KYMCO People GT 200i Service Manual Download Page 181

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14. STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

14-13

People GT 200i

FRONT FORK

REMOVAL

Remove the handlebar covers. (

2-3)

Remove the steering handlebar. (

15-4)

Remove the front cover. (

2-5)

Remove the front fender cover. (

2-6)

Remove the front wheel. (

15-5)

Remove the front brake caliper. (

15-11)

Remove the front shock absorbers.
Hold the steering stem top cone race and
remove the steering stem lock nut.
Remove the top cone race and remove the
front fork.

Inspect the ball races, cone races and steel
balls for wear or damage. Replace if
necessary.

BOTTOM CONE RACE REPLACEMENT

Remove the bottom cone race using a chisel.

Drive a new bottom cone race into place with
a proper driver.

BALL RACE REPLACEMENT

Drive out the ball races.
Drive in new ball races.

Be careful not to lose the steel balls (26
on top race and 19 on bottom race).

＊

Be sure to drive the ball races into place
completely.

＊

Bottom Ball Race

Be careful not to damage the steering
stem and front fork.

＊

Top Ball Race

Lock Nut Socket

Lock Nut Wrench

Top Cone Race

Summary of Contents for People GT 200i

Page 1: ...T 200i By KWANG YANG Motor Co Ltd 1st Edition July 2010 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300...

Page 2: ...uring methods of electrical equipment Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWAN...

Page 3: ..._________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFO...

Page 4: ...1 GENERAL INFORMATION 1 1 People GT 200i SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

Page 5: ...pe Forced pressure wet sump Oil pump type Inner outer rotor Oil filter type Full flow filtration Oil capacity 1 5 liter Exchanging capacity 1 3 liter Fi injection system Air cleaner type No Paper elem...

Page 6: ...sembly Apply or add designated greases and lubricants to the specified lubrication points When two persons work together pay attention to the mutual working safety Disconnect the battery negative term...

Page 7: ...has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover f...

Page 8: ...crews Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a...

Page 9: ...r surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not...

Page 10: ...sent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gea...

Page 11: ...1 GENERAL INFORMATION 1 8 People GT 200i TORQUE VALUES...

Page 12: ...1 GENERAL INFORMATION 1 9 People GT 200i TORQUE VALUES FRAME...

Page 13: ...embly assembly Thread Protector A120E00029 Protecting the crankshaft s thread Valve Cotter Installer A120E00051 Valve cotter installation Clutch Spring Compressor A120E00053 Clutch disassembly assembl...

Page 14: ...tion points for the frame Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorcycle...

Page 15: ...1 GENERAL INFORMATION 1 12 People GT 200i CABLE HARNESS ROUTING Tilt Switch Ignition Switch ECU Horn Winker Relay Hi Beam Relay Lo Beam Relay ECU Relay Fuel Pump Relay Tilt Switch...

Page 16: ...1 GENERAL INFORMATION 1 13 People GT 200i Oil Controller Tilt Switch Front Brake Hose...

Page 17: ...1 GENERAL INFORMATION 1 14 People GT 200i ISC Throttle Body TPS Injector MAP Sensor...

Page 18: ...1 GENERAL INFORMATION 1 15 People GT 200i Regulator Rectifier Ignition Coil Fuel Pump...

Page 19: ...ECU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck o...

Page 20: ...cleaner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct 5...

Page 21: ...trol orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating...

Page 22: ...egulator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or int...

Page 23: ...Camshaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steerin...

Page 24: ...__________________________________________________ ________________________________________________________________________________ ____________________________________________________________________...

Page 25: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 People GT 200i SCHEMATIC DRAWING...

Page 26: ...joint claws may be damaged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler lock bolt 35 N m Exhaust muffler joint lock nut 20 N m TROUBLESH...

Page 27: ...hing the met in box Remove the met in box Remove the four bolts attaching the rear carrier Remove the rear carrier FRAME BODY COVER REMOVAL Remove the two nuts attaching the rear protective cover Remo...

Page 28: ...over 2 3 Remove the four bolts attaching the floorboard Remove the floorboard The installation sequence is the reverse of removal LEG SHIELD REMOVAL Remove the met in box Remove the body cover Remove...

Page 29: ...shield Remove the two screws and four bolts attaching the handlebar rear cover Remove the handlebar rear cover The installation sequence is the reverse of removal Remove the two screws attaching the h...

Page 30: ...m joint in the exhaust muffler Remove the exhaust muffler two lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar The installation sequence is the reverse of remov...

Page 31: ...__________________________________________________ INSPECTION ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3...

Page 32: ...ear the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6 mm Spark plug NGK CR7E Spark plug gap 0 6 mm 0 7 mm Valve clearance IN 0 10 mm EX 0 10 mm Idle speed 1600 10...

Page 33: ...3 INSPECTION ADJUSTMENT 3 2 People GT 200i...

Page 34: ...tment of the throttle grip free play is made with the adjusting nut at the throttle body side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting...

Page 35: ...recommended oil through the oil filler hole OIL CAPACITY Engine oil capacity 1 5 L Engine oil exchanging capacity 1 3 L Engine Oil Viscosity SAE 5W50 OIL FILTER SCREEN INSPECTION Drain the engine oil...

Page 36: ...gine is at the normal operating temperature with the scooter In an upright position If the coolant level is below the LOWER level mark remove the left floor mat remove the lid screw the reserve tank l...

Page 37: ...rk plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7E Measure the spark plug...

Page 38: ...rm up the engine before compression test Remove the center cover and luggage box Remove the spark plug Insert a compression gauge Open the throttle fully and push the starter button to test the compre...

Page 39: ...w Transmission fluid type SAE 90 Transmission fluid capacity 0 23 L Transmission fluid exchanging capacity 0 20 L Install the transmission filler bolt and tighten it to the specified torque DRIVE BELT...

Page 40: ...e limit Check if the brake pad wear exceeds the wear indicator line BRAKE FLUID Turn the steering handlebar upright and check if both brake fluid levels is at the upper limit If the brake fluid is ins...

Page 41: ...hem several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Each shock absorber 4 on your scooter has 5 spring preload adjustment positions for different load or...

Page 42: ...kg cm Rear 1 75 kg cm 2 25 kg cm Tire Size Front 110 70 16 Rear 140 70 16 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the s...

Page 43: ...ride the scooter when the side stand is down Perform the following side stand inspection INTERLOCK FUNCTION CHECK Check the side stand ignition cut off system 1 Place the scooter on its center stand 2...

Page 44: ...4 4 LUBRICATION SYSTEM 4 0 SERVICE INFORMATION 4 1 TROUBLESHOOTING ENGINE OIL OIL FILTER OIL PUMP 4 4 4 1 4 People GT 200i Oil filter Dipstick Oil pump chain Oil pump OIL FILTER REPLACEMENT 4 3...

Page 45: ...ine Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its servicelimit Aftertheoilpumpisinstalled check each part foroilleaks TROUBLESHOOTING Oillevelto...

Page 46: ...n more easily while the engine is warm Remove the oil filter screen cap located on the bottom of the engine to drain the engine oil thoroughly Check the engine oil level each day before riding your sc...

Page 47: ...right under crankcase cover Oil Filter Cap The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Spring Install a new oil filt...

Page 48: ...ins Remove the starter idle gear andstarterclutch Remove thetwo bolts andoil separatorcover 4 LUBRICATION SYSTEM REMOVAL Dowel Pins Remove the oil pump driven gear clip to remove theoilpumpdriven gear...

Page 49: ...tighten the two mounting bolts 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 bolts Installth...

Page 50: ..._________________________________________________________________________ __________________________________________________________________________________ ___________________________________________...

Page 51: ...et Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil ca...

Page 52: ...Disconnect the O2 sensor connector Disconnect the throttle cables Disconnect the Regulator Rectifier connector Disconnect the starter relay wire from starter motor Disconnect the fuel hose from fuel...

Page 53: ...xle nut 2 Torque 12 0 kgf m 120 N m Remove two bolts 3 attaching to rear brake hose clamps Torque 3 2 kgf m 32 N m Disconnect the Regulator Rectifier connector 5 Disconnect the ignition pulse generato...

Page 54: ...ON 5 4 People GT 200i Remove the spark plug cap Disconnect the lower radiator hose from lower radiator pipe Remove the right and left rear cushion lower mount bolts Torque 4 0 kgf m 40N m Spark Plug C...

Page 55: ...tallation is in the reverse order of removal After installation inspect and adjust the following Throttle grip free play Fill the cooling system with coolant and start the engine to bleed air from the...

Page 56: ...unt nut and pull it out Remove the left right engine hanger mount bolt Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts t...

Page 57: ...6 CYLINDER HEAD VALVES 6 1 People GT 200i SCHEMATIC DRAWING...

Page 58: ...After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse orde...

Page 59: ...e stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve...

Page 60: ...er hose to air cleaner Remove the cylinder head cover four bolts Remove the cylinder head cover CAMSHAFT REMOVAL Remove the injector and inlet pipe Remove two screws attaching the thermostat Turn the...

Page 61: ...ttaching to the cylinder head Remove two bolts attaching to the camshaft gear Remove the camshaft gear from the cam chain Remove the set plate located beside the rocker arm shaft Diagonally loosen the...

Page 62: ...ave excessive play CYLINDER HEAD REMOVAL Remove the muffler Remove the throttle body Drain the coolant from the radiator and water hose then remove the thermostat water hose Remove the camshaft Remove...

Page 63: ...ace CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor Valve spring compressor E040 Remove carbon deposits fr...

Page 64: ...all the valve spring seats and 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 Install the valve spring Valve s...

Page 65: ...e cylinder head Install the camshaft Install the intake valve rocker arm and the rocker arm shafts CAMSHAFT INSTALLATION Install the set plate to prevent the rocker arm shaft from pull out Torque 1 2...

Page 66: ...lign two bolts on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear Install the thermostat bolt Torque 1...

Page 67: ...st the valve clearance Install a new cylinder head cover O ring and install the cylinder head cover Install the inlet pipe Install the injector Install and tighten the cylinder head cover bolts Be sur...

Page 68: ...________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLIN...

Page 69: ...7 CYLINDER PISTON 7 1 People GT 200i SCHEMATIC DRAWING...

Page 70: ...from bottom of skirt Piston to cylinder clearance 0 010 0 040 0 1 Piston pin hole I D 15 002 15 008 15 04 Piston pin O D 14 994 15 000 16 96 Piston to piston pin clearance 0 002 0 014 0 02 Connecting...

Page 71: ...asket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Water Hose Dowel Pins Cam Chain Guide Gasket C...

Page 72: ...oove clearance Service Limits Top 0 09 mm replace if over 2nd 0 09 mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Servi...

Page 73: ...o the piston pin in both X and Y directions Service Limit 66 10 mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1 mm repair or replace if over The true roundness...

Page 74: ...ton rings onto the piston Apply engine oil to each piston ring Be careful not to damage the piston and piston rings during assembly All rings should be installed with the markings facing up After inst...

Page 75: ...in clip CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Be careful not to drop foreign matters into the crankcase Position the piston IN mark on the intake valv...

Page 76: ...chain guide Install the cylinder head gasket and dowel pins Connect the water hose to the cylinder Install the cylinder head Tighten the cylinder base bolt Insert the tab on the cam chain guide into...

Page 77: ..._____________________________________ ________________________________________________________________________________ ________________________________________________________________________________...

Page 78: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 1 People GT 200i SCHEMATIC DRAWING...

Page 79: ...4 0 2 0 Clutch outer I D 152 1 152 2 152 2 Weight roller O D 19 92 20 08 20 TORQUE VALUES Drive face nut 9 5 kgf m 93 1 N m Apply oil Clutch outer nut 5 5 kgf m 54 N m Clutch drive plate nut 5 5 kgf...

Page 80: ...xcessive play DRIVE PULLEY DRIVE PULLEY FACE REMOVAL Remove the left crankcase cover Hold the drive pulley using a universal holder and remove the drive face nut and washer Remove the drive pulley fac...

Page 81: ...a new belt at every 20 000km MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face clutch outer driven pulley and belt Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY R...

Page 82: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 5 People GT 200i INSPECTION Check each weight roller for wear or damage Check the movable drive face bushing for wear or damage ASSEMBLY...

Page 83: ...the movable drive face INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 153 5 mm replace if over Check the clutch shoes for wear or damage Measure the...

Page 84: ...E033 Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Pull out the guide roller pins and guide rollers Remove the movable driven face from...

Page 85: ...ve the inner needle bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the d...

Page 86: ...V BELT 8 9 People GT 200i Press a new needle bearing into the driven face CLUTCH DISASSEMBLY Remove the clips and retainer plate to disassemble the clutch Keep grease off the clutch linings Clips Ret...

Page 87: ...nstall the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the clips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease...

Page 88: ...h assembly onto the clutch spring compressor Compress the tool and install the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 75 N m Clutch Sprin...

Page 89: ...tall washer and the clutch outer nut Hold the clutch outer with the universal holder to tighten clutch outer nut Torque 54 N m Universal HolderE017 Install the drive pulley face washer and drive face...

Page 90: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 13 People GT 200i Install the left crankcase cover Left Crankcase Cover...

Page 91: ..._______________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL...

Page 92: ...9 FINAL REDUCTION 9 1 People GT 200i SCHEMATIC DRAWING...

Page 93: ...ion SPECIFICATIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 23 liter At change 0 20 liter TORQUE VALUES Transmission case bolt 0 8 1 2 kgf m 9 8 N m Oil check drain bolt 1 8 2 2 kgf m 19 7 N...

Page 94: ...ver Remove the clutch outer driven pulleys Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gaske...

Page 95: ...e shaft and gear for wear or damage Check the transmission case covers bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Drive Shaft Bearing Countershaft Bear...

Page 96: ...he reverse order of removal Torque Transmission case bolt 0 8 1 2 kgf m 9 8 N m After installation fill the transmission case with the specified oil Specified Gear Oil SAE90 Oil Capacity At disassembl...

Page 97: ..._______________________________________________________________ ________________________________________________________________________________ A C GENERATOR STARTER CLUTCH __________________________...

Page 98: ...10 A C GENERATOR STARTER CLUTCH 10 1 People GT 200i SCHEMATIC DRAWING...

Page 99: ...oolant Remember to bleed air from the water hose SPECIFICATIONS Engine oil SAE 5W 50 API SJ above Oil capacity at change 1 3 Liter Coolant capacity Radiator capacity 0 766 liter Hose with cool coolant...

Page 100: ...hing the right crankcase cover and the cover Remove the bolt between water pump cover and oil filter Remove right crankcase cover STATOR REMOVAL Remove two screws attaching the pulsar coil Remove thre...

Page 101: ...move the flywheel nut and washer Flywheel holder E021 Remove the flywheel with a flywheel puller Flywheel puller E003 STARTER CLUTCH REMOVAL Remove the starter driven gear Remove the starter idle gear...

Page 102: ...lts and oil separator cover Spread the clip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the cam chain Remove the two oil pump bolts to remove the oil pump Bolts...

Page 103: ...wear or damage Measure the starter driven gear I D and O D Service Limits I D 22 15mm replace if over O D 41 50mm replace if below Inspect the starter idle gear and shaft for wear or damage Inspect th...

Page 104: ...w of oil pump is upside Install cam chain Install the pump drive chain and driven gear then set the clip securely on the pump shaft Install the oil separator cover properly Cam Chain Arrow Mark Fit th...

Page 105: ...key on the crankshaft with the groove in the flywheel Install washer and nut Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 5 5 6 5 kgf m 58 8 N m Remove the flywheel...

Page 106: ...o dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten 12 bolts attaching to right crankcase cover Conn...

Page 107: ...______________________________________ ________________________________________________________________________________ ________________________________________________________________________________...

Page 108: ...11 CRANKCASE CRANKSHAFT 11 1 People GT 200i SCHEMATIC DRAWING...

Page 109: ...aced in pair The following parts must be removed before separating the crankcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rea...

Page 110: ...ankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the engine oil screen Remove the crankshaft from the left crankcase Never use a d...

Page 111: ...INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6 mm replace if over Measure the connecting rod small end I D Service Limit 17 06 mm replace if over Measure the crankshaft...

Page 112: ...l and tighten the right and left crankcase attaching bolts Install the engine oil screen Install the right crankcase squarely and do not tap it with an iron or plastic hammer Avoid damaging the oil se...

Page 113: ..._________________ _________________________________________________________________________________ _________________________________________________________________________________ COOLING SYSTEM ___...

Page 114: ...12 COOLING SYSTEM 12 1 People GT 200i SCHEMATIC DRAWING...

Page 115: ...cooling system tester TORQUE VALUES Water pump impeller 1 0 1 4 kgf m 11 8 N m Water pump cover bolt 1 0 1 4 kgf m 11 8 N m TROUBLESHOOTING Engine temperature too high Coolant leaks Faulty temperatur...

Page 116: ...050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1 095 1 093 1 091 1 088 1 085 1 082 1 079 1 076...

Page 117: ...ef Pressure 0 9 0 15 kg cm Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connector...

Page 118: ...ystem 1 Start the engine and allow it to run until there are no air bubbles in the coolant and the level stabilizes 2 Open the air vent tube to see the hot coolant flow out 3 Stop the engine and add c...

Page 119: ...compressed air If insects are clogging the radiator wash them off Carefully straighten any bent fins REMOVAL Drain the coolant Disconnect the outlet tube of the reserve tank Remove the overflow tube...

Page 120: ...he thermostatic switch wire coupler Remove two bolts nuts on the radiator Remove the radiator RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator Check fan motor b...

Page 121: ...mostatic switch wire Connect the fan motor wire couplers Connect the overflow tube and secure with the tube clamp Fill the radiator with coolant Connect the vent tube to the radiator filler After inst...

Page 122: ...l WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose Remove four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller Inspect the mechanical wat...

Page 123: ...r pump assembly Remove the water pump shaft and inner bearing Remove the water pump shaft outer bearing WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump ass...

Page 124: ...er must be installed to the impeller Install the impeller onto the water pump shaft Torque 1 0 1 4 kgf m 11 8 N m Install two dowel pins and a new gasket Install the water pump cover and tighten the 4...

Page 125: ...nder cover A Drain the coolant Disconnect the thermosensor wire Remove the thermosensor INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the senso...

Page 126: ...rmostat housing halves Remove the thermostat from the thermostat housing INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operat...

Page 127: ...GRAM 13 3 PARTS LOCATION 13 4 TROUBLESHOOTING 13 6 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL 13 7 EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES 13 8 SELF DIAGNOSIS RESET PROCEDURE 1...

Page 128: ...Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed Do not damage the throttle body It ma...

Page 129: ...40 L Hr 294 6 kPa 3 Bar At 20 C 4 F 18 8 K At 40 C 104 F 1 136 K Water temperature sensor resistance At 100 C 212 F 0 1553 K Intake pressure sensor MAP pressure at 1 4 2 V 13 332 kPa 0 13332 kgf cm2 1...

Page 130: ...ch Angle detect sensor ROLL 03 Fuel pump Fuel level unit FP 04 Water temperature sensor WTS sensor 05 Crank position sensor Pulser CPS 06 Oxygen Oxygen heater sensor O2 O2 Heat sensor 08 Inductive ign...

Page 131: ...FUEL INJECTION SYSTEM 13 4 People GT 200i PARTS LOCATION Tilt Switch Ignition Switch ECU Horn Winker Relay Hi Beam Relay Lo Beam Relay ECU Relay Fuel Pump Relay ISC Throttle Body TPS Injector MAP Sens...

Page 132: ...p Clogged fuel filter throttle body Sticking fuel injector needle Faulty fuel pump operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Engine stall har...

Page 133: ...ne has problem the CELP will blink to show the failure codes There re 11 failure codes for the KEHIN system If the vehicle gets more failure codes the CELP will be blinking from a lower number then sh...

Page 134: ...is equal to ten For example one longer blink illumination and two shorter blinks 0 5 second x 2 of the indicator is equal to 12 blinks Follow code 12 If more than a damaged part has occurred the CELP...

Page 135: ...y open the throttle and wait for ten seconds 4 Release the throttle 5 The indicator will blink twice 0 5 second after five seconds quickly 6 Self diagnosis memory data is disappeared after the CELP la...

Page 136: ...r poor connection on ECT Open or short circuit on ECT wire Faulty ECT Engine operates normally 15 P1630 Faulty Tilt switch Roll Faulty Tilt switch voltage range inclined angle 65 0 4 1 4 V Inclined an...

Page 137: ...e or poor connection on fuel pump Open or short circuit on fuel pump wire Faulty fuel pump Engine fail to be operated 45 P0135 Faulty O2 Sensor Heater Faulty O2 sensor heater range 6 7 9 5 Loose or po...

Page 138: ...GT 200i SPARK PLUG ANTI FLOOD When have not failure code occurs and pressing starter switch repeatedly can still not start the engine maybe the spark plug is wet by fuel perform the spark plug anti f...

Page 139: ...en the ECU or the throttle body has been reinstalled It can cause engine stop hard to start engine or rough idling speed The throttle position sensor TPS and idle air bypass valve ISC have to be reset...

Page 140: ...be shown the current battery voltage for a few seconds If there is still battery voltage replace the fuel pump If there is not any battery voltage inspect the following Fuse B 10 A Fuel cut off relay...

Page 141: ...e and ensure the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 lbf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose fr...

Page 142: ...s Connection Black Red Black Connect 12 V battery with the fuel cut off relay connector Connection Blue Black Black There should be continuity only when 12 V battery connected If there is not continui...

Page 143: ...ink 0 4 1 4 V Incline the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage between the following terminals of the tilt switch connector with the...

Page 144: ...reverse order of the removal Do not disconnect or connect the ECU connector during the ignition switch ON it may cause the ECU damaged The throttle position sensor TPS and idle air bypass valve ISC h...

Page 145: ...ition power 19 BATT Battery 2 ROLL Roll sensor Tilt switch 20 3 CRK P Crank pulse sensor 21 MIL Multi indicator lamp ECLP 4 22 TW Water temperature sensor ECT 5 TH Throttle position sensor 23 6 PM Man...

Page 146: ...onnector from the fuel injector Remove the bolt of the fuel injector Take out of the fuel pipe and fuel injector from the Inlet pipe Remove the fuel injector from the fuel pipe Connector Bolt Ensure t...

Page 147: ...ounting bolt FUEL INJECTOR CLEANING PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard 1 6ms ANALYSIS Injector block With some carbons TROUBL...

Page 148: ...ensor and O ring Install a new O ring and WTS sensor Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Connect the WTS sensor connector Fill the cooling system with the...

Page 149: ...rols the fuel injector operation INSPECTION Disconnect the O2 sensor connector Measure the resistance between each White wire terminals of the O2 sensor side connector Standard 7 7 1 2 at 20 C 68 F RE...

Page 150: ...YMCO factory do not disassemble it by a wrong way Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchroniz...

Page 151: ...inal Normal Violet Red Green Pink 5 V Throttle position sensor TPS resistance at 20 C 68 F 3500 6500 REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from...

Page 152: ...e TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the thro...

Page 153: ...the throttle body being careful not to damage the O ring DIAGNOSTIC TOOL CONNECTOR INSPECTION Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure the voltage...

Page 154: ...13 FUELINJECTION SYSTEM 27 13 27 People GT 200i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00...

Page 155: ...power required of tool is connected with 12V battery z For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch z The side stand must be upw...

Page 156: ...INSPECTION PROCEDURE Showing four functions on the screen when switching on power A ECU version Including of model name ECU number identifications number and software version Press the Enter button LG...

Page 157: ...ELINJECTION SYSTEM 13 30 People GT 200i B Press the Down button and then turn to the first page C Press the Enter button to check the DTC failure code LGE6 is for People GT 200i LGE6 is for People GT...

Page 158: ...13 FUELINJECTION SYSTEM 31 13 31 People GT 200i D Press the Enter button E Press the Enter button F Display what s DTC number on this DTC List Press the Enter button and then turn to the previous page...

Page 159: ...13 FUELINJECTION SYSTEM 13 32 People GT 200i G Press the UP button H Press the Enter button and then turn to the previous page with red color I Press the UP button...

Page 160: ...13 FUELINJECTION SYSTEM 13 33 People GT 200i J Press the Enter button and then turn to the first page LGE6 is for People GT 200i LGE6 is for People GT 200i...

Page 161: ...13 FUELINJECTION SYSTEM 13 34 People GT 200i DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button C Choose Load DTC Press the Down button LGE6 is for People GT 200i LGE6 is for People GT 200i...

Page 162: ...13 FUELINJECTION SYSTEM 13 35 People GT 200i D Press the Enter button and the indicator is lighting E Clearing DTC completed if the indicator is off...

Page 163: ...Press the Down twice B Choose Data Analyze Press the Enter button to enter page 01 C Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Down button to...

Page 164: ...Press the Down button to enter page 03 E Down page 03 The measure figures including of Atmosphere pressure Fuel Injector interval and Ignition advance timing Press the Down button to enter page 04 F...

Page 165: ...ng of ISC target ISC step and ISC learn step Press the Down button to enter page 06 H Down page 06 The measure figures including of ISC motor state Press the Down button to enter page 07 I Down page 0...

Page 166: ...rottle Valve being changed or loose 5 Has the vehicle under regular service Is the gas station a good one 6 Is the spark plug the correct model of specified by the vehicle builder Vehicle can not be s...

Page 167: ...nd x 2 of the indicator equals 12 blinks Refer to DTC 12 2 If more than one failure occurs the CELP shows the blinks in the occurred order For example if the indicator blinks 6 times then shows one se...

Page 168: ...__________________________ ________________________________________________________________________________ ________________________________________________________________________________ STEERINGHAN...

Page 169: ...14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 14 1 People GT 200i SCHEMATIC DRAWING...

Page 170: ...e pads and brake disk SPECIFICATIONS Item Standard mm Service Limit mm Axle shaft runout 0 2 Radial 2 0 Front wheel rim runout Axial 2 0 Brake disk thickness 5 0 4 0 Brake disk runout 0 30 Brake calip...

Page 171: ...side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damp...

Page 172: ...and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Remove the handlebar lock nut then take out the bolt and collar Remove...

Page 173: ...aster cylinders FRONT WHEEL REMOVAL Disconnect the speed wire from the front right suspension unit Remove the front axle to pull out the axle Remove the front wheel INSPECTION AXLE RUNOUT Set the axle...

Page 174: ...FRONT WHEEL BEARING Remove the side collar and 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...

Page 175: ...ance collar Drive in the right bearing Special Tools Oil seal Bearing Driver E014 INSTALLATION Insert the axle and tighten the axle nut Torque 65 N m Do not allow the bearings to tilt while driving th...

Page 176: ...ove the brake lever bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master cylinder Clean t...

Page 177: ...and 2nd rubber cups for wear ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and snap ring Install t...

Page 178: ...er to avoid spilling brake fluid connect a transparent hose to the bleed valve Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air...

Page 179: ...pin and tighten them Install the brake caliper to the shock absorber and tighten the two bolts Torque 35 N m Connect the brake fluid tube with the attaching bolt and two sealing washers to the brake c...

Page 180: ...ber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers INSTALLATION Install the front shock absorbers onto the front fork Install and tighten the front shock absorber u...

Page 181: ...ut Remove the top cone race and remove the front fork Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race...

Page 182: ...and then turn the steering stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 63...

Page 183: ...___________________________________________ ________________________________________________________________________________ ___________________________________________________________________________...

Page 184: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 People GT 200i SCHEMATIC DRAWING...

Page 185: ...ter cylinder piston O D 26 95 26 90 TORQUE VALUES Exhaust muffler lock bolt 35 N m Exhaust muffler pipe nut 20 N m Rear axle nut 140 N m Rear shock absorber lower mount bolt 40 N m Rear shock absorber...

Page 186: ...aliper INSPECTION Inspect the brake pads and brake disk Measure the brake disk thickness Service Limit 4 0 mm replace if below Visually check the brake pad thickness and it should not exceed the wear...

Page 187: ...e the exhaust muffler 2 10 Remove the rear brake caliper 16 3 Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork The installation...

Page 188: ...place if over Axial 2 0mm replace if over INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 40 N m Rear axle nut 140 N m REAR SHOCK ABSORBER...

Page 189: ...is possible to adjust rear cushion in three positions A position soft B position medium C position hard When adjusting rear cushion the spring preload of rear cushions must be the same Standard sprin...

Page 190: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATT...

Page 191: ...16 BATTERY CHARGING SYSTEM 16 1 People GT 200i CHARGING SYSTEM LAYOUT AC Generator Battery Regulator Rectifier...

Page 192: ...ould be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not...

Page 193: ...ttery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or...

Page 194: ...isconnect the positive terminal lead Remove the battery from the battery box BATTERY INSTALLATION Install in the reverse order of the removal VOLTAGE INSPECTION Remove the battery cover Measure the ba...

Page 195: ...orming this test Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make ab...

Page 196: ...ctifier connectors Check the connectors for loose contacts of corroded terminals BATTERY WIRE Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all...

Page 197: ...regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity REMOVAL INSTALLATION Remove the side body cover...

Page 198: ...______________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM...

Page 199: ...17 IGNITION SYSTEM 17 1 People GT 200i IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Ignition Coil Ignition Switch Tilt switch...

Page 200: ...ower engine cranking speed as well as no spark at the spark plug Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS Item Stan...

Page 201: ...ITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 Primary coil 3 57 4 83 Secondary coil with plug cap 15 19 K Secondary c...

Page 202: ...rtical as shown at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the tilt switch 65 10 degree...

Page 203: ...200i REMOVAL INSTALLATION Disconnect the connector and remove two screws then remove tilt switch Installation is in the reverse order of removal Tighten the mounting screws securely Install the tilt...

Page 204: ..._________________________________________________ ________________________________________________________________________________ _____________________________________________________________________...

Page 205: ...18 STARTING SYSTEM 18 1 People GT 200i STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Ignition Switch...

Page 206: ...ounting bolt 6 7 10 8 N m Starter motor case screw 2 9 4 9 N m Starter clutch bolt 9 8 13 7 N m SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING Starter motor won t turn Lack of...

Page 207: ...goes to the starter relay and relax cable band to disconnect the starter motor cable Remove two start motor mounting bolts and the motor Before removing the starter motor turn the ignition switch OFF...

Page 208: ...e continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric meter to the starter relay...

Page 209: ...________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES __...

Page 210: ...LIGHTS SWITCHES FUEL PUMP 19 1 People GT 200i ELECTRICAL EQUIPMENT LAYOUT Tilt Switch Ignition Switch Horn Winker Relay Hi Beam Relay Lo Beam Relay ECU Relay Fuel Pump Relay Oil Controller Winker Rel...

Page 211: ...led on the scooter Route the wires and cables properly after servicing each component TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON correctly Bur...

Page 212: ...OVAL Remove the handle cover Disconnect the headlight connector from the headlight bulb INSTALLATION Install a new bulb into the headlight case Install the headlight and connect the headlight connecto...

Page 213: ...remove it then replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL LIGHT Remove the seat and met in Remove the body covers Remove the tailligh...

Page 214: ...be continuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front cover Disconnect...

Page 215: ...WITCH INSPECTION Remove the handle cover Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wire...

Page 216: ...ween the color code wires as follows AUXILIARY OUTLET INSPECTION Open the luggage box Disconnect the auxiliary outlet connector and check for continuity between the switch terminals There should be no...

Page 217: ...e before removing fuel pump or fuel hose Remove the six nuts and fuel unit connectors then remove the fuel hose Check the fuel pump O ring If was damage replace a new one INSPECTION Connect the fuel u...

Page 218: ...ETERS SWITCHES 19 9 People GT 200i Measure the resistance between the Red Black and Green wire of the fuel unit connector Standard at 20 C 68 F Float at full position About 1100 Float at empty positio...

Page 219: ...The side stand switch is located on the side stand Disconnect the side stand switch connector There should be continuity between the Yellow Green and Green with the side stand is up There should be c...

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KYMCO People GT 200i, Service Manual

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