KYMCO PEOPLE 125 Manual
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KYMCO PEOPLE 125 Manual

KYMCO PEOPLE 125 Manual

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1
. GENERAL INFORMATION
1
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
www.PlanDeGraissage.org
GENERAL INFORMATION
PEOPL E 125/150
1-1
1

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  • Page 1: Table Of Contents

    . GENERAL INFORMATION PEOPL E 125/150 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)...........
  • Page 2 . GENERAL INFORMATION PEOPL E 125/150 ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number Vehicle Identification Serial Number www.PlanDeGraissage.org...

  • Page 3: Specifications (125 Cc)

    . GENERAL INFORMATION PEOPL E 125/150 Cooling Type Forced air cooling SPECIFICATIONS Name & Model No. PEOPLE 125 Overall length (mm) 1950 Air cleaner type & No Paper element Overall width (mm) Fuel capacity 6.8 liters Overall height (mm) 1075...

  • Page 4: Specifications (150 Cc)

    . GENERAL INFORMATION PEOPL E 125/150 Cooling Type Forced air cooling SPECIFICATIONS Name & Model No. PEOPLE 150 Overall length (mm) 1950 Overall width (mm) Overall height (mm) 1075 Air cleaner type & No Paper element Wheel base (mm) 1335 Fuel capacity 6.8 liters Engine type...

  • Page 5: Service Precautions

    . GENERAL INFORMATION PEOPL E 125/150 SERVICE PRECAUTIONS n Hold the connector body when connecting or disconnecting it. n Make sure to install new gaskets, O-rings, n Do not pull the connector wire. circlips, cotter pins, etc. when reassembling. n Check if any connector terminal is bending, protruding or loose.
  • Page 6 . GENERAL INFORMATION PEOPL E 125/150 n Symbols: n Route harnesses so they are neither The following symbols represent the pulled tight nor have excessive slack. servicing methods and cautions included in this service manual. n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.

  • Page 7: Torque Values

    . GENERAL INFORMATION PEOPL E 125/150 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45_ 0.6　 5mm screw 0.35_ 6mm bolt, nut 6mm screw, SH bolt 0.7_ 　　 8mm bolt, nut 0.8_ 6mm flange bolt, nut 1.0_ 10mm bolt, nut 1.8_...
  • Page 8 . GENERAL INFORMATION PEOPL E 125/150 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page FLYWHEEL PULLER E002 14-8 LOCK NUT SOCKET WRENCH E009 16-7 TAPPET ADJUSTER E012 OIL SEAL & BEARING INSTALL E014 11-4,12-5 FLYWHEEL HOLDER E017 9-3,14-10 BEARING PULLER E008 10-4 BEARING PULLER...

  • Page 9: Lubrication Points

    PEOPL E 125/150 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYMCO Engine Oil (SAE15W-40) Cam lobes •API SE, SF or SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut...
  • Page 10 . GENERAL INFORMATION PEOPL E 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.

  • Page 11: Cable & Harness Routing

    . GENERAL INFORMATION PEOPL E 125/150 CABLE & HARNESS ROUTING Front Stop Switch Wire Front Brake Reservoir Rear Stop Switch Wire Front Brake Fluid Tube Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Regulator/ Rectifier Instrument Cable Horn Resistor Front Brake Fluid...
  • Page 12 . GENERAL INFORMATION PEOPL E 125/150 Regulator/Rectifier Resistor Throttle Cable Wire Harness Front Brake Fluid Tube Speedometer Cable Rear Brake Cable 1-12 www.PlanDeGraissage.org...
  • Page 13 . GENERAL INFORMATION PEOPL E 125/150 Battery (+) Cable Reserve Fuse Fuse CDI Unit Battery (-) Cable Wire Harness 1-13 www.PlanDeGraissage.org...
  • Page 14 . GENERAL INFORMATION PEOPL E 125/150 Crankcase Breather Tube Ignition Coil Vacuum Tee Auto Bystarter Wire Throttle Cable Fuel Valve Vacuum Tube Ground A.C. Fuel Tube Generator Wire 1-14 www.PlanDeGraissage.org...
  • Page 15 . GENERAL INFORMATION PEOPL E 125/150 Wire Harness Throttle Cable Auto Bystarter Wire Starter Motor Wire Fuel Tube Starter Relay Crankcase Breather Fuel Unit Tube Wire Harness Fuel Vapor Tube Vacuum Tee Carburetor Air Cleaner Vacuum Tube Auto Bystarter 1-15 www.PlanDeGraissage.org...

  • Page 16: Wiring Diagram (125 Cc)

    . GENERAL INFORMATION PEOPL E 125/150 WIRING DIAGRAM 1-16 www.PlanDeGraissage.org...

  • Page 17: Wiring Diagram (150 Cc)

    . GENERAL INFORMATION PEOPL E 125/150 WIRING DIAGRAM 150 cc ( SINGAPORE ) 1-17 www.PlanDeGraissage.org...

  • Page 18: Troubleshooting

    . GENERAL INFORMATION PEOPL E 125/150 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches...
  • Page 19 . GENERAL INFORMATION PEOPL E 125/150 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate Clogged air cleaner lightly for observation Restricted fuel flow Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed Engine speed does not Faulty auto bystarter increases increase sufficiently...
  • Page 20 . GENERAL INFORMATION PEOPL E 125/150 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fixed Check carburetor pilot position.
  • Page 21 . GENERAL INFORMATION PEOPL E 125/150 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fix position. Check carburetor pilot screw adjustment Improperly adjusted valve Correctly adjusted...
  • Page 22 . GENERAL INFORMATION PEOPL E 125/150 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 23 . GENERAL INFORMATION PEOPL E 125/150 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose spark plug cap...
  • Page 24 . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 FRAME COVERS/EXHAUST MUFFLER FRAME COVERS LAYOUT------------------------------------------ 2-1 SERVICE INFORMATION ------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------ 2-2 FRAME COVERS ------------------------------------------------------ 2-4 www.PlanDeGraissage.org...

  • Page 25: Frame Covers Layout

    . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 FRAME COVERS LAYOUT www.PlanDeGraissage.org...

  • Page 26: Service Information

    . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 3.5kg-m...
  • Page 27 . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 www.PlanDeGraissage.org...

  • Page 28: Frame Covers

    . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 FRAME COVERS (1) REAR HAND GRIP REMOVAL Remove the three bolts attaching the rear hand grip. Remove the rear hand grip. (2) MET-IN BOX REMOVAL Remove the three bolts and two nuts attaching the met-in box. Remove the met-in box.
  • Page 29 . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 www.PlanDeGraissage.org...
  • Page 30 . FRAME COVERS/EXHAUST MUFFLER PEOPL E 125/150 (8) FRONT TOOL BOX REMOVAL Remove the nut attaching the front tool box. Remove the ignition switch decorative ring. Remove (8-1) the six screws that combine the front cover with the front tool box. Remove (8-2) the two screws attaching the front cover.
  • Page 31 . INSPECTION/ADJUSTMENT PEOPL E 125/150 INSPECTION/ADJUSTMENT SERVICE INFORMATION............3-1 MAINTENANCE SCHEDULE............3-2 FUEL LINE .................3-3 THROTTLE OPERATION............3-3 AIR CLEANER................3-4 SPARK PLUG ................3-4 VALVE CLEARANCE ..............3-5 CARBURETOR IDLE SPEED............3-5 IGNITION TIMING ..............3-6 CYLINDER COMPRESSION............3-6 FINAL REDUCTION GEAR OIL..........3-7 DRIVE BELT................3-7 BRAKE SHOE................3-8 BRAKE SYSTEM ................3-8 HEADLIGHT AIM...............3-9 SUSPENSION................3-9 STEERING HANDLEBAR ............3-9...

  • Page 32: Service Information

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the en- gine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

  • Page 33: Maintenance Schedule

    In the interest of safety, we recommend these items should be serviced only by an author- • ized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas.

  • Page 34: Fuel Line

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 Fuel Filter FUEL LINE Remove the met-in box. ( 2) Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area.

  • Page 35: Air Cleaner

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the rear side covers. ( 2) Remove the six air cleaner case cover screws and the cover. Remove the air cleaner element by removing the three screws. Check the element and replace it if it is exces- sively dirty or damaged.

  • Page 36: Valve Clearance

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 Cylinder Head Cover VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃ ). Remove the center cover. ( 2) Remove the cylinder head cover. ( 7-4) Bolts Turn the flywheel counterclockwise so that the “T”...

  • Page 37: Ignition Timing

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 IGNITION TIMING ＊ The CDI unit is not adjustable. If the ig- nition timing is incorrect, check the igni- tion system. ( 15-6) Remove the rear right side cover. Remove the timing hole cap. Timing Light Check the ignition timing with a timing light.

  • Page 38: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 FINAL REDUCTION GEAR OIL OIL LEVEL CHECK ＊ Place the motorcycle on its main stand on level ground for oil level check. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole. If the oil level is low, add the recommended oil to the proper level.

  • Page 39: Brake System

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 Replace the brake shoes if the arm can not be aligned with the ＞ mark on the brake panel when the brake is fully applied. Refer to page ( 13-4) for brake shoe replace- ment. BRAKE SYSTEM FRONT BRAKE Measure the front brake lever free play.

  • Page 40: Suspension

    . INSPECTION/ADJUSTMENT PEOPL E 125/150 Turn the ignition switch ON and start the en- gine. Turn on the headlight switch. Adjust the headlight aim by turning the head- light aim adjusting screw. Adjusting Nut SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times.
  • Page 41 . INSPECTION/ADJUSTMENT PEOPL E 125/150 Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. TIRE PRESSURE 1 Rider 2 Riders Front 1.75kg/cm 1.75kg/cm Rear 2.00kg/cm 2.25kg/cm TIRE SIZE Front : 80/80-16 45P...
  • Page 42 . LUBRICATION SYSTEM PEOPL E 125/150 LUBRICATION SYSTEM SERVICE INFORMATION............4-2 TROUBLESHOOTING ..............4-2 ENGINE OIL/OIL FILTER ............4-3 OIL PUMP ..................4-3 www.PlanDeGraissage.org...
  • Page 43 . LUBRICATION SYSTEM PEOPL E 125/150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump www.PlanDeGraissage.org...

  • Page 44: Lubrication System

    . LUBRICATION SYSTEM PEOPL E 125/150 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.

  • Page 45: Engine Oil/Oil Filter

    . LUBRICATION SYSTEM PEOPL E 125/150 Lower Level Upper Level ENGINE OIL/OIL FILTER OIL LEVEL ＊ Place the motorcycle upright on • level ground for engine oil level check. Run the engine for 2_ • minutes and check the oil level after the engine is stopped for 2_ 3 minutes.
  • Page 46 . LUBRICATION SYSTEM PEOPL E 125/150 Remove the gasket and dowel pins. Starter Idle Gear Starter Clutch Remove the starter idle gear and starter clutch. ( 16-7) Gasket Bolts Remove the two bolts and oil separator cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
  • Page 47 . LUBRICATION SYSTEM PEOPL E 125/150 Pump Body DISASSEMBLY Remove the screw and disassemble the oil pump. Screw Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure the rotor end-to-pump body...
  • Page 48 . LUBRICATION SYSTEM PEOPL E 125/150 ASSEMBLY Inner Rotor Screw Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 49 . LUBRICATION SYSTEM PEOPL E 125/150 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 nut. Torque: 1.0kg-m Pump Driven Gear Bolts Install the oil separator cover and tighten the bolts.
  • Page 50 . FUEL SYSTEM PEOPL E 125/150 FUEL SYSTEM SERVICE INFORMATION............5-2 TROUBLESHOOTING ..............5-3 CARBURETOR REMOVAL ............5-4 AUTO BYSTARTER..............5-4 AIR CUT-OFF VALVE..............5-6 VACUUM CHAMBER ..............5-6 FLOAT CHAMBER..............5-7 CARBURETOR INSTALLATION ..........5-10 FUEL TANK................5-11 FUEL UNIT ................5-11 AUTO FUEL VALVE..............5-12 AIR CLEANER................
  • Page 51 . FUEL SYSTEM PEOPL E 125/150 FUEL SYSTEM www.PlanDeGraissage.org...

  • Page 52: Service Information

    . FUEL SYSTEM PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

  • Page 53: Troubleshooting

    . FUEL SYSTEM PEOPL E 125/150 TROUBLESHOOTING Engine is hard to start Misfiring during acceleration • No spark at plug • Faulty ignition system • Compression too low • Lean mixture • No fuel to carburetor -Clogged fuel filter Engine idles roughly, stalls or runs poorly -Restricted fuel line •...

  • Page 54: Carburetor Removal

    . FUEL SYSTEM PEOPL E 125/150 Auto Bystarter Wire CARBURETOR REMOVAL Remove the frame body cover. ( 2) Disconnect the auto bystarter wire connector. Fuel Tube Loosen the drain screw and drain the fuel from the float chamber. Disconnect the fuel tube and vacuum tube at the carburetor.
  • Page 55 . FUEL SYSTEM PEOPL E 125/150 Connect a hose to the fuel enriching circuit of the carburetor. Connect the auto bystarter Vacuum Pump yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal.

  • Page 56: Air Cut-Off Valve

    . FUEL SYSTEM PEOPL E 125/150 Set Plate Spring AIR CUT-OFF VALVE DISASSEMBLY Disconnect the vacuum tube from the air cut- off valve. Remove the two screws to remove the air cut- off valve cover, spring and vacuum diaphragm. Air Cut-off valve Vacuum Diaphragm Cover Screws...

  • Page 57: Float Chamber

    . FUEL SYSTEM PEOPL E 125/150 Vacuum Diaphragm/Piston Install Push the needle holder in and turn it left to remove the needle holder. Remove the spring and jet needle from the piston. ＊ Be careful not to damage the vacuum diaphragm.
  • Page 58 . FUEL SYSTEM PEOPL E 125/150 Screws Float Remove the float pin, float and float valve. Float Valve Float Pin INSPECTION Inspect the float valve and valve seat for damage or clogging. Inspect the float valve and valve seat contact area for stepped wear or contamination.
  • Page 59 . FUEL SYSTEM PEOPL E 125/150 ASSEMBLY Pilot Screw Slow Jet Install the slow jet, needle jet, needle jet holder, main jet and pilot screw. ＊ Return the pilot screw to the original position as noted during removal. Standard Opening: 3 turns Needle Jet Needle Jet Holder...

  • Page 60: Carburetor Installation

    . FUEL SYSTEM PEOPL E 125/150 Float Pin Float Valve Float Level Gauge FLOAT LEVEL INSPECTION ＊ • Check the operation of the float valve and float before float level inspection. • Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet.

  • Page 61: Fuel Tank

    . FUEL SYSTEM PEOPL E 125/150 Fuel Unit Wire Connector FUEL TANK REMOVAL Remove the frame body cover. Disconnect the fuel unit wire connector. Auto Fuel Valve Disconnect the fuel tube and vacuum tube at the auto fuel valve. Vacuum Tube Fuel Tank Remove the fuel tank frame mounting bolts and fuel tank frame.

  • Page 62: Auto Fuel Valve

    . FUEL SYSTEM PEOPL E 125/150 Nick Install the fuel unit. ＊ Make sure that the nick on the retainer is aligned with the nick on the fuel tank. Connect the fuel unit wire connector. INSTALLATION Inspect the fuel unit gasket for damage. Auto Fuel Valve AUTO FUEL VALVE ＊...

  • Page 63: Air Cleaner

    . FUEL SYSTEM PEOPL E 125/150 Bolt AIR CLEANER Loosen the air cleaner connecting tube band screw. Disconnect the transmission case breather tube from the air cleaner case. Remove the two bolts and air cleaner case. Air Cleaner Case The installation sequence is the reverse of removal.
  • Page 64 . ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ............6-2 ENGINE REMOVAL..............6-3 ENGINE INSTALLATION.............6-5 www.PlanDeGraissage.org...
  • Page 65 6. ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 4.0kg-m 5.0kg-m 2.5kg-m www.PlanDeGraissage.org...
  • Page 66 . ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The engine removal operation is required to support the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. •...
  • Page 67 6. ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 ENGINE REMOVAL Disconnect the battery negative cable. Auto Bystarter Wire Remove the frame body cover. ( 2) Connector Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Disconnect the A.C.G.
  • Page 68 . ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 Screw Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable. Rear brake adjusting nut Remove the two nut on the battery tank. Remove the rear shock absorbers mounting bolts.
  • Page 69 6. ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 following: Throttle grip free play ( 3-3) • Rear brake adjustment ( 3-8) • ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger. Remove the engine hanger bracket bolt and nut. Engine Hanger Bracket Bushings Remove the engine hanger bracket.
  • Page 70 . ENGINE REMOVAL/INSTALLATION PEOPL E 125/150 www.PlanDeGraissage.org...
  • Page 71 . CYLINDER HEAD/VALVES PEOPL E 125/150 CYLINDER HEAD/VALVES SERVICE INFORMATION............7-2 TROUBLESHOOTING ..............7-3 CAMSHAFT REMOVAL.............7-4 CYLINDER HEAD REMOVAL............7-7 CYLINDER HEAD DISASSEMBLY..........7-8 CYLINDER HEAD ASSEMBLY..........7-10 CYLINDER HEAD INSTALLATION ......... 7-10 CAMSHAFT INSTALLATION........... 7-11 www.PlanDeGraissage.org...
  • Page 72 7. CYLINDER HEAD/VALVES PEOPL E 125/150 1.2kg-m 2.0kg-m 0.8kg-m www.PlanDeGraissage.org...

  • Page 73: Service Information

    . CYLINDER HEAD/VALVES PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surface for initial lubrication. •...

  • Page 74: Troubleshooting

    7. CYLINDER HEAD/VALVES PEOPL E 125/150 TORQUE VALUES Cylinder head nut 2.0kg-m Apply engine oil to threads Valve clearance adjusting nut 0.8kg-m Apply engine oil to threads TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.

  • Page 75: Camshaft Removal

    . CYLINDER HEAD/VALVES PEOPL E 125/150 Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. Remove the four cylinder head cover bolts to remove the cylinder head cover. bolt O-ring Remove the cam chain tensioner cap screw and the O-ring. Tensioner Screw Turn the cam chain tensioner screw clockwise to tighten it.
  • Page 76 7. CYLINDER HEAD/VALVES PEOPL E 125/150 Remove the four cylinder head nuts and washers. ＊ Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins. Dowel Pins Cam Chain Remove the camshaft gear from the cam chain and remove the camshaft.
  • Page 77 . CYLINDER HEAD/VALVES PEOPL E 125/150 Camshaft Bearings Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive wear. Rocker Arm 5mm Bolt CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt.

  • Page 78: Cylinder Head Removal

    7. CYLINDER HEAD/VALVES PEOPL E 125/150 Intake Manifold CYLINDER HEAD REMOVAL Remove the camshaft. ( 7-4) Remove the carburetor. ( 5-4) Remove the exhaust muffler. Remove the carburetor intake manifold. Remove the cooling fan cover. ( 14-7) Remove the engine cover bolts and screws. Separate the engine cover joint claws.

  • Page 79: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES PEOPL E 125/150 Cylinder Head Remove the two cylinder head bolts. Remove the cylinder head. Bolts Dowel Pins Cylinder Head Gasket Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Cam Chain Guide Remove all gasket remnants from the cylinder surface.
  • Page 80 7. CYLINDER HEAD/VALVES PEOPL E 125/150 Remove carbon deposits from the combustion chamber. Clean off any gasket remnants from the cylinder head contact surface. ＊ Be careful not to damage the cylinder head mating surface. INSPECTION CYLINDER HEAD Check the spark plug hole and valve hole areas for cracks.

  • Page 81: Cylinder Head Installation

    . CYLINDER HEAD/VALVES PEOPL E 125/150 CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve 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. Tap the valve stems gently with a plastic hammer for 2_ 3 times to firmly seat the...

  • Page 82: Camshaft Installation

    7. CYLINDER HEAD/VALVES PEOPL E 125/150 Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the camshaft onto the...
  • Page 83 . CYLINDER HEAD/VALVES PEOPL E 125/150 O-ring Apply engine oil to a new O-ring and install Tighten the cam chain tension cap screw. ＊ Be sure to install the O-ring into the groove properly. Cylinder Head Cover Install a new cylinder head cover gasket and install the cylinder head cover.
  • Page 84 . CYLINDER/PISTON PEOPL E 125/150 CYLINDER/PISTON SERVICE INFORMATION............8-2 TROUBLESHOOTING ..............8-2 CYLINDER REMOVAL...............8-4 PISTON REMOVAL..............8-4 PISTON INSTALLATION............8-8 CYLINDER INSTALLATION ............8-8 www.PlanDeGraissage.org...
  • Page 85 . CYLINDER/PISTON PEOPL E 125/150 Do not bend www.PlanDeGraissage.org...

  • Page 86: Service Information

    . CYLINDER/PISTON PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. TROUBLESHOOTING •...
  • Page 87 . CYLINDER/PISTON PEOPL E 125/150 SPECIFICATIONS Item (125cc) Standard (mm) Service Limit (mm) I.D. 52.400_ 52.410 52.50 Warpage 0.05 æ Cylinder Cylindricity 0.05 æ True roundness 0.05 æ Ring-to-groove 0.015_ 0.055 0.09 clearance Second 0.015_ 0.055 0.09 0.10_ 0.25 Piston, Ring end gap Second 0.10_...

  • Page 88: Cylinder Removal

    . CYLINDER/PISTON PEOPL E 125/150 CYLINDER REMOVAL Bolt Turn the cam chain tension screw clockwise to tighten it. Remove the two bolts on the cam chain tension. Cylinder Remove the cylinder head. ( 7-7) Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder.
  • Page 89 . CYLINDER/PISTON PEOPL E 125/150 Piston Rings 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.
  • Page 90 . CYLINDER/PISTON PEOPL E 125/150 Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90° to the piston pin hole. (125cc) Service Limit: 52.3mm replace if below (150cc) Service Limit: 57.3mm replace if below...
  • Page 91 . CYLINDER/PISTON PEOPL E 125/150 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.

  • Page 92: Piston Installation

    . CYLINDER/PISTON PEOPL E 125/150 Second PISTON INSTALLATION Remove any gasket remnant from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Piston Pin Piston Install the piston, piston pin and a new piston pin clip. ＊...
  • Page 93 . CYLINDER/PISTON PEOPL E 125/150 www.PlanDeGraissage.org...
  • Page 94 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 DRIVE AND DRIVEN PULLEYS/KICK STARTER SERVICE INFORMATION............9-2 TROUBLESHOOTING..............9-2 LEFT CRANKCASE COVER ............9-3 DRIVE PULLEY................9-3 CLUTCH/DRIVEN PULLEY ............9-7 KICK STARTER ............... 9-14 www.PlanDeGraissage.org...
  • Page 95 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 5.5kg-m 5.5kg-m 5.5kg-m www.PlanDeGraissage.org...

  • Page 96: Drive And Driven Pulleys/Kick Starter

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • 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.

  • Page 97: Left Crankcase Cover

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 • Broken clutch weight spring Flywheel Holder LEFT CRANKCASE COVER REMOVAL Air Tube Band Loosen the drive belt air tube band screw. Remove the left crankcase cover bolts and left Screw crankcase cover.
  • Page 98 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 19.0mm replace if below ＊ Use specified genuine parts for replace- ment.
  • Page 99 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 17.4mm replace if below Measure the movable drive face bushing I.D. Service Limit: 24.06mm replace if over Check the drive pulley bushing for wear or damage.
  • Page 100 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Ramp Plate Install the ramp plate. www.PlanDeGraissage.org...
  • Page 101 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.
  • Page 102 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
  • Page 103 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Oil Seal Remove the oil seal from the movable driven face. INSPECTION Measure the driven face spring free length. Service Limit: 163.7mm replace if below Check the driven face for wear or damage. Measure the driven face O.D.
  • Page 104 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. ＊ Discard the removed bearing and replace with a new one. Outer Bearing Remove the snap ring and drive the outer bearing out of the driven face.
  • Page 105 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 CLUTCH / DRIVEN PULLEY ASS EMBLY 9-11 www.PlanDeGraissage.org...
  • Page 106 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Retainer Plate Install the damper rubbers on the drive plate Clutch Weights/Shoes Drive Plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
  • Page 107 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut. Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque.
  • Page 108 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Kick Lever KICK STARTER REMOVAL Remove the left crankcase cover. ( 9-2) Remove the seal rubber and dowel pins. Remove the kick lever. Remove the circlip and washer from the kick starter spindle.
  • Page 109 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPL E 125/150 Friction Spring Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage. Starter Driven Gear Kick Starter Spindle Forcing Inspect the kick starter spindle and starter Part driven gear forcing parts for wear or damage.
  • Page 110 . FINAL REDUCTION PEOPL E 125/150 FINAL REDUCTION SERVICE INFORMATION............10-2 TROUBLESHOOTING .............. 10-2 FINAL REDUCTION DISASSEMBLY ........10-3 FINAL REDUCTION INSPECTION........... 10-3 BEARING REPLACEMENT ............10-4 FINAL REDUCTION ASSEMBLY ..........10-5 10-0 www.PlanDeGraissage.org...
  • Page 111 . FINAL REDUCTION PEOPL E 125/150 10-1 www.PlanDeGraissage.org...
  • Page 112 . FINAL REDUCTION PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.181 liter At disassembly : 0.21 liter TORQUE VALUES...
  • Page 113 . FINAL REDUCTION PEOPL E 125/150 FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear wheel. ( 13-2) Remove the rear brake cable. ( 13-3) Remove the left crankcase cover. ( 9-2) Remove the clutch/driven pulley. ( 9-8) Drain the transmission gear oil into a clean container.
  • Page 114 . FINAL REDUCTION PEOPL E 125/150 Final Shaft Bearing Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Oil Seal Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage.
  • Page 115 . FINAL REDUCTION PEOPL E 125/150 Bearing Remover, 17mm BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing remover. Pilot Drive new bearings into the left crankcase. Install a new drive shaft oil seal.
  • Page 116 • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage. Specified Gear Oil: KYMCO SIGMA GEAR OIL SAE 90# Oil Capacity: Drain Bolt At disassembly : 0.21 liter At change : 0.181 liter...
  • Page 117 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 CRANKCASE/CRANKSHAFT SERVICE INFORMATION............11-2 TROUBLESHOOTING .............. 11-2 CRANKCASE SEPARATION ............ 11-3 CRANKSHAFT INSPECTION........... 11-4 CRANKCASE ASSEMBLY............11-4 11-0 www.PlanDeGraissage.org...
  • Page 118 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 11-1 www.PlanDeGraissage.org...
  • Page 119 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. -Cylinder head ( Section 7) -Cylinder/piston ( Section 8) -Drive and driven pulleys ( Section 9) -A.C.
  • Page 120 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 CRANKCASE SEPARATION Remove the two crankcase attaching bolts. Separate the left and right crankcase halves. ＊ Do not damage the crankcase gasket surface. Crankcase Bolts Gasket Remove the gasket and dowel pins. Dowel Pins Remove the crankshaft from the left crankcase.
  • Page 121 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration. The installation sequence is the reverse of removal. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.55mm replace if over Connecting Rod Big End Turn the crankshaft bearings and check for...
  • Page 122 . CRANKCASE/CRANKSHAFT PEOPL E 125/150 Gasket Install the dowel pins and a new gasket onto the left crankcase. ＊ Place the right crankcase over the crankshaft and onto the left crankcase. Dowel Pins Tighten the two crankcase attaching bolts. Torque: 0.9kg-m Crankcase Bolts 11-5 www.PlanDeGraissage.org...
  • Page 123 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION SERVICE INFORMATION............12-2 TROUBLESHOOTING.............. 12-3 FRONT WHEEL ............... 12-4 HYDRAULIC BRAKE DRAWING..........12-7 HYDRAULIC BRAKE ............... 12-8 FRONT SHOCK ABSORBER..........12-13 STEERING HANDLEBAR............12-14 STEERING STEM ..............12-15 12-0 www.PlanDeGraissage.org...
  • Page 124 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 4.5kg-m 4.5kg-m 12-1 www.PlanDeGraissage.org...

  • Page 125: Front Wheel/Front Brake/Front Suspension

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. •...

  • Page 126: Troubleshooting

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 SPECIAL TOOLS Lock nut wrench Driver handle A Outer driver, 28x30mm Pilot, 10mm Ball race remover Outer driver, 37x40mm Pliers (close) Bearing remover Bearing remover head, 10mm TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •...

  • Page 127: Front Wheel

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground. Disconnect the speedometer cable. Speedometer Cable Axle Nut Remove the front axle nut and pull out the axle. Remove the front wheel. Remove the front brake panel.
  • Page 128 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Side Collar FRONT WHEEL BEARING Remove the side collar and dust seal. Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
  • Page 129 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Dust Seal Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Side Collar Pawls INSTALLATION Apply grease to the brake panel dust seal lip. Apply grease to the speedometer gear engaging and sliding parts.

  • Page 130: Hydraulic Brake Drawing

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 HYDRAULIC BRAKE DRAWING 12-7 www.PlanDeGraissage.org...

  • Page 131: Hydraulic Brake

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 HYDRAULIC BRAKE (FRONT BRAKE) BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the brake fluid level on level ground. Lower Limit ＊ • When operating the brake lever, the brake reservoir cap must be tightened securely to avoid splash of brake fluid.
  • Page 132 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Install the brake pads in the reverse order of removal. Tighten the brake pad pin bolt. Fixed-Reed Torque: 1.5_ 2.0kg-m ＊ Keep grease or oil off the brake pads to avoid brake failure. BRAKE DISK Brake Pads Measure the brake disk thickness.
  • Page 133 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Master Cylinder Main Piston Diaphragm Remove the main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Spring Snap Ring INSPECTION Measure the brake master cylinder I.D.
  • Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Bolts Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.
  • Page 135 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Compressed Air Remove the pistons from the brake caliper. If necessary, use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.

  • Page 136: Front Shock Absorber

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.

  • Page 137: Steering Handlebar

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending or damage. •Weak front shock absorber spring. •Damper and damper rod bending. •Oil seal damage or wear. Mount Boot INSTALLATION Install the front shock absorbers onto the...

  • Page 138: Steering Stem

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Screw Remove the throttle seat screw. Throttle Pipe Remove the throttle seat from the handlebar and disconnect the throttle cable from the throttle pipe. Remove the throttle pipe from the handlebar. Bolt Remove the steering stem lock bolt, collar, nut and the handlebar.
  • Page 139 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Top Cone Race Remove the top cone race. ＊ • Be careful not to lose the steel balls (26 on top race and 19 on bottom race). • Clean the openings of frame covers with clean shop towels.
  • Page 140 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPL E 125/150 Front Fender Front Mold INSTALLATION Install the front mold and the front fender. 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.
  • Page 141 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SERVICE INFORMATION............13-2 TROUBLESHOOTING.............. 13-2 REAR WHEEL................13-3 REAR BRAKE................13-4 REAR SHOCK ABSORBER ............13-5 ADJUSTABLE REAR CUSHION..........13-6 13-0 www.PlanDeGraissage.org...
  • Page 142 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 2.2kg-m 1.0kg-m 12.0kg-m 3.5kg-m 13-1 www.PlanDeGraissage.org...

  • Page 143: Rear Wheel/Rear Brake/ Rear Suspension

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm) Service Limit (mm) æ Radial Rim runout æ Rear wheel Axial Rear brake drum I.D Rear brake lining thickness...

  • Page 144: Rear Wheel

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 REAR WHEEL Link Flake REMOVAL Remove the exhaust muffler joint lock nuts and exhaust muffler lock bolts. Remove the exhaust muffler. ( 2-6) Remove the rear axle nut. Remove the rear shock absorber. Remove the link flake.

  • Page 145: Rear Brake

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 REAR BRAKE Remove the rear wheel. ( 13-3) Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limits: 131mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below ＊...

  • Page 146: Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 REAR BRAKE ASSEMBLY Brake Arm Apply grease to the anchor pin. Apply grease to the brake cam and install it. Install the brake shoes. Brake Cam Apply engine oil to the felt seal and install it Bolt to the brake cam.

  • Page 147: Adjustable Rear Cushion

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION PEOPL E 125/150 Bolt Remove the rear shock absorber upper and lower mount bolts. Remove the rear shock absorber. Bolt Adjust Position ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring prelocad.
  • Page 148 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 BATTERY/CHARGING SYSTEM/A.C. GENERATOR CHARGING SYSTEM LAYOUT ..........14-1 SERVICE INFORMATION............14-2 TROUBLESHOOTING.............. 14-3 BATTERY ................. 14-4 CHARGING SYSTEM............... 14-5 REGULATOR/RECTIFIER ............14-6 A.C. GENERATOR CHARGING COIL........14-7 A.C. GENERATOR LIGHTING COIL ........14-7 RESISTOR INSPECTION............

  • Page 149: Battery/Charging System/A.c. Generator

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Resistors Fuse Regulator/Rectifier Battery A.C. Generator CHARGING CIRCUIT 14-1 www.PlanDeGraissage.org...

  • Page 150: Service Information

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 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 •...

  • Page 151: Troubleshooting

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 TORQUE VALUES Pulser coil bolt 0.5kg-m Coil lock bolt 0.9kg-m Flywheel nut 5.5kg-m Cooling fan bolt 0.9kg-m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power •...

  • Page 152: Battery

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 BATTERY REMOVAL Remove the frame cover screws. Open the cover and remove the battery cover screw. First disconnect the battery negative (-) cable and then the positive (+) cable. ＊ When disconnecting the battery positive (+) cable, do not touch the frame with tool;...

  • Page 153: Charging System

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 CHARGING SYSTEM (-) Terminal SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative (-) terminal and the ground wire. Turn the ignition switch OFF and check for short circuit.

  • Page 154: Regulator/Rectifier

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Regulator/Rectifier REGULATOR/RECTIFIER MAIN HARNES S CIRCUIT INS PECTION Remove the front cover. ( 2-4) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following : Item (Wire Color) Judgement Between battery (red)

  • Page 155: Generator Charging Coil

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Charging Coil Wire (White) A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 3P connector. Measure the resistance between the A.C. generator white wire and engine ground with an electric tester.
  • Page 156 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Cooling Fan Remove the cooling fan by removing the four cooling fan attaching bolts. Bolts Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 157 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Remove the A.C. generator wire set plate. Remove the pulser coil bolts. Remove the A.C. generator wire rubber sleeve and pulser coil from the right crankcase. Remove the two bolts and A.C. generator stator.
  • Page 158 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPL E 125/150 Woodruff Key Connect the A.C. generator wire connector. Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Holder Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
  • Page 159 . IGNITION SYSTEM PEOPL E 125/150 IGNITION SYSTEM SERVICE INFORMATION............15-2 TROUBLESHOOTING.............. 15-3 CDI UNIT INSPECTION ............15-4 IGNITION COIL ............... 15-5 PULSER COIL ................15-6 15-0 www.PlanDeGraissage.org...

  • Page 160: Ignition System

    . IGNITION SYSTEM PEOPL E 125/150 CDI Unit Ignition Switch Battery Pulser Coil Spark Plug A.C. Generator IGNITION CIRCUIT 15-1 www.PlanDeGraissage.org...

  • Page 161: Service Information

    . IGNITION SYSTEM PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 15) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. • If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts. •...

  • Page 162: Troubleshooting

    . IGNITION SYSTEM PEOPL E 125/150 TROUBLESHOOTING High voltage too low No high voltage • Weak battery or low engine speed • Faulty ignition switch • Loose ignition system connection • Faulty CDI unit • Faulty CDI unit • Poorly connected or broken CDI ground wire •...

  • Page 163: Cdi Unit Inspection

    . IGNITION SYSTEM PEOPL E 125/150 CDI Unit CDI UNIT INSPECTION Remove the front cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester.. ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.

  • Page 164: Ignition Coil

    . IGNITION SYSTEM PEOPL E 125/150 IGNITION COIL REMOVAL Remove the frame body cover. ( 2) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. Ignition Coil INSPECTION CONTINUITY TEST ＊...

  • Page 165: Pulser Coil

    . IGNITION SYSTEM PEOPL E 125/150 PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2) Disconnect the A.C. generator connector. Measure the pulser coil resistance between the blue/yellow and green wire terminals. Resistance: 70_ 130W/20℃...
  • Page 166 . STARTING SYSTEM PEOPL E 125/150 SERVICE INFORMATION............16-2 TROUBLESHOOTING.............. 16-2 STARTER MOTOR..............16-3 STARTER RELAY ..............16-5 STARTER CLUTCH..............16-6 16-0 www.PlanDeGraissage.org...
  • Page 167 . STARTING SYSTEM PEOPL E 125/150 Starter Button Stop Switches Starter Relay Starter Motor STARTING CIRCUIT 16-1 www.PlanDeGraissage.org...

  • Page 168: Service Information

    . STARTING SYSTEM PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to Section 4. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5 TORQUE VALUES...

  • Page 169: Starter Motor

    . STARTING SYSTEM PEOPL E 125/150 STARTER MOTOR Bolts 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 see if the starter motor operates properly.
  • Page 170 . STARTING SYSTEM PEOPL E 125/150 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary.

  • Page 171: Starter Relay

    . STARTING SYSTEM PEOPL E 125/150 Front Cover ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.

  • Page 172: Starter Clutch

    . STARTING SYSTEM PEOPL E 125/150 STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 173 . STARTING SYSTEM PEOPL E 125/150 Starter Idle Gear Shaft Remove the starter clutch lock nut. Special Lock Nut Wrench Universal Holder ＊ Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft. Lock Nut Lock Nut Wrench INSPECTION...
  • Page 174 . STARTING SYSTEM PEOPL E 125/150 Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Clutch Cover Starter Idle Gear Measure the starter idle gear I.D. Service Limit: 10.05mm replace if over Measure the starter idle gear shaft O.D. Service Limit: 9.94mm replace if below Idle Gear Shaft Plunger...
  • Page 175 . STARTING SYSTEM PEOPL E 125/150 Anchor Pin Clutch Cover ASSEMBLY Install the springs, plungers and rollers onto the clutch body. Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body. Apply locking agent to the threads of the clutch cover bolts and tighten them.
  • Page 176 . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 LIGHTS/INSTRUMENTS/SWITCHES ELECTRICAL EQUIPMENT LAYOUT ........17-1 SERVICE INFORMATION............17-2 TROUBLESHOOTING.............. 17-2 HEADLIGHT ................17-3 FRONT TURN SIGNAL LIGHT ..........17-3 POSITION/REAR TURN SIGNAL LIGHT........17-3 IGNITION SWITCH..............17-4 HANDLEBAR SWITCH ............17-4 STOP SWITCH ................. 17-6 HORN ..................

  • Page 177: Electrical Equipment Layout

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 ELECTRICAL EQUIPMENT LAYOUT Headlight Stop Switches Fuel Unit Auto Bystarter Dimmer Switch Turn Signal Switch Horn Button Auto Ignition Switch Horn Headlight Switch Bystarter Starter Button Resistor 17-1 www.PlanDeGraissage.org...

  • Page 178: Service Information

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment. • Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment. •...

  • Page 179: Headlight

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 Bulb Socket HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover. ( 2) Remove the rubber boot from the bulb socket. Remove the bulb socket by turning it counter- clockwise. Remove the bulb for replacement. Install a new bulb, aligning the groove on the bulb socket with the tab on the bulb.

  • Page 180: Ignition Switch

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 Ignition Switch Coupler IGNITION SWITCH INSPECTION Remove the front cover. ( 2-4) Disconnect the ignition switch wire coupler. Check for continuity between the wire terminals. Replacement Remove the two mounting bolts to remove the ignition switch holder. Remove the two screws to remove the ignition switch for replacement.
  • Page 181 . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 STARTER SWITCH Headlight Switch HORN SWITCH Starter Switch Horn Button TURN SIGNAL SWITCH DIMMER SWITCH Turn Signal Switch Dimmer Switch 17-5 www.PlanDeGraissage.org...

  • Page 182: Stop Switch

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 STOP SWITCH INSPECTION Remove the handlebar front cover. ( 2) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied. The switch is normal if there is continuity.

  • Page 183: Auto Bystarter

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 INSPECTION Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions. RESISTANCES Unit: W Float Upper Lower Color 38 450_ 450_ 550 26_ Y/W_ L/W 450_ 550 450_ The installation sequence is the reverse of removal.

  • Page 184: Instruments

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 Instruments INSTRUMENTS BULB REPLACEMENT Remove the front cover. ( 2) Remove the bulb socket and replace the bulb. The installation sequence is the reverse of removal. Bulb Socket Dimmer/ Fuel Gauge Wires Speedometer Cable Passing Wires INSTRUMENTS REPLACEMENT Remove the handlebar front cover.
  • Page 185 . LIGHTS/INSTRUMENTS/SWITCHES PEOPL E 125/150 DISASSEMBLY Remove the screws to disassemble the instruments. 17-9 www.PlanDeGraissage.org...

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