KYMCO PEOPLE 125 User manual

1. GENERAL INFORMATION
1-1
PEOPL E 12 5/ 150
1
GENERAL INFORMATION
ENGINE FRAME VIN SERIAL NUMBER ...................................1-2
SPECIFICATIONS (125 CC) .......................................................1-3
SPECIFICATIONS (150 CC) .......................................................1-4
SERVICE PRECAUTIONS ..........................................................1-5
TORQUE VALUES......................................................................1-7
TOOLS........................................................................................1-8
LUBRICATION POINTS .............................................................1-9
CABLE & HARNESS ROUTING...............................................1-11
WIRING DIAGRAM (125 CC)...................................................1-16
WIRING DIAGRAM (150 CC)...................................................1-17
TROUBLESHOOTING..............................................................1-18
1
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1. GENERAL INFORMATION
1-2
PEOPL E 12 5/ 150
Location of Engine Serial Number
Vehicle Identification Serial Number
Location of Frame Serial Number
ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER
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1. GENERAL INFORMATION
1-3
PEOPL E 12 5/ 150
SPECIFICATIONS
Name & Model No.
PEOPLE 125
Overall length (mm)
1950
Overall width (mm)
690
Overall height (mm)
1075
Wheel base (mm)
1335
Engine type
O.H.C.
Displacement (cc)
125
Fuel Used
92# nonleaded gasoline
Front wheel
41
Net weight (kg)
Rear wheel
70
Total
111
Front wheel
65
Gross weight(kg)
Rear wheel
116
Total
181
Front wheel
80/80-16 45P
Rear wheel
100/80-16 56P
Ground clearance (mm)
160
Perform
-
Braking distance (m)
4.4 (30km/h)
ance
Min. turning radius (m)
2
Starting system
Starting motor &
kick starter
Type
OHC air cooled 4-cycle
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
52.4 x 57.8
Compression ratio
9.6:1
Compression pressure
(kg/cm_)
13
Max. output (ps/rpm)
9.6/7500
Max. torque (kg m/rpm)
1.0/6500
Intake
Open
7.3
Valve
(mm)
Close
0
timin
g
Exhaust
Open
6.9
(mm)
Close
0
Valve clearance
Intake
0.10
(cold) (mm)
Exhaust
0.10
Idle speed (rpm)
1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
0.91 liter
Exchanging capacity
0.81 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element
Fuel capacity
6.8 liters
Type
VE
Piston dia. (mm)
24
Venturi
dia.(mm)
22.1 equivalent
Throttle type
Butterfly type
Type
CDI
Ignition timing
15°~28°BTDC/1700r
pm
Contact breaker
Non-contact point
type
Spark plug
NGK C7HSA
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
type
Type
Two-stage reduction
Reduction
1st
0.86~2.64
ratio
2nd
10.98
Front
Caster angle
25°
Axle
Trail length
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.00 (2.25)
Turning
Left
45°
angle
Right
45°
Brake system
Front
Disk brake
type
Rear
Drum brake
Suspension
Front
Telescope
type
Rear
Swing arm
Shock absorber
Front
Telescope
type
Rear
Swing arm
Frame type
Steel pipe
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
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1. GENERAL INFORMATION
1-4
PEOPL E 12 5/ 150
SPECIFICATIONS
Name & Model No.
PEOPLE 150
Overall length (mm)
1950
Overall width (mm)
690
Overall height (mm)
1075
Wheel base (mm)
1335
Engine type
O.H.C.
Displacement (cc)
150
Fuel Used
92# nonleaded gasoline
Front wheel
41
Net weight (kg)
Rear wheel
70
Total
111
Front wheel
65
Gross weight(kg)
Rear wheel
116
Total
181
Front wheel
80/80-16 45P
Rear wheel
100/80-16 56P
Ground clearance (mm)
160
Perform
-
Braking distance (m)
4.4 (30km/h)
ance
Min. turning radius (m)
2
Starting system
Starting motor &
kick starter
Type
OHC air cooled 4-cycle
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
57.4 x 57.8
Compression ratio
9.2:1
Compression pressure
(kg/cm_)
15
Max. output (ps/rpm)
10.5/7500
Max. torque (kg m/rpm)
1.1/5500
Intake
Open
7.3
Valve
(mm)
Close
0
timin
g
Exhaust
Open
6.9
(mm)
Close
0
Valve clearance
Intake
0.10
(cold) (mm)
Exhaust
0.10
Idle speed (rpm)
1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
0.91 liter
Exchanging capacity
0.81 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element
Fuel capacity
6.8 liters
Type
VE
Piston dia. (mm)
24
Venturi
dia.(mm)
22.1 equivalent
Throttle type
Butterfly type
Type
CDI
Ignition timing
15°~28°BTDC/1700r
pm
Contact breaker
Non-contact point
type
Spark plug
NGK C7HSA
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V6AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
Type
Type
Two-stage reduction
Reduction
1st
0.86~2.64
ratio
2nd
10.98
Front
Caster angle
25°
Axle
Trail length
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.00 (2.25)
Turning
Left
45°
angle
Right
45°
Brake system
Front
Disk brake
type
Rear
Drum brake
Suspension
Front
Telescope
type
Rear
Swing arm
Shock absorber
Front
Telescope
type
Rear
Swing arm
Frame type
Steel pipe
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
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1. GENERAL INFORMATION
1-5
PEOPL E 12 5/ 150
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
nUse genuine parts and lubricants.
nWhen servicing the motorcycle, be sure to
use special tools for removal and
installation.
nAfter disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
nApply or add designated greases and
lubricants to the specified lubrication
points.
nAfter reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, pay
attention to the mutual working safety.
nDisconnect the battery negative (-) terminal
before operation.
nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
nAfter operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
nWhen connecting the battery, the positive
(+) terminal must be connected first.
nAfter connection, apply grease to the
battery terminals.
nTerminal caps shall be installed securely.
nIf the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
nAfter operation, terminal caps shall be
installed securely.
nWhen taking out the connector, the lock on
the connector shall be released before
operation.
nHold the connector body when connecting
or disconnecting it.
nDo not pull the connector wire.
nCheck if any connector terminal is bending,
protruding or loose.
nThe connector shall be inserted
completely.
nIf the double connector has a lock, lock
it at the correct position.
nCheck if there is any loose wire.
nBefore connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
nCheck the double connector cover for
proper coverage and installation.
nInsert the terminal completely.
nCheck the terminal cover for proper
coverage.
nDo not make the terminal cover opening
face up.
nSecure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
nAfter clamping, check each wire to make
sure it is secure.
nDo not squeeze wires against the weld or
its clamp.
nAfter clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
nRoute wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
nRoute wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
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1. GENERAL INFORMATION
1-6
PEOPL E 12 5/ 150
nRoute harnesses so they are neither
pulled tight nor have excessive slack.
nProtect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
nWhen rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
nDo not break the sheath of wire.
nIf a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
nWhen installing other parts, do not press or
squeeze the wires.
nAfter routing, check that the wire harnesses
are not twisted or kinked.
nWire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
nWhen a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
nBe careful not to drop any parts.
nWhen rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
nDo not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
nSymbols:
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 grease for lubrication.
:Transmission Gear Oil (90#)
:Use special tool.
: Caution
:Warning
Engine Oil
Grease
Gear Oil
Special
＊
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1. GENERAL INFORMATION
1-7
PEOPL E 12 5/ 150
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45_0.6
0.8_1.2
1.8_2.5
3.0_4.0
5.0_6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35_0.5
0.7_1.1
1.0_1.4
2.0_3.0
3.5_4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler joint lock nut
Cylinder head nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Drive face seal cover bolt
Starter clutch cap bolt
Drive face nut
Spark plug
Starter clutch lock nut
Cam chain tensioner screw
2
4
1
2
4
2
1
1
1
1
3
3
1
1
1
1
8
8
30
8
8
5
6
8
12
12
4
6
12
10
22
6
0.9
0.9
1.5
2.2
2.0
0.9
1.0
1.3
5.5
5.5
0.3
1.2
5.5
1.2
9.5
0.4
Double end bolt
Double end bolt
Apply oil to
threads
Left hand threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Speedometer cable set screw
Front shock absorber tube bolt
Front shock absorberupper mount bolt
Front shock absorberlower mount bolt
Front shock absorber hex bolt
Rear shockabsorber lower joint locknut
1
1
1
1
1
1
1
2
2
1
1
10
12
14
10
8
5
5
8
8
8
8
12.0
6.0
12.0
4.0
2.5
0.45
0.45
0.1
1.8
3.0
3.5
U-nut
U-nut
U-nut
Apply lockingagent
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1. GENERAL INFORMATION
1-8
PEOPL E 12 5/ 150
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
FLYWHEEL PULLER
LOCK NUT SOCKET WRENCH
TAPPET ADJUSTER
OIL SEAL & BEARING INSTALL
FLYWHEEL HOLDER
BEARING PULLER
BEARING PULLER
BEARING PULLER
BEARING PULLER
BUSHING REMOVER
FLYWHEEL HOLDER
LONG SOCKET WRENCH
CLUTCH SPRING COMPERESSOR
CRANKSHAFT PROTECTOR
CRANKSHAF BEARING PULLER
BUSHING REMOVER
LONG SOCKET WRENCH
CUSHION ASSEMBLEN &
DISASSEMBLE TOOL
RACE CONE INSTALL
TOOL BOOX
E002
E009
E012
E014
E017
E008
E018
E020
E031
E019
E021
E022
E027
E029
E030
E032
F002
F004
F005
E033
14-8
16-7
3-5
11-4,12-5
9-3,14-10
10-4
10-4
10-4
13-0
9-3,9-13
9-8
11-0
6-0
12-5
13-0
12-16
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1. GENERAL INFORMATION
1-9
PEOPL E 12 5/ 150
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft right side oil seal
Crankshaft 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
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SE, SF or SG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads
Thread locking agent
A.C. generator connector
Transmission case breather tube
Adhesive
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1. GENERAL INFORMATION
1-10
PEOPL E 12 5/ 150
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Seat Lock
Rear Wheel Bearings
Grease
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Main Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot
Engine Oil
Grease
Grease
Grease
Grease
Front Brake Lever
Pivot
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease
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1. GENERAL INFORMATION
1-11
PEOPL E 12 5/ 150
CABLE & HARNESS ROUTING
Front Stop Switch Wire
Rear Stop Switch Wire
Throttle Cable
Regulator/
Rectifier
Resistor
Front
Brake
Fluid
Tube
Rear Brake Cable
Speedometer Cable
Horn
Instrument Cable
Ignition Switch
Front Brake Fluid Tube
Front Brake Reservoir
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1. GENERAL INFORMATION
1-12
PEOPL E 12 5/ 150
Throttle Cable
Regulator/Rectifier
Speedometer Cable
Wire Harness
Resistor
Front Brake Fluid Tube
Rear Brake Cable
Front Brake Fluid Tube
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1. GENERAL INFORMATION
1-13
PEOPL E 12 5/ 150
Wire Harness
Reserve Fuse
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
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1. GENERAL INFORMATION
1-14
PEOPL E 12 5/ 150
Fuel Valve Vacuum Tube
Throttle Cable
Vacuum Tee
Fuel Tube
Ignition Coil
Auto Bystarter Wire
Crankcase Breather Tube
Ground
A.C.
Generator
Wire
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1. GENERAL INFORMATION
1-15
PEOPL E 12 5/ 150
Throttle Cable
Fuel Tube
Carburetor
Vacuum Tube
Auto Bystarter Wire
Starter Motor Wire
Auto Bystarter
Fuel Vapor Tube
Fuel Unit
Wire Harness
Crankcase Breather
Tube
Vacuum Tee
Starter Relay
Wire Harness
Air Cleaner
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1. GENERAL INFORMATION
1-16
PEOPL E 12 5/ 150
WIRING DIAGRAM
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1. GENERAL INFORMATION
1-17
PEOPL E 12 5/ 150
WIRING DIAGRAM
150 cc ( SINGAPORE )
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1. GENERAL INFORMATION
1-18
PEOPL E 12 5/ 150
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel strainer
Faulty auto fuel valve
Faulty charging system
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Faulty auto bystarter
Air leaking through intake
pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw
Flooded carburetor
Faulty auto bystarter
Throttle valve excessively
open
Check if fuel reaches
carburetor by
loosening drain screw
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Inspection/Adjustment
Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder
compression
Start engine by follow-
ing normal starting
procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does not
reach carburetor
Wet spark plug
Dry spark plug
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1. GENERAL INFORMATION
1-19
PEOPL E 12 5/ 150
ENGINE LACKS POWER
Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
diaphragm
Faulty auto fuel valve
Faulty CDI unit
Faulty pulser coil
Improper valve clearance
adjustment
Worn valve seat (valve stem too
protruding
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing
Clogged carburetor jets
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too early
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
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 a timing light)
Test cylinder compression
Check carburetor for
clogging
Rapidly accelerate or run
at high speed
Remove spark plug and
inspect
Check if engine overheats
Check valve clearance
Correct
Incorrect
Normal
compression
Abnormal
compression
Remove oil dipstick and
check oil level and condition
Remove cylinder head oil
pipe bolt and inspect
Engine overheats
Engine does not
overheats
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not
contaminated
Incorrect or
contaminated
Valve train lubricated
properly
Valve train not
lubricated properly
Engine does not knock
Engine knocks
Not clogged
Clogged
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1. GENERAL INFORMATION
1-20
PEOPL E 12 5/ 150
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
The woodruff key in the
crankshaft is not fixed
position.
Mixture too rich (turn screw
out)
Mixture too lean (turn screw
in)
Deteriorated O-ring
Carburetor is not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Faulty air cut-off valve
Damaged vacuum tube
Clogged or damaged air vent
hole
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 air cut-off
valve
Check carburetor
gasket for air leaks
Check carburetor pilot
screw adjustment
Correct timing
Incorrect timing
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter-
mittent spark
Good
Faulty
Incorrectly
adjusted
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