KYMCO People S 250 Service Manual Download Page 181

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14.STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

14-8

PEOPLE 250

FRONT BRAKE

BRAKE MASTER CYLINDER

REMOVAL
Remove the handlebar covers. (

2-3)

First drain the brake fluid from the hydraulic

brake system.

Disconnect the front stop switch wire

connector.

Remove the brake fluid tube bolt.

Remove the two bolts attaching the brake

master cylinder

Remove the brake master cylinder.

DISASSEMBLY
Remove 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 the inside of the master cylinder and

brake reservoir with brake fluid.

Rubber Cover

•

When servicing the brake system, use

shop towels to cover rubber and plastic

parts and coated surfaces to avoid

being contaminated by brake fluid.

•

When removing the brake fluid tube

bolt, be sure to plug the tube end to

avoid brake fluid leakage.

＊

Bolts

Stop Switch Wire Connector

Holder

Main Piston

Snap Ring

Spring

Master Cylinder

Snap Ring Pliers (Close)

Snap Ring

Summary of Contents for People S 250

Page 1: ...0 C 2003 by KWANG YANG Motor Co Ltd First Edition Mar 2003 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 LLJ3 S00 ...

Page 2: ...rt with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 EXHAUST MUFFLER FRAME COVERS 2 INSPECTION ADJUSTMENT 3 LUBRICATION SYSTEM 4 ENGINE REMOVAL INSTALLATION 5 CYLINDER HEAD VALVES 6 CYLINDER PISTON...

Page 3: ..._______________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ SERIAL NUMBER 1 1 SPECIFICATION 1 2 SERVICE PRECAUTIONS 1 3 TORQUE VALUES 1 7 SPECIAL TOOLS 1 8 LUBRICATION POINTS ...

Page 4: ...1 GENERAL INFORMATION 1 1 PEOPLE 250 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number ...

Page 5: ...C 1 Valve Intake 0 1 clearance cold Exhaust 0 1 Idle speed rpm 1700 100rpm Lubrication type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 1 liters Air cleaner type No Paper element wet Fuel capacity 8 0 liters Type CVK Piston dia 30 Venturi dia 30 equivalent Throttle type Butterfly type Type CDI Ignition timing Repeatedly Contact ...

Page 6: ...ine oil before reassembly n Apply or add designated greases and lubricants to the specified lubrication points n After reassembly check all parts for proper tightening and operation n When two persons work together pay attention to the mutual working safety n Disconnect the battery negative terminal before operation n When using a spanner or other tools make sure not to damage the motorcycle surfa...

Page 7: ...truding or loose n The connector shall be inserted completely n If the double connector has a lock lock it at the correct position n Check if there is any loose wire n Before connecting a terminal check for damaged terminal cover or loose negative terminal n Check the double connector cover for proper coverage and installation n Insert the terminal completely n Check the terminal cover for proper ...

Page 8: ...n Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws n Route harnesses so they are neither pulled tight nor have excessive slack n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner n When rubber protecting cover is used to protect the wire harnesses it shall be installed securely n Do not brea...

Page 9: ...thoroughly and operate according to the operating instructions n Be careful not to drop any parts n When rust is found on a terminal remove the rust with sand paper or equivalent before connecting n Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply greas...

Page 10: ...y Thread dia mm Torque N m Remarks Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Cylinder head cap nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt Water pump impeller Drive face nut Transmission case cover bolt Gear oil check bolt ...

Page 11: ...0 8 12 10 8 8 6 8 8 8 40_ 50 29_ 35 110_ 130 35_ 45 35_ 45 29_ 35 45_ 55 45_ 55 29_ 35 29_ 35 10_ 14 18_ 22 32_ 38 29_ 35 SPECIAL TOOLS Tool Name Tool No Remarks Ref Page Clutch spring compressor E034 Clutch disassembly Bearing puller 10 12 15 18mm E037 Bearing removal Valve spring compressor E040 Valve removal Oil seal bearing installer E014 Oil seal bearing install Tappet adjuster E036 Tappet ad...

Page 12: ...necting rod big end Crankshaft Cranksahft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip GenuineKYMCO Engine Oil SAE15W 40 API SE SF or SG Egnine Oil Starter idle gear Friction springmovable part shaft movablepart Shaft movable grooved part Starter spindle m...

Page 13: ...or 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 Seat Lock Grease Engine Oil Grease Front Brake Lever Pivot Speedometer Gear Front Wheel Bearing Grease Rear Fork Bearing Grease Speedometer Cable Throttle Cable ...

Page 14: ...RNESS ROUTING Throttle Cable Front Brake Fluid Tube Speedometer Cable Radiator Air Ventilated Tube to Radiator Rear Brake Fluid Tube Winker Horn DIM Wire Fuel Tank Cap Open Cable Rear Brake Master Cylinder Front Brake Master Cylinder Horn Radiator ...

Page 15: ...rn DIM Wire Start Light ENG Stop Passing Wire Water Outlet Hose Rear Brake Fluid Tube Radiator Air Ventilated Tube Fuel Pump Vacuum Tube Fuel Hose between the Fuel Tank and Fuel Filler Radiator Air Ventilated Tube to Radiator Water Duct Radiator Front Brake Caliper Thermostatic Switch Water Duct Hose Fuel Pump Fuel Pump Outlet Tube Fuel Tank Cap ...

Page 16: ...ed Tube to Raciator Rear Brake Fluid Tube Fuel Tank Inlet Tube Water Inlet Hose Fuel Tank Breather Tube Wire Harness Winker Horn DIM Wire Start Light ENG Stop Passing Wire Front Brake Fluid Tube Fuel Tank Cap Open Cable Radiator Air Ventilated Tube Fan Motor Wire Ignition Switch Fuel Tank Cap ...

Page 17: ...on Coil Thermosensor Wire Thermostat Air Inlet Hose V belt Chamber A C G Starter Relay Wire CDI Unit Fuse Box Fuel Tank Inlet Tube Secondary Air Vacuum Tube Starter Motor wire Wire Harness Seat Open Cable Battery Cable Heater Wire Wire Harness Fuel Pump Vacuum Tube Battery ...

Page 18: ...GENERAL INFORMATION 1 15 PEOPLE 250 Ignition Coil Carburetor Secondary Air Inlet Tube Fuel Pump Wire Harness Fuel Unit Starter Relay Oil Vapor Recovery Tube Heater Control Unit Side Stand Switch Spark Cap ...

Page 19: ...ry Air Cleaner Fresh Air Outlet Hose Ignition Coil Regulator Rectifier Fuse Box Fuel Pump Fuel Unit Carburetor Battery Secondary Air Cleaner Secondary Air Cleaner Fresh Air Inlet Hose Starter Motor Wire Fuel Tube Between Fuel Pump and Fuel Filler ...

Page 20: ...ry Cable CDI Unit Ignition Coil Throttle Cable Wire Harness Auto Bystarter T P S Spark Plug Cap Thermosensor Thermostat Rear Brake Caliper Carburetor Rear Brake Fluid Tube Starter Relay Fuse Box Battery Cable Seat Open Cable Radiator Air Ventilated Tube ...

Page 21: ...1 GENERAL INFORMATION 1 18 PEOPLE 250 WIRING DIAGRAM ...

Page 22: ... piston rings ÖBlown cylinder head gasket ÜFlaws in cylinder head áSeized valve àImproper valve timing ÅFaulty auto bystarter ÇAir leaking through intake pipe ÉIncorrect ignition timing ÑIncorrectly adjusted pilot screw ÅFlooded carburetor ÇFaulty auto bystarter ÉThrottle valve excessively open Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it into spark pl...

Page 23: ...ition timing too early àAir in cooling system ÅExcessive carbon build up in combustion chamber ÇPoor quality fuel ÉClutch slipping ÑMixture too lean Ö Ignition timing too early Start engine and accelerate lightly for observation Inspection Adjustment Symptom Probable Cause Engine speed increases Correct timing Engine speed does not increase sufficiently Incorrect timing Check ignition timing using...

Page 24: ...r ÑFaulty ignition coil ÖBroken or shorted high tension wire ÜFaulty ignition switch ÅDamaged air cut off valve diaphragm ÇDamaged air cut off valve spring Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor air cut off valve Check carburetor gasket for air leaks Che...

Page 25: ...be ÅClean and unclog ÅCam timing gear aligning marks not aligned ÅFaulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel supply Correct timing Incorrect timing Check valve spring tension Check valve clearance Fuel flows freely Fuel flow restricted Correct Incorrect Not clogged Clogged Correctly adjusted Incorrect...

Page 26: ...xcessive carbon build up in combustion chamber ÅDamaged cam chain tensioner ÇWorn cam gear teeth ÉWorn or damaged cam chain ÑExtended cam chain ÅFaulty crankshaft bearing ÇWorn crank pin bearing ÅWorn or damaged final reduction gears ÇWorn final reduction gear shaft splines Valve noise Symptom Probable Cause Crankshaft noise Gear noise Piston noise Cam chain noise ...

Page 27: ...earings ÑWeak driven face spring ÖWorn or seized driven pulley bearings ÅWorn or slipping drive belt ÇWorn weight rollers ÉWorn or seized driven pulley bearings ÅOil or grease fouled drive belt ÇWorn drive belt ÉWeak driven face spring ÑWorn or seized driven pulley bearings Engine starts but motor cycle does not move Engine lacks power at start of a grade poor slope performance Symptom Probable Ca...

Page 28: ...ty starter pinion ÅStarter relay shorted or stuck Inspection Adjustmen t Inspection Adjustmen t Inspection Adjustmen t Symptom Symptom Symptom Check operation of stop switch by applying brake Stoplight does not come on Stoplight comes on Check battery circuit by operating turn signals Check battery circuit by operating turn signals Turn ignition switch OFF Probable Cause Probable Cause Probable Ca...

Page 29: ...nit ÅFaulty ignition coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abnormal Measure resistance between terminals of CDI unit coupler Check related parts Check ignition coil with a CDI unit tester Weak or no spark Not loose Good spark Loose Good Good Check spark p...

Page 30: ...egulator rectifier ÉBroken or poorly connected regulator rectifier black wire ÅLimit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an electric tester Test output voltage of regulator rectifier coupler red wire Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Normal Normal Voltage ...

Page 31: ...om Symptom Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain on or don t operate Signals operate properly Signals dim remain on or don t operate Check battery circuit by operating turn signals Check battery circuit by operating turn signals and horn Prob...

Page 32: ...ng stem nut POOR BRAKE PERFORMANCE ÅWorn brake linings ÇForeign matter on brake linings ÉRough brake drum contacting area ÅWorn brake linings ÇForeign matter on brake linings ÉRough brake drum contacting area ÅWorn brake linings ÇWorn brake cam contacting area on ÅWorn brake linings ÇForeign matter on brake linings ÅSluggish or elongated brake cables ÇBrake shoes improperly contact ÉWater and mud ...

Page 33: ..._________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING 2 1 SERVICE INFORMATION 2 2 TROUBLESHOOTING 2 2 FRAME ...

Page 34: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 35: ...t claws may be damaged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler lock bolt 32_ 38N m Exhaust muffler joint lock nut 18_ 22N m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler Exhaust muffler air leaks ...

Page 36: ... on the back mirror Remove the back mirror HANDLEBAR FRONT COVER REMOVAL Remove one bolt on the handlebar front cover Remove the four screws attaching handlebar rear cover to separate from handlebar rear cover Disconnect all of the wire connectors couplers Remove handlebar front cover Nuts Bolt Screws Wire Connectors ...

Page 37: ...r rear cover Remove the two screws attaching frame Disconnect all of the wire connectors couplers and the speedometer cable Remove the handlebar rear cover FRONT COVER REMOVAL Remove the bolt on the front of the front cover Remove the six screws attaching the leg shield Screw Screw Blot Handlebar Rear Cover Screw Wire Connectors Wire Connectors Speed Wire Screws ...

Page 38: ... the wire couplers Remove the front cover FRONT FENDER A B REMOVAL Remove the two screws that combine front fender A with the front fender B Remove the two screws under the front fender A Remover the front fender A Remover the bolt under front fender B that combine front fender B with frame Remover the front fender B Wire Couplers Screws Bolts Screws Bolts Bolt Front Fender Cover A ...

Page 39: ...e cover MET IN BOX AND REAR CARRIER REMOVAL Open the seat with key Remove two bolts and two nuts on the met in box Disconnect all of the wire couplers Remove met in box Remove three bolts and remove the rear carrier BODY COVER CENTER COVER REAR FENDER A REMOVAL Remove six screws on air cleaner cover Loosen band to remove air cleaner cover and disconnect air duct hose Screws Band Nuts Bolts Wire Co...

Page 40: ...ender A Disconnect all of the wire couplers Remove the body cover center cover and rear fender A together FLOORBOARD REMOVAL Remove the met in box and rear carrier 2 6 Remove the body cover center cover and rear fender A together 2 6 Remove right and left side cover 2 6 Remove the four bolts on the floor board Remove the floor board Screws Screws Bolts Wire Couplers Screws ...

Page 41: ... the body cover center cover and rear fender A together 2 6 Remove the floor board 2 7 Remove the front under cover 2 7 Remove the key molding and fuel tank cap molding Remove the bolt on the leg shield Remove the screw on the frame that combining the frame with the leg shield Remove the three screws that combine the reserve water tank with the leg shield Remove the leg shield CENTER UNDER COVER R...

Page 42: ...ENDER COVER B C REMOVAL Remove the met in box 2 6 Remove the body cover center cover and rear fender A together 2 6 Remove the four screws on the rear fender B Remove the rear fender B Remove the two bolts on the rear fender C Bolts Screws Screws Bolts Under Cover Rear Fender Cover B ...

Page 43: ...ve the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt next to exhaust pipe 32_ 38N m Exhaust muffler lock bolt 59N m Exhaust muffler joint lock nut 18_ 22N m Screws Joint Lock Nuts Lock Bolts Packing Collar Rear Fender Cover C Air Clean Case Lock Bolts next ...

Page 44: ..._____________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE FUEL FILTER 3 3 THROTTLE OPERATION 3 3 ENGINE OIL 3 4 AIR CLEANER 3 5 SPARK PLUG 3 5 VALVE CLEARANCE 3 6 CARBURETOR IDLE SPEED 3 6 CYLINDER COMPRESSION 3 7 FUEL TANK CAP CABLE WIRE SEAT CABL...

Page 45: ...es or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2_ 6mm Spark plug NGK DPR7EA9 Spark plug gap 0 7mm Valve clearance IN 0 1mm EX 0 1mm Idle speed 1700 100rpm Engine oil capacity Cylinder compression 15 2kg cm_ At disassembly 1 1 liter Ignition timing repeatedly At change 0 9 liter Coolant type water cooling Gear oil capacity At disassembly 0 20 l...

Page 46: ...r Note 2 3 I R R Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I Drive belt I Suspension I I Nut bolt fastener I Tire I I Steeringhead bearing I I I Brake fluid Perform pre ride inspection daily Radiator coolant Replace every year or at every 10000km R Radiator core I I Radiator cap I I Brake lever I I Brake shoe wear I I Shock absorber I I In the interest of saf...

Page 47: ...the throttle grip free play Free Play 2_ 6mm Remove the met in box Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut ...

Page 48: ...il through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 9 liter RecommendedOil SAE 15W40 API SJ Start the engine and check for oil leaks Stop the engine and recheck the oil level OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen and spring Clean the oil filter screen Install the oil filter screen spring and filter screen cap Fill the engine wit...

Page 49: ...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 DPR7EA9 Measure the spark plug gap Spark Plug Gap 0 7mm Torque 14 7_ 19 6N m Spark Plug The air cleaner element has a viscous type paper element Do not clean it with compressed air Be sure to install the air cleaner element and cover securely When in...

Page 50: ...er Inspect and adjust valve clearance Valve Clearance IN 0 1mm EX 0 1mm Loosen the lock nut and adjust by turning the adjusting nut Valve Adjuster E036 CARBURETOR IDLE SPEED Lift up the seat and remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700 100rpm When th...

Page 51: ..._Leaky valves _Valve clearance to small _Leaking cylinder head gasket _Worn pistons _Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head FUEL TANK CAP CABLE WIRE Please remove the front cover to inspect the fuel tank cap cable wire slack when operate the fuel tank cap hardly SEAT CABLE WIRE Please remove t...

Page 52: ... 8N m Fill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 230cc At change 180cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule Drive Belt Oil Check Bolt Hole Oil F...

Page 53: ...EM COOLANT LEVEL INSPECTION Place the scooter on its main stand on level ground Check the coolant level of the reserve tank and the level should be between the upper and lower level lines If necessary remove the screw and reserve tank cover to fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 30 COOLANT REPLACEMENT Lower Lin...

Page 54: ...line BRAKE SYSTEM BRAKE FLUID Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit If the brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk rubout is within the specified service limit Check if the brake...

Page 55: ...front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheels off the ground and move the rear...

Page 56: ...__________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE INFORMATION 4 2 TROUBLESHOOTING 4 2 ENGINE OIL OIL FILTER 4 3 OIL PUMP REMOVAL 4 4 OIL PUMP D...

Page 57: ...4 LUBRICATION SYSTEM 4 1 PEOPLE 250 LUBRICATION SYSTEM Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft ...

Page 58: ...ump is installed check each part for oil leaks SPECIFICATIONS OIL PUMP Standard mm Service Limit mm Inner rotor to outer rotor clearance 0 15 0 20 Outer rotor to pump body clearance 0 15_ 0 20 0 25 Rotor end to pump body clearance 0 04_ 0 09 0 12 ENGINE OIL Engine Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE15W40 API SJ TROUBLESHOOTING Oil level too low Poor lubric...

Page 59: ...the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and filter screen cap Torque 12 7N m Recommended Oil SAE15W40 API SJ Oil Capacity At disassembly 1 1 liter At change 0 9 liter Start the engine and check for oil leaks Start the en...

Page 60: ...3 Remove the attaching bolt and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the two oil pump bolts to remove the oil pump OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown Bolts Oil Separator Cover Circlip Oil Pump Driven Gear Oil Pump Drive chain Oil Pump Bolts ...

Page 61: ...re the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over OIL PUMP ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body There is one mark on the surface of the inner rotor and outer rotor The mark is upside Insert the pump shaft by aligning the flat on the shaft with t...

Page 62: ...arator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and driven gear then set the circlip securely on the pump shaft Install the oil separator cover properly Install the A C generator starter driven gear 10 8 Dowel Pin Hole Arrow Mark Oil Pump Bolts Circlip Oil Pump Driven Gear Oil Pump Drive chain Bolts Oil Sepa...

Page 63: ...______________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION 5 1 ENGINE REMOVAL 5 2 ENGINE INSTALLATI...

Page 64: ... with coolant and be sure to bleed air from the water jacket 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 capacity at disassembly 1 1 liter TORQUE VALUES Rear shock absorber upper mount bolt 35_ 45N m Rear shock absorber lower mount bolt 35_ 45N m Re...

Page 65: ...ay Disconnect the secondary air vacuum tube and fuel pump vacuum tube from inlet pipe Disconnect the air inlet hose v belt chamber from frame Loosen the intake manifold band air cleaner tube and inlet pipe Disconnect the radiator air ventilated tube and thermosensor wire coupler from thermostat Starter Relay Intake Manifold Band Fuel Pump Vacuum Tube A C Generator Wire Connectors Nut Starter Motor...

Page 66: ... plug cap from cylinder head Remove the screw attaching rear fender C Remove the three bolts on the air cleaner Remove the air cleaner and disconnect breather hose from transmission case cover Remove the right left rear shock absorber upper mount bolts Remove the left rear shock absorber lower mount bolts Spark Plug Cap Bolts Water Hoses Water Ducts Water Hose Bands Secondary Air Tube Breather Hos...

Page 67: ...rake fluid tube from the guide Remove the four bolts on the rear fork to remove rear brake caliper and rear fork Remove the bolt to disconnect the engine negative cable Remove the engine mounting nut Remove the two nuts of the right and left step bar Remove the right and left step bar Nut Bolts Bolt Rear Shock Absorber Rear Fork Brake Fluid Tube Bolt Engine Mounting Nut Nuts Nuts Step Bar Step Bar...

Page 68: ...r A together 2 6 Remove air cleaner 5 3 Remove the two nuts of the right and left step bar Remove the right and left step bar Remove the engine mounting nut and engine hanger bolt left side Remove the engine mounting bolt and engine hanger bolt right side Remove the starter motor 18 3 Remove the engine hanger Engine Mounting Bolt Nuts Nuts Step Bar Step Bar Engine Mounting Nut Bolt Engine Mounting...

Page 69: ...5 ENGINE REMOVAL INSTALLATION 5 6 PEOPLE 250 Inspect the engine hanger bushings and stopper rubber for wear or damage INSTALLATION Reverse the REMOVAL procedures Bushing Apply grease onto the bush ...

Page 70: ...___________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES __________________________________________________________________________________ SCHEMATIC DRAWING 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER HEAD COVER REMOVAL 6 4 CAMSHAFT REMOVAL 6 4 CYLINDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBL...

Page 71: ...6 CYLINDER HEAD VALVES 6 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 72: ...tem BC50AA BC50AA IN 0 10 0 10 æ æ EX 0 10 0 10 æ æ Cylinder head compression pressure 15kg cm_ 15kg cm_ æ Cylinder head warpage æ æ 0 05 0 05 IN 34 2987 34 14 EX 34 1721 34 02 IN 10 00_ 10 015 10 00_ 10 018 10 10 10 10 EX 10 00_ 10 015 10 00_ 10 018 10 10 10 10 Valve rocker arm shaft IN 9 972_ 9 987 9 972_ 9 987 9 9 9 9 O D EX 9 972_ 9 987 9 972_ 9 987 9 9 9 9 IN 1 2 1 2 1 8 1 8 EX 1 2 1 2 1 8 1 ...

Page 73: ... 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 spring Broken valve spring Damaged or worn camshaft Poor valve and seat contact Worn cam chain tensioner Leaking cylinder head gasket Worn camshaft and rocker arm Warped or cracked cylinder head Poorl...

Page 74: ...aligns with the index mark on the right crankcase cover Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the cam chain tensioner cap bolt Turn the cam chain tensioner screw clockwise to tighten it Remove the two bolts attaching cam chain tensioner and the tensioner First remove the two bolts between the cylinder head and cy...

Page 75: ...FT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 34 14mm replace if below EX 34 02mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play Cam Chain Camshaft Gear Camshaft Bearings Camshaft Holder Dowel Pins ...

Page 76: ...arm shaft O D Service Limits IN 9 90mm replace if below EX 9 90mm replaceif below CYLINDER HEAD REMOVAL First drain the coolant from the radiator and water jacket then remove the thermostat water hose Remove the camshaft 6 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Bolt Camshaft Holder Rocker Arm ...

Page 77: ...ing a valve spring compressor Valve spring compressor E040 Remove carbon deposits from the exhaust port and combustion chamber Valve Spring Compressor Cam Chain Guide Cylinder Head Combustion Chamber Cylinder Cylinder Head Gasket Dowel Pins Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Be careful not to drop any gasket...

Page 78: ... replace if below Outer IN EX 39 5mm replace if below VALVE VALVEGUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 925mm replace if below EX 4 915mm replace if below CYLINDER HEAD ASSEMBLY Install the valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the...

Page 79: ...ntake and exhaust valve rocker arms then installtherocker arm shafts Valve Rocker Arms Plastic Hammer Cam Chain Cylinder Head Camshaft Holder Be careful not to damage the valves Install the exhaust valve rocker arm shaft on the EX side of the camshaft holder and the exhaust rocker arm shaft is shorter Clean the intake valve rocker arm shaft off any grease before installation Align the cutout on th...

Page 80: ...tall the dowel pins Install the camshaft holder washers and nuts on the camshaft holder Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder Torque Cylinder head cap nut 24 5N m Cylinder cylinder head bolt 7 8_ 11 8N m Apply engine oil to the threads of the cylinder head cap nuts Diagonally tighten the cylinder head cap nuts in 2_ 3 times First tighten the c...

Page 81: ...AD COVER INSTALLATION Adjust the valve clearance 3 6 Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts and nuts Torque 7 8_ 11 8N m O ring Cylinder Head Cover O ring Be sure to install the gasket into the groove properly Bolts Cylinder Head Cover Bolts Nuts Be sure to install the O ring into the groove properly Tensioner ...

Page 82: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER PISTON __________________________________________________________________________________ SCHEMATIC DRAWING 7 1 SERVICE INFORMATION 7 2 TROUBLESHOOTING 7 2 CYLINDER REMOVAL 7 3 PISTON REMOVAL 7...

Page 83: ...7 CYLINDER PISTON 7 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 84: ...iston O D measuring position 9mm from bottom of skirt 9mm from bottomof skirt Piston to cylinder clearance 0 010_ 0 040 0 010_ 0 040 0 04 0 01 Piston pin hole I D 17 002_ 17 008 15 002_ 15 008 17 04 15 04 Piston pin O D 16 994_ 17 000 14 994_ 15 000 16 96 14 96 Piston to piston pin clearance 0 002_ 0 014 0 002_ 0 014 0 02 0 02 Connecting rod small end I D bore 17 016_ 17 034 15 016_ 15 034 17 06 1...

Page 85: ...ylinder Remove the cylinder gasket 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 Shop Towel Cylinder Piston Pin Piston Piston Rings Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Dowel Pins Cylinder...

Page 86: ...groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 17 04mm replace if over Take care not to damage or break the piston rings during removal Use the piston head to push each p...

Page 87: ...o the piston pin in both X and Y directions Service Limit 72 80mm repair or replace if Over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if Over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels is subject to the maximum value calculated Service Limits ...

Page 88: ...er PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Second Side Rail Top Be careful not to damage the piston and piston rings during assembly All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking Stagger the ring end gaps as the figure shown Second Top Side Rail Oil Ring ...

Page 89: ...clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Gasket Cylinder Dowel Pin Be careful not to drop foreign matters into the crankcase Position the piston IN mark on the intake valve side Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Be careful not to damage or break the piston rings The piston ring ...

Page 90: ... Install the cylinder head gasket and dowel pins Connect the water hose to the cylinder Install the cylinder head chapter 6 Tighten the cylinder base bolt Insert the tab on the cam chain guide into the cylinder groove Water Hose Gasket Dowel Pin Cam Chain Guide ...

Page 91: ...____________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS V BELT __________________________________________________________________________________ SCHEMATIC DRAWING 8 1 SERVICE INFORMATION 8 2 TROUBLESHOOTING 8 2 LEFT CRANKCASE C...

Page 92: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 93: ... 24 4 22 0 Clutch lining thickness 3 963_ 4 037 2 0 Clutch outer I D 153 0_ 153 2 153 5 Weight roller O D 22 92_ 23 08 22 0 Drive pulley collar O D 26 960_ 26 974 26 90 TORQUE VALUES Drive face nut 88 2_ 98N m Clutch outer nut 49 0_ 58 8N m Clutch drive plate nut 49 0_ 58 8N m SPECIAL TOOLS Universal holder Clutch spring compressor Bearing driver Lock nut wrench 39mm Kick starter spring remover TR...

Page 94: ...onnect the belt air tube from the frame Remove the left crankcase cover bolts and left crankcase covers Remove the seal rubber and dowel pins INSTALLATION Install the dowel pins and the seal rubber Install the left crankcase cover Install and tighten the left crankcase cover bolts Left Crankcase Cover Air Tube Bolts Dowel Pins Seal Rubber Left Crankcase Cover Left Crankcase Cover Bolts ...

Page 95: ...eft crankcase cover 8 3 Remove the drive pulley face 8 4 Hold the clutch outer with the universal holder and remove the clutch outer nut and washer Universal Holder E017 Remove the clutch outer driven pulley and belt together Remove the drive belt from the movable drive face INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Lim...

Page 96: ...lt 8 4 Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 22 00mm replace if below Drive Pulley Collar Ramp Plate Weight Roller Movable Drive Face Assembly ...

Page 97: ...m replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 26 90mm replace if below ASSEMBLY Install the weight rollers into the movable drive face Weight Roller The direction of all weight rolls is same The color side is towards to clockwise ...

Page 98: ...PLE 250 Install the ramp plate Insert the drive pulley collar into the movable drive face INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 153 5mm replace if over Drive Pulley Collar Ramp Plate ...

Page 99: ... pulley assembly with the clutch spring compressor Clutch Spring Compressor E034 Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar Clutch Driven Pulley Clutch Spring Compressor Be sure to use a clutch spring compressor to avoid spring damage Lock Nut Wrench C...

Page 100: ...e driven face Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 130 5mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 39 85mm replace if below Movable Driven Face Guide Roller Pin O ring Guide Roller Oil Seal ...

Page 101: ...er 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 driven face with the sealed end facing up Seat the snap ring in its groove Apply grease to the driven face bore areas Snap Ring Inner Bearing Outer Bearing Discard the removed bearing and replace with a new one ...

Page 102: ... V BELT 8 11 PEOPLE 250 Press a new needle bearing into the driven face CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Circlips Retainer Plate Keep grease off the clutch linings Clutch Lining ...

Page 103: ...l the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease from them Apply grease to the O rings and install them onto the moveable driven face Circlips Drive Plate Movable Driven Face ...

Page 104: ...bly 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 49 0_ 58 8N m Clutch Spring Compressor E034 Be sure to clean the driven face off any grease Align the flat surface of the driven face with the flat on the clutch drive plate Movable Driven Face Guide Roller Pin Seal Collar Gui...

Page 105: ...h outer with the universal holder to tighten clutch outer nut Torque 49 0_ 58 8kg m Universal Holder E017 Install the drive pulley face washer and drive face nut Hold the drive pulley with the universal holder and tighten the drive face nut Torque 88 2_ 98N m Universal Holder E017 Clutch Outer Movable Drive Face Assembly Drive Pulley Face Universal Holder Driven Pulley and Out Drive Pulley Collar ...

Page 106: ...8 DRIVE AND DRIVEN PULLEYS V BELT 8 15 PEOPLE 250 Install the left crankcase cover 8 3 ...

Page 107: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING 9 1 SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL ...

Page 108: ...9 FINAL REDUCTION 9 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 109: ...s operation SPECIFICATIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 23 liter At change 0 18 liter TORQUE VALUES Transmission case cover bolt 17 7_ 21 6N m Oil check bolt 7 8_ 11 8N m SPECIAL TOOLS Bearing puller E037 TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks ...

Page 110: ...ove the clutch outer driven pulleys 8 4 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final shaft Remove the final gear and countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Transmission Case Cover Dowel Pin Countersha...

Page 111: ...t 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 Final Shaft Bearing Countershaft Bearing Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing Final Shaft ...

Page 112: ...he bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Drive Shaft Bearing Bearing Remover Pilot Bearing Remover Drive Shaft ...

Page 113: ... Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Put the final gear on the left crankcase Pilot Drive Shaft Drive Shaft Final Gear ...

Page 114: ...OPLE 250 Install the countershaft and gear into the left crankcase Install the final shaft into the final gear and transmission case Install the dowel pins and a new gasket Countershaft Final Shaft Final Gear Gasket Dowel Pins ...

Page 115: ...cified oil Specified Gear Oil SAE90 Oil Capacity At disassembly 0 23 liter At change 0 18 liter Install and tighten the oil check bolt Torque 7 8_ 11 8N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low Transmission Case Cover Bolts Place the scooter on its main stand on level ground Che...

Page 116: ...________________________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING 10 1 SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 2 RIGHT CRANKCASE COVER REMOVAL 10 3 STATOR REMOVAL 10 3 FLYWHEEL REMOVAL...

Page 117: ...10 A C GENERATOR STARTER CLUTCH 10 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 118: ...ase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket SPECIFICATIONS Engine oil SAE15W 40 API SJ Oil capacity at change 0 9 liter Coolant distilled water coolant concentrate SPECIAL TOOLS Flywheel puller E003 Flywheel holder E021 SPECIFICATIONS Item Standard mm Service Limit mm Starter driven gear I D 22 026_ 22 ...

Page 119: ...e chapter 5 Remove the eight bolts attaching the right crankcase cover and the cover Remove the left and right rear shock absorber lower mount bolts chapter 5 Elevate the back of engine as possible by placing a suitable stand under the back of engine Remove the bolt between water pump cover and oil filter screen cap Remove right crankcase cover STATOR REMOVAL Remove the two pulser coil attaching s...

Page 120: ...flywheel with a flywheel holder and remove 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 Flywheel Nut Flywheel Holder Starter Driven Gear Flywheel Puller Oil Through Spring Special Special ...

Page 121: ...IL PUMP REMOVAL Remove the attaching bolts and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the cam chain Circlip Shaft Cam Cain Starter Idle Gear Bolts Oil Separator Cover Oil Pump Driven Gear Oil Pump Drive chain ...

Page 122: ...en gear for 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 the starter one way clutch for wear or damage Starter Idle Gear Shaft Starter Driven Gear Oil Pump Bolts Starter One way Clutch ...

Page 123: ...olts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install cam chain Install the pump drive chain and driven gear then set the circlip securely on the pump shaft Install the oil separator cover properly Bolts Cam Chain Oil Pump Pump Drive Chain Arrow Mark Fit the tab of the separator cover into the slit in the separator ...

Page 124: ...ing the 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 53 9_ 63 7N m remove the flywheel nut and washer Flywheel holder E021 Starter Driven Gear Starter Idle Gear Groove Shaft Flywheel Key Flywheel Holder Before installation check and make sure that the inside of the flywheel is not contami...

Page 125: ...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 the nine right crankcase cover bolts Connect the water hoses to the right crankcase cover and water pump cover Add the recommended engine oil 4 3 Fill the cooling system with the specified coolant 3 9 Screws A C Generator Stator Pulser Coil Dowel Pins Gask...

Page 126: ..._____________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING 11 1 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASE SEPARATION 11...

Page 127: ...11 CRANKCASE CRANKSHAFT 11 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 128: ...ating the crankcase Cylinder head chapter 6 Cylinder piston chapter 7 Right crankcase cover drive and driven pulley chapter 8 A C generator starter clutch chapter 10 Rear wheel rear shock absorber chapter 15 Starter motor chapter 18 Oil pump chapter 4 SPECIFICATIONS Item Standard mm Service Limit mm Connecting rod big end side clearance 0 15_ 0 35 0 6 Crankshaft Connecting rod big end radial clear...

Page 129: ...ase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Remove the oil seal from the left crankcase Bolt Left Crankcase Crankshaft Left Crankcase Right Crankcase Never use a driver to pry the crankcase mating surfaces apart Right Crankcase Right Crankcase Oil Seal ...

Page 130: ... CRANKSHAFT 11 4 PEOPLE 250 CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end I D Service Limit 17 06mm replace if over ...

Page 131: ...aft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oil seal into the left crankcase Axial Play Play Radial Avoid damaging the crankcase mating surfaces Left Crankcase Left Crankcase Oil Seal ...

Page 132: ...ht crankcase over the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 7 8_ 10 8N m Left Crankcase Gasket Right Crankcase Dowel Pins Bolts Install the right crankcase squarely and do not tap it with an iron or plastic hammer Avoid damaging the oil seal Apply grease to the lip of the oil seal Crankshaft Left Crankcase ...

Page 133: ...____________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING 12 1 SERVICE INFORMATION 12 2 TROUBLESHOOTING 12 2 COOLING SYSTEM TESTING 12 4 RADIATOR 1...

Page 134: ...12 COOLING SYSTEM 12 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 135: ...d coolant with fresh water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9 8_ 13 7N m Water pump cover bolt 7 8_ 11 8N m TROUBLESHOOTING Engine temperature too high Coolant leaks Faulty temperature gauge or thermosensor Faulty pump mechanical water seal Faulty radiator cap Deteriorat...

Page 136: ... 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 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 1 073 1 070 1 067 60 1 100 1 098 1 095 1 092 1 089 1 086 1 083 1 080...

Page 137: ...0 9 0 15kg 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 connectors for leaks RADIATOR RADIATOR INSPECTION Remove the front cover 2 5 Apply water to the cap sealing surface before testing Radiator Cap Radiator Tester The test pressure should not exceed 1 05 kg cm_ Excessive pre...

Page 138: ...nnect the outlet tube of the reserve tank Remove the overflow tube clamp and disconnect the overflow tube Disconnect the air vent tube from the radiator filler Disconnect the fan motor wire coupler Loosen the hose band and disconnect the upper hose and lower hose from the radiator Disconnect the thermostatic switch wire coupler Air Vent Tube Lower Hose Upper Hose Overflow Tube Thermostatic Switch ...

Page 139: ...ve the two bolts and two nuts on the radiator Remove the radiator RADIATOR DISASSEMBLY Remove the three bolts and then remove the fan shroud from the radiator Check fan motor by battery Fan Shroud Radiator Bolts Fan Motor Battery Nuts Bolts ...

Page 140: ...ATIC SWITCH When coolant temperature lower then 88 92 the thermostatic switch OFF When coolant temperature over 88 92 the thermostatic switch ON Install the fan shroud on the radiator with the three bolts Radiator Thermostatic Switch Fan Shroud Bolts ...

Page 141: ... tube to the radiator filler After installation check for coolant leaks Connect the outlet tube of the reserve tank and secure with the tube clamp Radiator Bolts Nuts Lower Hose Upper Hose Thermostatic Switch Wire Thermostatic Switch Outlet Tube of Reserve Tank Air Vent Tube Overflow Tube Fan Motor Wire Coupler If you want to refill the coolant the following procedure must be checked 1 Please make...

Page 142: ...ove the right crankcase cover and replace the mechanical seal WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose Remove the four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller Impeller Left Hand Threads Water Pump Cover Bolts Right Crankcase Cover Telltale Hole Water Pump Outlet Hose Inlet Hose The impeller has left hand threads ...

Page 143: ...ase cover Remove the eight bolts attaching the right crankcase cover Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and inner bearing Mechanical Seal Seal Washer Porcelain Water Pump Assembly Bolts Impeller The mechanical seal and seal washer must be replace as a set Inner Bearing Snap Ring Water Pump Assembly Water Pump Shaft ...

Page 144: ...he mechanical seal out of the water pump assembly from the inside Drive in a new mechanical seal using a mechanical seal driver Mechanical Seal Water Seal Mechanical Seal Driver Inner Bearing Water Pump Assembly Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal ...

Page 145: ...l the snap ring to secure the inner bearing properly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover Tighten the eight bolts to secure the right crankcase cover Inner Bearing Snap Ring Water Pump Shaft Water Pump Assembly Outer Bearing Water Pump Assembly Bolts When installing the water pump assembly aligning the groove on the water pum...

Page 146: ...to the impeller Install the impeller onto the water pump shaft Torque 9 8_ 13 7N m Install the two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 7 8_ 11 8N m Mechanical Seal Seal Washer Porcelain Impeller Impeller Left Hand Threads Water Pump Cover Bolts Dowel Pins The impeller has left hand threads ...

Page 147: ...burner and measure the resistance through the sensor as the water heats up Temperature 50 80 100 120 Resistance W 154 52 27 16 THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads and install it into the thermostat housing Connect the thermosensor wire Fill the radiator with coolant 3 9 Install the center cover met in box and seat 2 3 Be sure to bleed ai...

Page 148: ... from the thermosensor Disconnect the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove the two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Thermostat Thermostat Bolts Thermostat Water Hose Air Vent Tube Bolt Thermose...

Page 149: ...STAT INSTALLATION The installation sequence is the reverse of removal Fill the cooling system with the specified coolant 3 9 Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room temperature Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 O ring Thermosensor Replace the O ring with a...

Page 150: ...______ FUEL SYSTEM CARBURETOR FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM 13 1 SCHEMATIC DRAWING 13 2 OPERATION OF CARBURETOR JETS 13 3 SERVICE INFORMATION 13 5 CARBURETOR REMOVAL 13 7 VACUUM CHAMBER DISASSEMBLY 13 7 FLOAT CHAMBER DISASSEMBLY 13 9 AUTO BYSTARTER INSPECTION REMOVAL 13 11 AIR CUT OFF VALVE A C V 13 12 AUTO BYSTARTER INSTAL...

Page 151: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK 13 1 PEOPLE 250 FUEL SYSTEM ...

Page 152: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK 13 2 PEOPLE 250 SCHEMATIC DRAWING ...

Page 153: ...Low Speed Small Jet Holes 2 MIDDLE SPEED Venturi halfway opened throttle valve High Speed Air Jet Fuel in Float Chamber Main Jet Main Jet The slow jet also works Low Middle Speed Supplementary Device Air Air Air Bleed Holes Mixture Air Bleed Holes Mixture Vacuum Tube Low Speed Air Jet Main Jet Vacuum Diaphragm Low Middle Speed Supplementary Fuel Inlets Slow Jet Bypass Jet Pilot Screw ACV Air ...

Page 154: ...uel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve FUEL PUMP CONSTRUCTION Diaphragms Inlet Outlet Suction Valve Outlet Valve Pulsating Pressure from Crankcase ...

Page 155: ...hragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away from the working area When removing the fuel tank the remaining fuel in the tank must be lower than _ of the fuel tank capacity to avoid gasoline overflowing Fuel tank capacity 8 0 liters SPECIFICATIONS BC50AA VE0222 B 18 5 2_ _ 150cc 35 1500 100rpm 40cc 15...

Page 156: ...e Damaged vacuum piston diaphragm Auto bystarter valve opens excessively Clogged diaphragm hole Faulty float valve Float level too high Lean mixture Clogged air jets Clogged fuel jets Auto bystarter valve set plate installed in Clogged fuel tank cap breather hole the wrong groove Clogged fuel filter Clogged air cleaner Bent kinked or restricted fuel line Faulty float valve Float level too low Faul...

Page 157: ...n the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then remove the carburetor VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Auto Bystarter Wire Auto Bystarter Fuel Tube Intake Manifold Band Air Cleaner Connecting Tube B...

Page 158: ...um piston Remove the needle holder spring and jet needle from the piston VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears Vacuum Chamber Cover Diaphragm Screws Spring Vacuum Piston Vacuum Piston Needle Holder Jet Needle Be careful not to damage the vacuum piston diaphragm ...

Page 159: ...AMBER DISASSEMBLY Remove the three float chamber screws and the float chamber Remove the float pin float and float valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Chamber Float Valve Float Float Pin Float Valve Seat Screws Float Valve ...

Page 160: ...main jet needle jet holder needle jet and slow jet with detergent oil Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record the rotating turns Do not force the pilot screw against its seat to avoid seat damage Pilot Screw P S Pilot Screw Slow Jet Main Jet Needle Jet Holder Needle Jet Slow Jet Main Jet Be sure to use clean detergent oil ...

Page 161: ...t of the carburetor Connect the auto bystarter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter is norma...

Page 162: ...r damage If any faulty part is found replace the auto bystarter with a new one AIR CUT OFF VALVE A C V A C V REMOVAL Remove the two screws and the air cut off valve cover Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage Bystarter Needle Air Cut off Valve Cover Bystarter Valve Spring Screws Cover Diaphragm ...

Page 163: ...buretor body Install the O ring onto the air cut off valve body securely Install the diaphragm spring and cover Install and tighten the two screws attaching the air cut off valve cover Connect the hose Make sure that no fuel jet is clogged Install the O ring with the flat face toward the valve body side Screws Spring Cover Diaphragm O ring ...

Page 164: ...r cracks damage or deterioration Replace if necessary Assemble the accelerating pump in the reverse order of disassembly AUTO BYSTARTER INSTALLATION Install the auto bystarter and set plate Install and tighten the two screws Auto Bystarter Screws Screws Spring Cover Diaphragm O ring Insert the auto bystarter into the carburetor body until it bottoms and position the set plate into the upper groove...

Page 165: ...OPLE 250 FLOAT CHAMBER ASSEMBLY Install the main jet Install the slow jet Install the pilot screw Install the float valve float and float pin Float Valve Float Float Pin Pilot Screw Slow Jet Main Jet Be sure to record the rotating turns when it is removed ...

Page 166: ...float chamber VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Install the vacuum piston into the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Diaphragm Float Spring Vacuum Piston Vacuum Piston Needle Holder Jet Needle Be careful not to let the diaphragm slip If the d...

Page 167: ...e cable to the carburetor Connect the heater carburetion wire coupler Connect the auto bystarter wire Connect the fuel tube and vacuum tube to the carburetor Connect the throttle position sensor wire Perform the following inspections and adjustments Throttle grip free play 3 3 Idle speed 3 6 Install the seat met in box and frame body cover Heater Auto Bystarter Wire Auto Bystarter Fuel Tube Intake...

Page 168: ...he body cover center cover and rear fender cover A Disconnect the fuel pump inlet outlet and vacuum tubes Remove the two fuel pump attaching nuts and the fuel pump FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws Disassemble the fuel pump Inlet Screws Outlet Tube Vacuum Tube Inlet Tube Vacuum Tube Outlet Nuts ...

Page 169: ...e in the fuel pump body for damage cracks or foreign matters FUEL PUMP ASSEMBLY Assemble the fuel pump in the reverse order of disassembly Inlet Spring Suction Valve Diaphragm Outlet Valve Gaskets Relief Valve Outlet Dowel Pins Dowel Pin Holes Fuel Pump Body Spring During assembly be sure to install the gaskets and diaphragms properly to avoid damage Do not allow any foreign matter to enter the fu...

Page 170: ...nstall the body cover center cover and rear fender A Measure the fuel pump output Start the engine and disconnect the fuel outlet tube and place a clean container under the tube to check the fuel output Output 40cc 1700rpm 10 seconds FUEL TANK REMOVAL Remove the floor board 2 7 Remove four nuts at the tank shield and remove the tank shield Container Fuel Pump Outlet Tube Outlet Tube Vacuum Tube In...

Page 171: ...he fuel tank and the fuel filler Disconnect the fuel vapor tube Disconnect the fuel tube between the fuel tank and fuel strainer Remove the four bolts on the fuel tank Remove the fuel tank The installation sequence is the reverse of removal Fuel Unit Wire Connector Fuel Vapor Tube Tube to Fuel Strainer Tube to Fuel Filler Bolts Bolts ...

Page 172: ...om the fuel line INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump Fuel Strainer Fuel Strainer When removing the fuel strainer do not allow flames or sparks near the working area and drain the residual gasoline into a container ...

Page 173: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCK ABSORBER FRONTFORK __________________________________________________________________________________ SCHEMATIC DRAWING 14 1 SERVICE INFORMATION 14 2 TROUBL...

Page 174: ...14 STEERING HANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 14 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 175: ...ke 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 4 0 3 0 Brake disk runout 0 30 Brake caliper piston O D 25 33_ 25 36 25 3 Brake caliper cylinder I D 25 4_ 25 45 25 45 Brake master cylinder O D 12 65_ 12 68 12 64 Brake master cylinder I D 12 70_ 12 74 12 75 Front Fork oil 160cc SAE 20 TORQUE VALUES Steer...

Page 176: ...de 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 damper oil Poor brake performance Front shock absorber noise Worn brake pads Slider bending Contaminated brake pad surface Loose fork fasteners Deformed brake disk Lack of lubrication Air in brake system De...

Page 177: ...ht 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 the handlebar INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 40_ 50N m Brake Master Cyl...

Page 178: ... Remove the screw from the speedometer gear unit then disconnect the speed wire from the speedometer gear unit Remove the front axle to pull out the axle Remove the front wheel and the speedometer gear unit INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is _ of the total indicator reading Service Limit 0 2mm replace if over Bolt Throttle...

Page 179: ...RONT 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 hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub BEARING REPLACEMENT Remove the front wheel bearings and distance collar Wheel Bearing Collar Dust Se...

Page 180: ...er gear unit groove with the front shock absorber tab Insert the axle and tighten the axle Torque 29_ 35N m Install and tighten the two bolts Torque 29_ 35N m Tab Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the sealed end facing out Groove Pawl If not aligned the retaining pawl will be deformed when the axle nut is tightened After installing the axle ...

Page 181: ...er 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 the inside of the master cylinder and brake reservoir with brake fluid Rubber Cover When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by b...

Page 182: ...nd 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 the rubber cover Install the brake lever Rubber Cover Main Piston Spring Master Cylinder Snap Ring During assembly the main piston and spring must be installed as a unit without exchange When assembling ...

Page 183: ... 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 bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pad...

Page 184: ...e brake caliper Remove the brake pads Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil...

Page 185: ...oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the two brake pads Install the two brake pad dowel pin and tighten them Brake Pads Ins...

Page 186: ...que 29_ 35N m Connect the brake fluid tube with the attaching bolt and two sealing washers to the brake caliper and tighten the fluid tube bolt Torque 24_ 30N m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 14 10 Bolts Washers Brake Fluid Tube When installing the brake fluid tube be sure to install the two sealing washers ...

Page 187: ... Remove the front shock absorber 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 upper mount bolts Tighten the lower mount bolts Torque 29_ 35N m Install the front wheel 14 7 Upper Mount Bolts Front Fork Front Shock Absorber Align the upper mount bolt h...

Page 188: ...ck 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 Front fork oil qty 160cc SAE 20 BOTTOMCONERACEREPLACEMENT 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 Top Cone Race Lock ...

Page 189: ...n 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 80_ 120N m Install the front wheel 14 7 Install the front brake caliper 14 12 Install the front fender cover A and B 2 6 Install the throttle grip and the right and left handlebar switches 14 5 Install the righ...

Page 190: ..._________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REARBRAKE REARFORK REARWHEEL REARSHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING 15 1 SERVICE INFORMATION 15 2 TROUBLESHOOTI...

Page 191: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 PEOPLE 250 SCHEMATIC DRAWING ...

Page 192: ...der piston O D 26 95 26 90 TORQUE VALUES Exhaust muffler lock bolt 32_ 38N m Exhaust muffler pipe nut 18_ 22N m Rear axle nut 110_ 130N m Rear shock absorber lower mount bolt 35_ 45N m Rear shock absorber upper mount bolt 35_ 45N m Rear brake caliper holder bolt 29_ 35N m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteriorated brake fluid Ax...

Page 193: ...ECTION Inspect the brake pads and brake disk Measure the brake disk thickness Service Limit 3 0mm replace if below Visually check the brake pad thickness and it should not exceed the wear indicator mark DISASSEMBLY Remove the two brake pads dowel pins and three bolts from the brake caliper Remove the brake pads When removing the brake fluid tube use shop towels to cover plastic parts and coated su...

Page 194: ...ination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 26 90mm Check the caliper cylinder for scratches or wear and measure the cylinder bore Service Limit ...

Page 195: ...e fluid Install the brake caliper piston with grooved side facing out Install the two spring plate into the groove of the caliper Install the two brake pads and brake pad dowel pin Dowel Pin Install the piston with its outer end protruding 3_ 5mm beyond the brake caliper Spring Plate Brake Pads Longer Shorter Caliper Inside Caliper Outside Make sure the spring plate next to the brake pad dowel pin...

Page 196: ...ler 2 10 Remove the rear brake caliper 15 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 sequence is the reverse of removal 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 Replace the bearings if the races d...

Page 197: ... replace if over Axial 2 0mm replace if over INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 35_ 45N m Rear axle nut 110_ 130N m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier 2 6 Remove the body cover center cover and rear fender A together 2 6 Remove the right left rear shock absorber upper and lower mount bolts Remove t...

Page 198: ...oad condition rear cushion could be adjusted in spring preload It is possible to adjust rear cushion in three positions A position soft B position medium C position hard When you adjust rear cushion the spring preload of rear cushions must be the same A cushion adjust wrench is provided with PEOPLE 250 The rear right cushion can be adjusted directly with the wrench Remove the four bolts from air c...

Page 199: ...R BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 9 PEOPLE 250 Disconnect the breather hose from air cleaner and keep air cleaner up to adjust rear left cushion with wrench Wrench Air Cleaner Breather Hose ...

Page 200: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT 16 1 SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 3 BATTERY 16 4 CHARGING SYSTEM ...

Page 201: ...16 BATTERY CHARGING SYSTEM 16 1 PEOPLE 250 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT Fuse Regulator Rectifier A C Generator Battery R ...

Page 202: ...ng Do not disconnect and soon reconnect the power of any electricalequipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation It is not necessary to check the MF battery electrolyte or fill with distilled water Check the load of the whole charging system Do not quick charge the battery Quick charging should only be done in an eme...

Page 203: ... connection Disconnected battery 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 shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier ...

Page 204: ...ndard 1 2A Quick 5A Charging time Standard 5_ 10 hours Quick 60 minutes After charging Open circuit voltage 12 8Vmin Battery Cover When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel Keep flames and sparks away from a charging battery Turn power ON OFF at the charger not at the battery terminals to prevent...

Page 205: ...ST Engine Speed 2500rpm 5000rpm Charging Current 7A min 9A min If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION Remove the met in box Disconnect the A C generator connector Check the continuity between the yellow wires and ground There should be continuity between the yellow wires and no continuity between each yellow wire and ground Resistanc...

Page 206: ...ion Continuity Probe Probe I Yellow Green II Red White Yellow Reverse Direction No Continuity Probe Probe I Green Yellow II Yellow Red White VOLTAGE REGULATION TEST Connect a voltmeter across the battery terminals Start the engine and gradually increase the engine speed The battery terminal voltage should be within 14 0_ 15 0V A C Generator Stator Voltage Sensor Black Regulator Rectifier Bolts Pul...

Page 207: ..._________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING 17 2 SPARK PLUG 17 3 IGNITION COIL INSPECTION 17...

Page 208: ...17 IGNITION SYSTEM 17 1 PEOPLE 250 IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Pulser Coil Ignition Switch Ignition Coil CDI Unit A C Generator ...

Page 209: ...ction 3 Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Item Standard Spark plug Standard type NGK DPR7EA9 Spark plug gap 0 7mm Ignition timing F mark Full advance repeatedly Primary coil 3 6_ 4 1W Ignition coil resistance 20 Secondary without plug cap 14KW coil with plug cap 19KW Pulser coil resistance 20 105_ 110W Exciter coil resistance 20 1 8_ 2 1W Ignition coil...

Page 210: ...NTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 Primary coil 3 6_ 4 1W Secondary coil without plug cap 14KW Secondary coil with plug cap 19KW Electric tester YF 3501 Ignition Coil This is a general test Accurate ignition coil test must be performed with a CDI tester Ignition Coil Secondary Coil Primary Coil Ignit...

Page 211: ...val installation refer to pages 10 3 and 10 6 Disconnect the pulser coil wire coupler Measure the pulser coil resistance between the blue white and green white wire terminals Blue Yellow_ Green Whit e 105_ 110 W Electric tester YF 3501 CDI UNIT RESISTANCE INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not within the specifications in the table belo...

Page 212: ... 4KW V B 150KW 12MW 150KW 99KW 103KW 103KW V G 46KW 12MW 47KW 4KW 103KW 0 5W G 46KW 12MW 47KW 4KW 103KW 0 5W Y G Electric tester YF 3501 Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings In this table Needle swings then returns indicates that there is a chargingcurrent applied to...

Page 213: ..._________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 2 STARTER MOTOR 18 3 STARTER ...

Page 214: ...18 STARTING SYSTEM 18 1 PEOPLE 250 STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Starter Button Starter Motor Stop Switch Relay R ...

Page 215: ... TORQUE VALUES Starter motor mounting bolt 6 7_ 10 8N m Starter motor case screw 2 9_ 4 9N m Starter clutch bolt 9 8_ 13 7N m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or...

Page 216: ...emove the two starter motor case screws front cover rear cover motor case and other parts INSPECTION Inspect the removed parts for wear damage or discoloration Replace if necessary Clean the commutator if there is metal powder between the segments Nut 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 b...

Page 217: ...uld be no continuity 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 Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity repla...

Page 218: ...ds of the armature shaft Insert the commutator into the front cover Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws INSTALLATION Connect the starter motor cable Check the O ring for wear or damage and replace if necessary Apply grease to the O ring and install it to th...

Page 219: ...y 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 tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity b...

Page 220: ..._______________________________________________________________ __________________________________________________________________________________ SWITCHES HORN FUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT 19 1 SERVICE INFORMATION 19 2 TROUBLESHOOTING 19 2 SWITCHES 1...

Page 221: ...GAUGE INSTRUMENTS LIGHTS 19 1 PEOPLE 250 ELECTRICAL EQUIPMENT LAYOUT Turn Signal Switch Stop Switches Horn Button Passing Dimmer Switch Fuel Unit Starter Button Engine Stop Switch Ignition Switch Thermostati c Switch Headlight Switch Horn Heater Control Unit ...

Page 222: ...re gauge does not register switch is ON correctly Burned bulb Faulty temperature gauge Faulty switch Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between temperature gauge and thermosensor Fuel gauge pointer does not move or register correctly Faulty fuel gauge Faulty fuel unit Poorly connected wire between fuel gauge and fuel unit Fuse burned out SPECIFICATIO...

Page 223: ... 3 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals Color Position White Blue Brown Blue Brown Brown White n P H STARTER SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the starter switch wire couplers Depress the starter button and check for continuity between the wire terminals Color Position Yellow Red Green FREE PUSH ENGINE STOP S...

Page 224: ...or continuity between the wire terminals Color Position Light Blue Gray Orange L N R DIMMER SWITCH INSPECTION Remove the handlebar front covers 2 3 Disconnect the headlight dimmer switch wire couplers Turn on the dimmer switch and check for continuity between the wire terminals Color Position White Blue Blue White Brown Blue LO HI PASSING STOP SWITCH INSPECTION Remove the handlebar front covers 2 ...

Page 225: ...s Upper Lower Y W_ G 9 1_ 9 3W 95_ 96W Use the W range for YF 3501 FUEL METER INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel meter for correct indication by moving the fuel unit float up and down Float Position Display Upper Much Full Lower Less Empty Wire Terminals Display Free From Much to Less Apply From Less to Much The fuel meter is normal if i...

Page 226: ...reen If there is no voltage check for the following Blown or faulty fuse Loose terminals or connectors Shorted wire in the wire harness TEMPERATURE METER Disconnect the wire from the thermosensor and ground it to the engine Turn the ignition switch ON The temperature gauge needle should move all the way to H HEATER CONTROLER UNIT INSPECTION 1 Open ignition switch to check if the brown bluewireof i...

Page 227: ...s from the handlebar rear cover INSTALLATION The installation sequence is the reverse of removal FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the two screws attaching the turn signal light shell and remove the screw attaching bulb shell Remove the bulb and replace with a new one REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the one screw attaching the turn signal light shell and remove the scr...

Page 228: ...lace with new one Install the bulb aligning the bulb socket tab with the groove and set the lock clip Install the rubber boot Install the handlebar front cover in the reverse order of removal TAILLIGHT LIGHT BULB EPLACEMENT Remove the two screws attaching the rear light shell and remove the light shell Remove the bulb and replace with new ones The installation sequence is the reverse of removal SI...

Page 229: ...19 SWITCHES HORN FUELUNIT THERMOSTATICSWITCH TEMPERATUREGAUGE INSTRUMENTS LIGHTS 19 9 PEOPLE 250 HEATER WIRING DIAGRAM ...

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