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PEOPL E 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

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Chapters

Troubleshooting

   Also See for KYMCO PEOPLE 250

   Summary of Contents for KYMCO PEOPLE 250

  • Page 1

    PEOPL E 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the EXHAUST MUFFLER/FRAME COVERS technical features and servicing procedures for the KYMCO People 250. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual. ENGINE REMOVAL/INSTALLATION Read them carefully before any operation is started.

  • Page 3: General Information

    . GENERAL INFORMATION PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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...

  • Page 4: General Information

    . GENERAL INFORMATION PEOPL E 250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

  • Page 5: Specification

    . GENERAL INFORMATION PEOPL E 250 SPECIFICATIONS Name & Model No. BC50AA Motorcycle Name & Type PEOPLE 250 Overall length 2219mm Air cleaner type & No Paper element, wet Overall width 742mm Fuel capacity 8.0 liters Overall height 1145mm Type...

  • Page 6: Service Precautions

    . GENERAL INFORMATION PEOPL E 250 SERVICE PRECAUTIONS n Apply or add designated greases and n Make sure to install new gaskets, O-rings, lubricants to the specified lubrication circlips, cotter pins, etc. when points. reassembling. n After reassembly, check all parts for proper tightening and operation.

  • Page 7

    . GENERAL INFORMATION PEOPL E 250 n If the fuse is burned out, find the cause and n The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. n If the double connector has a lock, lock it at the correct position.

  • Page 8

    . GENERAL INFORMATION PEOPL E 250 n After clamping, check each wire to make n Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight n Do not squeeze wires against the weld or its clamp.

  • Page 9

    . GENERAL INFORMATION PEOPL E 250 n After routing, check that the wire harnesses n Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points.

  • Page 10: Torque Values

    . GENERAL INFORMATION PEOPL E 250 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 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 Torque specifications listed below are for important fasteners.

  • Page 11: Special Tools

    . GENERAL INFORMATION PEOPL E 250 FRAME Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks Steering stem lock nut Front axle Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt (frame side) Engine hanger bolt (ENG.

  • Page 12: Lubrication Points

    . GENERAL INFORMATION PEOPL E 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE15W-40) Camshaft protruding surface •API SE, SF or SG Egnine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings...

  • Page 13

    . GENERAL INFORMATION PEOPL E 250 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 14: Cable & Harness Routing

    . GENERAL INFORMATION PEOPL E 250 CABLE & HARNESS ROUTING Front Brake Master Cylinder Winker/Horn/DIM Wire Rear Brake Master Cylinder Speedometer Cable Throttle Cable Rear Brake Fluid Tube Front Brake Fluid Tube Horn Radiator Air Ventilated Tube (to Radiator) Fuel Tank Cap Open Cable Radiator 1-11...

  • Page 15

    . GENERAL INFORMATION PEOPL E 250 Start/Light/ENG Stop/Passing Wire Winker/Horn/DIM Wire Radiator Cap Water Duct Hose Radiator Air Radiator Ventilated Tube (to Radiator Water Duct) Fuel Tank Cap Thermostatic Switch Radiator Air Ventilated Tube Water Inlet Hose Fuel Tank Water Outlet Hose Inlet Hose Front Brake Fluid Tube Fuel Pump...

  • Page 16

    . GENERAL INFORMATION PEOPL E 250 Winker/Horn/DIM Wire Start/Light/ENG Stop/Passing Wire Radiator Air Ventilated Tube (to Raciator) Throttle Cable Front Brake Fluid Tube Radiator Air Ignition Switch Ventilated Tube Water Inlet Hose Fuel Tank Cap Fan Motor Wire Rear Brake Fluid Tube Fuel Tank Breather Tube...

  • Page 17

    . GENERAL INFORMATION PEOPL E 250 Secondary Air Vacuum Tube Fuel Tank Inlet Tube Thermostat Wire Harness Thermosensor Wire Fuel Pump Vacuum Tube Starter Motor wire Heater Wire Starter Relay Air Inlet Hose (V- belt Chamber) Ignition Coil Battery (+) Cable Fuse Box A.C.G/Starter Relay Wire...

  • Page 18

    . GENERAL INFORMATION PEOPL E 250 Starter Relay Heater Control Unit Carburetor Fuel Pump Ignition Coil Oil Vapor Recovery Tube Secondary Air Inlet Tube Spark Cap Side Stand Switch Fuel Unit Wire Harness 1-15...

  • Page 19

    . GENERAL INFORMATION PEOPL E 250 Battery Fuse Box Ignition Coil Starter Motor Carburetor Wire Regulator/ Rectifier Fuel Unit Secondary Air Cleaner Fresh Air Inlet Hose Secondary Air Cleaner Fuel Pump Secondary Air Cleaner Fresh Air Outlet Hose Fuel Tube (Between Fuel Pump and Fuel Filler) 1-16...

  • Page 20

    . GENERAL INFORMATION PEOPL E 250 Battery Battery (+) Cable Battery (-) Cable Fuse Box CDI Unit Rear Brake Caliper Seat Open Cable Starter Relay Ignition Coil Throttle Cable Wire Harness Rear Brake Fluid Tube Carburetor Auto Bystarter Thermostat T.P.S Radiator Air Ventilated Tube Thermosensor...

  • Page 21: Wiring Diagram

    . GENERAL INFORMATION PEOPL E 250 WIRING DIAGRAM 1-18...

  • Page 22: Troubleshooting

    . GENERAL INFORMATION PEOPL E 250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by ÅEmpty fuel tank loosening drain screw ÇClogged carburetor fuel inlet tube, vacuum tube or fuel tube ÉClogged auto fuel valve Fuel reaches Fuel does not...

  • Page 23

    . GENERAL INFORMATION PEOPL E 250 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate ÅClogged air cleaner lightly for observation ÇRestricted fuel flow ÉClogged fuel line between fuel tank and carburetor Engine speed Engine speed does ÑClogged exhaust muffler increases not increase ÖFaulty auto bystarter...

  • Page 24

    . GENERAL INFORMATION PEOPL E 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check carburetor pilot screw adjustment ÅMixture too rich (turn screw Incorrectly adjusted Correctly adjusted out)

  • Page 25

    . GENERAL INFORMATION PEOPL E 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check valve clearance ÅImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance ÇWorn valve seat Check fuel pump for fuel supply ÅEmpty fuel tank...

  • Page 26

    . GENERAL INFORMATION PEOPL E 250 ENGINE NOISE Symptom Probable Cause ÅValve clearance too large Valve noise ÇWorn camshaft lobe ÅWorn piston rings ÇWorn piston pin and connecting rod Piston noise small end ÉExcessive carbon build-up in combustion chamber ÅDamaged cam chain tensioner ÇWorn cam gear teeth Cam chain noise ÉWorn or damaged cam chain...

  • Page 27

    . GENERAL INFORMATION PEOPL E 250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause ÅWorn or slipping drive belt ÇBroken ramp plate ÉBroken drive face spring Engine starts but ÑSeparated clutch lining motor-cycle does not move ÖDamaged driven pulley shaft splines ÜDamaged final gear áSeized final gear ÅBroken shoe spring...

  • Page 28: Inspection/adjustment

    . GENERAL INFORMATION PEOPL E 250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustmen Probable Cause Check operation of stop switch by ÅBurned out fuse applying brake ÇWeak or dead battery Stoplight does not ÉFaulty stop switch Stoplight comes come on ÑLoose or disconnected Check battery...

  • Page 29

    . GENERAL INFORMATION PEOPL E 250 closed 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 ÅFaulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose...

  • Page 30

    . GENERAL INFORMATION PEOPL E 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals ÅFaulty AC generator Voltage does not Normal voltage ÇFaulty regulator/rectifier increase ÉFaulty battery Measure resistance between AC generator coil terminals...

  • Page 31

    . GENERAL INFORMATION PEOPL E 250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn ÅBurned out fuse signals ÇWeak or dead battery Signals operate Signals dim, remain ÉFaulty ignition switch properly on or don‘t...

  • Page 32

    . GENERAL INFORMATION PEOPL E 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) ÅSteering stem nut too tight Steering is heavy ÇBroken steering steel balls ÅExcessive wheel bearing play Front or rear wheel is ÇBent rim wobbling ÉLoose axle nut...

  • Page 33

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-10...

  • Page 34: Schematic Drawing

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 SCHEMATIC DRAWING...

  • Page 35: Service Information

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use 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 38N-m...

  • Page 36: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 FRAME COVERS REMOVAL RIGHT AND LEFT BACK MIRROR REMOVAL Loosen the nut on the back mirror. Remove the back mirror. Nuts HANDLEBAR FRONT COVER REMOVAL Remove one bolt on the handlebar front cover. Bolt Remove the four screws attaching handlebar rear cover to separate from handlebar rear...

  • Page 37

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 HANDLEBAR REAR COVER REMOVAL Remove handlebar front cover. ( 2-3) Remove front cover. ( 2-4 ) Remove the bolt on the handlebar rear cover. Blot Remove the two screws attaching frame. Screw Screw Speed Wire Disconnect all of the wire connectors, couplers and the speedometer cable.

  • Page 38

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 Remove the four screws attaching the front under cover. Disconnect the front cover from leg shield and front under cover. Screws Disconnect all of the wire couplers. Wire Couplers Remove the front cover. Bolts Bolts FRONT FENDER A/B REMOVAL...

  • Page 39

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 RIGHT/LEFT SIDE COVER REMOVAL Remove the screw combine right (left) side cover with front under cover. Remove the screw combine right (left) side cover with the floor board. Remove the right (left) side cover. Screws Wire Couplers MET-IN BOX AND REAR CARRIER...

  • Page 40

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 Screws Screws Remove the met-in box and rear carrier. ( 2- Remove the four screws attaching the floor board. Screws Remove the two screws on the rear fender A. Wire Couplers Disconnect all of the wire couplers. Remove the body cover, center cover and rear fender A together.

  • Page 41

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 FRONT UNDER COVER REMOVAL Screw Screw Remove the front cover. ( 2-8 ) Remove the right and left side cover. ( 2-6 ) Remove the two screws that combine the front under cover with the leg shield. Remove the front under cover.

  • Page 42

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 Bolts Remove the center under cover. Under Cover Screws REAR FENDER COVER B/C REMOVAL Remove the met-in box. ( 2-6 ) Remove the body cover, center cover and rear fender A together. ( 2-6 ) Remove the four screws on the rear fender B.

  • Page 43: Exhaust Muffler Removal

    . EXHAUST MUFFLER/FRAME COVERS PEOPL E 250 Remove the screw attaching the air cleaner case. Rear Fender Cover C Air Clean Case Remove the rear fender C. EXHAUST MUFFLER REMOVAL Screws Remove the two exhaust muffler joint lock nuts. Joint Lock Nuts Remove the three exhaust muffler lock bolts to remove the exhaust muffler.

  • Page 44

    . INSPECTION/ADJUSTMENT PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3 THROTTLE OPERATION --------------------------------------------- 3- 3 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5 SPARK PLUG ----------------------------------------------------------- 3- 5 VALVE CLEARANCE ------------------------------------------------- 3- 6 CARBURETOR IDLE SPEED ----------------------------------------- 3- 6...

  • Page 45: Service Information

    . INSPECTION/ADJUSTMENT PEOPL E 250 SERVICE INFORMATION GENERAL WARNING •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. •Gasoline is extremely flammable and is explosive under some conditions.

  • Page 46: Maintenance Schedule

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

  • Page 47: Fuel Line/fuel Filter

    . INSPECTION/ADJUSTMENT PEOPL E 250 Fuel Filter FUEL LINE/FUEL FILTER Remove the right side cover. Check the fuel lines and replace any parts, which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged. •...

  • Page 48: Engine Oil

    . INSPECTION/ADJUSTMENT PEOPL E 250 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on level ground. Wait for 2 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.

  • Page 49: Air Cleaner

    . INSPECTION/ADJUSTMENT PEOPL E 250 Air Cleaner Case Cover AIR CLEANER Remove the six air cleaner case cover screws and the cover. Screws Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.

  • Page 50: Valve Clearance

    . INSPECTION/ADJUSTMENT PEOPL E 250 Cylinder Head Cover Upper Bolts VALVE CLEARANCE • Inspect and adjust valve clearance while the engine is cold (below 35 Remove the met-in box and center cover. Disconnect oil vapor recovery tube and secondary air cleaner fresh air outlet hose from cylinder head cover.

  • Page 51: Cylinder Compression

    . INSPECTION/ADJUSTMENT PEOPL E 250 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug. Insert a compression gauge. Open the throttle valves fully and pushes the starter button to test the compression. Compression: 15±2kg/cm_ If the compression is low, check for the following:...

  • Page 52: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT PEOPL E 250 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL • Place the scooter on its main stand on level ground. Stop the engine and remove the oil checks bolt. The oil level shall be at the oil check blowhole.

  • Page 53: Headlight Aim

    . INSPECTION/ADJUSTMENT PEOPL E 250 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.

  • Page 54: Brake System

    . INSPECTION/ADJUSTMENT PEOPL E 250 Radiator Cap Remove the front cover. Remove the radiator cap. Remove the drain bolt to drain the coolant and tilt the scooter to the right and the coolant will drain more easily. Drain the coolant in the reserve tank. Reinstall the drain bolt.

  • Page 55: Nuts/bolts/fasteners

    . INSPECTION/ADJUSTMENT PEOPL E 250 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Pressure Gauge Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.

  • Page 56

    . LUBRICATION SYSTEM PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY ------------------------------------------- 4-4 OIL PUMP INSPECTION ---------------------------------------------- 4-5 OIL PUMP ASSEMBLY------------------------------------------------ 4-5 OIL PUMP INSTALLATION------------------------------------------ 4-6...

  • Page 57

    . LUBRICATION SYSTEM PEOPL E 250 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 58: Lubrication System

    . LUBRICATION SYSTEM PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Drain the coolant before starting any operations. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 59: Engine Oil/oil Filter

    . LUBRICATION SYSTEM PEOPL E 250 Oil Dipstick ENGINE OIL/OIL FILTER Place the scooter 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 60: Oil Pump Removal

    . LUBRICATION SYSTEM PEOPL E 250 Bolts OIL PUMP REMOVAL First drain the coolant. Remove the right crankcase cover. ( 10-3) Remove the A.C. generator starter driven gear. ( 10-3) Remove the attaching bolt and oil separator cover. Oil Separator Cover Oil Pump Driven Gear Circlip Pry the circlip off and remove the oil pump...

  • Page 61: Oil Pump Inspection

    . LUBRICATION SYSTEM PEOPL E 250 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Inner Rotor Measure the rotor end-to-pump body clearance.

  • Page 62: Oil Pump Installation

    . LUBRICATION SYSTEM PEOPL E 250 Pump Hole Screw Cover Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.

  • Page 63

    . ENGINE REMOVAL/INSTALLATION PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 5-1 ENGINE REMOVAL --------------------------------------------------- 5-2 ENGINE INSTALLATION -------------------------------------------- 5-5 ENGINE HANGER REMOVAL --------------------------------------- 5-4...

  • Page 64: Service Information

    5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. •...

  • Page 65: Engine Removal/installation

    . ENGINE REMOVAL/INSTALLATION PEOPL E 250 ENGINE REMOVAL Drain the coolant. ( 3-9) Remove the met-in box, carrier. ( 2-6 ) Remove the frame body cover, center cover and rear fender A together. ( 2-6 ) Remove the exhaust muffler. ( 2-10 ) Disconnect all of the A.C.

  • Page 66

    5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 Engine Oil Pressure Water Hoses Water Ducts Switch Wire Disconnect the engine oil pressure switch wire. Loosen the water hose bands to disconnect water hoses from the water ducts. Disconnect the secondary air tube from the secondary air inlet tube.

  • Page 67

    . ENGINE REMOVAL/INSTALLATION PEOPL E 250 Rear Shock Absorber Bolts Remove the left rear shock absorber. Remove the right rear shock absorber lower mount bolts. Remove the right rear shock absorber. Remove the rear wheel nut. Disconnect the rear brake fluid tube from the guide.

  • Page 68: Engine Hanger Removal

    5. ENGINE REMOVAL/INSTALLATION PEOPL E 250 Remove the engine mounting bolt and pull out the engine. ENGINE INSTALLATION Reverse the “REMOVAL” procedures. Apply grease onto the O-rings, oil seals and bush). Engine Mounting Bolt Nuts Nuts ENGINE HANGER REMOVAL Remove met-in box and carrier. ( 2-6 ) Remove the body cover, center cover and rear fender A together.

  • Page 69

    . ENGINE REMOVAL/INSTALLATION PEOPL E 250 Inspect the engine hanger bushings and stopper Bushing rubber for wear or damage. INSTALLATION Reverse the “REMOVAL” procedures. Apply grease onto the bush.

  • Page 70: Cylinder Head/valves

    . CYLINDER HEAD/VALVES PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 6- 1 SERVICE INFORMATION -------------------------------------------- 6- 2 TROUBLESHOOTING ------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ----------------------------- 6- 4 CAMSHAFT REMOVAL----------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL --------------------------------------- 6- 6 CYLINDER HEAD DISASSEMBLY --------------------------------- 6- 7 CYLINDER HEAD ASSEMBLY -------------------------------------- 6- 8 CYLINDER HEAD INSTALLATION -------------------------------- 6- 9...

  • Page 71: Cylinder Head/valves

    . CYLINDER HEAD/VALVES PEOPL E 250 SCHEMATIC DRAWING...

  • Page 72: Service Information

    . CYLINDER HEAD/VALVES PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

  • Page 73: Troubleshooting

    . CYLINDER HEAD/VALVES PEOPL E 250 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low •...

  • Page 74: Cylinder Head Cover Removal

    . CYLINDER HEAD/VALVES PEOPL E 250 Bolts CYLINDER HEAD COVER REMOVAL Remove the met-in box, carrier. ( 2-6) Remove the body cover, center cover and rear fender A. ( 2-6) Disconnect the secondary air inlet tube connector and breather hose (air cleaner). ( 5-2) Remove the cylinder head cover four bolts and two nuts attaching the secondary air inlet...

  • Page 75

    . CYLINDER HEAD/VALVES PEOPL E 250 Remove the camshaft holder. Camshaft Holder Remove the dowel pins. Dowel Pins Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. CAMSHAFT INSPECTION Camshaft Gear Check each cam lobe for wear or damage. Measure the cam lobe height.

  • Page 76: Cylinder Head Removal

    . CYLINDER HEAD/VALVES PEOPL E 250 Valve Rocker Arms CAMSHAFT HOLDER DISASSEMBLY Remove the valve rocker arms. Rocker Arm Shafts Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

  • Page 77: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES PEOPL E 250 Remove the dowel pins and cylinder head Cylinder Dowel Pins gasket. Remove the cam chain guide. Remove all gasket material from the cylinder head mating surface. Be careful not to drop any gasket material into the engine. Cylinder Head Gasket Cam Chain Guide CYLINDER HEAD DISASSEMBLY...

  • Page 78: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES PEOPL E 250 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if over Feeler Gauge VALVE SPRING FREE LENGTH...

  • Page 79: Cylinder Head Installation

    . CYLINDER HEAD/VALVES PEOPL E 250 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters. Be careful not to damage the valves. Cylinder Head Cylinder Dowel Pins CYLINDER HEAD INSTALLATION Install the cam chain guide. Install the dowel pins and a new cylinder head gasket.

  • Page 80: Camshaft Installation

    . CYLINDER HEAD/VALVES PEOPL E 250 Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the A.C. generator flywheel so that the “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 the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes...

  • Page 81: Cylinder Head Cover Installation

    . CYLINDER HEAD/VALVES PEOPL E 250 Tensioner Turn the cam chain tension screw counter Screw clockwise to release it. Bolts O-ring Apply engine oil to a new O-ring and install Tighten the cam chain tension cap screw. Be sure to install the gasket into the groove properly.

  • Page 82: Cylinder/piston

    . CYLINDER/PISTON PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL ---------------------------------------------------- 7-3 PISTON INSTALLATION --------------------------------------------- 7-7 CYLINDER INSTALLATION----------------------------------------- 7-7...

  • Page 83: Cylinder/piston

    . CYLINDER/PISTON PEOPL E 250 SCHEMATIC DRAWING...

  • Page 84: Service Information

    . CYLINDER/PISTON PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 85: Cylinder Removal

    . CYLINDER/PISTON PEOPL E 250 Dowel Pins Cylinder Head Gasket Cylinder CYLINDER REMOVAL Remove the cylinder head. ( chapter 6) Remove the dowel pins and cylinder head gasket. Remove the water hose from the cylinder. Water Hose Remove the cam chain guide. Remove the cylinder.

  • Page 86

    . CYLINDER/PISTON PEOPL E 250 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 87

    . CYLINDER/PISTON PEOPL E 250 Measure the piston pin O.D. Service Limit: 16.96mm replace if below Measure the piston O.D. • Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 72.60mm replace if below Measure the piston-to-piston pin clearance.

  • Page 88

    . CYLINDER/PISTON PEOPL E 250 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: 17.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.

  • Page 89: Piston Installation

    . CYLINDER/PISTON PEOPL E 250 PISTON INSTALLATION Remove any gasket material from the crankcase surface. • Be careful not to drop foreign matters into the crankcase. “IN” Mark Piston Pin Clip Install the piston, piston pin and a new piston pin clip. Position the piston “IN”...

  • Page 90

    . CYLINDER/PISTON PEOPL E 250 Install the cam chain guide. • Insert the tab on the cam chain guide into the cylinder groove. Cam Chain Guide Dowel Pin Gasket Install the cylinder head gasket and dowel pins. Connect the water hose to the cylinder. Water Hose Install the cylinder head.

  • Page 91: Drive And Driven Pulleys/v- Belt

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/ V-BELT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3 DRIVE PULLEY -------------------------------------------------------- 8- 4 CLUTCH OUTER/DRIVEN PULLEY/V-BELT --------------------- 8- 4...

  • Page 92: Drive And Driven Pulleys/ V-belt

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT SCHEMATIC DRAWING...

  • Page 93: Service Information

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT 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 94: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Air Tube LEFT CRANKCASE COVER REMOVAL Remove the met-in box and carrier. ( 2-6 ) Remove the body cover, center cover and rear fender A together. ( 2-6 ) Disconnect the belt air tube from the frame Left Crankcase Cover Bolts Remove the left crankcase cover bolts and left...

  • Page 95: Drive Pulley

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Air Tube Connect the drive belt air tube to frame. DRIVE PULLEY Drive Pulley Face Universal Holder DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover. ( 8-3 ) Hold the drive pulley using a universal holder and remove the drive face nut and washer.

  • Page 96: Movable Drive Face

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Drive Pulley Collar MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face, clutch outer, driven pulley and belt. ( 8-4)) Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate.

  • Page 97

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Measure the movable drive face bushing assembly I.D. Service Limit: 27.13mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.

  • Page 98

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D. Service Limit: 153.5mm replace if over...

  • Page 99

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch Lining Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Lock Nut Wrench Hold the clutch/driven pulley assembly with the clutch spring compressor.

  • Page 100

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Movable Driven Face Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Guide Roller Pin O-ring Remove the oil seal from the movable driven Oil Seal face.

  • Page 101

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 40.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.

  • Page 102

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Press a new needle bearing into the driven face. Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch • linings. Retainer Plate Clutch Lining 8-11...

  • Page 103

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT CLUTCH ASS EMBLY Circlips 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 circlips.

  • Page 104

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.

  • Page 105

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Drive Pulley Collar INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft. Movable Drive Face Assembly Driven Pulley and Out Drive Pulley Collar Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.

  • Page 106

    . DRIVE AND DRIVEN PULLEYS/ PEOPL E 250 V-BELT Install the left crankcase cover. ( 8-3) 8-15...

  • Page 107

    . FINAL REDUCTION PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 9-1 SERVICE INFORMATION -------------------------------------------- 9-2 TROUBLESHOOTING ------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY------------------------------- 9-3 FINAL REDUCTION INSPECTION---------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ----------------------------------- 9-6...

  • Page 108

    . FINAL REDUCTION PEOPL E 250 SCHEMATIC DRAWING...

  • Page 109

    . FINAL REDUCTION PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • 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:...

  • Page 110: Final Reduction

    . FINAL REDUCTION PEOPL E 250 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. ( 2-10) Remove the rear brake caliper. ( 15-3) Remove the right rear shock absorber. ( 15-7) Remove the rear fork. ( 15-6) Remove the rear wheel. ( 15-7) Remove the left crankcase cover.

  • Page 111

    . FINAL REDUCTION PEOPL E 250 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Drive Shaft and Gear 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.

  • Page 112

    . FINAL REDUCTION PEOPL E 250 Drive Shaft Bearing BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Drive new bearings into the transmission case cover. Pilot Drive Shaft BEARING REPLACEMENT (LEFT...

  • Page 113

    . FINAL REDUCTION PEOPL E 250 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Drive Shaft Put the final gear on the left crankcase. Final Gear...

  • Page 114

    . FINAL REDUCTION PEOPL E 250 Countershaft Install the countershaft and gear into the left crankcase. Final Shaft Install the final shaft into the final gear and transmission case. Final Gear Gasket Install the dowel pins and a new gasket. Dowel Pins...

  • Page 115

    . FINAL REDUCTION PEOPL E 250 Bolts Install the transmission case cover. Install and tighten the transmission case cover bolts. Install the clutch outer/driven pulley. Install other removed parts in the reverse order of removal. Transmission Case Cover Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil.

  • Page 116: Generator/starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 10-1 SERVICE INFORMATION -------------------------------------------- 10-2 TROUBLESHOOTING ------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3 STATOR REMOVAL --------------------------------------------------- 10-3 FLYWHEEL REMOVAL----------------------------------------------- 10-4 STARTER CLUTCH ---------------------------------------------------- 10-4 FLYWHEEL INSTALLATION---------------------------------------- 10-8 STATOR INSTALLATION -------------------------------------------- 10-9 RIGHT CRANKCASE COVER INSTALLATION------------------- 10-9...

  • Page 117

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 SCHEMATIC DRAWING 10-1...

  • Page 118

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.) •...

  • Page 119

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Water Pump Cover RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover. ( chapter 5 ) Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover.

  • Page 120: Flywheel Removal

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Spring Oil Through Remove the oil through and spring. Flywheel Flywheel Holder FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer. Special Flywheel holder E021 Remove the flywheel with a flywheel puller. Flywheel Puller Special Flywheel puller...

  • Page 121

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Shaft Starter Idle Gear Remove the starter idle gear and shaft. Bolts OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover. Oil Separator Cover Oil Pump Driven Gear Circlip Pry the circlip off and remove the oil pump driven gear, then remove the oil pump drive chain.

  • Page 122

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Bolts Remove the two oil pump bolts to remove the oil pump. Oil Pump INSPECTION Inspect the starter driven gear for wear or damage. Measure the starter driven gear I.D. and O.D. Service Limits: I.D.

  • Page 123

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Arrow Mark Oil Pump INSTALLATION Install oil pump and tighten the two bolts. Make sure that the pump shaft rotates freely. The arrow of oil pump is upside. Bolts Cam Chain Install cam chain. Pump Driven Gear Circlip Install the pump drive chain and driven gear,...

  • Page 124: Flywheel Installation

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Shaft Starter Idle Gear Install the starter idle gear and shaft. Starter Driven Gear Install the starter driven gear onto the crankshaft. Flywheel FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel.

  • Page 125

    . A.C. GENERATOR/STARTER CLUTCH PEOPL E 250 Screws Screws STATOR INSTALLATION Install the A.C. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws. Install the wire grommet in the groove in the right crankcase cover securely.

  • Page 126: Crankcase/crankshaft

    . CRANKCASE/CRANKSHAFT PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT INSPECTION----------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5 11-0...

  • Page 127

    . CRANKCASE/CRANKSHAFT PEOPL E 250 SCHEMATIC DRAWING 11-1...

  • Page 128

    . CRANKCASE/CRANKSHAFT PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.

  • Page 129

    . CRANKCASE/CRANKSHAFT PEOPL E 250 Bolt CRANKCASE SEPARATION Remove the three right crankcase attaching bolts. Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. Never use a driver to pry the • crankcase mating surfaces apart.

  • Page 130

    . CRANKCASE/CRANKSHAFT PEOPL E 250 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over 11-4...

  • Page 131

    . CRANKCASE/CRANKSHAFT PEOPL E 250 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.

  • Page 132

    . CRANKCASE/CRANKSHAFT PEOPL E 250 Left Crankcase Crankshaft Place the left crankcase down and install the crankshaft into the left crankcase. Avoid damaging the oil seal. • Apply grease to the lip of the oil • seal. Gasket Install the two dowel pins and a new gasket. Dowel Pins Left Crankcase Right Crankcase...

  • Page 133: Cooling System

    . COOLING SYSTEM PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------- 12- 2 TROUBLESHOOTING ------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------- 12- 4 RADIATOR -------------------------------------------------------------- 12- 4 WATER PUMP ---------------------------------------------------------- 12- 9 THERMOSENSOR ------------------------------------------------------ 12-14 THERMOSTAT---------------------------------------------------------- 12-15 12-0...

  • Page 134

    . COOLING SYSTEM PEOPL E 250 SCHEMATIC DRAWING 12-1...

  • Page 135

    . COOLING SYSTEM PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100 , never remove the radiator cap to release the pressure because the boiling coolant may cause danger.

  • Page 136

    1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water 425cc 975cc -44.5 Cautions for Using Coolant: •...

  • Page 137

    . COOLING SYSTEM PEOPL E 250 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 cap sealing surface before testing.

  • Page 138

    . COOLING SYSTEM PEOPL E 250 Radiator Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. Outlet Tube of Reserve RADIATOR REMOVAL Tank...

  • Page 139

    . COOLING SYSTEM PEOPL E 250 Radiator Nuts Remove the two bolts and two nuts on the radiator. Remove the radiator. Bolts Fan/Shroud RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan/shroud from the radiator. Bolts Battery Check fan motor by battery. Fan Motor 12-6...

  • Page 140

    . COOLING SYSTEM PEOPL E 250 Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 88~92 the thermostatic switch OFF. When coolant temperature over 88~92 the thermostatic switch ON. Radiator Fan/Shroud Install the fan shroud on the radiator with the three bolts.

  • Page 141

    . COOLING SYSTEM PEOPL E 250 Radiator Nuts RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and two nuts. Bolts Upper Hose Thermostatic Switch Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire.

  • Page 142: Water Pump

    . COOLING SYSTEM PEOPL E 250 Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.

  • Page 143

    . COOLING SYSTEM PEOPL E 250 Impeller Mechanical Seal Inspect the mechanical (water) seal and seal washer for wear or damage. The mechanical seal and seal washer must be replace as a set. Seal Washer (Porcelain) Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover.

  • Page 144

    . COOLING SYSTEM PEOPL E 250 Water Pump Assembly Remove the water pump shaft outer bearing. Inner Bearing Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Mechanical Seal Driver Drive in a new mechanical seal using a...

  • Page 145

    . COOLING SYSTEM PEOPL E 250 Outer Bearing WATER PUMP SHAFT INS TALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside. Water Pump Assembly Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly.

  • Page 146

    . COOLING SYSTEM PEOPL E 250 Impeller Mechanical Seal WATER PUMP/IMPELLER INSTALLATION When the mechanical seal is replaced, a new seal washer must be installed to the impeller. Seal Washer (Porcelain) Impeller (Left Hand Threads) Install the impeller onto the water pump shaft.

  • Page 147

    . COOLING SYSTEM PEOPL E 250 Thermosensor 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 Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water Thermosensor over a burner and measure the resistance...

  • Page 148

    . COOLING SYSTEM PEOPL E 250 THERMOSTAT Thermostat Water Hose Bolt 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 from the thermostat housing.

  • Page 149

    . COOLING SYSTEM PEOPL E 250 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80±2 Full-open Valve lift 4.5mm O-ring •...

  • Page 150: Fuel System/carburetor/fuel Pump Fuel Tank

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM --------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ---------------------------------------------- 13- 2 OPERATION OF CARBURETOR JETS------------------------------ 13- 3 SERVICE INFORMATION -------------------------------------------- 13- 5 CARBURETOR REMOVAL ------------------------------------------- 13- 7 VACUUM CHAMBER DISASSEMBLY------------------------------ 13- 7 FLOAT CHAMBER DISASSEMBLY--------------------------------- 13- 9...

  • Page 151

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK FUEL SYSTEM 13-1...

  • Page 152

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK SCHEMATIC DRAWING 13-2...

  • Page 153: Fuel System/carburetor/fuel Pump

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK OPERATION OF CARBURETOR JETS LOW SPEED Venturi (slightly opened throttle valve) Air Bleed Holes‡ Mixture……. Low Speed Air Inlet Fuel in Float Chamber‡ Slow Jet -------------------- Low Speed Small Jet Holes 2.MIDDLE SPEED Venturi (halfway opened throttle valve) Air Bleed Holes‡...

  • Page 154

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK FUEL PUMP CONSTRUCTION: The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.

  • Page 155: Service Information

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly.

  • Page 156

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly • No fuel in tank • Incorrect idle speed • Restricted fuel line • Rich mixture • Too much fuel getting to cylinder •...

  • Page 157: Carburetor Removal

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Auto Bystarter T.P.S Fuel Tube CARBURETOR REMOVAL Remove the met-in box. Disconnect the fuel tube at the carburetor. Disconnect the auto bystarter wire. Disconnect the throttle position sensor wire. T.P.S Wire Auto Bystarter Wire Air Cleaner Connecting Tube Band...

  • Page 158

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Diaphragm Vacuum Piston Remove the needle holder, spring and jet needle from the piston.

  • Page 159: Float Chamber Disassembly

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Valve Float Pin Float Valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear.

  • Page 160

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK JETS/SCREWS REMOVAL • Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns. Do not force the pilot screw against its seat to avoid seat damage.

  • Page 161: Auto Bystarter Inspection/removal

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10W (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.

  • Page 162: Air Cut-off Valve (a.c.v.)

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle Bystarter Valve Air Cut-off Valve Cover AIR CUT-OFF VALVE (A.C.V.)

  • Page 163

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body. • Make sure that no fuel jet is clogged. O-ring Install the O-ring onto the air-cut-off valve body securely.

  • Page 164

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Screws ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. Diaphragm Cover INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration.

  • Page 165: Float Chamber Assembly

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Main Jet Slow Jet FLOAT CHAMBER ASSEMBLY Install the main jet. Install the slow jet. Install the pilot screw. • Be sure to record the rotating turns when it is removed. Pilot Screw Float Install the float valve, float and float pin.

  • Page 166: Float Level Inspection

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet (just contacting the float valve). Float Level: 18.5±1.0mm Replace the float if the level is incorrect. Check the operation of the float and then reinstall the float chamber.

  • Page 167: Carburetor Installation

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Heater Air Cleaner Connecting Tube Band Intake Manifold Band CARBURETOR INSTALLATION Tighten the drain screw.

  • Page 168: Fuel Pump Removal/disassembly

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Vacuum Tube Outlet Tube FUEL PUMP REMOVAL Remove met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Disconnect the fuel pump inlet, outlet and vacuum tubes.

  • Page 169: Fuel Pump Inspection

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Relief Valve Outlet Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.

  • Page 170: Fuel Pump Installation

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Vacuum Tube Outlet Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two nuts. Connect the fuel pump inlet, outlet and vacuum tubes. Install the met-in box and carrier. Install the body cover, center cover and rear fender A.

  • Page 171

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK Fuel Unit Wire Tube to Fuel Filler Disconnect the fuel unit wire connector. Connector Remove the fuel tube between the fuel tank and the fuel filler. Disconnect the fuel vapor tube. Disconnect the fuel tube between the fuel tank and fuel strainer.

  • Page 172

    . FUEL SYSTEM/CARBURETOR/ PEOPL E 250 FUEL PUMP/ FUEL TANK FUEL STRAINER REMOVAL Remove the right side cover. Remove the fuel strainer from the fuel line. Fuel Strainer INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air. When removing the fuel strainer, do not allow flames or sparks near the working area and drain the residual gasoline into a...

  • Page 173

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 14- 1 SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 STEERING HANDLEBAR--------------------------------------------- 14- 4 FRONT WHEEL--------------------------------------------------------- 14- 5 FRONT BRAKE --------------------------------------------------------- 14- 8 FRONT SHOCK ABSORBER------------------------------------------ 14-14...

  • Page 174: Schematic Drawing

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...

  • Page 175

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.

  • Page 176: Troubleshooting

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate •...

  • Page 177: Steering Handlebar/front Wheel/front Brake/front

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 2-3) Remove the front and rear brake master cylinder attaching bolts. Bolts Throttle Cable Remove the four screws attaching the right and left handlebar switches.

  • Page 178: Front Wheel

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.

  • Page 179

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Collar FRONT WHEEL BEARING Remove the side collar and dust seal. Dust Seal Wheel Bearing Turn the inner race of each bearing with your...

  • Page 180

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. Do not allow the bearings to tilt • while driving them in.

  • Page 181: Front Brake

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder Bolts FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. ( 2-3) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.

  • Page 182

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear.

  • Page 183

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Place the brake master cylinder on the handlebar and install the holder with the “up” Stop Switch mark facing up. Also align the punch mark “UP” Mark Wire Connector with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.

  • Page 184

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper. Fluid Tube Bolt DISASSEMBLY Remove the two brake pad dowel pins from...

  • Page 185

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore. Service Limit: 25.45mm ASSEMBLY Clean all removed parts.

  • Page 186

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Install the brake caliper to the shock absorber and tighten the two bolts. Torque: 29 35N-m Connect the brake fluid tube with the attaching bolt and two sealing washers to the brake caliper and tighten the fluid tube bolt.

  • Page 187: Front Shock Absorber

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front cover. ( 2-5) Remove the front fender cover A and B. ( 2- Remove the front wheel. ( 14-5) Remove the front brake caliper. ( 14-11) Remove the front shock absorber upper mount bolts.

  • Page 188: Front Fork

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. ( 2-3) Remove the steering handlebar. ( 14-4) Remove the front cover. ( 2-5) Remove the front leg shield. ( 2-8) Remove the front fender cover A and B.

  • Page 189

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT PEOPL E 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race. Then, install the front fork. Bottom Ball Race Apply grease to the top cone race and install Tighten the top cone race and then turn the...

  • Page 190: Rear Brake/rear Fork/rear Wheel/rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 REAR BRAKE ----------------------------------------------------------- 15-3 REAR FORK ------------------------------------------------------------- 15-6 REAR WHEEL ---------------------------------------------------------- 15-7 REAR SHOCK ABSORBER-------------------------------------------- 15-7 15-0...

  • Page 191

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...

  • Page 192

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk. SPECIFICATIONS Item Standard (mm)

  • Page 193: Rear Brake

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. ( 2-10) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove the two bolts attaching the rear brake caliper.

  • Page 194

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.

  • Page 195

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.

  • Page 196: Rear Fork

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts. Torque: 29 35N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.

  • Page 197: Rear Wheel

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-10) Remove the rear brake caliper. ( 15-3) Remove the rear fork. ( 15-6) Remove the rear axle collar. Remove the rear wheel. Rear Brake Rear Axle Collar Disk...

  • Page 198

    When you adjust rear cushion, the spring preload of rear cushions must be the same. Wrench A cushion adjust wrench is provided with PEOPLE 250. The rear right cushion can be adjusted directly with the wrench. Bolts Remove the four bolts from air cleaner before rear left cushion to be adjusted.

  • Page 199

    . REAR BRAKE/REAR FORK/REAR PEOPL E 250 WHEEL/REAR SHOCK ABSORBER Disconnect the breather hose from air cleaner and keep air cleaner up to adjust rear left cushion with wrench. Breather Hose Wrench Air Cleaner 15-9...

  • Page 200

    . BATTERY/CHARGING SYSTEM PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6 16-0...

  • Page 201

    . BATTERY/CHARGING SYSTEM PEOPL E 250 CHARGING SYSTEM LAYOUT Fuse Battery Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 16-1...

  • Page 202: Battery/charging System

    . BATTERY/CHARGING SYSTEM PEOPL E 250 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 203

    . BATTERY/CHARGING SYSTEM PEOPL E 250 SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out •...

  • Page 204

    . BATTERY/CHARGING SYSTEM PEOPL E 250 Battery Cover Screw BATTERY Remove the seat and met-in box. ( 2-3) Remove the battery cover screw and the battery cover. Remove the battery. 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 205

    . BATTERY/CHARGING SYSTEM PEOPL E 250 Red Wire CHARGING SYSTEM CURRENT TEST Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.

  • Page 206

    . BATTERY/CHARGING SYSTEM PEOPL E 250 A.C. Generator Stator Pulser Coil A.C. GENERATOR REMOVAL A.C. generator removal ( 10-3) A.C. generator installation ( 10-6) Right Crankcase Cover Bolts REGULATOR/RECTIFIER INSPECTION Remove the met-in box. ( 2-6) Remove the regulator/rectifier wire coupler. Check the continuity between the wire terminals.

  • Page 207: Ignition System

    . IGNITION SYSTEM PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4 CDI UNIT RESISTANCE INSPECTION----------------------------- 17-4 17-0...

  • Page 208

    . IGNITION SYSTEM PEOPL E 250 IGNITION SYSTEM LAYOUT Ignition Switch CDI Unit Ignition Coil A.C. Generator Pulser Coil IGNITION CIRCUIT 17-1...

  • Page 209

    . IGNITION SYSTEM PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 1-28) • 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. Inspect the CDI unit with a CDI tester •...

  • Page 210

    . IGNITION SYSTEM PEOPL E 250 Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. ( 2-6) Remove the ignition coil Ignition Coil Primary Coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil, primary coil and secondary coil.

  • Page 211

    . IGNITION SYSTEM PEOPL E 250 A .C. GENERATOR INSPECTION EXCITER COIL/PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the seat and met-in box. ( 2-6) Disconnect the A.C. generator connector. Measure the exciter coil resistance between the black/white wire terminal and ground.

  • Page 212

    . IGNITION SYSTEM PEOPL E 250 • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing. Use of an improper tester in an improper range may give false readings. • In this table, “Needle swings then returns”...

  • Page 213

    . STARTING SYSTEM PEOPL E 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION----------------------------------- 18-6 STARTER RELAY INSPECTION ------------------------------------ 18-6 18-0...

  • Page 214: Starting System

    . STARTING SYSTEM PEOPL E 250 STARTING SYSTEM LAYOUT Stop Switch Starter Button Starter Relay Starter Motor STARTING CIRCUIT Relay 18-1...

  • Page 215: Starting System

    . STARTING SYSTEM PEOPL E 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 10-3. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.

  • Page 216: Starter Motor

    . STARTING SYSTEM PEOPL E 250 STARTER MOTOR 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 217

    . STARTING SYSTEM PEOPL E 250 Check for continuity between pairs of the commutator segments and there should be continuity. Also, make a continuity check between individual commutator segments and the armature shaft. There should be no continuity. STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and...

  • Page 218

    . STARTING SYSTEM PEOPL E 250 Bushing Check if the needle bearing in the front cover turns freely and has no excessive play. Replace if necessary. Check the dust seal for wear or damage. Dust Seal ASSEMBLY Apply grease to the dust seal in the front cover.

  • Page 219: Starter Relay Inspection

    . STARTING SYSTEM PEOPL E 250 STARTER CLUTCH INSPECTION Refer to pages 10-4 and 10-5 for the starter clutch removal, inspection and installation. STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed.

  • Page 220: Switches/horn/fuel Unit/thermostatic

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5 THERMOSTATIC SWITCH ------------------------------------------- 19-6 TEMPERATURE METER---------------------------------------------- 19-6 INSTRUMENTS--------------------------------------------------------- 19-7...

  • Page 221: Electrical Equipment Layout

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Starter Button Engine Stop Switch Headlight Stop Switches Switch Passing Ignition Switch Dimmer Switch Turn Signal Switch Horn Button Thermostati Fuel Unit c Switch Horn Heater Control Unit 19-1...

  • Page 222: Service Information

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS • After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT Electric tester TROUBLESHOOTING Lights do not come on when ignition...

  • Page 223: Switches

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. ( 2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/Wh Green Black Position PARK LOCK HEADLIGHT SWITCH INSPECTION Remove the handlebar front covers.

  • Page 224

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN BUTTON INSPECTION Remove the handlebar front covers. ( 2-3) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Br/L Color Light Green Brown/Blue Position FREE...

  • Page 225: Horn Inspection

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN INSPECTION Horn Remove the front cover. ( 2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.

  • Page 226: Thermostatic Switch

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS THERMOSTATIC SWITCH INSPECTION Remove the front covers. ( 2-5) Start and run the engine to make the water temperature reaches 85 and check if the cooling fan motor operates. Lower the water temperature to 85 check if the fan motor stops.

  • Page 227: Instruments

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS THROTTLE POSTTION SENSOR Unit:KW 0~5±1 0~5±1 T.P.S. Screws INSTRUMENTS REMOVAL Remove the handlebar rear cover. ( 2-4) Remove the three screws under instruments. Remove the instruments from the handlebar rear cover. INSTALLATION The installation sequence is the reverse of removal.

  • Page 228: Headlight Bulb Replacement

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Rubber Boot FRONT POSITION LIGHT /HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover. ( 2-3) Remove the bulb socket by turning them counterclockwise. Remove the bulb and replace with new one. Disconnect the headlight wire couplers.

  • Page 229: Heater Wiring Diagram

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH PEOPL E 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HEATER WIRING DIAGRAM 19-9...

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