Kymco People 250 repair service manual

PEOPLE 250 C 2003 by KWANG YANG Motor Co., Ltd. First Edition, Mar 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LLJ3-S00 Downloaded from www.Manualslib.com manuals search engine

PEOPLE 250 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO People 250. Section 1 contains the precautions for all operations stated in this manual. Read them carefully before any operation is started. Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations. Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance. Sections 5 through 13 give instructions for disassembly, assembly and adjustment of engine parts. Section 14 is the removal/ installation of chassis. Section 16 states the testing and measuring methods of electrical equipment. Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section. KWANG YANG MOTOR CO., LTD. OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 EXHAUST MUFFLER/FRAME COVERS 2 INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 DRIVE AND DRIVEN PULLEYS/V- BELT 8 FINAL REDUCTION 9 A.C. GENERATOR/STARTER CLUTCH 10 CRANKCASE/CRANKSHAFT 11 COOLING SYSTEM 12 FUEL SYSTEM/CARBURETOR/FUEL PUMP FUEL TANK 13 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 14 REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER` 15 BATTERY/CHARGING SYSTEM 16 IGNITION SYSTEM 17 STARTING SYSTEM 18 SWITCHES/HORN/FUEL UNIT / THERMO-STATIC SWITCH/TEMPERATURE GAUGE/INSTRUMENTS/ LIGHTS 19 The information and contents included in this manual may be different from the motorcycle in case specifications are changed. CHASSIS EQUIPMENT ENGINE Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-0 PEOPLE 250 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER-------------------------------------------------------- 1-1 SPECIFICATION---------------------------------------------------------- 1-2 SERVICE PRECAUTIONS----------------------------------------------- 1-3 TORQUE VALUES------------------------------------------------------- 1-7 SPECIAL TOOLS--------------------------------------------------------- 1-8 LUBRICATION POINTS------------------------------------------------- 1-9 CABLE & HARNESS ROUTING-----------------------------------------1-11 WIRING DIAGRAM-------------------------------------------------------------------1-18 TROUBLESHOOTING --------------------------------------------------1-19 1 Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-1 PEOPLE 250 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-2 PEOPLE 250 SPECIFICATIONS Name & Model No. BC50AA Motorcycle Name & Type PEOPLE 250 Overall length 2219mm Overall width 742mm Overall height 1145mm Wheel base 1515mm Engine type Water cooled 4-stroke, OHC engine Displacement 249.1cc Fuel Used 92# nonleaded gasoline 1 person (55kg) Front wheel 86 weight (kg) Rear wheel 127 Total 213 2 person (110kg) Front wheel 93 weight(kg) Rear wheel 175 Total 268 Front wheel 110/70-16 52P Rear wheel 140/70-16 65P Ground clearance 145mm Perform - Braking distance (m) 4.0m/30km/hr ance Min. turning radius 2180mm Starting system Starting motor Type Gasoline, 4-stroke Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve arrangement O.H.C. Bore x stroke (mm) 72.7 x 60 Compression ratio 10.3:1 Compression pressure (kg/cm_) 15±2 Max. output (kw/rpm) 13.93/7000 Max. torque (kg.m/rpm) 2.0/5500 BTDC -8° Port Intake ABDC 42° timin g BBDC 33° Exhaust ATDC 1° Valve Intake 0.1 clearance (cold) Exhaust 0.1 Idle speed (rpm) 1700±100rpm Lubrication type Forced pressure & Wet sump Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration Oil capacity 1.1 liters Air cleaner type & No Paper element, wet Fuel capacity 8.0 liters Type CVK Piston dia. 30 Venturi dia. 30 equivalent Throttle type Butterfly type Type CDI Ignition timing Repeatedly Contact breaker Non-contact point type Spark plug NGK DPR7EA-9 Spark plug gap 0.7mm Battery Capacity 12V10AH Clutch Type Dry multi-disc clutch Type Non-stage transmission Operation Automatic centrifugal Type Type Two-stage reduction Reduction 1st 0.83~2.2 ratio Final 8.72 Front Caster angle 27° Axle Connecting rod Front 1.75 Tire pressure (kgf/cm_) Rear 2.0 Turning Left 45° angle Right 45° Front Disk brake Brake system type Rear Disk brake Suspension Front Telescope type Rear Double swing Shock absorber Front Telescope type Rear Double swing Frame type Under bone Tires Engine System Fuel System Carburetor Electrical Ignition System Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-3 PEOPLE 250 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. Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-4 PEOPLE 250 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. Confirm Capacity Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-5 PEOPLE 250 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. 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. Do not pull too tightð No Contact Do not press or squeeze the wire Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-6 PEOPLE 250 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 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) : Use special tool. : Caution : Warning Special Engine Oil Grease Gear Oil ＊ Do you understand the instrument？ Remove Rust∴ Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-7 PEOPLE 250 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut 4.5_ 6 8 _ 12 18_ 25 30_ 40 50_ 60 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut 3.5_ 5 7 _ 11 10_ 14 24_ 30 35_ 45 Torque specifications listed below are for important fasteners. ENGINE Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Cylinder head cap nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt Water pump impeller Drive face nut Transmission case cover bolt Gear oil check bolt 2 2 1 4 2 1 1 1 1 1 2 4 1 1 1 1 9 1 8 8 30 8 5 6 12 12 12 14 5 6 10 6 8 12 8 8 8.9 8.9 12.7 24.5 8.8 8.8 14.7 53.9 53.9 58.8 3.9 11.8 17.2 11.8 11.8 93 20 10 Double end bolt Double end bolt Apply oil to threads Downloaded from www.Manualslib.com manuals search engine

Kymco People 250 repair service manual

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