KYMCO PEOPLE S 125 Service Manual
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KYMCO PEOPLE S 125 Service Manual

4t stroke
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KYMCO

SERVICE MANUAL

PEOPLE S 50/125/200
4T STROKE
KYMCO
Overseas Sales Division
Overseas Service Department

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Summary of Contents for KYMCO PEOPLE S 125

  • Page 1: Service Manual

    KYMCO SERVICE MANUAL PEOPLE S 50/125/200 4T STROKE KYMCO Overseas Sales Division Overseas Service Department...
  • Page 2 PEOPLE S 4T By KWANG YANG Motor Co., Ltd. First Edition, JUL 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. 4122-LCD2/3/4-S00...

  • Page 3: Table Of Contents

    PEOPLE S 4T PREFACE This Service Manual describes the TABLE OF CONTENTS technical features and servicing procedures for the KYMCO People S GENERAL INFORMATION 50/125/200 4 STROKE. EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this INSPECTION/ADJUSTMENT manual.
  • Page 4 . GENERAL INFORMATION PEOPLE S 4T GENERAL INFORMATION ENGINE FRAME VIN SERIAL NUMBER ..............1-2 SPECIFICATIONS (50 CC)..................1-3 SERVICE PRECAUTIONS ..................1-6 TORQUE VALUES ....................1-8 TOOLS ........................1-9 LUBRICATION POINTS ..................1-10 CABLE & HARNESS ROUTING ................1-12 WIRING DIAGRAM....................

  • Page 5: General Information

    . GENERAL INFORMATION PEOPLE S 4T ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

  • Page 6: General Information

    . GENERAL INFORMATION PEOPLE S 4T SPECIFICATIONS Name & Model No. PEOPLE S 50 Air cleaner type & No Paper element Overall length (mm) 2010 Fuel capacity 6.7 liters Overall width (mm) Type Overall height (mm) 1300 Piston dia. (mm) Wheel base (mm) 1360 Venturi dia.(mm)
  • Page 7 . GENERAL INFORMATION PEOPLE S 4T SPECIFICATIONS Name & Model No. PEOPLE S 125 Air cleaner type & No Paper element Overall length (mm) 2010 Fuel capacity 6.8 liters Overall width (mm) Type Overall height (mm) 1300 Piston dia. (mm)
  • Page 8 . GENERAL INFORMATION PEOPLE S 4T SPECIFICATIONS Name & Model No. PEOPLE S 200 Air cleaner type & No Paper element Overall length (mm) 2010 Fuel capacity 6.8 liters Overall width (mm) Type Overall height (mm) 1300 Piston dia. (mm) Wheel base (mm) 1350 Venturi dia.(mm)

  • Page 9: Service Precautions

    . GENERAL INFORMATION PEOPLE S 4T SERVICE PRECAUTIONS When taking out the connector, the lock on Make sure to install new gaskets, O-rings, the connector shall be released before circlips, cotter pins, etc. when operation. reassembling. Hold the connector body when connecting When tightening bolts or nuts, begin with or disconnecting it.
  • Page 10 . GENERAL INFORMATION PEOPLE S 4T When fixing the wire harnesses, do not make it contact the parts which will Symbols: generate high heat. The following symbols represent the servicing methods and cautions included in Route wire harnesses to avoid sharp edges this service manual.

  • Page 11: Torque Values

    . GENERAL INFORMATION PEOPLE S 4T TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45～0.6 5mm screw 0.35～0.5 6mm bolt, nut 0.8～1.2 6mm screw, SH bolt 0.7～1.1 8mm bolt, nut 1.8～2.5 6mm flange bolt, nut 1.0～1.4 10mm bolt, nut 3.0～4.0...

  • Page 12: Tools

    . GENERAL INFORMATION PEOPLE S 4T SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page FLYWHEEL PULLER E002 14-8 LOCK NUT SOCKET WRENCH E009 16-7 TAPPET ADJUSTER E012 OIL SEAL & BEARING INSTALL E014 11-4,12-5 FLYWHEEL HOLDER E017 9-3,14-10 BEARING PULLER E008 10-4 BEARING PULLER...

  • Page 13: Lubrication Points

    . GENERAL INFORMATION PEOPLE S 4T LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SE, SF or SG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut...
  • Page 14 . GENERAL INFORMATION PEOPLE S 4T 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 15: Cable & Harness Routing

    . GENERAL INFORMATION PEOPLE S 4T CABLE & HARNESS ROUTING Throttle Cable Ignition Switch Front Brake Fluid Tube Horn Instrument Cable Regulator/ Rectifier C.D.I. unit Speedometer Cable 1-12...
  • Page 16 . GENERAL INFORMATION PEOPLE S 4T Throttle Cable Wire Harness C.D.I. unit Throttle Cable Rear Brake Cable Front Brake Fluid Tube 1-13...
  • Page 17 . GENERAL INFORMATION PEOPLE S 4T Ignition Switch Battery (+) Cable Regulator/ Rectifier Speedometer Cable Fuse Wire Harness Battery (-) Cable 1-14...
  • Page 18 . GENERAL INFORMATION PEOPLE S 4T Throttle Cable Ignition Coil A.C. Generator Wire Starter Relay Ground Crankcase Breather Tube Air Injection Cut-off Valve Fuel Valve Vacuum Tube Fuel Tube T.P.S. Auto Bystarter Vacuum Tee 1-15...
  • Page 19 . GENERAL INFORMATION PEOPLE S 4T Auto Bystarter Wire Crankcase Breather Tube Carburetor Vacuum Tee Auto Bystarter Throttle Cable Starter Motor Starter Relay Fuel Tube Fuel Unit Fuel Vapor Tube 1-16...
  • Page 20 . GENERAL INFORMATION PEOPLE S 4T WIRING DIAGRAM(50cc) 1-17...

  • Page 21: Wiring Diagram

    . GENERAL INFORMATION PEOPLE S 4T WIRING DIAGRAM 1-18...
  • Page 22 . GENERAL INFORMATION PEOPLE S 4T WIRING DIAGRAM (always light) 1-19...

  • Page 23: Troubleshooting

    . GENERAL INFORMATION PEOPLE S 4T TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches...
  • Page 24 . GENERAL INFORMATION PEOPLE S 4T ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel tank cap breather hole Engine speed does Engine speed Clogged exhaust muffler not increase increases Faulty auto bystarter...
  • Page 25 . GENERAL INFORMATION PEOPLE S 4T POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fixed position. Check carburetor pilot screw adjustment Mixture too rich (turn screw out)
  • Page 26 . GENERAL INFORMATION PEOPLE S 4T POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil The woodruff key in the crankshaft is not fix position. Check carburetor pilot screw adjustment Improperly adjusted valve Correctly adjusted...
  • Page 27 . GENERAL INFORMATION PEOPLE S 4T POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 28 . GENERAL INFORMATION PEOPLE S 4T NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose spark plug cap...
  • Page 29 . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS ________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------------------------------ 2-1 SERVICE INFORMATION ---------------------------------------------------------------------- 2-2 TROUBLESHOOTING --------------------------------------------------------------------------- 2-2 FRAME COVERS REMOVAL------------------------------------------------------------------ 2-3 EXHAUST MUFFLER REMOVAL ------------------------------------------------------------ 2-6...

  • Page 30: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T SCHEMATIC DRAWING...

  • Page 31: Service Information

    . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T 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 3.3kg-m...

  • Page 32: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T Bolts Nuts FRAME COVERS REMOVAL REAR CARRIER Remove the met-in box. First remove the two bolts and three nuts attaching the met-in box. Remove the met-in box. Carrier Remove the three bolts attaching the rear carrier.

  • Page 33: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T Side Cover FLOOR-FOOT REMOVAL Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them outward. Screws Battery Disconnect the battery wire. Remove the battery. Battery Wire Bolts Remove the floor mat.
  • Page 34 . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T Adjusting Screws FRONT UPPER COVER REMOVAL Remove the six screws on the back of the front upper cover. Remove the bolt and two adjusting screws on the front of the front upper cover. Disconnect the signal light wire connector.

  • Page 35: Exhaust Muffler Removal

    . EXHAUST MUFFLER/FRAME COVERS PEOPLE S 4T Bolt HANDLEBAR COVER REMOVAL First remove the windshield. Remove the four screws and two bolts attaching the handlebar rear cover. Remove the handlebar rear cover. The installation sequence is the reverse of removal. Screws Bolts Remove the three nuts attaching the...
  • Page 36 . INSPECTION/ADJUSTMENT PEOPLE S 4T INSPECTION/ADJUSTMENT SERVICE INFORMATION..................3-1 MAINTENANCE SCHEDULE ................... 3-2 FUEL LINE ........................ 3-3 THROTTLE OPERATION ..................3-3 AIR CLEANER ......................3-4 SPARK PLUG ......................3-4 VALVE CLEARANCE ....................3-5 CARBURETOR IDLE SPEED ................... 3-5 IGNITION TIMING ..................... 3-6 CYLINDER COMPRESSION ..................

  • Page 37: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT PEOPLE S 4T 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 38: Maintenance Schedule

    • In the interest of safety, we recommend these items should 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 39: Fuel Line

    . INSPECTION/ADJUSTMENT PEOPLE S 4T Fuel Filter FUEL LINE Remove the met-in box. ( 2) Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area.

  • Page 40: Air Cleaner

    . INSPECTION/ADJUSTMENT PEOPLE S 4T Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the rear side covers. ( 2) Remove the six air cleaner case cover screws and the cover. Remove the air cleaner element by removing the three screws. Check the element and replace it if it is ex- cessively dirty or damaged.

  • Page 41: Valve Clearance

    . INSPECTION/ADJUSTMENT PEOPLE S 4T Cylinder Head Cover VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the center cover. ( 2) Remove the four cylinder head cover bolts and secondary air inlet tube nuts to remove the cylinder head cover.

  • Page 42: Ignition Timing

    . INSPECTION/ADJUSTMENT PEOPLE S 4T Timing Hole Cap IGNITION TIMING ＊ The CDI unit is not adjustable. If the igni- tion timing is incorrect, check the ignition system. ( 15-6) Remove the rear right side cover. Remove the timing hole cap. Timing Light Check the ignition timing with a timing light.

  • Page 43: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT PEOPLE S 4T Oil Check Bolt FINAL REDUCTION GEAR OIL OIL LEVEL CHECK ＊ Place the motorcycle on its main stand on level ground for oil level check. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole. If the oil level is low, add the recommended oil to the proper level.

  • Page 44: Brake Shoe

    . INSPECTION/ADJUSTMENT PEOPLE S 4T BRAKE SHOE Replace the brake shoes if the arm can not be aligned with the ＞ mark on the brake panel when the brake is fully applied. Refer to page ( 13-4) for brake shoe re- placement.

  • Page 45: Headlight Aim

    . INSPECTION/ADJUSTMENT PEOPLE S 4T HEADLIGHT AIM Turn the ignition switch ON and start the en- gine. Turn on the headlight switch. Adjust the headlight aim by turning the head- light aim adjusting screw. Adjusting Nut SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times.

  • Page 46: Wheels/Tires

    . INSPECTION/ADJUSTMENT PEOPLE S 4T WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. TIRE PRESSURE 1 Rider 2 Riders Front 1.75kg/cm 1.75kg/cm Rear 2.00kg/cm 2.25kg/cm TIRE SIZE...

  • Page 47: Lubrication System

    . LUBRICATION SYSTEM PEOPLE S 4T LUBRICATION SYSTEM SERVICE INFORMATION..................4-2 TROUBLESHOOTING ....................4-2 ENGINE OIL/OIL FILTER ..................4-3 OIL PUMP ......................... 4-3...
  • Page 48 . LUBRICATION SYSTEM PEOPLE S 4T LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Pump...

  • Page 49: Service Information

    . LUBRICATION SYSTEM PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 50: Engine Oil/Oil Filter

    . LUBRICATION SYSTEM PEOPLE S 4T ENGINE OIL/OIL FILTER OIL LEVEL ＊ • Place the motorcycle upright on level ground for engine oil level check. • Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
  • Page 51 . LUBRICATION SYSTEM PEOPLE S 4T Starter Clutch Starter Idle Gear Remove the gasket and dowel pins. Remove the starter idle gear and starter clutch. ( 16-7) Gasket Bolts Remove the two bolts and oil separator cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
  • Page 52 . LUBRICATION SYSTEM PEOPLE S 4T Oil Pump Drive Gear (50cc type) Remove the gasket and dowel pins. Remove the oil pump drive gear nut. Remove the oil pump gear. Oil Pump Gear Bolts Remove the oil pump mounting bolts. Remove the oil pump.
  • Page 53 . LUBRICATION SYSTEM PEOPLE S 4T Pump Body DISASSEMBLY Remove the screw and disassemble the oil pump. Screw Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure the rotor end-to-pump body...
  • Page 54 . LUBRICATION SYSTEM PEOPLE S 4T Inner Rotor ASSEMBLY Screw Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 55 . LUBRICATION SYSTEM PEOPLE S 4T Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft. Install and tighten the pump driven gear nut. Torque: 1.0kg-m Pump Driven Gear Bolts Install the oil separator cover and tighten the bolts.
  • Page 56 . FUEL SYSTEM PEOPLE S 4T FUEL SYSTEM SERVICE INFORMATION..................5-2 TROUBLESHOOTING ....................5-3 CARBURETOR REMOVAL ..................5-4 AUTO BYSTARTER....................5-4 AIR CUT-OFF VALVE....................5-6 VACUUM CHAMBER....................5-6 FLOAT CHAMBER ....................5-7 CARBURETOR INSTALLATION ................5-10 FUEL TANK ......................5-11 FUEL UNIT ......................
  • Page 57 . FUEL SYSTEM PEOPLE S 4T FUEL SYSTEM...

  • Page 58: Fuel System

    . FUEL SYSTEM PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

  • Page 59: Troubleshooting

    . FUEL SYSTEM PEOPLE S 4T TROUBLESHOOTING Engine is hard to start Misfiring during acceleration • No spark at plug • Faulty ignition system • Compression too low • Lean mixture • No fuel to carburetor −Clogged fuel filter Engine idles roughly, stalls or runs poorly −Restricted fuel line •...

  • Page 60: Carburetor Removal

    . FUEL SYSTEM PEOPLE S 4T Auto Bystarter Wire CARBURETOR REMOVAL Remove the frame body cover. ( 2) Disconnect the auto bystarter wire connector. Fuel Tube Loosen the drain screw and drain the fuel from the float chamber. Disconnect the fuel tube and vacuum tube at the carburetor.
  • Page 61 . FUEL SYSTEM PEOPLE S 4T Vacuum Pump Connect a hose to the fuel enriching circuit of the carburetor. Connect the auto bystarter yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal.

  • Page 62: Air Cut-Off Valve

    . FUEL SYSTEM PEOPLE S 4T Air Cut-off valve Cover AIR CUT-OFF VALVE DISASSEMBLY Disconnect the vacuum tube from the air cut- off valve. Remove the two screws to remove the air cut-off valve cover, spring and vacuum diaphragm. Spring Vacuum Diaphragm Screws ASSEMBLY...

  • Page 63: Float Chamber

    . FUEL SYSTEM PEOPLE S 4T Install Push the needle holder in and turn it left to remove the needle holder. Remove the spring and jet needle from the piston. ＊ Be careful not to damage the vacuum diaphragm. Remove Jet Needle INSPECTION Inspect the needle for stepped wear.
  • Page 64 . FUEL SYSTEM PEOPLE S 4T Float Remove the float pin, float and float valve. Float Valve Float Pin INSPECTION Inspect the float valve and valve seat for damage or clogging. Inspect the float valve and valve seat contact area for stepped wear or contamination. ＊...
  • Page 65 . FUEL SYSTEM PEOPLE S 4T Pilot Screw Slow Jet ASSEMBLY Install the slow jet, needle jet, needle jet holder, main jet and pilot screw. ＊ Return the pilot screw to the original position as noted during removal. Standard Opening: 2 3 /8 ± 3 /4 turns 50cc: 1 3 /4 ±...

  • Page 66: Carburetor Installation

    . FUEL SYSTEM PEOPLE S 4T Float Level Gauge FLOAT LEVEL INSPECTION ＊ • Check the operation of the float valve and float before float level inspection. • Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet.

  • Page 67: Fuel Tank

    . FUEL SYSTEM PEOPLE S 4T Fuel Unit Wire Connector FUEL TANK REMOVAL Remove the frame body cover. Disconnect the fuel unit wire connector. Auto Fuel Valve Disconnect the fuel tube and vacuum tube at the auto fuel valve. Vacuum Tube Fuel Tank Remove the fuel tank frame mounting bolts and fuel tank frame.

  • Page 68: Auto Fuel Valve

    . FUEL SYSTEM PEOPLE S 4T Fuel Unit Wire Install the fuel unit. ＊ Make sure the fuel unit wire on the connect position. Connect the fuel unit wire connector. INSTALLATION Inspect the fuel unit gasket for damage. Auto Fuel Valve AUTO FUEL VALVE ＊...

  • Page 69: Air Cleaner

    . FUEL SYSTEM PEOPLE S 4T Bolts AIR CLEANER Loosen the air cleaner connecting tube band screw. Disconnect the transmission case breather tube from the air cleaner case. Remove the two bolts and air cleaner case. Air Cleaner Case The installation sequence is the reverse of removal.

  • Page 70: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION................... 6-2 ENGINE REMOVAL ....................6-3 ENGINE INSTALLATION ................... 6-5...
  • Page 71 . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T 5.0kg-m 5.0kg-m...
  • Page 72 . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • The engine removal operation is required to support the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal. •...
  • Page 73 . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T Auto Bystarter Wire ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. ( 2) Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Disconnect the A.C.G.
  • Page 74 . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable. Rear brake adjusting nut Remove the battery connection wire. Wire Remove the rear shock absorbers mounting bolts. Rear Shock Absorber Bolts Bolts Remove the engine mounting bolt and pull...
  • Page 75 . ENGINE REMOVAL/INSTALLATION PEOPLE S 4T ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger. Remove the engine hanger bracket bolt and nut. Remove the engine. Engine Remove the engine hanger bracket. Inspect the engine hanger bushings and stopper rubbers for wear or damage.
  • Page 76 . CYLINDER HEAD/VALVES PEOPLE S 4T CYLINDER HEAD/VALVES SERVICE INFORMATION..................7-2 TROUBLESHOOTING ....................7-3 CAMSHAFT REMOVAL.................... 7-4 CYLINDER HEAD REMOVAL .................. 7-7 CYLINDER HEAD DISASSEMBLY ................7-8 CYLINDER HEAD ASSEMBLY ................7-10 CYLINDER HEAD INSTALLATION ................ 7-10 CAMSHAFT INSTALLATION ................. 7-11...

  • Page 77: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES PEOPLE S 4T 1.2kg-m 2.0kg-m 0.8kg-m...

  • Page 78: Service Information

    . CYLINDER HEAD/VALVES PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts, valve arm and camshaft sliding surface for initial lubrication. •...

  • Page 79: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES PEOPLE S 4T Standard (mm) Service Limit (mm) Item 125cc 200cc 125cc 200cc － － 0.10 0.10 Valve clearance (cold) － － 0.10 0.10 － － 15 (kg/cm²) 15 (kg/cm²) Cylinder head compression pressure － － － －...

  • Page 80: Troubleshooting

    . CYLINDER HEAD/VALVES PEOPLE S 4T TORQUE VALUES Cam shaft holder nut (125/200cc) 2.0kg-m Apply engine oil to threads Cam shaft holder nut (50cc) 1.4kg-m Apply engine oil to threads Valve clearance adjusting nut 0.9kg-m Apply engine oil to threads TROUBLESHOOTING •...

  • Page 81: Camshaft Removal

    . CYLINDER HEAD/VALVES PEOPLE S 4T Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. Remove the four cylinder head cover bolts and secondary air inlet tube bolts to remove the cylinder head cover. Bolts Bolts O-ring Remove the cam chain tensioner cap screw and the O-ring.
  • Page 82 . CYLINDER HEAD/VALVES PEOPLE S 4T Remove the four cylinder head nuts and washers. ＊ Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins. Dowel Pins Cam Chain Remove the camshaft gear from the cam chain and remove the camshaft.
  • Page 83 . CYLINDER HEAD/VALVES PEOPLE S 4T Camshaft Bearings Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive wear. 5mm Bolt Rocker Arm CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt.

  • Page 84: Cylinder Head Removal

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

  • Page 85: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES PEOPLE S 4T Cylinder Head Remove the two cylinder head bolts. Remove the cylinder head. Bolts Cylinder Head Gasket Dowel Pins Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Cam Chain Guide Remove all gasket remnants from the cylinder surface.
  • Page 86 . CYLINDER HEAD/VALVES PEOPLE S 4T Remove carbon deposits from the combustion chamber. Clean off any gasket remnants from the cylinder head contact surface. ＊ Be careful not to damage the cylinder head mating surface. INSPECTION CYLINDER HEAD Check the spark plug hole and valve hole areas for cracks.
  • Page 87 . CYLINDER HEAD/VALVES PEOPLE S 4T CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals. Lubricate each valve stem with engine oil and insert the valves into the valve guides. Be sure to install new valve stem seals. Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters.

  • Page 88: Camshaft Installation

    . CYLINDER HEAD/VALVES PEOPLE S 4T Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the camshaft onto the...
  • Page 89 . CYLINDER HEAD/VALVES PEOPLE S 4T O-ring Apply engine oil to a new O-ring and install it. Tighten the cam chain tension cap screw. ＊ Be sure to install the O-ring into the groove properly. Cylinder Head Cover Install a new cylinder head cover gasket and install the cylinder head cover.
  • Page 90 . CYLINDER/PISTON PEOPLE S 4T CYLINDER/PISTON SERVICE INFORMATION..................8-2 TROUBLESHOOTING ....................8-2 CYLINDER REMOVAL ..................... 8-4 PISTON REMOVAL ....................8-4 PISTON INSTALLATION ..................8-8 CYLINDER INSTALLATION ..................8-8...
  • Page 91 . CYLINDER/PISTON PEOPLE S 4T Do not bend...

  • Page 92: Cylinder/Piston

    . CYLINDER/PISTON PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. TROUBLESHOOTING •...
  • Page 93 . CYLINDER/PISTON PEOPLE S 4T Item (125cc) Standard (mm) Service Limit (mm) 52.400～52.410 I.D. 52.50 ⎯ Warpage 0.05 Cylinder ⎯ Cylindricity 0.05 ⎯ True roundness 0.05 0.015～0.055 Ring-to-groove 0.09 0.015～0.055 clearance Second 0.09 0.10～0.25 0.10～0.25 Piston, Ring end gap Second ⎯...

  • Page 94: Cylinder Removal

    . CYLINDER/PISTON PEOPLE S 4T Bolt CYLINDER REMOVAL Turn the cam chain tension screw clockwise to tighten it. Remove the two bolts on the cam chain tension. Cylinder Remove the cylinder head. ( 7-7) Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder.
  • Page 95 . CYLINDER/PISTON PEOPLE S 4T 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 96 . CYLINDER/PISTON PEOPLE S 4T Measure the piston pin O.D. 125/200 cc Service Limit: 14.96mm replace if below 50 cc Service Limit: 12.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90° to the piston pin hole. (50cc) Service Limit: 39.9mm replace if below (125cc) Service Limit: 52.3mm replace if...
  • Page 97 . CYLINDER/PISTON PEOPLE S 4T 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. 125/200cc Service Limit: 15.06mm replace if over 50cc Service Limit: 13.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.

  • Page 98: Piston Installation

    . CYLINDER/PISTON PEOPLE S 4T PISTON INSTALLATION Remove any gasket remnant from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Piston Pin Piston Install the piston, piston pin and a new piston pin clip. ＊...

  • Page 99: Drive And Driven Pulleys/Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T DRIVE AND DRIVEN PULLEYS/KICK STARTER SERVICE INFORMATION ..................9-2 TROUBLESHOOTING....................9-2 LEFT CRANKCASE COVER..................9-3 DRIVE PULLEY ......................9-3 CLUTCH/DRIVEN PULLEY..................9-7 KICK STARTER...................... 9-14...
  • Page 100 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T 5.5kg-m 5.5kg-m 5.5kg-m...

  • Page 101: Service Information

    . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T 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 102: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Step LEFT CRANKCASE COVER REMOVAL Remove the bar assembly right rear step. Screw Left Crankcase Cover Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Bolts Starting Ratchet Drive Pulley Face...
  • Page 103 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 19.0mm replace if below 50cc 17.0mm replace if below ＊ Use specified genuine parts for replace- ment.
  • Page 104 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 17.4mm replace if below 50cc 12.4mm replace if below Measure the movable drive face bushing I.D. Service Limit: 24.06mm replace if over 50cc 20.06mm replace if over Check the drive pulley bushing for wear or...
  • Page 105 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Ramp Plate Install the ramp plate.
  • Page 106 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly INSPECTION Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.
  • Page 107 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor Set the clutch spring compressor in a vise and remove the clutch drive plate nut.
  • Page 108 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Oil Seal Remove the oil seal from the movable driven face. INSPECTION Measure the driven face spring free length. Service Limit: 163.7mm replace if below 50cc 92.8mm replace if below Check the driven face for wear or damage.
  • Page 109 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face. ＊ Discard the removed bearing and replace with a new one. Outer Bearing Remove the snap ring and drive the outer bearing out of the driven face.
  • Page 110 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T CLUTCH / DRIVEN PULLEY ASSEMBLY 9-11...
  • Page 111 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Clutch Weights/Shoes Retainer Plate 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 112 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut. Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque.
  • Page 113 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Circlip KICK STARTER REMOVAL Remove the left crankcase cover. ( 9-2) Remove the seal rubber and dowel pins. Remove the kick lever. Remove the circlip and washer from the kick starter spindle.
  • Page 114 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T Starter Driven Gear Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage. Friction Spring Kick Starter Spindle Forcing Part Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage.
  • Page 115 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER PEOPLE S 4T STARTER PINION(50cc) REMOVAL Remove the left crankcase cover. Remove the drive pulley. Remove the starter pinion holder. Remove the starter pinion. INSPECTION Inspect the starter pinion shaft forcing part for wear or damage. Inspect the starter pinion for smooth Starter Pinion operation.
  • Page 116 . FINAL REDUCTION PEOPLE S 4T FINAL REDUCTION SERVICE INFORMATION..................10-2 TROUBLESHOOTING .................... 10-2 FINAL REDUCTION DISASSEMBLY ..............10-3 FINAL REDUCTION INSPECTION ................. 10-3 BEARING REPLACEMENT ..................10-4 FINAL REDUCTION ASSEMBLY ................10-5 10-0...
  • Page 117 . FINAL REDUCTION PEOPLE S 4T 10-1...
  • Page 118 . FINAL REDUCTION PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.181 liter, 50cc 0.12liter At disassembly : 0.21 liter, 50cc 0.09liter TORQUE VALUES...

  • Page 119: Final Reduction

    . FINAL REDUCTION PEOPLE S 4T FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear wheel. ( 13-2) Remove the rear brake cable. ( 13-3) Remove the left crankcase cover. ( 9-2) Remove the clutch/driven pulley. ( 9-8) Drain the transmission gear oil into a clean container.
  • Page 120 . FINAL REDUCTION PEOPLE S 4T Final Shaft Bearing Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Oil Seal Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage.
  • Page 121 . FINAL REDUCTION PEOPLE S 4T Bearing Remover, 17mm BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing remover. Pilot Drive new bearings into the left crankcase. Install a new drive shaft oil seal.
  • Page 122 • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage. Specified Gear Oil: KYMCO SIGMA GEAR OIL SAE 90# Drain Bolt Oil Capacity: At disassembly : 0.21 liter, 50cc 0.12liter At change : 0.181 liter, 50cc 0.09liter...

  • Page 123: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT PEOPLE S 4T CRANKCASE/CRANKSHAFT SERVICE INFORMATION..................11-2 TROUBLESHOOTING .................... 11-2 CRANKCASE SEPARATION ................. 11-3 CRANKSHAFT INSPECTION ................. 11-4 CRANKCASE ASSEMBLY ..................11-4 11-0...
  • Page 124 . CRANKCASE/CRANKSHAFT PEOPLE S 4T 11-1...
  • Page 125 . CRANKCASE/CRANKSHAFT PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. −Cylinder head ( Section 7) −Cylinder/piston ( Section 8) −Drive and driven pulleys ( Section 9) −A.C.
  • Page 126 . CRANKCASE/CRANKSHAFT PEOPLE S 4T CRANKCASE SEPARATION Remove the crankcase attaching two bolts. Separate the left and right crankcase halves. ＊ Do not damage the crankcase gasket surface. Crankcase Bolts Dowel Pins Remove the gasket and dowel pins. Gasket Remove the crankshaft from the left crankcase.
  • Page 127 . CRANKCASE/CRANKSHAFT PEOPLE S 4T Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration. The installation sequence is the reverse of removal. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.55mm replace if over Connecting Rod Big End Turn the crankshaft bearings and check for...
  • Page 128 . CRANKCASE/CRANKSHAFT PEOPLE S 4T Dowel Pins Install the dowel pins and a new gasket onto the left crankcase. ＊ Place the right crankcase over the crankshaft and onto the left crankcase. Gasket Tighten the crankcase attaching two bolts. Torque: 0.9kg-m Crankcase Bolts 11-5...
  • Page 129 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION SERVICE INFORMATION ..................12-2 TROUBLESHOOTING.................... 12-3 FRONT WHEEL ...................... 12-4 HYDRAULIC BRAKE DRAWING................12-7 HYDRAULIC BRAKE ..................... 12-8 FRONT SHOCK ABSORBER ................12-13 STEERING HANDLEBAR ..................12-14 STEERING STEM ....................
  • Page 130 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T 4.5kg-m 6.0kg-m 12-1...

  • Page 131: Front Wheel/Front Brake/Front Suspension

    . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. • During servicing, keep oil or grease off the brake drum and brake linings. •...

  • Page 132: Troubleshooting

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T SPECIAL TOOLS Lock nut wrench Driver handle A Outer driver, 28x30mm Pilot, 10mm Ball race remover Outer driver, 37x40mm Pliers (close) Bearing remover Bearing remover head, 10mm TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •...

  • Page 133: Front Wheel

    . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION FRONT WHEEL REMOVAL Remove the motorcycle front wheel off the ground. Disconnect the speedometer cable. Speedometer Cable Axle Nut Remove the front axle nut and pull out the axle. Remove the front wheel. Remove the front brake panel.
  • Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T Side Collar FRONT WHEEL BEARING Remove the side collar and dust seal. Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub.
  • Page 135 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION Dust Seal Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Pawls INSTALLATION Apply grease to the brake panel dust seal lip. Apply grease to the speedometer gear engaging and sliding parts.

  • Page 136: Hydraulic Brake Drawing

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T HYDRAULIC BRAKE DRAWING 12-7...

  • Page 137: Hydraulic Brake

    . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION HYDRAULIC BRAKE (FRONT BRAKE) BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the brake fluid level on level ground. ＊ • When operating the brake lever, the Lower Limit brake reservoir cap must be tightened securely to avoid splash of brake fluid.
  • Page 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T Fixed-Reed Install the brake pads in the reverse order of removal. Tighten the brake pad pin bolt. Torque: 1.5～2.0kg-m ＊ Keep grease or oil off the brake pads to avoid brake failure. Brake Pads BRAKE DISK Measure the brake disk thickness.
  • Page 139 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION Master Cylinder Main Diaphragm Remove the main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Spring Snap Ring INSPECTION Measure the brake master cylinder I.D.
  • Page 140 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T Bolts Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.
  • Page 141 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION Compressed Air Remove the pistons from the brake caliper. If necessary, use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.

  • Page 142: Front Shock Absorber

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.
  • Page 143 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending or damage. •Weak front shock absorber spring. •Damper and damper rod bending. •Oil seal damage or wear. INSTALLATION Mount Boot Install the front shock absorbers onto the...

  • Page 144: Steering Stem

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T Screw Remove the throttle seat screw. Remove the throttle seat from the handlebar Throttle Pipe and disconnect the throttle cable from the throttle pipe. Remove the throttle pipe from the handlebar. Remove the steering stem lock bolt, collar, nut and the handlebar.
  • Page 145 . FRONT WHEEL/FRONT BRAKE/ PEOPLE S 4T FRONT SUSPENSION Top Cone Race Remove the top cone race. ＊ • Be careful not to lose the steel balls (20 on top race and 15 on bottom race). • Clean the openings of frame covers with clean shop towels.
  • Page 146 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION PEOPLE S 4T Top Steel Ball INSTALLATION Install the top and bottom steel balls. Apply grease to the top and bottom ball races and install 20 steel balls on the top ball race and 15 steel balls on the bottom ball race. Apply grease to the ball races and install the front fork.
  • Page 147 . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SERVICE INFORMATION ..................13-2 TROUBLESHOOTING.................... 13-2 REAR WHEEL ......................13-3 REAR BRAKE ......................13-4 REAR SHOCK ABSORBER................... 13-5 ADJUSTABLE REAR CUSHION ................13-6 13-0...
  • Page 148 . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION 12.0kg-m 1.0kg-m 4.0kg-m 2.7kg-m 3.5kg-m 2.2kg-m 13-1...

  • Page 149: Rear Wheel/Rear Brake/ Rear Suspension

    . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm) Service Limit (mm) ⎯ Radial Rim runout ⎯ Rear wheel Axial Rear brake drum I.D Rear brake lining thickness...
  • Page 150 . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION Link Flake REAR WHEEL REMOVAL Remove the lock nuts on the exhaust muffler joint and exhaust muffler lock bolts. Remove the exhaust muffler. ( 2-6) Remove the rear axle nut. Remove the rear shock absorber. Remove the link flake.
  • Page 151 . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION REAR BRAKE Remove the body cover. ( 2-3) Remove the rear cushion. Remove the rear wheel. ( 13-3) Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limits: 131mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness.
  • Page 152 . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION Brake Arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin. Apply grease to the brake cam and install it. Install the brake shoes. Brake Cam Apply engine oil to the felt seal and install it to Bolt the brake cam.

  • Page 153: Adjustable Rear Cushion

    . REAR WHEEL/REAR BRAKE/ PEOPLE S 4T REAR SUSPENSION Bolt Remove the rear shock absorber upper and lower mount bolts. Remove the rear shock absorber. Bolt Adjust Position ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring prelocad.

  • Page 154: Battery/Charging System

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T BATTERY/CHARGING SYSTEM/A.C. GENERATOR CHARGING SYSTEM LAYOUT ................14-1 SERVICE INFORMATION ..................14-2 TROUBLESHOOTING.................... 14-3 BATTERY ....................... 14-4 CHARGING SYSTEM ..................... 14-5 REGULATOR/RECTIFIER..................14-6 A.C. GENERATOR CHARGING COIL..............14-7 RESISTOR INSPECTION ..................14-7 A.C.
  • Page 155 BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Resistors Regulator/Rectifier Fuse Battery A.C. Generator CHARGING CIRCUIT 14-1...
  • Page 156 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T 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 157 BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T TORQUE VALUES Pulser coil bolt 0.5kg-m Coil lock bolt 0.9kg-m Flywheel nut 5.5kg-m Cooling fan bolt 0.9kg-m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power •...
  • Page 158 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T BATTERY REMOVAL Remove the panel-foot cover screws. Open the cover and remove the battery cover screw. First disconnect the battery negative (-) cable and then the positive (+) cable. ＊ When disconnecting the battery positive (+) cable, do not touch the frame with tool;...
  • Page 159 BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T (-) Terminal CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative (-) terminal and the ground wire. Turn the ignition switch OFF and check for short circuit.
  • Page 160 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Regulator/Rectifier REGULATOR/RECTIFIER MAIN HARNESS CIRCUIT INSPECTION Remove the front cover. ( 2-4) Remove the regulator/rectifier 5P coupler and check for continuity between the wire harness terminals according to the following : Item (Wire Color) Judgement Between battery (red) Battery has...
  • Page 161 BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Charging Coil Wire (Pink) A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 3P connector. Measure the resistance between the A.C. generator Pink wire and yellow with an electric tester.
  • Page 162 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Cooling Fan Remove the cooling fan by removing the cooling fan attaching four bolts. Bolts Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 163 BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Wire Set Plate Remove the A.C. generator wire set plate. Remove the pulser coil bolts. Remove the A.C. generator wire rubber sleeve and pulser coil from the right crankcase. Remove the two bolts and A.C. generator stator.
  • Page 164 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR PEOPLE S 4T Woodruff Key Connect the A.C. generator wire connector. Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
  • Page 165 . IGNITION SYSTEM PEOPLE S 4T IGNITION SYSTEM SERVICE INFORMATION ..................15-2 TROUBLESHOOTING.................... 15-3 CDI UNIT INSPECTION..................15-4 IGNITION COIL....................... 15-5 PULSER COIL ......................15-6 15-0...
  • Page 166 . IGNITION SYSTEM PEOPLE S 4T Ignition Switch CDI Unit Battery Spark Plug Pulser Coil A.C. Generator IGNITION CIRCUIT 15-1...
  • Page 167 . IGNITION SYSTEM PEOPLE S 4T 50cc SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 15) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. •...

  • Page 168: Ignition System

    . IGNITION SYSTEM PEOPLE S 4T SPECIFICATIONS Item Standard Standard type C7HSA(NGK) Spark plug Hot type C6HSA(NGK) Cold type C8HSA(NGK) Spark plug gap 0.6～0.7mm “F” mark 15°BTDC/1,700±100rpm Ignition timing Full advance 28°BTDC/5,000±100rpm Primary coil 0.1～1.0Ω Ignition coil resistance (20℃) Secondary with plug cap 7～12KΩ...
  • Page 169 . IGNITION SYSTEM PEOPLE S 4T CDI Unit CDI UNIT INSPECTION Remove the front cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester. ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.
  • Page 170 . IGNITION SYSTEM PEOPLE S 4T IGNITION COIL REMOVAL Remove the frame body cover. ( 2) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. Ignition Coil INSPECTION CONTINUITY TEST ＊...
  • Page 171 . IGNITION SYSTEM PEOPLE S 4T PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2) Disconnect the A.C. generator connector. Measure the pulser coil resistance between the blue/yellow and green wire terminals. Resistance: 70～130Ω/20℃...
  • Page 172 . STARTING SYSTEM PEOPLE S 4T STARTING SYSTEM SERVICE INFORMATION ..................16-2 TROUBLESHOOTING.................... 16-2 STARTER MOTOR ....................16-3 STARTER RELAY ....................16-5 STARTER CLUTCH....................16-6 16-0...
  • Page 173 . STARTING SYSTEM PEOPLE S 4T Stop Switches Starter Button Starter Relay Starter Motor STARTING CIRCUIT 16-1...

  • Page 174: Starting System

    . STARTING SYSTEM PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to Section 4. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Starter motor brush length 12.5 TORQUE VALUES...
  • Page 175 . STARTING SYSTEM PEOPLE S 4T Starter Motor Cable 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 176 . STARTING SYSTEM PEOPLE S 4T STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary.
  • Page 177 . STARTING SYSTEM PEOPLE S 4T Front Cover ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.
  • Page 178 . STARTING SYSTEM PEOPLE S 4T STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 179 . STARTING SYSTEM PEOPLE S 4T Remove the starter clutch lock nut. Special Lock Nut Wrench Universal Holder ＊ Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft. Lock Nut Lock Nut Wrench INSPECTION Inspect the operation of the starter drive gear...
  • Page 180 . STARTING SYSTEM PEOPLE S 4T Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Clutch Cover Starter Idle Gear Measure the starter idle gear I.D. Service Limit: 10.05mm replace if over Measure the starter idle gear shaft O.D. Service Limit: 9.94mm replace if below Idle Gear Shaft Plunger...
  • Page 181 . STARTING SYSTEM PEOPLE S 4T Anchor Pin Clutch Cover ASSEMBLY Install the springs, plungers and rollers onto the clutch body. Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body. Apply locking agent to the threads of the clutch cover bolts and tighten them.

  • Page 182: Lights

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T LIGHTS/INSTRUMENTS/SWITCHES ELECTRICAL EQUIPMENT LAYOUT................ 17-1 SERVICE INFORMATION ..................17-2 TROUBLESHOOTING.................... 17-2 HEADLIGHT ......................17-3 FRONT TURN SIGNAL LIGHT................17-3 TAIL LIGHT/REAR TURN SIGNAL LIGHT..............17-3 IGNITION SWITCH ....................17-4 HANDLEBAR SWITCH ..................17-4 STOP SWITCH ....................... 17-6 HORN........................

  • Page 183: Lights/Instruments/Switches

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Turn Signal Switch Dimmer Switch Auto Bystarter Starter Button Resistor Fuel Unit Horn Button Horn Auto Bystarter Ignition Switch 17-1...
  • Page 184 . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment. • Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment. •...

  • Page 185: Front Turn Signal Light

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T Bulb Socket HEADLIGHT BULB REPLACEMENT Remove the handlebar front cover. ( 2) Remove the rubber boot from the bulb socket. Remove the bulb socket by turning it counter- clockwise. Remove the bulb for replacement. Install a new bulb, aligning the groove on the bulb socket with the tab on the bulb.

  • Page 186: Ignition Switch

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T Ignition Switch Coupler IGNITION SWITCH INSPECTION Remove the front cover. ( 2-4) Disconnect the ignition switch wire coupler. Check for continuity between the wire terminals. Front Luggage Box Cable Seat Cable Replacement Remove the two mounting bolts to remove the ignition switch holder.
  • Page 187 . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T Green Yellow/Red STARTER SWITCH Starter Switch HORN SWITCH Light Green Green Green Horn Button Turn Signal Switch TURN SIGNAL SWITCH Orange Sky Blue Gray DIMMER SWITCH White Dimmer Switch Black Blue Blue/White 17-5...
  • Page 188 . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T STOP SWITCH INSPECTION Remove the handlebar front cover. ( 2) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied. The switch is normal if there is continuity.

  • Page 189: Auto Bystarter

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T INSPECTION Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions. Unit: Ω RESISTANCES Float Upper Lower Color G～Y/W 5～10 85～105 The installation sequence is the reverse of removal.

  • Page 190: Instruments

    . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T Instruments INSTRUMENTS BULB REPLACEMENT Remove the handlebar rear cover. ( 2) Remove the bulb socket and replace the bulb. The installation sequence is the reverse of removal. Bulb Socket Dimmer/ Speedometer Passing Wires Fuel Gauge Wires Cable INSTRUMENTS REPLACEMENT Remove the handlebar rear cover.
  • Page 191 . LIGHTS/INSTRUMENTS/SWITCHES PEOPLE S 4T DISASSEMBLY Remove the screws to disassemble the instruments. 17-9...
  • Page 192 . EXHAUST EMISSION CONTROL PEOPLE S 4T SYSTEM ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING..................18-1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION ........18-1 TROUBLESHOOTING .................... 18-2 SERVICE INFORMATION..................18-2 SECONDARY AIR CLEANER ................18-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)............18-3 REED VALVE......................

  • Page 193: Exhaust Emission Control System

    . EXHAUST EMISSION CONTROL SYSTEM PEOPLE S 4T SCHEMATIC DRAWING Air Injection Carburetor Cut-off Valve Vacuum Reed Valve Secondary Secondary Air Air Cleaner Cleaner Into Hole EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
  • Page 194 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE S 4T TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
  • Page 195 . EXHAUST EMISSION CONTROL SYSTEM PEOPLE S 4T Secondary Air Cleaner / A.I.C.V. SECONDARY AIR CLEANER / AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL Remove the seat. ( 2-4) Remove the body cover. Disconnect the secondary air cleaner /(A.I.C.V) connecting tube. Air Inlet Tube Air Outlet Tube Vacuum Tube INSPECTION...

  • Page 196: Reed Valve

    . EXHAUST EMISSION CONTROL SYSTEM PEOPLE S 4T Reed Valve Cover Cylinder Head Cover REED VALVE REMOVAL Remove the frame body cover. Remove the floor-foot cover. Disconnect the secondary air inlet tube connector. Remove the reed valve cover three bolts and two secondary air outlet tube bolts.

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