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1. GENERAL INFORMATION GENERAL INFORMATION

1. 3 7 1304 0 Bf eec M m 3 7 3 8 BRAKE SYS LEM 2490595229924 5 9999 9250500099990 0 000 0000000 b 0005 3 8 TAD Jc 3 9 SUSPENSION erra 3 9 STEERING 3 9 ES PAS PEIN ERD cerier nienti ER 3 9 TIRE S 3 10 KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 SERVICE INFORMATION GENERAL e Before running the engine make sure that the working area is well ventilated Never run the en gine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people Gasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area o fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2_ 6mm Spark plug gap 06 0 7mm Spark plug Standard C7HSA Valve clearance IN 0 12mm EX 0 12mm Idle speed 1700 100rpm Engine oil capacity At disassembly 0 91 liter At change 0 81 liter Gear oil capacity At disassembly 210cc At change 180 Cylinder compression 125 150 13 15 kg cm Ignition timing BTDC 15 28 2 1700 100rpm BODY Front brake free play 10 20mm Rear brake
2. STEERING STE Vlacucssdsaocoptus 12 0 12 FRONT WHEEL FRONT BRAKE KYMCO FRONTSUSPENSION PEOPLE 125 150 12 1 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing the front wheel Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down During servicing keep oil or grease off the brake drum and brake linings Contaminated brake disk or brake pads reduce stopping power Clean the contaminated brake disk with high performance brake degreaser and replace the brake pads Do not use brake fluid for cleaning Bleed air from the brake system if the brake system is removed or the brake is soft Do not allow any foreign matters to enter the brake system when filling it with brake fluid Brake fluid will damage painted surfaces and plastic parts When servicing the brake system use shop towels to cover and protect rubber plastic parts and coated surfaces Wipe off any spilled brake fluid with a clean shop towel nspect the brake system before riding SPECIFICATIONS tem Standard mm Service Limit mm Axle shaftrunout 0 __ 02 __ Front wheel rim runout Axial 20 Front brake lining thickness 5355 275 Front shock absorber spring free length ___ 20 252 Brake disk thickne
3. EN 7 m a E a ia m LENT EN TES BON VB ae ir Brown O Orange Light Blue WIRING DIAGRAM 1 16 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 WIRING DIAGRAM 150 cc SINGAPORE dis H HORI I am TE Bar Er uh E m EA Lal B ans FC 1 17 1 GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Check if fuel reaches carburetor by loosening drain screw Remove spark plug and o into spark EM cap to test spark by connecting it to engine ground Test cylinder 023 compression Start engine by follow ing normal starting procedure Engine does not Engine fires but fire does not start Remove spark plug and inspect again Dry spark plug Wet spark plug 1 18 KYMCO PEOPLE 125 150 Probable Cause Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage logged fuel tank cap breather ole Clogged fuel filter Ls ged fuel strainer aulty auto fuel valve Faulty
4. Install fuel unit by aligning groove on fuel unit with tab the fuel tank AUTO BYSTARTER AUTO BYSTARTER INSPECTION Remove the rear right side cover 2 Disconnect the auto bystarter wire connector Measure the resistance between the yellow and green black wire terminals Resistance 1000 max Perform this operation when engine is cold RESISTOR INSPECTION Remove the front cover 2 Disconnect the green black and green wires and measuring the resistance between the wire terminals Resistance 5 2 max If the needle remains at It indicates that the resistor 1s faulty and must be replaced 99 Auto Bystarter Resistor 17 7 dC KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 INSTRUMENTS REPLACEMENT Remove front cover 2 Remove bulb socket and replace the bulb The installation sequence is the reverse of removal INSTRUMENTS REPLACEMENT Remove handlebar front cover 2 Remove handlebar rear cover 2 Disconnect the right and left handlebar switches wire couplers Disconnect the speedometer cable Remove the instrument bulb sockets Disconnect the three fuel gauge wires Remove the instrument wire clamp screw Lighting Stop Light Turn Signal Start Wires Wires Wires Remove the three screws attaching the instruments to the handlebar rear cover Remove the instruments ASSEMBLY
5. 1 GENERAL INFORMATION PEOPLE 125 150 1 GENERAL INFORMATION ENGINE FRAME VIN SERIAL NUMBER 1 2 SPECIFICATIONS 125 1 3 SPECIFICATIONS 150 CC 1 4 SERVICE 1 5 TORQUE VALUES ccccsssssscssssccssceesscescsccessccessccsscassceacsceesaees 1 7 TOOLS 1 8 LUBRICATION POINTS lt 1 9 CABLE amp HARNESS ROUTING 1 11 WIRING DIAGRAM 125 000 1 16 WIRING DIAGRAM 150 4 1 17 TROUBLESHOOTING 1 18 1 1 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER Vehicle Identification Serial Number 1 GENERAL INFORMATION SPECIFICATIONS Overall length mm 1950 Overall width mm Overall height mm 1075 Wheel base mm 1335 Name amp Model No PEOPLE 125 Engine type Fuel Used 92 nonleaded gasoline Net weight kg Total Gross weight kg Total 100 80 16 56 Perform Braking distance m Starting system Compression pressure kg cm 160 kick starter 52 4 x 57 8 Valve 9 6 7500 1 0 6500 pe mm timin 8 mm 0 Valve clearanc
6. REPLACEMENT 7 a 7 Drive out top and bottom ball races 1 Fe 1 4 Outer Driver 37x40mm Drive new top and bottom ball races into the e steering head using outer driver Ti gt T 1 5 3 Special 4 gt J Outer Driver 37x40mm 4 12 16 12 FRONT WHEEL FRONT BRAKE _ FRONT SUSPENSION PEOPLE 125 150 _Front INSTALLATION Front Fender Install the front mold and the front fender it i Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Apply grease to the ball races and install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0 12 0kg m Install the front wheel 12 15 Top Cone Race Top Cone Race Lock Nut Wrench Steering Stem Lock Nut Bolt HANDLEBAR INSTALLATION 1 Install the handlebar onto the steering stem tube and then install and tighten bolt Torque 4 5kg m Install the front wheel 12 6 Install the brake levers
7. 11 4 11 0 KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 11 1 dC KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft The engine must be removed for this operation The following parts must be removed before separating the crankcase Cylinder head Section 7 Cylinder piston Section 8 Drive and driven pulleys Section 9 A C generator Section 14 Carburetor air cleaner Section 4 Rear wheel rear shock absorber Section 13 Starter motor Section 16 Oil pump Section 4 SPECIFICATIONS S Lalldd nein M big end side clearance Crankshaft elencate rod big end radial clearance 0 008 0 05 Runout 4 0 10 VALUES Crankcase bolt 0 9kg m Cam chain cover bolt 0 9kg m TROUBLESHOOTING Excessive engine noise Excessive bearing play Excessive crankpin bearing play 11 2 dC KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 CRANKCASE SEPARATION Remove the two crankcase attaching bolts Separate the left and right crankcase halves Do not damage crankcase gasket surface Crankcase Bolts Gasket Remove the gasket and dowel pins 3 Remove the crankshaft from the left crankcase Clean off all gasket material from the crankcase mating surfaces Avoid damaging crankcase mating surfaces
8. 7 11 7 0 KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 dC KYMCO 7 CYLINDER HEAD VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts valve arm and camshaft sliding surface for initial lubrication The camshaft 1s lubricated by engine oil through the cylinder head engine oil passages Clean the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection PEOPLE 125 150 After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS alve clearance cold Cylinder head compression pressure Cylinder head warpage Camshaft cam height alve rocker arm I D Valve rocker arm shaft O D alve seat width Valve stem to guide clearance Standard mm 29 7064 29 803 29 4251 29 4388 29 15 29 05 service Limit mm 10 000 10 015 10 00 10 015 9 972 9 987 9 972 9 987 4 975 4 990 4 975 4 990 5 000 5 012 5 000 5 012 0 030 0 057 7 2 7 CYLINDER HEAD VALVES TORQUE VALUES Cylinder head nut 2 0kg m Valve clearance adjusting nut 0 8kg m TROUBLESHOOTING KYMCO PEOPLE 125 150 Apply engine oil to threads Apply engine oil to threads T
9. 2 MET IN BOX REMOVAL Remove 1 the three bolts and 2 two nuts attaching the met in box Remove the met in box 3 REAR FENDER REMOVAL Remove 1 the screw on each side of the rear fender Remove 3 1 two nuts attaching the rear fender Remove the rear fender Remove 3 2 light wire connector 4 UNDER COVERS REMOVAL Remove the frame center cover screws Remove 1 the two screws attaching the part of the frame 21 Remove 4 2 taillight rear turn signal light wire connector E 5 BOTTOM COVER REMOVAL Remove the one bolt attaching each side of the bottom ctor cover Remove the bolt on site stand 6 FLOOP BOARD REMOVAL Remove the two bolts attaching the rear floor board Remove 6 1 the four bolts attaching the floor board e Remove the six screws attaching the floor board 3 4 Remove floor board 7 FRONT COVER REMOVAL Remove the bolt on the front of the front COVCT a Remove the front cover 2 4 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 10 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 FRONT TOOLBOX REMOVAL Remove the nut attaching the front tool box 1 Remove the ignition switch decorative ring six screws that combine the front cover with the front tool box Remove 8 2 screws attaching the front cover Remove the fro
10. Blue Yellow Black Yellow Black Blue b Green Black Blue 15 4 KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 IGNITION COIL REMOVAL Remove the frame body cover 2 Remove the spark plug cap Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil INSPECTION CONTINUITY TEST This test is to inspect the continuity of ignition coil Measure the resistance between the ignition coil primary coil terminals Resistance 0 1 1 0Q 20C Measure the secondary coil resistances with and without the spark plug cap Resistances with plug 7 12 0 20 without plugcap 2_ 4KQ 20C Correctly operate the tester followmg the manufacturer s instructions 15 5 KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 PULSER COIL INSPECTION This test 15 performed with stator installed engine Remove frame body cover 2 Disconnect generator connector Measure pulser coil resistance between the blue yellow and green wire terminals Resistance 70 1309 20 Refer to page 14 7 for the A C generator removal IGNITION TIMING INSPECTION The CDI unit is not adjustable If the ignition timing 15 incorrect inspect the CDI unit pulser coil and A C generator and replace any faulty parts Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When
11. OIL LEVEL Ky Place motorcycle upright on level ground for engine oil level check Run the engine 072 3 minutes and check the oil level after the engine is stopped for 2_ 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level is near the lower level fill to the upper level with the specified engine oil OIL CHANGE The engine oil will drain more easily while the engine 15 warm Remove the oil filter screen cap located on the bottom of the engine to drain the engine oil thoroughly After the oil has been completely drained check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring and filter screen cap Torque 1 5kg m Fill with the specified SAEI5W40 API SG CD engine oil to the proper level Oil Capacity At disassembly 0 90 liter At change 0 75 liter Check for oil leaks and then start the engine and let it idle for few minutes Recheck the oil level OIL PUMP REMOVAL Remove the A C generator flywheel 14 7 Remove the nine right crankcase cover bolts and the right crankcase cover stator Right Crankcase Cover KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 Remove the gasket and dowel pins Starter Idle Gear Starter Clutch Remove the starter idle gear and starter clutch 16 7 Remove two bolts separator cover Remove oil
12. x H 2 dE p Outer Rotor Dowel Pin Pump Cover Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding INSTALLATION Install the oil pump into the crankcase Install the pump with arrow on the pump body facing up and fill the oil pump with engine oil before installation After the oil pump 15 installed tighten the two mounting bolts 4 LUBRICATION SYSTEM Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft Install and tighten the pump driven gear nut Torque 1 0kg m Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch 16 9 Install the gasket and dowel pins Install the right crankcase cover and tighten the nine bolts Torque 0 9kg m Diagonally tighten the bolts in 2 3 times 4 7 KYMCO PEOPLE 125 150 Pump Driven Gear Oil Separator Cover Starter Idle Gear Starter Clutch Stator Right Crankcase Cover FUEL SYSTEM PEOPLE 125 150 FUEL SYSTEM SERVICE INFORMATION 5 2 TROUBLESHOOTING 326090300212 9985851506 5 3 CARBURETOR REMOVAE 200535d52038649 8241906009083 Usa edad 5 4 AUTO BY STARTER nada 5 4 AIR 5 0 VACUU
13. 11 3 dC KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 Remove the oil seal from the right crankcase Check the oil seal lip for wear or deterioration The installation sequence 15 the reverse of removal CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 55mm replace if over Turn the crankshaft bearings and check for excessive play If they do not turn smoothly quietly or if they fit loosely in the crankshaft replace the crankshaft as a set CRANKCASE ASSEMBLY Install the crankshaft into the left crankcase 11 CRANKCASE CRANKSHAFT Install the dowel pins and a new gasket onto the left crankcase Place right crankcase over crankshaft and onto left crankcase Tighten the two crankcase attaching bolts Torque 0 9kg m 11 5 KYMCO PEOPLE 125 150 Gasket D h af i 51 z 4 1 1 Crankcase Bolts 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION KYMCO PEOPLE 125 150 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SERVICE ZROUBLESHOOUTINGOL21 89922095090998 PRONT VV ce HYDRAULIC BRAKE DRAWING HXDRAULIC 2319920304590 500690129 FRONT SHOCK STEERING
14. Measure resistance between AC generator eee gt coil terminals Faulty generator coil Loose connector Connect battery wire to regulator rectifier E coupler red wire battery wire to engine Normal voltage Broken red wire Check regulator rectifier gt coupler for loose ommsdied coup Poorly connected coupler Faulty A C generator Overcharging Connect battery Wire to E regulator rectifier coupler green wire and battery wire to engine Inspection Adjustment Probable Cause E Battery has Battery has no voltage with voltage wth Broken green wire ignition switch ignition switch Check regulator rectifier gt coupler for loose Faulty regulator rectifier 1 22 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Replace with a new Spark plug and inspect i again Good spark Weak or no spark Faulty spark plug Check spark plug and high tension wire gt for looseness Check CDI unit coupler for looseness d Poorly connected coupler Measure resistance between terminals Of CDI unit coupler Check related paris gt Faulty ignition switch Weak battery Faulty pulser coil Faulty ignition coil Fau
15. 12 15 Install the handlebar covers 12 17 13 REAR WHEEL REAR BRAKE ___ 505 51 __ PEOPLE 125 150 WHEEL REAR BRAKE REAR SUSPENSION SEARCY ICE INFORMATION ieseevstose us aeo aao Ue PSV 13 2 DROUBEESEHOOTLLINGL 292318 9985 0595985 98 059 85 8 925009500996 13 2 KEAR Pme c 13 3 13 4 REAR SHOCK ABSORBER Ee 13 5 ADJUSTABLE REAR 13 6 13 0 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEopLEt257150 13 1 13 WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS During servicing keep oil or grease off the brake drum and brake linings SPECIFICATIONS Standard mm Service Limit mm m T ma Rear brake drum I D Rear brake lining thickness 4 204 Rear shock absorber spring free length 200 5 TORQUE VALUES Rear axle nut 11 0_ 13 0kg m Rear shock absorber upper mount bolt 4 0kg m Rear shock absorber lower mount 2 5kg m Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock 3 5kg m Brake arm bolt 1 0kg m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Brake not adjusted properly Faulty tire Worn brake linings Axle not tightened
16. 14 7 GENERATOR LIGHTING 14 7 RESISTOR INSPECTION 14 7 ALe EHI MEO qc M 14 7 14 0 dC KYMCO PEOPLE 125 150 Resistors 14 BATTERY CHARGING SYSTEM Regulator Rectifier A C GENERATOR Fuse IN A C Generator Battery CHARGING CIRCUIT gulator Rectifier 2V6AH Testigter Handlebar switches 14 1 14 BATTERY CHARGING SYSTEM GENERATOR 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid 1s poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention The battery can be charged and discharged repeatedly If a discharged battery 15 not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after it is used for 2 3 years capacity decreased battery will resume its voltage after it is recharged but its voltage decreases suddenly and then increases when a load is added When a battery 1s overcharged some symptoms can be found If there is a short circuit inside the battery no voltage 1s produced on the battery terminals If the rectifier would not operate the voltage will become too high and short
17. Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3_ 5mm beyond the brake caliper cylinder Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Torque 2 5 3 5 Fill the brake reservoir with recommended brake fluid and bleed air from the brake system FRONT SHOCK ABSORBER REMOVAL Remove the front cover 2 Remove the front wheel Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Mount Bolt 12 13 12 FRONT WHEEL FRONT BRAKE KYMCO _ FRONT SUSPENSION PEOPLE1257150 INSPECTION Inspect the following items and replace if necessary shock absorber tube bending or damage Weak front shock absorber spring Damper and damper rod bending Oil seal damage or wear INSTALLATION Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align upper mount hole with the groove on the front fork Front shock ab
18. m V 1 aligned with the nick on the fuel tank TV Connect the fuel unit wire connector INSTALLATION Inspect the fuel unit gasket for damage AUTO FUEL VALVE No Smoking First clean the fuel tube Disconnect fuel tube and vacuum tube from the carburetor Connect vacuum pump to vacuum tube and apply vacuum Check if fuel flows out The valve is operating normally if fuel flows out of the fuel tube when the vacuum 1s applied The fuel shall stop flowing out when the vacuum pump is disconnected If the fuel valve does not operate normally Check the vacuum diaphragm for poor installation or damage and inspect the fuel tube for clogging 5 12 KYMCO FUEL SYSTEM PEOPLE 125 150 AIR CLEANER Loosen the air cleaner connecting tube band Screw Disconnect the transmission case breather tube from the air cleaner case Remove the two bolts and air cleaner case Air Cleaner Case The installation sequence is the reverse of removal 5 13 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 N N 2E SERVICE INFORMATION 5 EFE SENSE 6 2 ENGINE REMOVAL ERR OVES 6 3 ENGINE 66 6 5 KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPL
19. MAIN HARNESS CIRCUIT INS PECTION Remove the front cover 2 4 Remove the regulator rectifier 4P coupler and check for continuity between the wire harness terminals according to the following Wire Color Between battery red Battery has and engine ground voltage Between ground wire Continuity exists geen and engine ground Between lighting wire yellow and engine ground Remove the A C generator resistor coupler and auto coil has bystarter coupler and resistance turn the lighting switch OFF for inspection Between charging coil A C generator white and engine coil has ground resistance REGULATO R RECTIFIER INS PECTION If the main harness terminals are normal Red check the regulator rectifier coupler for loose F connection and measure the resistances between the regulator rectifier terminals Do not touch the tester probes with your finger because human body has resistance Use the following specified testers for accurate testing Use of an improper tester in an improper range may give false readings Kowa Electric Tester Sanwa Electric Tester White Kowa Electric Tester TH 5H Proper range for testing Use range for Sanwa Tester Use X100Q range for Kowa Tester f the dry battery in the tester is weak the readings will be incorrect In this case check the dry battery The Kowa tester readings are 100 times the actual values Be careful during
20. brake fluid to the upper limit and bleed air according to the method stated in page 12 8 BRAKE CALIPER FRONT REMOVAL Remove the brake caliper and brake pad springs 12 9 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces DISASSEMBLY Remove the brake caliper seat from the brake caliper 12 11 12 FRONT WHEEL FRONT BRAKE KYMCO _ FRONT SUSPENSION PEOPLE 125 150 Remove the pistons from the brake caliper US EOS If necessary use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons Check each piston cylinder for scratches or wear and replace if necessary Push the piston oil seals outward to remove them Clean each oil seal groove with brake fluid Be careful not to damage piston surface Check each piston for scratches or wear Measure each piston O D with a micrometer gauge Service Limit 33 90mm Check each caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 33 45mm 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION PEOPLE 125 150 ASSEMBLY Clean all removed parts Apply silicon grease to the pistons and oil seals Lubricate the brake caliper cylinder inside wall with brake fluid
21. 3 1 1 1 1 Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upp er mount bolt Rear shock absorber lower mount bolt Speedometer cable set screw Front shock absorber tube bolt Front shock absorberupp er mount bolt Front shock absorber lower mount bolt Front shock absorber hex bolt Rear shock absorber lower joint lock nut KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 SPECIAL TOOLS FLYWHEEL PULLER 14 8 LOCK NUT SOCKET WRENCH 16 7 TAPPET ADJUSTER 3 5 OIL SEAL amp BEARING INSTALL 11 4 12 5 FLYWHEEL HOLDER 9 3 14 10 BEARING PULLER 10 4 BEARING PULLER 10 4 BEARING PULLER 10 4 BEARING PULLER BUSHING REMOVER FLYWHEEL HOLDER LONG SOCKET WRENCH CLUTCH SPRING COMPERESSOR CRANKSHAFT PROTECTOR CRANKSHAF BEARING PULLER BUSHING REMOVER LONG SOCKET WRENCH CUSHION ASSEMBLEN amp DISASSEMBLE TOOL RACE CONE INSTALL TOOL BOOX dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 LUBRICATION POINTS ENGINE Valve guide valve stem movable part e Genuine KYMCO Engine Oil SAEI5W 40 Cam lobes SE SF or SG Engine Oil 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
22. 5000rpm Resistor Resistance 20C 5W5Q 40 6 00 Resistance 20C 30W7 5Q 7 0 8090 14 2 Regulator Rectifier Lighting 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR TORQUE VALUES Pulser coil bolt 0 5kg m lock 0 9kg m Flywheel 5 5kg m Cooling fan bolt 0 9kg m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Dead battery Disconnected battery cable Fuse burned out Faulty ignition switch Low power Weak battery Loose battery connection Charging system failure Faulty regulator rectifier Charging indicator light does not come on Dead battery Faulty charging indicator Faulty indicator light bulb Charging indicator light does not go out Faulty battery Faulty charging indicator Faulty regulator rectifier 14 3 PEOPLE 125 150 Intermittent power Loose battery cable connection Loose charging system connection oose connection or short circuit in lighting system Charging system failure Loose broken or short circuit wire or connector Faulty regulator rectifier Faulty A C generator 14 BATTERY CHARGING SYSTEIM A C GENERATOR BATTERY REMOVAL Remove the frame cover screws Open the cover and remove the battery cover screw First disconnect the battery negative cable and then the positive cable When disconnec
23. CYLINDER HEAD VALVES PEOPLE 125 150 Remove the four cylinder head nuts and washers Diagonally loosen cylinder head nuts in 2 or 3 times Remove the camshaft holder and dowel pins Remove the camshaft gear from the cam chain and remove camshaft CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits 125 IN 29 30mm replace if below EX 29 15mm replace if below 150 cc IN 29 40mm replace if below EX 29 05mm replace if below 7 5 dC KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive wear Camshaft Bearings 5mm Bolt Rocker Arm CAMSHAFT HOLDER DISASSEMBLY Take out valve rocker arm shafts using a 5mm bolt Remove the valve rocker arms Rocker Arm Shaft Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface 15 worn check each cam lobe for wear or damage Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 91 mm replace if below EX 9 91mm replace if below KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CY
24. Green Brown Blue TURN SIGNAL SWITCH DIMMER SWITCH Bue Whit Dium Switch 17 5 4O KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 STOP SWITCH INSPECTION Remove the handlebar front cover 2 Disconnect the front stop switch wire coupler Check for continuity between the wire terminals when the front brake lever is applied The switch 15 normal if there 15 continuity HORN INSPECTION Remove the front cover 2 Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery 15 connected across the horn wire terminals FUEL GAUGE INSPECTION Remove the rear right side cover 2 Disconnect the fuel gauge wire connector Turn the ignition switch ON Connect the green and yellow white wires and the fuel gauge needle should move from E to Connect the green and blue white wires and the fuel gauge needle should move from F to FUEL UNIT REMOVAL Remove the met in box 2 Remove the rear right side cover 2 Disconnect the fuel unit wire connector Remove the fuel unit Be careful not to bend or damage the fuel unit float arm Fuel Unit Connector 17 6 dC KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 INSPECTION Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions RESISTANCES Unit 2 re ue AW 0 450 The installation sequence is the reverse of removal
25. INSTALLATION The assembly and installation sequence is the reverse of removal i Bulb Socket KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 DISASSEMBLY Remove the screws to disassemble the instruments 17 9
26. PEOPLE 125 150 Brake Cam Brake Arm Pin Bolt 13 REAR WHEEL REAR BRAKE REAR SUSPENSION PEOPLE 125 150 Remove rear shock absorber upper and lower mount bolts Remove the rear shock absorber ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring prelocad 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 INSTALLATION Install the rear shock absorber First install the upper mount bolt and then the lower mount bolts and tighten them Install the air cleaner case and tighten the two bolts Install the frame body cover Torque Upper Mount Bolt 4 0kg m Lower Mount Bolt 2 5kg m 13 6 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR A PEOPLE 125 150 BATTERY CHARGING SYSTEM A C GENERATOR CHARGING SYSTEM BA YOU veses eis ues eivsecs 14 1 SERVICE INMOUNKIWINIIOU 14 2 TROUBLESHOOTING 22199 923955240 14 3 DA DEI Y 2032029191029 989999190010 92 0950549 8838004125 18000939 3 14 4 CHARGING SY SI BV sed esesoduba ERR SOR 14 5 REGULATOR RECTIFIER APP 14 0 GENERATOR CHARGING
27. and bulbs of the same specifications to avoid damage of electrical equipment After installation of each switch a continuity check must be performed A continuity check can usually be made without removing the part from the motorcycle TROUBLESHOOTING Lights do not come on and horn does not Engine starts but stalls during idling sound when ignition switch is ON auto bystarter Faulty ignition switch Faulty auto bystarter resistor Fuse burned out Poorly connected or broken wire Weak battery Clogged carburetor Burned bulb Faulty switch Faulty horn Poorly connected broken or shorted wire Fuel gauge pointer does not register Fuel gauge pointer does not move correctly Faulty fuel gauge Faulty fuel gauge Faulty fuel unit Faulty fuel unit Poorly connected broken or shorted wire Faulty fuel unit float 17 2 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 Bulb Socket HEADLIGHT BULB REPLACEMENT Remove handlebar front cover 2 Remove the rubber boot from the bulb socket Remove the bulb socket by turning it counter clockwise Remove the bulb for replacement Install a new bulb aligning the groove on the bulb socket with the tab on the bulb Install the bulb socket Install the rubber boot Install the front cover 2 HEADLIGHT REMOVAL Remove the handlebar front cover 2 Remove the two screws attaching the headlight Remove the headl
28. charging system Faulty spark plug Fouled spark plug Faulty CDI unit Fale 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 mproper valve and seat contact Worn cylinder piston and piston rings eaking cylinder head gasket eized 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 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 ENGINE LACKS POWER Inspection Adjustment Probable Cause Start engine and accelerate 5 sss oe lightly for observation Ree ted fuel flow Clogged fuel tank cap breather hole Engine speed Engine speed does not logged exhaust muffler increases increase aulty auto bystarter Split carburetor vacuum piston Check ignition timing diaphragm using timing gt Faulty auto fuel valve aulty CDI unit Cormecttiming Incorrect timing aulty pulser coil e e Ee 3 5 ga Improper valve clearance Worn valve seat valve stem too nnm protruding Improper valve and seat contact Normal Abnormal Worn cylinder and piston rings compression compression Leaking cylinder head gasket Improper valve timing Che
29. damage Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover When installing return spring use screw driver to press the inward and outward return spring hooks into their original positions respectively Install the starter driven gear and friction spring as the figure shown Install the kick lever Install the left crankcase cover and tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw 9 15 KYMCO PEOPLE 125 150 Friction Spring Starter Driven Gear Kick Starter Spindle Forcing di eae Starter Driven Gear Shaft Forcing Starting Ratchet if Kick Starter Spindle Friction Spring KYMCO 10 FINAL REDUCTION PEOPLE 125 150 FINAL REDUCTION 10 2 TROUBLESHOOTING 10 2 FINAL REDUCTION DISASSEMBLY 10 3 FINAL REDUCTION 10 3 BEARING 0 10 4 FINAL REDUCTION 8 10 5 10 0 KYMCO PEOPLE 125 150 10 FINAL REDUCTION 10
30. damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps shall be installed securely B If the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation KYMCO PEOPLE 125 150 B Hold the connector body when connecting or disconnecting it B Do not pull the connector wire Check if any connector terminal 15 bending protruding or loose B Ihe connector shall be inserted completely B If the double connector has a lock lock it at the correct position Check if there 1s any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal B Check the double connector cover for proper coverage and installation B Insert the terminal completely B Check the terminal cover for proper coverage B Do not make the terminal cover opening face up B Secure 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
31. free play 10_ 20mm TIRE PRESSURE _ Rider 2Rides 1 75kgcm 1 75kgcm 2 00kgcm 2 25kg em TIRE SIZE Front 80 80 16 45 Rear 100 80 16 56 TORQUE VALUES Front axle nut 6 0kg m Rear axle nut 11 0kg m 3 1 dC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace 1f necessary A Adjust C Clean R Replace T Tighten Whichever Regular Service Mileage km comes 4000 6000 8000 9000 10000 New 1 1116 T 1 Gear oil Note 3 0107901 eese sh eee Clean ar every 2000km and replace ifnecessary Bessem it te 1111111 seresa In the interest of safety we recommend these items should be serviced only by an author ized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 FUEL LINE Fuel Filter Remove the met in box 2 Chec
32. harnesses B After clamping check each wire to make sure it 1S secure Do not squeeze wires against the weld or its clamp After clamping check each harness to make sure that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 1 5 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 B Symbols W Route harnesses so they are neither The following symbols represent the pulled tight nor have excessive slack servicing methods and cautions included in this service manual Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover 15 used to protect the wire harnesses it shall be installed securely we specified points Use Do not break the sheath of wire Engine Oil designated engine oil for lubrication B fa wire or harness 15 with a broken sheath repair by wrapping it with protective tape or replace it Grease Apply grease for lubrication B When installing other parts do not press or squeeze the wires B After routing check that the wire harnesses Transmission Gear Oil 90
33. in the Troubleshooting dC KYMCO PEOPLE 125 150 15 The ignition system adopts CDI unit and the ignition timing cannot be adjusted f the timing is incorrect inspect the CDI unit and A C generator and replace any faulty parts Loose connector and poor wire connection are the main causes of faulty 1gnition system Check each connector before operation Use of spark plug with improper heat range 1s the main cause of poor engine performance The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance 15 also described in this section Inspect the ignition switch according to the continuity table specified page 17 4 nspect the spark plug referring to Section 3 Remove the A C generator and pulser coil referring to Section 14 SPECIFICATIONS Item Spark plug Hot type Standard standard type C7HSA NGK C6HSA NGK Cold type CSHSA NGK Spark plug gap Ignition timing F mark Full advance Primary coil Ignition coil resistance 20C Secondary coil Pulser coil resistance 20 Ignition coil primary side max voltage Pulser coil max voltage TESTING INSTRUMENT Kowa Electric Tester 06 0 7mm 13 BTDC 1 700 100rpm 27 BTDC 5 000 100rpm 0 1 70_ with plug without plug cap 13002 15 2 15 SYSTEM TROUBLESHOOTING High voltage too low Weak battery or low engi
34. master cylinder and brake reservoir with brake fluid INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 75mm Before assembly inspect Ist and 2nd rubber cups for wear or damage ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the Ist rubber cup During assembly the main piston and spring must be installed as a unit without exchange When assembling the piston soak cups in brake fluid for a while Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the diaphragm Install the brake lever PEOPLE 125 150 Diaphragm Main Piston Master Cylinder PN snap Ring Spring 12 10 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION PEOPLE 125 150 Place the brake master cylinder on the handlebar and install the holder with the mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 10 1 4kg m Bolts Install the brake fluid tube with the attaching bolt and two sealing washers Install the handlebar covers Connect the front and rear stop switch wire connectors the brake reservoir with recommended
35. properly Worn brake shoes at cam contacting area Soft rear shock absorber Worn brake cam Weak shock absorber spring Worn brake drum Faulty damper 13 2 13 REAR WHEEL REAR BRAKE KYMCO U REAR SUSPENSION PEOPLE 125 150 REAR WHEEL REMOVAL Remove the exhaust muffler joint lock nuts and exhaust muffler lock bolts Remove the exhaust muffler 2 6 Remove the rear axle nut Remove the rear shock absorber Remove the link flake Remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over If the rim runout exceeds the specified service limits check the final shaft bearing for excessive play and the final shaft for bending Inspect the rear wheel and wheel rim for runout 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 INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle shaft threads Then tighten the rear axle nut Torque 11 0 13 0kg m Install the exhaust muffler 2 6 Tighten the exhaust muffler joint lock nuts and exhaust muffler lock bolt C Torque Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m 13 3 ut Re
36. the cylinder head contact surface Be careful not to damage cylinder head mating surface INSPECTION CYLINDER HEAD Check the spark plug hole and valve hole areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if Over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner 31 2mmr replace if below Outer 34 1mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 90mm replace if below EX 4 90mm replace if below 7 9 KYMCO PEOPLE 125 150 An b B M l dC KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals Tap the valve stems gently with a plastic hammer for 2_ 3 times to firmly seat the cotters Be careful not to damage valves CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket Install the cam chain guide Install the cylinder head C Cylinder Head CAMSHAFT HOLDER ASSEMBLY Install the exhaust valve rocker arm to the mark side of camsh
37. 1 KYMCO 10 FINAL REDUCTION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil GEAR OIL SAE 907 Capacity At change 0 181 liter At disassembly 0 21 liter TORQUE VALUES Transmission case cover bolt 1 2kg m SPECIAL TOOLS Driver handle A Outer driver 32x35mm Outer driver 37x40mm Outer driver 42x47mm Pilot 15mm Pilot 17mm Pilot 20mm Crankcase assembly tool Assembly shaft Assembly collar TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission e Seized or burnt transmission Oil leaks Oil level too high Worn or damaged oil seal 10 2 dC KYMCO 10 FINAL REDUCTION PEOPLE 125 150 FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler Remove the rear wheel 13 2 Remove the rear brake cable 13 3 Remove the left crankcase cover 9 2 Remove clutch driven pulley 9 8 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 gear and countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Inspect the final gear and final shaft for wear damage or seizure 10 3 10 FINAL REDUCTION Check left crank
38. 5 150 IGNITION TIMING The CDI unit is not adjustable If ig nition timing is incorrect check the igni tion system 15 6 Remove the rear right side cover Remove the timing hole cap Check the ignition timing with a timing light When the engine is running at idle speed the ignition timing is correct if mark on the flywheel aligns with the index mark on the crankcase Also use a timing light to check the advance mark Raise the engine speed to 5 000rpm and the index mark on the crankcase should be aligned with the advance mark on the flywheel CYLINDER COMPRESSION Warm up the engine before compression test Remove the met in box and frame center cover 2 Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 12 8kg cm 570rpm If the compression is low check for the fol lowing Leaky valves Valve clearance to small Leaking cylinder head gasket Piston rings are worn out Piston cylinder 15 worn out If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head Timing Hole Cap KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 FINAL REDUCTION GEAR OIL OIL LEVEL CHECK i Place the motorcycle on its main stand on level ground for oil level check Stop the engine and remove the oil check bolt The
39. 8 are not twisted or kinked Gear Oil Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or Special surrounding parts in all steering positions Use special tool B When a testing device is used make sure to Caution understand the operating methods thoroughly and operate according to the operating instructions V Warning Be careful not to drop any parts B When rust 15 found on a terminal remove the rust with sand paper or equivalent before connecting B not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind 1 6 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 TORQUE VALUES STANDARD TORQUE VALUES 5mm bolt nut 45 5mm screw 6mm bolt nut 6mm screw SH bolt Smm bolt nut 6mm flange nut 10mm bolt nut 8 Smm flange bolt nut 12mm nut l 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE NO Cylinder head bolt A Double end bolt Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head nut alve adjusting lock nut Cam chain tensioner slipper bolt Double end bolt Apply oil to threads Drive face seal cover bolt Starter clutch cap bolt Drive face nut Spark plug Starter clutch lock nut Cam chain tensioner screw Left hand threads 4 1 2 4 2 1 1 1 1 3
40. Compressor Hold the clutch driven pulley assembly with the clutch spring compressor Be sure to use clutch spring compressor to avoid spring damage Clutch Spring Compressor Set the clutch spring compressor 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 Check the driven face for wear or damage Measure the clutch lining thickness Service Limit 33 94mm replace if below Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Movable Driven Face 9 8 9 DRIVE AND DRIVEN PULLEYS KICK STARTER Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 163 7mm replace if below Check the driven face for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if over 9 9 KYMCO PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER PEOPLE 125 150 Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face Discard the removed bearing and replace with new Remove the snap ring and drive the outer bearing o
41. E 125 150 6 1 KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The engine removal operation 15 required to support the engine Be careful not to damage the motorcycle body cables and wires during engine removal Use shop towels to protect the motorcycle body during engine removal Parts requiring engine removal for servicing Crankcase Crankshaft 6 2 6 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Disconnect the battery negative cable Remove the frame body cover 2 Disconnect the engine negative cable Disconnect the spark plug high tension wire Disconnect the auto bystarter wire connector Disconnect the A C G wire connector Disconnect the starter motor cable from the starter relay Remove the spark plug cap Disconnect the fuel tube at the carburetor side Disconnect the auto fuel valve vacuum tube from the tee tube Disconnect the throttle cable from the carburetor Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube 6 3 KYMCO PEOPLE 125 150 dC KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 Screw Remove the air cleaner bolts Remove the rear brake adjusting nut connecting pin and rear brake cable Remove the two nut on the battery tank Remove the rear shock absorbers mounting bolts Remove the four A C generator cooling fan cover bolts and cooling fan cover
42. LINDER HEAD REMOVAL Remove the camshaft 7 4 A 1 Remove the carburetor 5 4 Remove the exhaust muffler Remove the carburetor intake manifold ta 4 gt L in T 1 1 LI 1 4 J J Seas Remove the cooling fan cover 14 7 Remove the engine cover bolts and screws Separate the engine cover joint claws 7 7 dC KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Remove the two cylinder head bolts Remove the cylinder head Dowel Pins Cylinder Head Gasket Remove the dowel pins and cylinder head gasket Remove the cam chain guide Eu Ua 1 i m us m i Remove all gasket remnants from cylinder surface Avoid damaging cylinder contact surface Be careful not to drop any gasket remnants into the engine CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassemble Valve Spring Compressor Valve Spring Compressor Attachment Valve Spring Compressor Attachment 7 8 7 CYLINDER HEAD VALVES Remove carbon deposits from the combustion chamber Clean off any gasket remnants from
43. M CHAMBER 5 6 FEOA TC HA MBER 5 7 CARBURETOR INSTALLATION ee eee ee eere eere nete rere rere neon 5 10 5 11 5 11 AUTOTUEL VAI 5 12 AIR CLEE SNEER rc ie 5 13 5 0 KYMCO FUEL SYSTEM PEOPLE 125 150 FUEL SYSTEM KYMCO 5 FUEL SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous When working with gasoline keep sparks and flames awa from the working area Gasoline is extremely flammable and is explosive under certain conditions Be sure to work in a well ventilated area Do not bend or twist control cables Damaged control cables will not operate smoothly When disassembling fuel system parts note the locations of O rings Replace them with new ones during assembly Before float chamber disassembly loosen the drain screw to drain the residual gasoline into a clean container After the carburetor 15 removed plug the intake manifold side with a clean towel to prevent foreign matters from entering Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel The
44. ON and the starter relay is normal if you hear a click when the starter button 1s depressed If there 1s no click sound nspect the starter relay voltage nspect the starter relay ground circuit nspect the starter relay operation STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand Measure the voltage between the starter relay connector green yellow wire and engine ground Turn the ignition switch ON and the battery voltage should be normal when the brake lever is fully applied If the battery has no voltage inspect the stop switch continuity and cable 16 5 dC KYMCO 16 STARTING SYSTEM PEOPLE 125 150 STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire terminal and ground There should be continuity when the starter button 1s 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 between the starter relay large terminals The relay is normal if there 1s continuity INSTALLATION Connect the starter motor cable connector and properly install the waterproof rubber jacket Check
45. R WIA LION estote eesur REPRE 17 2 17 2 HEADLIGHT 17 3 FRONT TURN SIGNAL LIGH gre 17 3 POSITION REAR TURN SIGNAL LIGHT 17 3 IGNITION SAEI 17 4 OWN 17 4 SWW EE OT Bm 17 6 HORN 17 6 17 6 FUEC D 17 6 VEM ES 17 7 INSTRUMENT S mr seuss iecesesnes 17 8 17 0 dC KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 ELECTRICAL EQUIPMENT LAYOUT Headlight Auto Bystarter Fuel Unit witch 5100 Switches 2 p 1 gt z 4 1 Lati x 4 4 4 Y Bb 4 ae P 4 4 4 Flip T amp 7147 i rs NI EMT a me ur i gere ari Headlight Switch Ignition Switch Auto Horn Starter Button Bystarter 17 1 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS An electric tester 15 needed to measure or test the electric equipment Be sure to use fuses
46. Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 following Throttle grip free play 3 3 ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger Remove the engine hanger bracket bolt and nut Remove the engine hanger bracket Inspect the engine hanger bushings and stopper rubbers for wear or damage ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine Install the engine hanger bracket bolt and tighten the nut ENGINE INSTALLATION Install the engine and tighten the engine mounting bolts Torque 5 0kg m Tighten the rear shock absorbers mounting bolts Torque Up side 4 0kg m Down side 2 5kg m Install the removed parts in the reverse order of removal wires and cables properly After installation inspect adjust 0 5 dC KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CYLINDER HEAD VALVES SERVICE INFORMA NON 7 2 IROUBLESHOOTENG 7 3 CAMSHAFT 7 4 CYLINDER HEAD REMOVAL ee 7 7 CYLINDER HEAD 5 4 7 8 CYLINDER HEAD ASSEMBLY ee 7 10 CYLINDER HEAD INSTALLATION cernentes 7 10 CAMSHAF TINS TALLA TON
47. aft holder Install the intake valve rocker arm and the rocker arm shafts Align the cutout on the front end of the intake valve rocker arm shaft with the bolt of the camshaft holder Align the cross cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder 45 L4 Te Valve Rocker Arm 7 10 KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CAMSHAFT INSTALLATION _ MES 10 M Turn the flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the camshaft onto the cylinder head Install the cam chain over the camshaft gear Round Hole Punch Marks Dowel Pins Install the dowel pins Install camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts and two bolts Torque Cylinder head nut 2 0kg m Apply engine oil to threads of the cylinder head nuts Diagonally tighten cylinder head nuts 02 3 times Washer Nut Tensioner Screw Adjust the valve clearance 3 5 Turn cam chain tension screw counter clockwise to release it 7 11 dC KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Apply engine oil to a new O ring and install i
48. alve cover and then tighten the two screws Be sure to set vacuum diaphragm lip into the groove on the carburetor When installing the air cut off valve cover make sure that the vacuum diaphragm 15 properly installed VACUUM CHAMBER DISASSEIMBLY Remove the two vacuum chamber cover screws and cover Remove the spring and vacuum diaphragm piston dC KYMCO FUEL SYSTEM PEOPLE 125 150 Vacuum Diaphragm Piston Push the needle holder in and turn it left to remove the needle holder Remove the spring and jet needle from the piston Be careful not to damage the vacuum diaphragm INSPECTION Inspect the needle for stepped wear Inspect the vacuum piston for wear or damage Inspect the diaphragm for deterioration and tears ASS FMBLY Install the vacuum piston diaphragm in the carburetor body and align the tab on the diaphragm with the groove in the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Becareful not to damage the diaphragm Hold the vacuum piston while tightening the vacuum chamber cover FLOAT CHAMBER DIS ASSEMBLY Remove the four float chamber screws and the float chamber 5 7 dC KYMCO FUEL SYSTEM PEOPLE 125 150 Screws Remove the float pin float and float valve Float Valve Float Pin INSPECTION Inspect the float valve and valve seat for damage or cl
49. ar 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEOPLE 125 150 REAR BRAKE Remove the rear wheel 13 3 Inspect the rear brake drum Measure the rear brake drum I D Service Limits 131mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil or grease off the brake linings REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Remove the brake arm bolt to remove the brake arm Remove the brake cam 13 4 13 REAR WHEEL REAR BRAKE REAR SUSPENSION REAR BRAKE ASSEMBLY Apply grease to the anchor pin Apply grease to the brake cam and install it Install the brake shoes Apply engine oil to the felt seal and install it to the brake cam Install the brake arm Align wide groove on wear indicator plate with the wide tooth of the brake cam Install and tighten the brake arm bolt Align the scribed line on the brake arm with the punch mark on the brake cam Torque 1 0kg m Install the brake arm return spring Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel 13 3 Adjust the rear brake lever free play 3 8 REAR SHOCK ABSORBER REMOVAL Remove the frame body cover 2 Remove air cleaner case 5 13 13 5 Brake Arm Bolt KYMCO
50. are loose tighten them to the specified torques Torques Front 6 0kg m Rear 11 0kg m 3 10 4 LUBRICATION SYSTEM PEOPLE 125 150 LUBRICATION SYSTEM SERVICE INFORMATION 4 2 UNE 4 2 ENGINE OIL OM 4 3 DIUI 4 3 4 LUBRICATION SYSTEM PEOPLE 125 150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump 4 1 KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump 15 installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm es _ Oil pump Rotor end to pump body clearance 0 05 09 10 TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter or oil passages Worn or poorly installed piston rings Not use the specified oil Worn valve guide or seal 4 2 KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 ENGINE OIL OIL FILTER Upper Level Lower Level
51. case bearings for excessive play and inspect the oil seal for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using a bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover dC KYMCO PEOPLE 125 150 Final Shaft Bearing Drive Shaft Bearing LE i14 i EJ p Countershaft Bearing Drive Shaft Bearing Oil Seal Countershaft Bearing Countershaft Bearing dC KYMCO 10 FINAL REDUCTION PEOPLE 125 150 Bearing Remover 17mm BEARING REPLACEMENT LEFT CRANKCASE Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using a bearing remover Drive new bearings into left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Inspect the drive shaft and gear for wear or damage Drive Shaft Final Gear Install the final gear and final shaft into the DG left crankcase Install the countershaft and gear into the left crankcase Install the washer
52. ck carburetor for clogging Not clogged Clogged Clogged carburetor jets Remove spark plug and inspect Plug not fouled or Plug fouled or ouled spark plug discolored discolored Incorrect heat range plug dipstick and check oil level and condition level too high Correct and not Incorrect or level too 1 il M du Remove cylinder head oil pipe bolt and inspect LC d Valve train lubricated Valve train not logged oil pipe properly lubricated properly aulty oil pump Check if engine overheats isse x Worn cylinder and piston rings Mixture too lean overheats Excessive carbon buildup in combustion chamber Rapidly accelerate or run ignition timing too early at high speed E Excessive carbon build up in combustion chamber Engine does not knock Engine knocks Poor quality fuel lutch slipping Mixture too lean Ignition timing too early 1 19 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check carburetor pilot woodruff key in crankshaft 15 not fixed screw adjustment position ixture too rich turn screw out ixture too lean turn screw in Check carburetor gasket for air leaks Deteriorated O ring Carburetor is not securely Damaged insulator rubber Broken vacuum tube Re
53. e Intake 0 10 cold mm Idle speed rpm 1700rpm 1216846 uomneornmqnT TT Forced pressure amp Oil pump type Inner outer rotor type Oil filter type Full flow filtration 0 91 liter 0 81 liter 4 on 8012914 5 E lt lt MAA SUIAOIA dC KYMCO PEOPLE 125 150 Air cleaner type amp No 6 8 liters JO039JnQ I 54 uous length dia mm ignition timing 157 28 BTDC L 700 Non contact point type Spark plug NGK C7HSA 06 0 7mm 12V6AH Dry multi disc clutch Type Non stage transmission Operation Automatic centrifugal Two stage reduction Reduction 1st 0 86 2 64 ratio 10 98 23 SIUISUEI kg cm 2 00 2 25 Turning angle Brake svstem type Disk brake Suspension Front Telescope Rear Swing arm type Shock absorber type Steel pipe KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Name amp Model No PEOPLE 150 ulojs S Jon 10391192270 8012914 54 uous Perform Braking distance m SIUISUE 9 lt lt e MAd SUIAOJA width mm 690 Type Ended TY CDI 181 Non contact point Tires Spark plug NGK C7HSA 44 ance E Starting motor amp Operation Automatic ce
54. eck to confirm that there 1s 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 15 continuity replace with new ones Dust Seal Check if the needle bushing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage Bushing 16 4 KYMCO 16 STARTING SYSTEM PEOPLE 125 150 Front Cover ASSEMBLY Apply grease to the dust seal in the front Install brushes onto brush holders Apply thin coat of grease to two ends of the armature shaft Insert the commutator into the front cover Be careful not to damage the brush and armature shaft mating surfaces When installing the commutator the armature shaft should not damage the dust seal lip Commutator Groove 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 When assembling front cover motor case slightly press down the armature shaft to assemble them STARTER RELAY INSPECTION Remove the frame body cover 2 2 Turn the ignition switch
55. edometer Cable Regulator Rectifier Instrument Cable Horn Resistor Front Brake Fluid Tube 1 11 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Regulator Rectifier Resistor E Bu 2 Throttle Cable i EE 2 Es r Wire Harness 1 12 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Battery Cable Reserve Fuse j E Fa i Fuse CDI Unit Wire Harness 1 13 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Crankcase Breather Tube d X p Auto Bystarter Wire Ignition Coil 1 E Vacuum Tee b Hi p F MER Jd a Throttle Cable Fuel Valve Vacuum Tube am Wyte 1 Ground _ Generator Wire Fuel Tube 1 14 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Throttle Cable Wire Harness Auto Bystarter Wire Starter Motor Wire Starter Relay Fuel Tube iN Crankcase Braten Tube Fuel Unit Carburetor Vacuum Tee Vacuum Tube SL Cleaner Auto Bystarter 1 15 PEOPLE 125 150 KYMCO 1 GENERAL INFORMATION EE
56. en the battery service life f a battery 15 not used for a long time it will discharge by itself and should be recharged every 3 months A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when capacity is insufficient Recharging a new battery will prolong its service life nspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation t 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 emergency Remove the battery from the motorcycle for charging When replacing the battery do not use a traditional battery When charging check the voltage with an voltmeter SPECIFICATIONS Standard Capacity Model 12V 6AH Voltage Fully charged 13 1V Battery 20 Undercharged 12 3V Charging current STD 0 7A Quick 3 0A Charging time STD 5_ 10hr Quick 30min 0 1 14K W 5000rpm A C Generator 2 coil resistance Yellow Green 0 1 1 00 2 POIL isa White Green 0 2 120 ST 12 0_ 14 0 5000 Electric tester tachometer Limit voltage 10_ 13 0V 5000rpm Charging 13 5 15 5V
57. engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip starter idle gear Friction spring movable part shaft movable part High temperature resistant grease shaft movable grooved part Starter spindle movable part starter one way clutch threads Thread locking agent A C generator connector Adese Transmission case breather tube 1 9 KYMCO PEOPLE 125 150 1 GENERAL INFORMATION 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 Engine Oil Dn Grease Front Brake Lever Grease Pivot Seat Lock Pd Grease Rear Wheel Bearings Front Brake Cable Speedometer Cable Throttle Cable Fi Grease Speedometer Gear Front Wheel Grease Engine Oil Grease Bearings Brake Cam Anchor Pin Main Stand Pivot Rear Brake Cable Brake Cam Front Shock Absorber Lower Anchor Pin Mount Bushings Pivot 1 10 1 GENERAL INFORMATION PEOPLE 125 150 CABLE amp HARNESS ROUTING Front Stop Switch Wire Front Brake Reservoir Rear Stop Switch Wire 3 Front Brake Fluid Tube STET CL EE v xo 1 Throttle Cable Rear Brake Cable Ignition Switch Spe
58. er piston oil seal Clogged brake fluid line Deformed brake disk Unevenly worn brake caliper 12 3 KYMCO PEOPLE 125 150 Driver handle A Pilot 10mm Outer driver 37x40mm Bearing remover Front wheel wobbling Bent rim Excessive wheel bearing play Bent spoke plate Faulty tire mproperly tightened axle nut Soft front shock absorber Weak shock springs nsufficient damper oil Front shock absorber noise Slider bending Loose fork fasteners ack of lubrication 12 WHEEL FRONT BRAKE FRONT SUSPENSION PEOPLE 125 150 FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Disconnect the speedometer cable mg Speedometer Cable Axle Nut Remove the front axle nut and pull out the axle Remove the front wheel Remove the front brake panel INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout 1s 1 2 of the total indicator reading Service Limit 0 2mm replace if over WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 12 4 12 FRONT WHEEL FRONT BRAKE __ FRONTSUSPENSION PEOPLE 125 150 FRONT WHEEL BEARING Side Sol Remove the side collar and dust seal 1 nmi h Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly A
59. ery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not start Faulty starter motor Faulty starter clutch Starter motor rotates reversely Weak battery 16 2 KYMCO 16 STARTING SYSTEM PEOPLE 125 150 STARTER MOTOR REMOVAL Before removing starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly Remove the two starter motor mounting bolts and the motor Remove the waterproof rubber jacket and disconnect the starter motor cable connector DISASSEMBLY Remove the two starter motor case screws front cover motor case and other parts Motor Case INSPECTION Inspect the removed parts for wear damage or discoloration and replace if necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity 16 3 dC KYMCO 16 STARTING SYSTEM PEOPLE 125 150 SIARTER MOTOR CASE CONTINUITY CHECK Ch
60. fied brake fluid or mix different brake fluids be cause it will damage the brake system Make sure to bleed air from the brake system BRAKE PAD DISK REPLACEMENT The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Compress the brake caliper seat and press down the fixed reed to take out the brake pads 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION PEOPLE 125 150 Install brake pads in reverse order of removal Tighten the brake pad pin bolt Torque 1 5 2 0kg m Keep grease or oil off brake pads to avoid brake failure BRAKE DISK Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKEMAS TER CYLINDER REMOVAL First drain the brake fluid from the hydraulic brake system When servicing 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 DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder 1 2 9 snap Ring 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION Remove the main piston and spring from the brake master cylinder Clean the inside of the
61. four bolts attaching the cooling fan cover to remove the fan cover 14 7 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR PEOPLE 125 150 Remove the cooling fan by removing the four Cooling Fan cooling fan attaching bolts pos Hold the flywheel with an universal holder Remove the flywheel nut Special Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Flywheel Puller Remove the A C generator wire connector 14 8 14 BATTERY CHARGING SYSTEM KYMCO ____ GENERATOR PEOPLE 125 150 Remove the A C generator wire set plate Remove the pulser coil bolts Remove the A C generator wire rubber sleeve and pulser coil from the right crankcase Remove the two bolts and A C generator stator Wire Set Plate INSTALLATION Flywheel 3 5kg A Cooling Fan Fan Cover Fd Generator ire Set Plate A C Generator Wire x Rubber Sleeve Stator Install the generator stator pulser coil onto right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 5kg m Stator 0 9kg m Install the A C generator wire rubber sleeve and A C generator wire set plate Pulser Coil Set Plate 14 9 14 BATTERY CHARGING SYSTEM KYMCO GENERATOR Connect generator wire connector Clean the taper hole in the flywheel off any burrs and dirt Install t
62. h or lean mixture Contaminated fuel Intake air leak Incorrect idle speed Incorrectly adjusted pilot screw Clogged idle system or auto bystarter passages Incorrectly adjusted float level Lean mixture Clogged fuel jets Faulty float valve Float level too low e Clogged fuel system Intake air leak Faulty vacuum piston Faulty throttle dC KYMCO FUEL SYSTEM PEOPLE 125 150 CARBURETOR REMOVAL Auto Bystarter Wire Remove frame body cover 2 Disconnect the auto bystarter wire connector 1 Loosen drain screw and drain fuel from the float chamber Disconnect the fuel tube and vacuum tube at the carburetor Vacuum Tube Lock Nut Adjusting Nut Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the carburetor intake manifold band and air cleaner connecting tube band screws and then remove the carburetor Intake Manifold Air Cleaner mE Band Tube Band Throttle Cable AUTO BYSTARTER OPERATION INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5 9 max 10 minutes minimum after stopping the engine If the reading 15 not within the limit replace the auto bystarter with a new one FUEL SYSTEM PEOPLE 125 150 Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter yellow wi
63. he movable drive face assembly Remove the drive pulley collar Movable Drive Assembly DISASSEMBLY Remove the ramp plate Remove the weight rollers 9 DRIVE AND DRIVEN PULLEYS KICK STARTER INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 17 4mm replace if below Measure the movable drive face bushing I D Service Limit 24 06mm replace if over Check the drive pulley bushing for wear or damage Measure the O D of the drive pulley bushing sliding surface Service Limit 23 94mm replace if below 9 5 dC KYMCO PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER PEOPLE 125 150 ASSEMBLY Install the weight rollers into the movable drive face Install the ramp plate 9 6 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER PEOPLE 125 150 Insert the drive pulley collar into the movable Drive Pulley Collar drive face prc 1 22 E S Saad 1 CC gam m 4 i er INSTALLATION Install the movable drive face onto the crankshaft INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 125 5mm replace if over CLUTCH DRIVEN PULLEY DISASSEMBLY 4 77 Driven Pulley 9 7 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICKSTARTER PEOPLE 125 150 Clutch Spring
64. he poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed Compression too low Compression too low ncorrect valve clearance adjustment Burned or bend valves ncorrect valve timing Broken valve spring Poor valve and valve seat contact Leaking cylinder head gasket Warped or cracked cylinder head contact surface Poorly installed spark plug Compression too high Excessive carbon build up in combustion chamber 7 3 White smoke from exhaust muffler Worn valve stem or valve guide Damaged valve stem seal Abnormal noise ncorrect valve clearance adjustment e Sticking valve or broken valve spring Damaged or worn camshaft Worn cam chain guide Worn camshaft and rocker arm dC KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Cylinder Head Cover V p 4 A 1 CAMSHAFT REMOVAL Remove the center cover Remove the four cylinder head cover bolts to remove the cylinder head cover Remove the cam chain tensioner cap screw and the O ring Turn the cam chain tensioner screw clockwise to tighten it Turn the flywheel counterclockwise so that the mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Punch Marks Round Hole dC KYMCO 7
65. he woodruff key in the crankshaft keyway Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key inside of the flywheel is magnetic Make sure that there 15 or nut before installation Hold the flywheel with the universal holder and tighten the flywheel nut Torque 5 5kg m Universal Holder Install the cooling fan Torque 0 9kg m Install the fan cover Install the rear right side cover 2 PEOPLE 125 150 Woodruff Key KYMCO 15 SYSTEM PEOPLE 125 150 IGNITION SYSTEM 15 2 5 15 3 CDI UNIT 15 4 15 5 PULSER 6 15 6 15 0 dC KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 Battery CDI Unit Ignition Switch Pulser m Spark Plug IGNITION CIRCUIT Ignition Switch e Batterv 2 CDI Unit Generator 15 1 15 SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Check the ignition system according to the sequence specified
66. ight unit Remove adjust the headlight beam bolt The installation sequence 15 the reverse of removal After installation adjust the headlight beam 3 9 FRONT TURN SIGNAL LIGHT Remove the turn signal bulb shell screw 2 Remove the front turn signal bulb socket and replace the bulb The installation sequence 15 the reverse of removal Screw Position Light Shell F F POSITION LIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the bulb shell screw The installation sequence is the reverse of removal 17 3 dC KYMCO l7 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 IGNITION SWITCH Ignition Switch Coupler INSPECTION Remove the front cover 2 4 Disconnect the ignition switch wire coupler Check for continuity between the wire terminals jock oo TE o Replacement Remove the two mounting bolts to remove the ignition switch holder Remove the two screws to remove the ignition switch for replacement Ignition Switch Bolts Headlight Switch HANDLEBAR SWITCHES HEADLIGHT SWITCH INSPECTION Remove the handlebar front and rear covers 2 4 Disconnect headlight switch wire couplers Check for continuity between wire terminals OFF Brown Whi 17 4 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 STARTER SWITCH HRW bow COLOR Yellow Red HORN SWITCH COLOR Light
67. imits True Roundness 0 05mm repair or replace if over Cylindricity 0 05mm or rep lace if over Middle 7 dC KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Inspect the top of the cylinder for warpage Service Limit 0 05mmrepair or replace if over Measure the connecting rod small end I D Service Limit 15 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Be careful not to damage or break the piston and piston rings All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking Second ce rai ias Side Rail Oil Ring gt Side Rail 8 7 dC KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Second PISTON INSTALLATION Remove any gasket remnant from the crankcase surface i Be careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip 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 CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Be ca
68. in jet Measure the float level Float Level 18 5mm Float Level Gauge CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold aligning the tab on the carburetor with the cutout in the intake manifold Tighten the band screw Install the air cleaner connecting tube and tighten the band screw Connect the throttle cable to the throttle wheel on the carburetor Connect the fuel tube and vacuum tube to the carburetor Connect the auto bystarter wire connector Perform the following inspections and adjustments Throttle grip free play 3 3 Carburetor idle speed 3 6 dC KYMCO PEOPLE 125 150 KYMCO FUEL SYSTEM PEOPLE 125 150 FUEL TANK REMOVAL Remove the frame body cover Disconnect the fuel unit wire connector Disconnect the fuel tube and vacuum tube at the auto fuel valve Remove the fuel tank frame mounting bolts and fuel tank frame Remove the four fuel tank mounting bolts and fuel tank INSTALLATION Install the fuel tank in the reverse order of removal FUEL UNIT Refer to Section 17 for the fuel unit inspection REMOVAL Disconnect the fuel unit wire connector Removal the three bolts on the fuel unit Do not bend the fuel unit float arm otherwise the fuel unit metering values 5 ill dC KYMCO FUEL SYSTEM PEOPLE 125 150 Install the fuel unit Make sure that the nick on the retainer 15
69. ine Turn on the headlight switch Adjust the headlight aim by turning the head light aim adjusting screw SUSPENSION FRONT Fully apply front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage shen Check action shock absorber by compressing it several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn STEERING HANDLEBAR Raise the 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 stem ball race 12 15 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found 1 11 3 9 KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE Sheen Rogo 22kgem TIRE SIZE Front 80 80 16 45 Rear 100 80 16 56P Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts
70. iven face Install the movable driven face onto the driven face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Guide Roller Pin Guide Roller Install the seal collar iris Remove any excessive grease sure to clean driven face off grease the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor ui Align the flat surface of the driven face with the flat on the clutch drive plate Driven Face 9 12 9 DRIVE AND DRIVEN PULLEYS KYMCO __KICK STARTER 125 50 Compress the clutch spring compressor and Clutch Spring Sse install the drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 5kg m Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor INSTALLATION Install the clutch driven pulley onto the drive shaft Keep grease off drive shaft Clutch Driven Pulley Clutch Outer Install the clutch outer Hold the clutch outer with the flywheel holder Install and tighten the clutch outer nut Torque 5 5kg m Flywheel Holder Install the drive belt Flywheel Holder Install drive pulley face starting ratchet _ Drive Pulley and drive face nut When installing
71. k the fuel lines and replace any parts which show signs of deterioration damage or leakage ui Do not smoke or allow flames or sparks in your working area THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free 2 6mm Major adjustment of the throttle grip free play is made 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 loos ening the lock nut and turning the adjusting nut E Adjusting Nut 3 3 dC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 AIR CLEANER LL AIR CLEANER REPLACEMENT 1 Remove the rear side covers 2 Remove the six air cleaner case cover screws and the cover Remove the air cleaner element by removing the three screws Check the element and replace it if it 1s exces sively dirty or damaged Air Cleaner Case Cover Air Cleaner Element CHANGE INTERVAL More frequent replacement 15 required when riding in unusually dusty or rainy areas The air cleaner element has a vis cous type paper element Do not clean it with compressed air Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire b
72. lder Clutch spring compressor Driver handle A Lock nut wrench 39mm Pilot 20mm Flywheel holder Bearing driver TROUBLESHOOTING Engine starts but motorcycle won t move Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Fouled drive face Engine stalls or motorcycle creeps 9 2 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 125 150 Broken clutch weight spring LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw Remove the left crankcase cover bolts and left crankcase cover Remove the seal rubber and dowel pins DRIVE PULLEY REMOVAL Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet Remove the drive pulley face Special Universal Holder CLUTCH DRIVEN PULLEY Remove the drive pulley and drive belt Hold the clutch outer with the flywheel holder and remove the clutch outer nut Remove the clutch outer Remove the clutch driven pulley and drive belt Special Flywheel Holder 9 3 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER PEOPLE 125 150 INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 19 0mm replace if below Use specified genuine parts for replace ment Remove t
73. lso 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 Special Bearing Remover Bearing Remover Head 12mm Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the sealed end facing out Driver handle 1 Driver Handle A 12 5 12 FRONT WHEEL FRONT BRAKE KYMCO _ FRONT SUSPENSION 125 150 Apply grease to new dust seal and mE Seal install the dust seal Install side INSTALLATION Apply grease to the brake panel dust seal hp Apply grease to speedometer gear engaging and sliding parts Install the brake panel by aligning the speedometer retaining pawls with the hub cutouts If not aligned retaining will be deformed when the axle nut is tightened After installing the axle turn the wheel to make sure that the speedometer drive shaft rotates freely Apply a thin coat of grease to the axle shaft Install the front wheel by aligning the brake panel groove with the front fork tab Insert the axle shaft Install and tighten the axle nut Torque 6 0kg m Install the fr
74. lty charging system Broken wire harness Poorly connected coupler Check CDI unit with the CDI unit tester 5 d Check ignition coil with the CDI unit Faulty ignition coil 1 23 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 2 FRAME COVERS EXHAUST MUFFLER FRAME COVERS LAYOUT 2 1 SERVICE INFORMATION 2 2 cee 2 2 FRAME COVERS e 2 4 dC KYMCO 2 FRAME COVERS EXHAUST MUFFLER _ PEOPLE 125 150 FRAME COVERS LAYOUT 2 1 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When removing frame covers use special care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Exhaust muffler air leaks Clogged exhaust muffler 2 2 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 dC KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 FRAME COVERS 1 REAR HAND GRIP REMOVAL Remove three bolts attaching the rear hand grip Remove the rear hand grip
75. move spark plug and install it into Spark plug cap to test gt spark by connecting it no Faulty or fouled spark plug Faulty CDI unit Weak or inter Faulty A C generator Good spark mittent spark Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch aulty air cut off valve Damaged vacuum tube logged or damaged air vent ole 1 20 dC KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Probable Cause mm aulty CDI unit Faulty pulser coil he woodruff key in the crankshaft 1s not fix position Check carburetor pilot screw adjustment Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat Check fuel pump for fuel supply Empty fuel tank logged fuel tube or filter Fuel flows freely Fuel flow restricted logged Fuel tank cap breather hole HH Faulty auto fuel valve Check carburetor jets for clogging Clean and unclog Cam timing gear aligning marks not aligned Check valve spring tension 1 21 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause 6 Start engine and test limit voltage of EMMA battery terminals Normal voltage Voltage does not Dead battery increase Faulty battery
76. ne speed Loose ignition system connection Faulty CDI unit Faulty ignition coil Faulty pulser coil Normal high voltage but no spark at plug Faulty spark plug e Electric leakage in ignition secondary circuit Faulty ignition coil Good spark at plug but engine would not start Faulty CDI unit or incorrect ignition timing mproperly tightened A C generator flywheel 15 3 KYMCO PEOPLE 125 150 No high voltage Faulty ignition switch Faulty CDI unit Poorly connected or broken CDI ground wire Dead battery or faulty regulator rectifier Faulty ignition coil connector Faulty pulser coil 4O KYMCO 15 SYSTEM PEOPLE 125 150 CDI UNIT INSPECTION fL CDI Unit Remove the front cover screws Disconnect the CDI coupler and remove the CDI unit Measure the resistance between the terminals using electric tester Due to semiconductor circuit 1t 18 necessary to use specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use a Sanwa Electric Tester or Kowa Electric Tester n this table Needle swings then returns indicates that there 1s a charging current applied to a condenser The needle will then remain at eo unless the condenser 15 discharged Unit A Black Black Blue G Blue Yellow Yellow nds Black 150 28
77. nt tool box ie 9 HANDLEBAK COVER REMOVAL Remove the handlebar front cover bolt Remove 9 1 two screws attaching the handlebar rear cover uu Disconnect headlight wire connector and remove the front cover Remove the bolt attaching the handlebar rear cover Remove 9 2 two screws inside the handlebar 4 over The installation sequence the reverse of removal 10 EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove 10 1 the two exhaust muffler lock bolts the exhaust muffler Remove the exhaust muffler joint packing collar 2 When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m 2 6 dC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 INSPECTION ADJUSTMENT SERVICE TINEGORNLATI N sac sccostessnnetararsensnscssensassssnrsobsussoseasmorens 3 1 MAINTENANCE SCHEDULE 3 2 EE NEE 3 3 THROTLE OPERATION ERE bra EFIE ors 3 3 MNO NINE 3 4 SPARKE PLUG eiea r E E EE 3 4 VACYECEEARANC E s E VERE 3 5 CARBURETOR IDLE SPEED 20 98148 8 20689 149999089 202299 psonn 3 5 IGNETTON NIME 3 6 CYLINDER CO VIP 22412315 04042 0020008898 3 6 FINAL REDUCTION GEAR
78. ntrifugal Type Two stage reduction Semi sphere Reduction 151 0 86 2 64 O H C chain drive ratio 2nd 10 98 574 x 57 8 Frond Casterangle 25 9 2 1 Axle Trail length E pressure 1 5 kg7em_ angle Valve mm Close 0 Brake svstem E mm Clse 0 Suspension Valve ckaraned Swing amm cold mm Shock absorbe Idle speed rpm 1700rpm Swing arm Forced pressure amp Steel pipe type Oil filter type Full flow filtration 0 91 liter 0 81 liter 1216846 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants When servicing the motorcycle be sure to use special tools for removal and installation After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly B Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety B Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to
79. ogging Inspect the float valve and valve seat contact area for stepped wear or contamination Worn or contaminated float valve and valve seat must be replaced because it will result 1n float level too high due to incomplete airtightness Remove the main jet needle jet holder needle Jet slow jet and pilot screw Be careful not to damage fuel jets and pilot screw Before removing turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this Do not force the pilot screw against its seat to avoid seat damage Needle Jet Holder Needle Jet Main Jet Clean the removed fuel jets with detergent oil and blow them open with compressed air Blow compressed air through all passages of the carburetor body Also remove and clean vacuum chamber and air cut off valve dC KYMCO FUEL SYSTEM PEOPLE 125 150 ASSEMBLY Install the slow jet needle jet needle jet holder main jet and pilot screw Return the pilot screw to the original position as noted during removal Standard Opening 3 3 turns Install the float valve float and float pin 5 FUEL SYSTEM Float Valve Float Pin FLOAT LEVEL INSPECTION Check the operation of the float valve and float before float level inspection Measure the float level by placing the float level gauge on the float chamber face parallel with the ma
80. oil level shall be at the oil check bolt hole If the oil level is low add the recommended oil to the proper level Recommended Oil GEAR OIL VISCOSITY SAE90 Install the oil check bolt sure washer 15 in good condition OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt Torque 1 0kg m Make sure that the sealing washer is in good condition Fill with the recommended oil Oil Capacity At disassembly 210cc At change 180cc Reinstall the oil check bolt and check for oil leaks Torque 1 2kg m DRIVE BELT Remove the left crankcase cover 9 3 Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if nec essary and in accordance with the Mainte nance Schedule Oil Check Bolt 3 7 dC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 Replace the brake shoes if the arm can not be aligned with the gt mark on the brake panel when the brake is fully applied Refer to 13 4 for brake shoe replace ment BRAKE SYSTEM FRONT BRAKE Measure the front brake lever free play Free Play 10 20mm REAR BRAKE Measure the rear brake lever free play Free Play 10 20mm If the free play do not fall within the limit adjust by turning the adjusting nut KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 Turn the ignition switch ON and start the en g
81. ont brake cable and rotate the front tire to check the speedmeter if be performed Connect the speedometer cable Speedometer Cable 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION PEoPLE1257150 HYDRAULIC BRAKE DRAWING 12 7 12 FRONT WHEEL FRONT BRAKE KYMCO SUSPENSION 125 150 HYDRAULIC BRAKE FRONT BRAKE BRAKE FLUID REPLACEMENT AIR BLEEDING Check the brake fluid level on level ground When operating the brake lever the brake reservoir cap must be tightened securely to avoid splash of brake fluid When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid BRAKE FLUID BLEEDING In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Spilled brake fluid on brake pads or brake disk reduces stopping power Clean the brake pads and brake disk with a high performance brake degreaser 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 15 free of air BRAKE FLUID REFILLING Add DOT 3 brake fluid to brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system Never use dirty or unspeci
82. onto the countershaft Install the dowel pins and a new gasket y E 24 Caunitesshiaht Drive Shaft 10 5 dC KYMCO 10 FINAL REDUCTION PEOPLE 125 150 Transmission Case Cover Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 9 13 Install the rear wheel 13 3 Install the rear brake cable 13 5 After installation fill the transmission case with the specified oil 3 7 Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Specified Gear Oil KYMCO SIGMA GEAR OIL SAE 908 7 Oil Capacity At disassembly 0 21 liter Drain Bolt At change 0 181 liter Install and tighten the oil check bolt Torque 1 0_ 1 5kg 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 10 6 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 CRANKCASE CRANKSHAFT SERVICEINFORMA TION 11 2 DURS Rie espe ETUR Spe 6s 11 2 CRANKCASE SEPARATION 11 3 CRANK SHARD NSPE 11 4 CRANK CG ASE ASS VIBE
83. pilot screw 15 factory pre set and no adjustment is necessary During carburetor disassembly note the number of turns of the pilot screw and use as a reference when reinstalling it A tachometer must be used when adjusting the engine speed Turn the pilot screw in or out slowly to obtain the highest engine speed SPECIFICATIONS 150 cc Item Standard Venir din ion a Identification number VE0S2A VEOSAA 108 110 3 5 Idle speed 1700 100rpm 1700 100rpm Throttle grip free play 2 6mm Pilot screw opening 21 SPECIAL TOOL Float level gauge 5 2 FUEL SYSTEM TROUBLESHOOTING Engine is hard to start No spark at plug Compression too low No fuel to carburetor Clogged fuel filter Restricted fuel line Faulty float valve ncorrectly adjusted float level Engine flooded with fuel Clogged air cleaner Fuel overflowing Intake air leak e Contaminated fuel Faulty auto bystarter Clogged idle system or auto bystarter passages Rich mixture Faulty auto bystarter Faulty float valve Float level too high Clogged air jets Dirty air cleaner Flooded carburetor Backfiring at deceleration Faulty air cut off valve Lean mixture In idle system 5 3 KYMCO PEOPLE 125 150 Misfiring during acceleration Faulty ignition system e Lean mixture Engine idles roughly stalls or runs poorly Clogged fuel system Ignition malfunction Ric
84. pump driven gear nut to remove the oil pump driven gear and drive chain gt 4 4 Oil Pump Driven Gear Bolts Remove the two oil pump mounting bolts and the oil pump 4 LUBRICATION SYSTEM DISASSEMBLY Remove the screw and disassemble the oil pump INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 12mm Measure the inner rotor to outer rotor clearance Service Limit 0 12mm Measure the rotor end to pump body clearance Service Limit 0 2mm 4 5 Pump Body Pump Body Outer Rotor dC KYMCO PEOPLE 125 150 Screw dC KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 ASSEMBLY Inner Rotor Install the outer rotor inner rotor and pump into pump body Insert pump shaft by aligning on shaft with the flat in the inner rotor 1 1 US Le F i i y P k E P 4 1 AN J bt ag E AE 4 1 E T E T d EU PE D gt b 2 a L2 mri gt i e F LI b y 4 4 FL et Install the dowel pin Install the pump cover by aligning the hole in the cover with the dowel pin i M
85. re to the positive terminal of a battery and green wire to the negative terminal Wait 5 minutes and blow the hose with mouth or vacuum pump 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 or vacuum pump If air can be blown into the hose the auto bystarter is normal Vacuum Pump REMOVAL Remove the set plate screws and set plate Remove the auto bystarter from the carburetor Screws tarter Valve AUTO BYSTARTER INSPECTION Check auto bystarter valve and needle nicks wear or damage If any faulty part 1s found replace the auto bystarter as a set Bystarter Needle 7 INSTALLATION Insert the auto bystarter into the carburetor body until it bottoms Position set plate into groove in auto bystarter and tighten the screws Be sure to install the auto bystarter and set plate properly nstall the set plate with its bottom face facing down dC KYMCO 5 FUEL SYSTEM PEOPLE 125 150 Set Plate AIR CUT OFF VALVE URS DISASSEMBLY Disconnect vacuum tube from the air cut off valve Remove two screws to remove air cut off valve cover spring and vacuum diaphragm Vacuum Diaphragm Air Cut off valve ASSEMBLY Install the vacuum diaphragm onto the carburetor Install the spring and air cut off v
86. reful not to damage or break the piston rings Stagger the ring end gaps at 120 to the piston pin Loosely install the cylinder base bolts Install the cam chain guide Install the cam chain tension Tighten the cam chain tension bolts KYMCO 8 CYLINDER PISTON PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER PEOPLE 125 150 DE AND DE NE KICK ARTEE SERVI ETNFORMA TION Reb uos dress dai 9 2 IROUBLESHOOTIUNG OE eae E depu o 9 2 LEFT CRANKCASE 9 3 DILYS BJ I M 9 3 DRIVEN PULLEY 9 7 KICK IO NINE 9 14 0 9 DRIVE AND DRIVEN PULLEYS KICK STARTER PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley clutch and driven pulley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS tem Clutch lining thickness 15 O Driven face spring free length Movable driven face I D 34 000 34 025 Weight roller O D 17 920 18 080 Driven face O D 33 965_ 33 485 TORQUE VALUES Drive face nut 5 5kg m Clutch outer nut 5 5kg m SPECIAL TOOLS Universal ho
87. rush Specified Spark Plug NGK C7HSA Measure the spark plug gap Spark Plug Gap 0 0 0 7mm When installing first screw in spark plug by hand and then tighten it with a Cracks Damage E Washer De formation spark plug wrench 4 KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 VALVE CLEARANCE Cylinder Head Cover Inspect and adjust valve clearance while the engine is cold below 35 C Remove the center cover 2 Remove the cylinder head cover 7 4 Turn the flywheel counterclockwise so that the mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Inspect and adjust the valve clearance Valve Clearance IN 0 12mm EX 0 12mm Loosen the lock nut and adjust by turning the adjusting nut Valve Wrench Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED The engine must be warm for accurate idle speed inspection and adjustment 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 100 When the engine misses or run erratic adjust the pilot screw 3 5 dC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 12
88. sorbers are installed at the same altitude Install the front wheel STEERING HANDLEBAR REMOVAL Remove the handlebar covers 2 Remove the rear brake lever holder bolt to remove the holder Remove the front brake master cylinder holder bolts to remove the brake master cylinder 12 FRONT WHEEL FRONT BRAKE KYMCO FRONTSUSPENSION PEOPLE 125 150 Screw Remove the throttle seat screw Remove the throttle seat from the handlebar and disconnect the throttle cable from the throttle pipe Remove the throttle pipe from the handlebar Remove the steering stem lock bolt collar nut and the handlebar T3 Collar Nu STEERING STEM REMOVAL Remove the steering stem lock nut Special Steering Stem Lock Nut Wrench Lock Nut wrench NM Steering Stem Lock Nut Wrench 12 15 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION PEOPLE 125 150 Remove top cone careful not to lose steel balls 26 on top race and 19 on bottom race Clean the openings of frame covers with clean shop towels Remove the front fork BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Be careful not to damage the steering stem and front fork Drive a new bottom cone race into place with a proper driver a Bottom Cone Race Ball Race Remover 1 E BALL
89. ss 32 35 390 Brake disk runout 025 Brake master cylinder 1D 270 12743 1275 Brake master cylinder piston O D 1267 12 684 1264 Brake caliper piston O D 33910 5994 33901 Brake caliper cylinder LD 5390 33990 3401 5 5 260 3 2_ TORQUE VALUES Steering stem bolt 40 5 0kg m Brake caliper bleed valve 0 6kg m Steering stem lock nut 8 0 12 0kg m Brake fluid tube bolt 2 5 3 5kg m Steering top cone race 0 5 1 3kg m Brake pad pin bolt 1 5 2 0kg m Front shock absorber bolt 2 0 2 5kg m Brake caliper bolt 2 9 3 5kg m Front axle 6 0kg m Brake master cylinder bolt 1 0 l Akg m 12 2 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SPECIAL TOOLS Lock nut wrench Outer driver 28x30mm Ball race remover Pliers close Bearing remover head 10mm TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls nsufficient tire pressure Steers to one side or does not track straight Uneven front shock absorbers Bent front fork Bent front axle or uneven tire Poor brake performance ncorrectly adjusted brake Worn brake linings Contaminated brake lining surface Worn brake shoes at cam contacting area Worn brake drum Poorly connected brake arm Poor brake performance Disk Brake Air in brake system Deteriorated brake fluid Contaminated brake pads and brake disk Worn brake pads Worn brake master cylind
90. stall the piston rings onto the piston and measure the piston ring to 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 Use the piston head to push each piston ring into cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 15 04mm replace if over dC KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Measure the piston pin O D Service Limit 14 96mm replace if below Measure the piston O D Take measurement at 9mm from the bottom 90 to piston hole 12Scc Service Limit 52 3mm replace if below 150cc Service Limit 57 3mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston both X and Y directions 12Scc Service Limit 52 50mm repair or replace if over 150cc Service Limit 57 50mm repair or replace If over Measure the cylinder to piston clearance 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 1s subject to the maximum value calculated Service L
91. sure the clutch cover O D Service Limit 27 94mm replace if over Clutch Cover Starter Idle Gear Measure the starter idle gear I D Service Limit 10 05mm replace if over Measure the starter idle gear shaft O D Service Limit 9 94mm replace if below Idle Gear Shaft Plunger Clutch Body Starter Drive Gear 1 Clutch Cover Roller i Lock Nut Anchor Pin Bolt 10 8 KYMCO 16 STARTING SYSTEM PEOPLE 125 150 ASSEMBLY Anchor Pin Clutch Install the springs plungers and rollers onto the clutch body Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body Apply locking agent to the threads of the clutch cover bolts and tighten them Torque 1 2kg m Apply engine oil to the needle bearing and starter drive gear and then install them to the clutch body INSTALLATION Install the starter clutch onto the crankshaft Apply engine oil to the starter idle gear and shaft and then install them Hold the starter drive gear with the universal holder and tighten the starter clutch lock nut Torque 9 5kg m Special Universal Holder Note that lock nut is left threaded Install the right crankcase cover 4 7 16 9 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 LIGHTS INSTRUMENTS SWITCHES ELECTRICAL EQUIPMENT 17 1 SERVICE INF O
92. t Tighten the cam chain tension cap screw Be sure to install the O ring into groove properly Install a new cylinder head cover gasket and install the cylinder head cover Install and tighten the cylinder head cover bolts Be sure to install gasket into groove properly 7 12 8 CYLINDER PISTON PEOPLE 125 150 CYLINDER PISTON 8 SERVICE INFORMA ION ERES EMI d0E 8 2 TROUBEES HOO NN 8 2 CYLINDER REMOVAL 8 4 PESTONJICEVIOS X315 8 4 PISTONIENSELALIZATION 8 8 CYLINDER INSTALLA 8 8 8 0 KYMCO 8 CYLINDER PISTON PEOPLE 125 150 8 CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO PEOPLE 125 150 The cylinder and piston can be serviced with the engine installed in the frame After disassembly clean the removed parts and dry them with compressed air before inspection TROUBLESHOOTING When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low Worn stuck or broken piston rings Worn or damaged cylinder and piston Compression too high Excessive carbon build up in combustion chamber or on piston head White smoke from exha
93. testing Replace the regulator rectifier if the readings are not within the specifications in the table Regulator Rectifier 4O KYMCO PEOPLE 125 150 UE Yellow 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 A C GENERATOR CHARGING EN ____ Coil Wire White COIL The inspection of generator charging coil can be made with the engine installed INSPECTION Disconnect the A C generator 3P connector Measure the resistance between the A C generator white wire and engine ground with an electric tester Standard 0 2 120 20 Replace the A C generator charging coil if the reading 1s not within the specifications uy A C GENERATOR LIGHTING EE m The inspection of A C generator lighting coil can be made with the engine installed INSPECTION Disconnect the A C generator 3P connector Measure the resistance between the A C generator yellow wire and engine ground with an electric tester Standard 02 1 2Q at20C Replace the A C generator lighting coil if the reading 1s not within the specifications RESISTOR INSPECTION Remove the front cover 2 4 Measure the resistance between the resistor lead and engine ground Resistances 30W7 5 2 7 0 8 00 5W5 0 2 4 0 6 0 Em Fan Cover A C GENERATOR REMOVAL Remove the rear right side cover 2 Remove the
94. the O ring for wear or damage and replace if necessary Apply grease to the O ring and install the starter motor Tighten the two mounting bolts starter motor cable connector must be installed properly STARTER CLUTCH REMOVAL Remove the generator 14 7 Remove the right crankcase cover 4 3 KYMCO 16 STARTING SYSTEM PEOPLE 125 150 Remove the starter clutch lock nut Idle 1 Shaft Lock Nut Wrench Universal Holder Note that the lock nut is left threaded Remove the starter clutch Remove the starter idle gear and shaft INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch The starter drive gear should turn clockwise freely and should not turn counterclockwise STARTER CLUTCH DISASSEMBLY Inspect the starter drive gear for wear or damage and replace if necessary Measure the starter drive gear I D Service Limit 32 06mm replace if over Inspect the needle bearing for wear or damage and replace if necessary Needle Bearing CLUTCH BODY DISASSEMBLY u Clutch Body Remove the rollers plungers and springs from the clutch body 4 Inspect the clutch body wear or damage Et 7 and replace if necessary Inspect each roller and plunger for wear or M damage and check for weak spring Replace if necessary Spring Roller 16 7 dC KYMCO 16 STARTING SYSTEM PEOPLE 125 150 Mea
95. the battery and connect an ammeter across the battery negative terminal and the ground wire Turn the ignition switch OFF and check for short circuit Connect electric tester positive terminal to ground wire and the tester negative terminal to the battery negative terminal If any abnormality is found check the ignition switch and wire hamess for short circuit CURRENT TEST This inspection must be performed with an electric tester when the battery is fully charged Warm up the engine for inspection Connect the electric tester across the battery terminals Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal as shown Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 135 15 5 0 5 A max 5000rpm max If the limit voltage 1s not within the specified range check the regulator rectifier 14 LIGHTING SYSTEM LIMIT VOLTAGE INSPECTION Remove the headlight cover 2 Measure the voltage with electric tester in the AC range Limit Voltage 12 14 5000 If the limit voltage 1s not within the specified range check the regulator rectifier 14 PERFORMANCE TEST Perform this test with a ful charged of battery 14 5 14 BATTERY CHARGING SYSTEIM A C GENERATOR REGULATOR RECTIFIER
96. the drive pulley face compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened Install the starting ratchet by aligning the starting ratchet teeth with the crankshaft teeth Do not get oil or grease on the drive belt or pulley faces Torque 5 5kg m AE Starting Ratchet 13 ee Holder 9 DRIVE AND DRIVEN PULLEYS KICK STARTER KICK STARTER REMOVAL Remove the left crankcase cover 9 2 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushings for wear or damage dC KYMCO PEOPLE 125 150 Kick Lever p i r ex Kick Starter Spindle Starter Driven Gear Friction Spring Kick Starter Spindle Return Spring Spindle Plastic Bushing s Spring Spindle Bushing 9 14 9 DRIVE AND DRIVEN PULLEYS KICK STARTER Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or
97. the engine 15 running at 1700rpm the ignition timing is correct if the F mark aligns with the index mark within 3 Ignition Timing 13 BTDC 1700rpm 15 6 KYMCO 16 STARTING SYSTEM PEOPLE 125 150 LION eee osse OPUS 16 2 IROUBLESHOOTING 2 SiS FRE PET CER ERE 16 2 STARTER MOTOR 16 3 cena 16 5 16 6 16 0 16 STARTING SYSTEM Sto dC KYMCO PEOPLE 125 150 Starter Button p Switches 4 a Starter Motor Starter Relay STARTING CIRCUIT R 15 lenition Switch Battery 12V6AH Front Stop Switch Starter 16 1 dC KYMCO 16 STARTING SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The removal of starter motor can be accomplished with the engine installed For the starter clutch removal refer to Section 4 SPECIFICATIONS Standard mm service Limit mm TORQUE VALUES Starter clutch cover socket bolt 1 2kg m starter clutch lock nut 9 5kg m SPECIAL TOOLS Lock nut wrench Universal holder TROUBLESHOOTING Starter motor would not turn Lack of power Fuse burned out Weak batt
98. ting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence 15 the reverse of removal First connect the positive cable and then negative cable to avoid short circuit BATTERY VOLTAGE OPEN CIRCUIT VOLTAGE INSPECTION Open the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 1V Undercharged 12 3V max Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Keep flames and sparks away from a charging battery Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery to avoid explosion according to Quick charging should only be done in an emergency Measure the voltage 30 minutes after the battery 1s charged Charging current Standard 0 7A Quick 3 0A Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min 4O KYMCO PEOPLE 125 150 14 4 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR PEOPLE 125 150 CHARGING SYSTEM Terminal SHORT CIRCUIT TEST Disconnect the ground wire from
99. ust muffler Worn or damaged piston rings Worn or damaged cylinder and piston Abnormal noisy piston Worn cylinder piston and piston rings Worn piston pin hole and piston pin 8 2 KYMCO 8 CYLINDER PISTON PEOPLE 125 150 SPECIFICATIONS Tine roundness Piston OLD measuring position 9mm from botomorskin 95 Tine roundness 96 Piston OLD measuring position 9mm from botomorskin dC KYMCO 8 CYLINDER PISTON PEOPLE 125 150 CYLINDER REMOVAL Turn the cam chain tension screw clockwise to tighten it Remove the two bolts on the cam chain tension Remove the cylinder head 7 7 Remove the cam chain guide Remove the cylinder base bolts Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket remnant from the cylinder surface PISTON REMOVAL Remove the piston pin clip Place clean shop towel in to keep piston pin clip from falling into the crankcase Press the piston pin out of the piston and remove the piston dC KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Piston Rings Inspect the piston piston pin and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves In
100. ut of driven face i Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Special Bearing Driver Seat the snap ring in its groove Apply grease to the driven face bore areas Pack bearing cavities with9_ 9 50 Specified grease Heat resistance 230 Press a new needle bearing into the driven face Special Bearing Driver Pilot 20mm CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Keep grease off the clutch linings i Clutch Lining Circlip 9 10 PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS KICK STARTER CLUTCH DRIVEN PULLEY ASS EMBLY 9 11 9 DRIVE AND DRIVEN PULLEYS O KYMCO __ KICK STARTER PEOPLE 125 150 Install the damper rubbers on the drive plate pins Install the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips Retainer Plate Clutch Weights Shoes Drive Plate EN ak mI 47 4 1 lt b t one Springs Circlip Movable Dri F CLUTCH DRIVEN PULLEY ASSEMBLY on ea Clean the driven pulley faces and remove any grease from them Install the seal onto the moveable driven face Apply grease to the O rings and install them onto the moveable dr

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