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- Page 1 PEOPLE/PEOPLE S 250 By KWANG YANG Motor Co., Ltd. First Edition, Jan 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LLJ3/LDH1-S00...
- Page 2 PEOPLE/PEOPLE S 250 PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing GENERAL INFORMATION procedures for the KYMCO People/People s 250. EXHAUST MUFFLER/FRAME COVERS INSPECTION/ADJUSTMENT Section 1 contains the precautions for all operations stated in this LUBRICATION SYSTEM manual.
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Page 3: Table Of Contents
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1 SPECIFICATION ------------------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-4 TORQUE VALUES ----------------------------------------------------------------------------------- 1-8 SPECIAL TOOLS ------------------------------------------------------------------------------------- 1-9 LUBRICATION POINTS -------------------------------------------------------------------------- 1-10 CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-12... -
Page 4: General Information
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number... -
Page 5: Specification
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SPECIFICATIONS Name & Model No. BC50AA Air cleaner type & No Paper element, wet Motorcycle Name & Type PEOPLE 250 Fuel capacity 8.5 liters Overall length 2130mm Type Overall width 750mm Piston dia. Overall height 1170mm Venturi dia. - Page 6 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 SPECIFICATIONS Name & Model No. BA50AA Air cleaner type & No Paper element, wet Motorcycle Name & Type PEOPLE S 250 Fuel capacity 10.0 liters Overall length 2140mm Type Overall width 750mm Piston dia.
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Page 7: Service Precautions
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. After reassembly, check all parts for proper tightening and operation. - Page 8 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.
- Page 9 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight Do not squeeze wires against the weld or its clamp.
- Page 10 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 After routing, check that the wire harnesses 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. (Use...
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Page 11: Torque Values
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 4.5～6 5mm screw 3.5～5 6mm bolt, nut 8～12 6mm screw, SH bolt 7～11 8mm bolt, nut 18～25 6mm flange bolt, nut 10～14... -
Page 12: Special Tools
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 FRAME Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks Steering stem lock nut 40～50 Front axle nut 60～70 Rear axle nut 110～130 Rear shock absorber upper bolt 35～45 35～45 Rear shock absorber lower bolt Front shock absorber lock bolt 29～35... -
Page 13: Lubrication Points
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SE, SF or SG Egnine Oil Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain... - Page 14 1. GENERAL INFORMATION PEOPLE/PEOPLE S 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.
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Page 15: Cable & Harness Routing
1. GENERAL INFORMATION PEOPLE/PEOPLE S 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... - Page 16 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Start/Light/ENG Stop/Passing Wire Winker/Horn/DIM Wire Radiator Cap Water Duct Hose Radiator Air Ventilated Radiator Tube (to Radiator Water Duct) Fuel Tank Cap Thermostatic Switch Radiator Air Ventilated Tube Water Inlet Hose Fuel Tank Water Outlet Hose...
- Page 17 1. GENERAL INFORMATION PEOPLE/PEOPLE S 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...
- Page 18 1. GENERAL INFORMATION PEOPLE/PEOPLE S 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...
- Page 19 1. GENERAL INFORMATION PEOPLE/PEOPLE S 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 1-16...
- Page 20 1. GENERAL INFORMATION PEOPLE/PEOPLE S 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)
- Page 21 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 Battery Battery (+) Cable Battery (-) Cable Fuse Box Ignition 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...
- Page 22 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 People s 250 model Battery Fuse Box Ignition Coil Starter Motor Wire Carburetor Regulator/ Rectifier Fuel Cap Fuel Pump Secondary Air Cleaner Fresh Air Outlet Hose Fuel Tube (Between Fuel Pump and Fuel Filler) Starter Relay C.D.l Unit...
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Page 23: Wiring Diagram
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 WIRING DIAGRAM (PEOPLE 250) 1-20... - Page 24 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 WIRING DIAGRAM (PEOPLE S 250) 1-21...
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Page 25: Troubleshooting
1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 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 carburetor fuel inlet tube, vacuum tube or fuel tube... - Page 26 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel line between fuel tank and carburetor Engine speed Engine speed does Clogged exhaust muffler...
- Page 27 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too rich (turn screw...
- Page 28 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty ignition unit Correct timing Incorrect timing Faulty A.C. generator Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...
- Page 29 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Worn piston pin and connecting rod small Piston noise Excessive carbon build-up in combustion chamber Damaged cam chain tensioner...
- Page 30 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Engine starts but Separated clutch lining motor-cycle does not Damaged driven pulley shaft splines...
- Page 31 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight does not Faulty stop switch Stoplight comes on...
- Page 32 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 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...
- Page 33 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Faulty AC generator Voltage does not Normal voltage Faulty regulator/rectifier increase Faulty battery...
- Page 34 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Probable Cause Inspection/Adjustment Symptom Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Signals operate Signals dim, remain...
- Page 35 1. GENERAL INFORMATION PEOPLE/PEOPLE S 250 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play Front or rear wheel is...