Use special tool. : Caution : Warning Engine Oil Grease Gear Oil Special ＊

1. GENERAL INFORMATION 1-7 PEOPLE 125/150 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut 0.45_ 0.6 0.8_ 1.2 1.8_ 2.5 3.0_ 4.0 5.0_ 6.0 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut 0.35_ 0.5 0.7_ 1.1 1.0_ 1.4 2.0_ 3.0 3.5_ 4.5 Torque specifications listed below are for important fasteners. ENGINE Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Drive face seal cover bolt Starter clutch cap bolt Drive face nut Spark plug Starter clutch lock nut Cam chain tensioner screw 2 4 1 2 4 2 1 1 1 1 3 3 1 1 1 1 8 8 30 8 8 5 6 8 12 12 4 6 12 10 22 6 0.9 0.9 1.5 2.2 2.0 0.9 1.0 1.3 5.5 5.5 0.3 1.2 5.5 1.2 9.5 0.4 Double end bolt Double end bolt Apply oil to threads Left hand threads FRAME Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upp er mount bolt Rear shock absorber lower mount bolt Speedometer cable set screw Front shock absorber tube bolt Front shock absorber upp er mount bolt Front shock absorber lower mount bolt Front shock absorber hex bolt Rear shock absorber lower joint lock nut 1 1 1 1 1 1 1 2 2 1 1 10 12 14 10 8 5 5 8 8 8 8 12.0 6.0 12.0 4.0 2.5 0.45 0.45 0.1 1.8 3.0 3.5 U-nut U-nut U-nut Apply lockingagent

1. GENERAL INFORMATION 1-8 PEOPLE 125/150 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page FLYWHEEL PULLER LOCK NUT SOCKET WRENCH TAPPET ADJUSTER OIL SEAL & BEARING INSTALL FLYWHEEL HOLDER BEARING PULLER BEARING PULLER BEARING PULLER BEARING PULLER BUSHING REMOVER FLYWHEEL HOLDER LONG SOCKET WRENCH CLUTCH SPRING COMPERESSOR CRANKSHAFT PROTECTOR CRANKSHAF BEARING PULLER BUSHING REMOVER LONG SOCKET WRENCH CUSHION ASSEMBLEN & DISASSEMBLE TOOL RACE CONE INSTALL TOOL BOOX E002 E009 E012 E014 E017 E008 E018 E020 E031 E019 E021 E022 E027 E029 E030 E032 F002 F004 F005 E033 14-8 16-7 3-5 11-4,12-5 9-3,14-10 10-4 10-4 10-4 13-0 9-3,9-13 9-8 11-0 6-0 12-5 13-0 12-16

1. GENERAL INFORMATION 1-9 PEOPLE 125/150 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one-way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O-ring face Oil seal lip •Genuine KYMCO Engine Oil (SAE15W-40) •API SE, SF or SG Engine Oil Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Starter spindle movable part High-temperature resistant grease Starter one-way clutch threads Thread locking agent A.C. generator connector Transmission case breather tube Adhesive

1. GENERAL INFORMATION 1-10 PEOPLE 125/150 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle. Seat Lock Rear Wheel Bearings Grease Front Brake Cable/ Speedometer Cable/ Throttle Cable Main Stand Pivot Speedometer Gear/ Front Wheel Bearings/ Brake Cam/ Anchor Pin /Front Shock Absorber Lower Mount Bushings/Pivot Engine Oil Grease Grease Grease Grease Front Brake Lever Pivot Engine Oil Rear Brake Cable Brake Cam/ Anchor Pin Grease

Kymco People 125 & 150 Workshop Manual 2004-2007

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