Home

Service Manual - Kymco Spare Parts

1. Cam Chain Guide Valve Spring Compressor Attachment 7 8 KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Remove carbon deposits from the combustion chamber Clean off any gasket remnants from the cylinder head contact surface Be careful not to damage the cylinder head mating surface INSPECTION CYLINDER HEAD Check the spark plug hole and valve hole areas for cracks 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 2mm 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 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 the valves CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket Install the cam c
2. FUEL SYSTEM SERVICE INFORMA TION 5 2 IROUBEESHOO T G eee eue 5 3 CARBURETOR 5 4 AUTO BY STAR E 5 4 AIRC Bid Re 5 6 VACCUM CHA R 5 6 GENII 5 7 CARBURETOR INSTALLATION iiie eee stesse eese 5 10 5 11 5 11 AUTO FUEL VALVE nmn MI 5 12 AIR CEEANER M M 5 13 5 0 dO KYMCO FUEL SYSTEM PEOPLE 125 150 FUEL SYSTEM 5 1 dO KYMCO FUEL SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous When working with gasoline keep sparks and flames away from the working area Gasoline is extremely flammable and is explosive under certain conditions Be sure to work in a well ventilated area e Do not bend or twist control cables Damaged control cables will not operate smoothly e When disassembling fuel system parts note the locations of O rings Replace them with new ones during assembly e Before float chamber disassembly loosen the drain screw to drain the residual gasoline into a clean container e After the carburetor 1s removed plug the intake manifold sid
3. A gt Normal Abnormal Poorly connected coupler Measure resistance between terminals Of nnn CDI unit coupler Faulty ignition switch Weak battery Faulty pulser coil Faulty 1gnition coil Faulty charging system Broken wire harness Poorly connected coupler Check CDI unit with CDI unit tester Check ignition coil with the CDI unit tester Faulty ignition coil 1 23 dO KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 FRAME COVERS EXHAUST MUFFLER FRAME COVERS LAYOUT 2 1 SERVICE INFORMATION 2 2 TROUBLESHOOTING eee 2 2 1 VA 2 4 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 FRAME COVERS LAYOUT 2 1 dO KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use special care not to pull them by force because the cover joint claws may be damaged e 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 e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power e Caved exhaust muffler e Exhaust muffler air leaks e Clogged exhaust muffler 2 2 KYMCO 2 FRAME COVERS EXHAU
4. 3 3 M 3 4 SPARK MM 3 4 bd em 3 5 CARBURETOR IDLE SPEED oe to base edes 3 5 8 D C 3 6 CYLINDER COMPRESSIQN eoe o venero 3 6 FINAL REDUCTION GEAR OL 3 7 DRIVE M 3 7 15319 91 DU 3 8 BRAKE SYSTEM 3 8 078 07 TAD reme 3 9 SUSPENSION nn nin ore 3 9 SEREERING TENUNDIJOD A Toii Dodo 3 9 NUISBOLISFASTENERS concoconii iiini pA 3 9 VY ESTE ect 3 10 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 SERVICE INFORMATION GENERAL WARNING eBefore running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and 1s explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6mm Spark plug gap 0 6 0 7mm Spark plug Standard NGK C7HSA Valv
5. Max torque kg m rpm 1 1 5500 rom eke eS Valve mm Close Shock absorber timing Exhaust Open mm Steel pipe Valve clearance 0 10 cold mm 0 10 Idle speed rpm 1700rpm sump Inner outer rotor type Full flow filtration 0 91 liter Exchanging capacity 0 81 liter Cooling Type Forced air cooling SUMON 0193845 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B 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 E When servicing the motorcycle be sure to use special tools for removal 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 Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface E After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the ba
6. Wale carburetor Auto Bystarter Wire Connector MIL WERT Connect the auto bystarter wire connector Perform the following inspections adjustments Throttle grip free play 3 3 Carburetor idle speed 3 6 IN Fi wy KYMCO FUEL SYSTEM PEOPLE 125 150 FUEL TANK Fuel Unit Wire Connector 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 will be incorrect 5 11 KYMCO FUEL SYSTEM PEOPLE 125 150 Nick Install the fuel unit Make sure that the nick on the retainer 1s aligned with the nick on the fuel tank Connect the fuel unit wire connector INSTALLATION Inspect the fuel unit gasket for damage AUTO FUEL VALVE No Smoking X First clean the fuel tube Disconnect the fuel tube and vacuum tube from the carburetor Connect a vacuum pump to the vacuum tube
7. SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative terminal and the ground wire Turn the ignition switch OFF and check for short circuit Connect the 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 harness 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 13 5 15 5V 0 5A max 5000rpm max If the limit voltage 1s not within the specified range check the regulator rectifier gt 14 LIGHTING SYSTEM LIMIT VOLTAGE INSPECTION Remove the headlight cover 222 Measure the voltage with the 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 gt 14 PERFORMAN
8. PISTON REMOVAL Remove the piston pin clip Place clean shop towel in crankcase to keep the piston pin clip from falling into the crankcase Press the piston pin out of the piston and remove the piston KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Inspect the piston piston pin and piston rings Remove the piston rings X Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace 1f over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Use piston head to push each piston ring into the 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 GQ 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 and 90 to the piston pin 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 ID at three l
9. Side Collar Pawls INSTALLATION UP Apply grease to the brake panel dust seal lip Apply grease to the speedometer gear engaging and sliding parts Install the brake panel by aligning the speedometer retaining pawls with the hub cutouts If not aligned the retaining pawl will be deformed when the axle nut 1s 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 front brake cable and rotate the front tire to check the speedmeter if be performed Connect the speedometer cable Dni i of EM 1 P i 4 E Speedometer Cable 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 HYDRAULIC BRAKE DRAWING 12 7 12 FRONT WHEEL FRONT BRAKE O KYMCO ___ FRONT SUSPENSION PEOPLE 125 150 HYDRAULIC BRAKE FRONT BRAKE BRAKE FLUID REPLACEMENT AIR BLEEDING Check the brake fluid level on level ground e When operating the brake lever the brake reservoir cap must be tightened securely to avoid splash of brake fluid e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of br
10. coll terminals Faulty A C generator coil Resistance too high Broken yellow wire Loose connector Connect battery wire to regulator rectifier coup er red wire and gt battery wire to engine ground and test voltage Normal voltage No voltage Broken red wire Check regulator rectifier coupler for loose Hr connection Faulty regulator rectifier poorly connected coupler generator Overcharging Inspection Adjustment Probable Cause Connect battery wire to regulator rectifier coupler green wire and 5 battery wire to engine ground and test voltage dom ui HN nds dede CE Battery has voltage has with ignition VO ao with ignition Broken green wire switch ON switc Check regulator rectifier coupler for loose Faulty regulator rectifier 1 22 dO KYMCO 1l GENERAL INFORMATION PEOPLE 125 150 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Q Replace with new SDark plug and inspect again Good spark Weak or no spark Faulty spark plug Vy meique pus and high tension wire looseness Loose spark plug Check CDI unit coupler looseness
11. Flywheel Holder Flywheel Holder 9 3 9 DRIVE AND DRIVEN PULLEYS 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 1f below X Use specified genuine parts for replace ment Remove the movable drive face assembly Remove the drive pulley collar ovable Drive Face 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 dO KYMCO PEOPLE 125 150 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 125 150 ASSEMBLY 8 f Install the weight rollers into the movable drive face Install the ramp plate 9 DRIVE AND DRIVEN PULLEYS KICK STARTER PEOPLE 125 150 Insert the drive pulley collar into the movable Drive Pulley Collar drive face INSTALLATION Install the movable drive face onto the crankshaft INSPECTION Inspect the clutch outer for we
12. Flooded carburetor Faulty auto bystarter Throttle valve excessively open Wet spark plug 1 18 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation PPP using a timing light Check valve clearance Test cylinder compression Normal Abnormal compression compression Check carburetor for clogging ___ _ __ Remove spark plug and gt Inspect Plug fouled Plug fouled discolored discolored Remove oil dipstick and check oil level and condition i Correct and not Incorrect or contaminated contaminated Remove cylinder head pipe bolt and inspect ine M Valve train lubricated Valve train not properly lubricated properly Check if engine overheats gt Rapidly accelerate or run at high speed Engine does not knock Engine knocks PEOPLE 125 150 Probable Cause Clogged air cleaner Restricted fuel flow Clogged fuel tank cap breather hole exhaust muffler Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Faulty CDI unit Faulty pulser coil Improper valve clearance adjustment Worn valve seat valve stem too protruding Improper valve and seat contact Worn cylinder and
13. Generator KS Wire Set Plate Generator Wire 2 Rubber Sleeve Stat ator EN Install the A C generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 5kg m Stator 0 9kg m Install the generator wire rubber sleeve and A C generator wire set plate Pulser Coil Set Plate 14 9 14 BATTERY CHARGING SYSTEM O KYMCO ___ GENERATOR PEOPLE 125 150 Woodruff Key Connect the A C generator wire connector lt lt Clean the taper hole flywheel off gt burrs and dirt 4 gt Install the woodruff key in the crankshaft Ox 1 keyway Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key The inside of the flywheel is magnetic Make sure that there is no bolt 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 52 dO KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 IGNITION SYSTEM SERVICE INFORMATION vccccccssssssccsscssssssssssssssssssssscsssssssesssssssessesees 15 2 TROUBLESHOOTING cccccccscccsssssssssssssssssssssssssssssssssssssessessesssesssessesees 15 3 CDI UNIT INSPECTION occccccccscscssssccssss
14. Float Valve Seat Slow Jet Pilot Screw Needle Jet Holder Needle Jet Main Jet KYMCO FUEL SYSTEM PEOPLE 125 150 A ASSEMBLY Pilot Mid Slow Jet Install the slow jet needle jet needle jet holder main jet and pilot screw X Return the pilot screw to the original position as noted during removal a g x Standard Opening 3 3 5 turns C N a NN Needle Jet Holder Needle Jet Jet Install the float valve float and float pin 44 E i CUT Float Valve Float Pin 5 9 dO KYMCO FUEL SYSTEM PEOPLE 125 150 FLOAT LEVEL INSPECTION Float Level Gauge Check the of the valve and float before float level inspection e Measure the float level by placing the float level gauge on the float chamber face parallel with the main 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 Vacuum Tube Connect the fuel tube and vacuum tube to the
15. 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 cables properly After installation inspect and adjust the following Throttle grip free play 43 3 Rear brake adjustment 3 8 6 5 Engine Hanger Bracket Bushings Nut Stopper Rubbers Engine Hanger Bracket Bolt F dO KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CYLINDER HEAD VALVES SERVICE 7 2 TRO HK31 070 WING 7 3 CAMSHAET REMOVAL utet ddr d 7 4 CYLINDER HEAD REMOVAL 7 7 CYLINDER HEAD DISASSEMBLY 7 8 CYLINDER HEAD ASSEMBLY 2 2 7 10 CYLINDER HEAD INSTALLATION ccssssssessssssssssssecsssssesnsseees 7 10 CAMSHAFT INSTALLATION 7 11 dO KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 dO KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame e When assembling apply molybdenum disulfide grea
16. REMOVAL Remove the front cover 52 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 PEOPLE 125 150 INSPECTION Inspect the following items and replace if necessary eFront shock absorber tube bending or damage eWeak front shock absorber spring eDamper and damper rod bending eOil 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 the upper mount bolt hole with the groove on the front fork Front shock absorbers are installed at the um same altitude Washer Bolt Install the front wheel Bolts Brake Master Cylinder us E m ES d E E s EE 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 FRONT SUSPENSION 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
17. without exchange e When assembling the piston soak the cups in brake fluid for a while e nstall 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 12 FRONT WHEEL FRONT BRAKE O KYMCO __ SUSPENSION PEOPLE 125 150 Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Washers 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 Fill the brake reservoir with recommended 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 c 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 Compressed Air If necessary use compressed air to squeeze out the pistons through th
18. 125 150 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment carburetor by m d MEN Check if fuel reaches drain screw Fuel reaches Fuel does not carburetor reach carburetor Probable Cause Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage logged fuel tank cap breather hole Clogged fuel filter vi ie fuel strainer Fau ty auto fuel valve Remove spark plug and install it into spark plug to test spark by X Faulty charging system connecting 1t to engine Faulty spark plug ground Fouled spark plug ER Faulty CDI unit Spark jumps Weak or no spark Faulty pulser coil Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch BEES UU UO Weak or dead battery Test cylinder 0 0 0 0 Faulty starter clutch Valve clearance too small valve and seat contact compression compression rings eaking cylinder head gasket seized valve Improper valve timing Start engine by follow ing normal starting H P procedure Faulty auto bystarter Engine does not Engine fires but Air leaking through intake pipe fire does not start Incorrect ignition timing Incorrectly adjusted pilot screw Remove spark plug and Inspect again Urn Dry spark plug
19. 2 3 times Washer _ Nut Tensioner Screw Adjust the valve clearance 3 5 Turn cam chain tension screw counter clockwise to release it 7 11 KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Apply engine oil to a new O ring and install it Tighten the cam chain tension cap screw Be sure to install the O ring into the groove properly 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 the gasket into the groove properly 7 12 dO KYMCO 8 CYLINDER PISTON PEOPLE 125 150 CYLINDER PISTON r3 SERVICE MOU 5 8 2 ITROUBELSHOOTING sones EE o E 8 2 CYCEINDERRKEMOY A Da E RS 8 4 PISTON irr a E E O 8 4 PISTON INSTALL TION e eE TS 8 8 CYLINDER INSTAELAT TION reee ESEE ES 8 8 8 0 GQ KYMCO PEOPLE 125 150 8 CYLINDER PISTON om Wi not bend a 8 1 8 CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS dO KYMCO PEOPLE 125 150 e The cylinder and piston can be serviced with the engine installed in the frame e After disassembly clean the removed parts and dry them with compressed air before inspection TROUBLESHOOTING e 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
20. 2 25 Cylinder arrangement Single cylinder Combustion chamber type Semi sphere Turning O H C chain drive Bore x stroke mm 52 4 x 57 8 9 6 1 angle type R Max output ps rpm 9 6 7500 Max torque kg m rpm 1 0 6500 m ype uds I Stock absorber timing Exhaust Open mm Steel pipe Valve clearance 0 10 cold mm 0 10 Idle speed rpm 1700rpm sump Inner outer rotor type Full flow filtration 0 91 liter Exchanging capacity 0 81 liter Cooling Type Forced air cooling SUMON 0193845 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 SPECIFICATIONS 6 8 liters Overallwidth mm 690 Type VE Wheel base mm 1335 CDI Spark plug gap 0 6 0 7mm 12V6AH 181 Dry multi disc clutch Operation Automatic centrifugal 100 80 16 56 Reduction Perform Braking distance m 4 4 30km h ance ratio 10 98 19 5 lt on 1013TmdTB UIo S S UOUS STUISUBL 1290 reor uois uononpoy Min turning radius m 2 starting motor amp UI9 S S 1904 piuouidmbg 014991 starting system Pw Gaude 29 5 Axle Tmillngh Tire pressure kg cm 2 00 2 25 Cylinder arrangement Single cylinder Combustion chamber type Semi sphere Turning O H C chain drive Bore x stroke mm 57 4 x 57 8 9 2 1 angle type R Max output ps rpm 10 5 7500
21. 9 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 128 150 Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT a W Drive the inner needle bearing out of the 4 driven pulley face X Discard the removed bearing and replace with a new one Aa i Outer Bearin Remove the snap ring and drive the outer 5 bearing out of driven face 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 Bearing Driver Seat the snap ring in its groove Apply grease to the driven face bore areas Pack all bearing cavities with 9 9 5g grease Specified grease Heat resistance 230 C 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 X PEDEM A 4 p NI Clutch Lining Circlip 9 10 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 125 150 CLUTCH DRIVEN PULLEY ASSEMBLY oy S 2 9 11 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 125 150 Install the damper rubbers on the drive plate pins Install the clutch weights shoes and clutch springs onto the d
22. and apply vacuum Check if fuel flows out The valve is operating normally if fuel flows out of the fuel tube when the vacuum is applied e 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 Bolt 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 Aii Cleaner Case The installation sequence is the reverse of removal 5 13 dO KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 OoOo ENGINE REMOVAL INSTALLATION SERVICE UNG OV IOM 6 2 ENGINE REMOVAL porren E S 6 3 ENGINE INSTALLA TION ecserin e arr Serro EE n Terr Na 6 5 dO KYMCO PEOPLE 125 150 6 ENGINE REMOVAL INSTALLATION 6 1 dO KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e The engine removal operation is required to support the engine Be careful not to damage the motorcycle body cables and wires during engine removal e Use shop towels to protect the motorcycle body during engine removal e Parts requiring engine removal for servicing Crankcase Crankshaft 6 2 KYMCO 6 ENGINE REMOVAL IN
23. e Broken valve spring e Poor valve and valve seat contact e Leaking cylinder head gasket e Warped or cracked cylinder head contact surface e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber 7 3 White smoke from exhaust muffler e Worn valve stem or valve guide e Damaged valve stem seal Abnormal noise e Incorrect valve clearance adjustment e Sticking valve or broken valve spring e Damaged or worn camshaft e Worn cam chain guide e Worn camshaft and rocker arm KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CAMSHAFT REMOVAL Cylinder Head Cover e i Remove the center cover V j w 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 x b d 4 1 T E 1 pr ET rj d m r 4 7 m J ay d Ji j M 1 A n a i y j P Fr a CI T Round Hole Punch Marks dO KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 Remove the four cylinder head nuts
24. each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 91 mm replace if below 9 91mm replace if below 7 CYLINDER HEAD VALVES PEOPLE 125 150 ake Manifold CYLINDER HEAD REMOVAL 2 Remove camshaft 2 7 4 Remove the carburetor 5 4 Remove the exhaust muffler Remove the carburetor intake manifold Remove the cooling fan cover gt 14 7 Remove the engine cover bolts and screws Separate the engine cover joint claws 7 1 7 CYLINDER HEAD VALVES KYMCO PEOPLE 125 150 Remove the two cylinder head bolts Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket remnants from the cylinder surface e Avoid damaging the cylinder contact surface e 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 e Be sure to compress valve springs with a valve spring compressor e Mark all disassembled parts to ensure correct reassemble Valve Spring Compressor Valve Spring Compressor Attachment Cylinder Head Bolts Dowel Pins Cylinder Head Gasket uU e i FN l ES zis 4 _
25. from the handlebar Remove the steering stem lock bolt collar nut and the handlebar STEERING STEM REMOVAL Remove the steering stem lock nut Steering Stem Lock Nut Wrench Lock Nut wrench 12 15 12 FRONT WHEEL FRONT BRAKE O KYMCO _ FRONTSUSPENSION PEOPLE 125 150 Remove the top cone race Top Cone Race e Be careful not to lose the steel balls 26 on top race and 19 on bottom race e 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 BALL RACE REPLACEMENT Drive out the top and bottom ball races Drive new top and bottom ball races into the steering head using the outer driver Outer Driver 37x40mm 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION PEOPLE 125 150 INSTALLATION Front Mold 22 Front Fender Install the front mold and the front fender AYS S wy D l grease to the top 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
26. oil filter screen spring and filter screen cap Torque 1 5kg m Fill with the specified SAEISW40 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 A C generator flywheel gt 14 7 Remove the nine right crankcase cover bolts and the right crankcase cover Upper Level Oil Filter Screen Ca Stator Lower Level ET 55 2 ET il Right Crankcase Cover 4 LUBRICATION SYSTEM dO KYMCO PEOPLE 125 150 Remove the gasket and dowel pins Remove the starter idle gear and starter clutch 216 7 Remove the two bolts and oil separator cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain Remove the two oil pump mounting bolts and the oil pump Starter Idle Gear Starter Clutch 7L 8 E i J i EX VUA of E Ll Oil Separator Cover 4 LUBRICATION SYSTEM KYMCO PEOPLE 125 150 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 Sc
27. piston rings are worn stuck or broken Compression too low e Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high e Excessive carbon build up in combustion chamber or on piston head White smoke from exhaust muffler e Worn or damaged piston rings e Worn or damaged cylinder and piston Abnormal noisy piston e Worn cylinder piston and piston rings e Worn piston pin hole and piston pin 8 2 dO KYMCO 8 CYLINDER PISTON PEOPLE 125 150 SPECIFICATIONS Cylinder Wapage ue 1 rae rouniness piston ring Oil side rail Piston to cylinder clearance 0 010 0 040 Piston pin hole I D 15 002 15 008 15 04 Piston pin O D 14 994 15 000 14 96 Piston to piston pin clearance 0 002 0 014 Connecting rod small end I D bore 15 016 15 034 15 06 95 rae roundness piston ring Oil side rail Piston O D 57 370 57 390 Piston to piston pin clearance 0 002 0 014 Connecting rod small end I D bore 15 016 15 034 8 3 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 47 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
28. shock absorber upper mount bolt Rear shock absorber lower mount bolt Speedometer cable set screw Front shock absorber tube bolt Front shock absorber upper mount bolt Front shock absorber lower mount bolt Front shock absorber hex bolt Rear shock absorber lower joint lock nut dO 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 13 0 FLYWHEEL HOLDER 9 3 9 13 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 1 8 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAE15W 40 Cam lobes eAPI 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 engaging part Final gear engaging part Bearing movable part
29. to make sure that it is not interfering with any moving or sliding parts B 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 B Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 1 5 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 B Route harnesses so they are neither pulled tight nor have excessive slack B Symbols The following symbols represent the Protect wires and harnesses with electrical servicing methods and cautions included in tape or tube if they contact a sharp edge or this service manual corner B When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire db die specified points Use B Ifa wire or harness 1S with broken sheath Engine Oil designated engine oil for repair by wrapping it with protective tape lubrication or replace it B When installing other parts do not press squeeze the wires Grease Apply grease for lubrication B After routing check that the wire harnesses are not twisted or kinked Transmission Gear Oil 907 B Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surro
30. 50 STARTER SWITCH Headlight Switch POSITION xw Lo Y COLOR Yellow Red HORN SWITCH Cece TURN SIGNAL SWITCH Dimmer Switch 17 5 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 STOP SWITCH INSPECTION Remove handlebar front cover c2 Disconnect the front stop switch wire coupler Check for continuity between the wire terminals when the front brake lever is applied The switch is normal if there 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 is connected across the horn wire terminals FUEL GAUGE INSPECTION Remove the rear right side cover c2 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 F 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 gt 2 Remove the rear right side cover 222 Disconnect the fuel unit wire connector Remove the fuel unit careful not to bend or damage the fuel unit float arm Fuel Unit Connector 17 6 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 positio
31. 50 Kick Lever her Kick Starter Spindle Starter Driven Gear Friction Spring Kick Starter Spindle 4 Return Spring Spindle Plastic Bushing IN t y _ eae MA n X Spindle Bushing 9 14 5 Return Sprin 9 DRIVE AND DRIVEN PULLEYS KICK STARTER Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or 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 X When installing the return spring use a 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 Friction Spring KYMCO PEOPLE 125 150 Friction Spring Ri SE Starter Driven Gear Kick Starter Spindle Forcing Part Starter Driven Gear Shaft Forcing Part Starting Ratchet Kick Starter Spindle Left dO KYMCO 10 FINAL REDUCTION PEOPLE 125 150 FINAL REDUCTION SERVICE INF
32. 6 STARTING SYSTEM PEOPLE 125 150 SIARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there 1s continuity replace with new ones 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 dO KYMCO 16 STARTING SYSTEM PEOPLE 125 150 ASSEMBLY Apply grease to the dust seal in the front COVer Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shaft Insert the commutator into the front cover e Be careful not to damage the brush and armature shaft mating surfaces e 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 the front cover and motor case slightly press down the armature shaft to assemble them STARTER RELAY INSPECTION Remove frame b
33. CASE CRANKSHAFT PEOPLE 125 150 CRANKCASE CRANKSHAFT SERVICE 4040 11 2 5 06600 11 2 CRANKCASE SEPARATION te 11 3 CRANKSHAFT INSPECTION ocecccccssescsssssscsssssssssssssssssssssssssssssssssssee 11 4 CRANKCASE ASSEMBLY vecsccsscssscsscssssscssssssssssscssssssssssssssssssssssscssees 11 4 11 0 dO KYMCO PEOPLE 125 150 11 CRANKCASE CRANKSHAFT 11 1 dO KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e The following parts must be removed before separating the crankcase Cylinder head gt Section 7 Cylinder piston gt Section 8 Drive and driven pulleys Section 9 A C generator gt Section 14 Carburetor air cleaner gt Section 4 Rear wheel rear shock absorber gt Section 13 Starter motor gt Section 16 pump gt Section 4 SPECIFICATIONS tem Standard mm Service Limit mm Connecting rod big end side clearance 0 10 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 0 05 Runout 0 10 TORQUE VALUES Crankcase bolt 0 9kg m Cam chain cover bolt 0 9kg m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bea
34. CE TEST Perform this test with a fully charged of battery 14 5 14 BATTERY CHARGING SYSTEIM A C GENERATOR REGULATOR RECTIFIER MAIN HARNESS CIRCUIT INSPECTION 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 Item Wire Color Between battery red Battery has and engine ground voltage Between ground wire Conca ontinuity exists green 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 coll A C generator white and engine coil has ground resistance REGULATOR RECTIFIER INSPECTION If the main harness terminals are normal check the regulator rectifier coupler for loose connection and measure the resistances between the regulator rectifier terminals e Do not touch the tester probes with your finger because human body has resistance e 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 Kowa Electric Tester TH 5H e Proper range for testing Use range for Sanwa Tester Use X100Q range for Kowa Tester e If the dry battery in the tester is weak the readings wi
35. E DISK Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKE MASTER CYLINDER REMOVAL First drain the brake fluid from the hydraulic brake system When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage DISASSEIMBLY Remove the piston rubber cover and snap ring from the brake master cylinder 12 9 12 FRONT WHEEL FRONT BRAKE KYMCO FRONTSUSPENSION 125 150 Diaphragm Piston Master Cylinder Remove the main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid A i MF Snap Ring 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 the lst and 2nd rubber cups for wear or damage ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup e During assembly the main piston and spring must be installed as a unit
36. ENSION SERVICE INFORMATION TROUBEESHOOTTN niente E EEE 1 HYDRAULIC BRAKE eene nennen nennt HYDRAULIC DIXIE FRONT SHOCK ABSORBER STEERING HANDLEBAR GS 12 0 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 12 1 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e 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 e During servicing keep oil or grease off the brake drum and brake linings e Contaminated brake disk or brake pads reduce stopping power Clean the contaminated brake disk with high performance brake degreaser and replace the brake pads e Do not use brake fluid for cleaning e Bleed air from the brake system if the brake system 15 removed or the brake is soft e Do not allow any foreign matters to enter the brake system when filling it with brake fluid e 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 e nspect the brake
37. NFORMATION PEOPLE 125 150 Battery Cable Fuse CDI Unit Battery Cable Wire Harness 1 13 KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Fuel Tube Fuel Valve Vacuum Tube Vacuum Tee Crankcase Breather Tube A C Ground Throttle Cable Auto Bystarter Wire Ignition Coil Generator Wire 1 14 GQ KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 Crankcase Breather Starter Relay Starter Motor Wire Auto Bystarter Wire Throttle Cable Fuel Unit Tube Carburetor Vacuum Tee Auto Bystarter Fuel Tube Vacuum Tube Fuel Vapor Tube 1 15 GQ KYMCO PEOPLE 125 150 1l GENERAL INFORMATION POSITION LIGHT WIRING DIAGRAM HEAD LIGHT 12V START SW a SPEEDOMETER HIGH BEAM PILO 12V 17W LOW BEAM PILO 12V 1 7W z w START LIGHT SW Y R Am BR Y P LAN B BR Y R L ds 3 SB G Y FL SoB3555 EQ 0 MT mum DIMMER PASSING WINKER amp HORN SW coton re for 1OTO O coror pw a 5 RH RR WINKER STOP TAIL LIGHT 12V 21 5W BR G p __ LICENCE LIGHT 12V 3 4W gt P M 21 pn a fore G G ds jj Rx ae m Uy gt alle P TE a oc NAM gt 0 COIL AUTO e 7 REG REC P
38. NSPECTION ADJUSTMENT PEOPLE 125 150 BRAKE SHOE 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 page gt 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 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 HEADLIGHT AIM Turn the ignition switch ON and start the en P gine NT Turn on the headlight switch C 2 na Adjust headlight aim by turning head V c P light aim adjusting screw ting Nut Adjus SUSPENSION FRONT Fully apply the 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 REAR Check the action of the rear 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 u
39. O 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 LIGHTS INSTRUMENTS SWITCHES ELECTRICAL EQUIPMENT LAYOUT e eee eee 17 1 SERVICE INFORMA ON 17 2 TROUBLESHOOTING 17 2 s M 17 3 FRONT TURN SIGNAL LIGHLI a 17 3 POSITION REAR TURN SIGNAL LIGHT 17 3 IGINETION SW eiee32 17 4 HANDLEBAR 17 4 OS 4 61 foem 17 6 HORN 17 6 FUERE e mis E 17 6 FUEC 17 6 AUTO BYXSLARTER ciii etieeebeeeeseetiutese 17 7 INSTRUMEN c M 17 8 17 0 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 ELECTRICAL EQUIPMENT LAYOUT Headlight _ Dimmer Switc Stop Switches IRI GA CE Fuel Unit Auto Bystarter M A Headlight Switch Ignition Switch Auto Bystarter Horn Starter Button Resistor 17 1 dO KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e An electric teste
40. 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 Adhesive Transmission case breather tube 1 9 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 FRAME The following is the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Engine 0 Grease Front Brake Cable Front Brake Lever Speedometer Cable Pivot Grease Throttle Cable Seat Lock K Grease 4 Rear Wheel Bearings Grease Grease Speedometer Gear Front Wheel Bearings Brake Cam Anchor Pin Main Stand Pivot ain Stand Pivo Front Shock Absorber Lower Rear Brake Cable Mount Bushings Pivot 1 10 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 CABLE amp HARNESS ROUTING Front Brake Regulator Throttle Cable Ignition Switch Fluid Tube Rectifier d L Speedometer Cable Horn Resistor Rear Cable Instrument Cable 1 11 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 C D I unit Throttle Cable Wire Harness ront brake Fluid lube Resistor Rear Brake Cable 1 12 KYMCO 1 GENERAL I
41. ORMATION ccscccsccsscssssscsssccesssssssssssessssssssssessessssssssseees 10 2 TROUBLESHOOTING vecscscsssccessscsssssccsescsscesssssessessssssssssssssssessssssesees 10 2 FINAL REDUCTION DISASSEMBLY ctt 10 3 FINAL REDUCTION INSPECTION 10 3 BEARING REPLACEMENT cccsscsscscssssccescsscsssesssssssssssssssssssessessssesssee 10 4 FINAL REDUCTION ASSEMBLY cette 10 5 10 0 PEOPLE 125 150 OOM 10 FINAL REDUCTION 10 1 dO KYMCO 10 FINAL REDUCTION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil GEAR OIL SAE 9072 Oil 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 e Damaged transmission e Seized or burnt transmission Oil leaks e Oil level too high e Worn or damaged oil seal 10 2 dO KYMCO 10 FINAL REDUCTION PEOPLE 125 150 FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler Remove the rear wheel gt 13 2 Remove the rear brake cable gt 13 3 Remove the left crankcase cover 9 2 Remove c
42. ST MUFFLER PEOPLE 125 150 dO KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 FRAME COVERS 1 REAR HAND GRIP REMOVAL Remove 1 the three bolts attaching the rear hand grip Remove the rear hand grip 2 MET IN BOX REMOVAL Remove the three bolts and 2 two nuts attaching tne met in box Remove the met in box 3 REAR FENDER REMOVAL Remove D the screw on each side of the rear fender Remove 3 1 the two nuts attaching the rear fender Remove the rear fender Remove 3 2 the license light wire connector 4 UNDER COVERS REMOVAL Remove D the frame center cover screws Remove 2 the two screws attaching the part of the trame body cover Remove 4 2 4 taillight 5 rear turn signal light wire connector 5 BOTTOM COVER REMOVAL Remove the one bolt attaching each side of the bottom protector cover Remove 2 the bolt on site stand 6 FLOOP BOARD REMOVAL Remove the two bolts attaching the rear floor 1 Remove 6 1 2 the four bolts attaching the floor board Remove 3 the six screws attaching floor board Remove the floor board 7 FRONT COVER REMOVAL Remove D the bolt on the front of the front cover Remove the front cover 2 4 KYMCO 2 FRAME COVERS EXHAUST MUFFLER PEOPLE 125 150 2 5 2 FRAME COVERS EXHAUST MUFFLER 8 FRONT TOOL BOX REMOVAL Remove the nut attaching the front to
43. STALLATION PEOPLE 125 150 ENGINE REMOVAL Auto Bystarter Wire Connector 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 dO KYMCO 6 ENGINE REMOVAL INSTALLATION PEOPLE 125 150 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 Nut Remove the rear shock absorbers mounting bolts Remove the four A C generator cooling fan cover bolts and cooling fan cover Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward 6 ENGINE REMOVAL INSTALLATION KYMCO PEOPLE 125 150 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
44. ULSER Bis UNIT edi SPARK PLUG 756 5 FRAME LHFRWINKER cow sw EARTH Black Brown Yellow JO Orange 1 ISblLightBlue P Pink W White GrjGray 1 16 GQ KYMCO PEOPLE 125 150 1l GENERAL INFORMATION RH FR WINKER START SW FRSTOPSW jpviow COMB SW e 12V 6AH Lui gt BATTERY sie re G SPEEDOMETER 12V LI S mo CLOCK B B L SB SB G G RH RR WINKER HEAD LIGHT ibi 12V 10 12V 35 35W I2VLTW Y B pd Es Gry GN G BR E BR BR R TURN PHOT Y R gt e w GR _ p 4 12V 21 3W piu 1111411 B POSITION c y SW LOW BEAM PILOT 1 2 LAW G rad TE feel De LH RR WINKER 12V 10W 1 ORE m lu REG REC 2 UNIT SPARK PLUG 12V LOW gt at LH FR WINKER 3W EARTH 1 2 WINKE HORN ACG T x RELAY RR STOP DIMMER PASSING Brown lt SW WINKER amp HORN SW COMB SW WINKER SW Black Br Brown FA d PASSING SW HORN SW Bar Y Yellow 0 Orange 2 ofo L Blue X Sb LightBlue zz xs lo ol G Green Lg Light Green orto 05 aloo oc P Pink 8 SS W White Gr Gray gt u 1 17 dO KYMCO 1 GENERAL INFORMATION PEOPLE
45. ake 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 the brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e Never use dirty or unspecified 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 KYMCO FRONT SUSPENSION PEOPLE 125 150 Fixed Reed Install the brake pads in the reverse order of A removal Tighten the brake pad pin bolt Torque 1 5 2 0kg m Keep grease oil off the brake pads to avoid brake failure BRAK
46. aminated brake lining surface e Worn brake shoes at cam contacting area e Worn brake drum e Poorly connected brake arm Poor brake performance Disk Brake e Air in brake system e Deteriorated brake fluid e Contaminated brake pads and brake disk e Worn brake pads e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Deformed brake disk e Unevenly worn brake caliper 12 3 dO KYMCO PEOPLE 125 150 Driver handle A Pilot 10mm Outer driver 37x40mm Bearing remover Front wheel wobbling e Bent rim e Excessive wheel bearing play e Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs e nsufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Disconnect the speedometer cable Speedometer Cable Axle Nut Remove the front axle nut and pull out the axle Remove the front wheel Remove the front brake panel INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 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 ove
47. and washers Diagonally loosen the cylinder head nuts in 2 or 3 times Washer Nut _ Camshaft Holde r Li B PI Remove the camshaft holder and dowel pins Tha 1 Ou Ue Ne 1 21 b y i a M T M z h TA Ea OON TERM Dowel Pins Cam Chain Remove the camshaft gear from the cam 2 m chain and remove the camshaft w V y A ez gt D D HU 2 P E A i 3 N AN CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits 125 ec IN 29 30mm replace if below 29 15mm replace if below 150 ec IN 29 40mm replace 1f below EX 29 05mm replace if below 7 5 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 5mm Bolt Rocker Arm CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt Remove the valve rocker arms Rocker Arm Shaft Camshaft Holder IN M M 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
48. 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 Torque Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m Rear Nut 13 3 13 REAR WHEEL REAR BRAKE REAR SUSPENSION REAR BRAKE Remove the rear wheel gt 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 KYMCO REAR SUSPENSION PEOPLE 125 150 REAR BRAKE ASSEMBLY Brake Arm 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 Bolt to the brake cam 5 Install the brake arm Align the wide groove on the wear indicator plate with the wide tooth of the brake cam Install and tighten the brake arm bolt Align the scribed line the brake arm with the punch mark on the bra
49. ar or damage Measure the clutch outer I D Service Limit 125 5mm replace if over CLUTCH DRIVEN PULLEY DISASSEMBLY b 22 a E M 2 Driven Pulley 9 7 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER PEOPLE 125 50 Clutch Spring Compressor Hold the clutch driven pulley assembly with the clutch spring compressor 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 r zu Pull out the guide roller pins and guide rollers O ring Guide Roller Pin Remove the movable driven face from the NG driven face 9 DRIVE AND DRIVEN PULLEYS KICK STARTER PEOPLE 125 150 Remove the oil seal from the movable driven _ Oil Seal face a 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
50. ccsssssssssssscsssssssssessssessesscessevees 15 4 IGNITION COIL ae 15 5 PULSER COLL III ae 15 6 15 0 KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 Batte Pulser Coil Spark Plug Generator IGNITION CIRCUIT Ignition Switch e Battery 12V6AH CDI Unit Generator 15 1 dO KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e Check the ignition system according to the sequence specified in the Troubleshooting gt 15 e The ignition system adopts CDI unit and the ignition timing cannot be adjusted e If the timing 15 incorrect inspect the CDI unit and generator and replace any faulty parts e Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation e Use of spark plug with improper heat range 1s the main cause of poor engine performance e The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance 1s also described in this section e nspect the ignition switch according to the continuity table specified in page 17 4 e nspect the spark plug referring to Section 3 e Remove the generator and pulser coil referring to Section 14 SPECIFICATIONS Standard type C7HSA NGK Cold type CSHSA NGK Spark plug gap 0 6 0 7mm DEM mark 13 BTDC 1 700 100rpm Ignition timing Ful
51. d a new piston pin clip e Position the piston IN mark on the intake valve side e 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 e Be careful not to damage or break the piston rings e 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 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER PEOPLE1257150 DRIVE AND DRIVEN PULLEYS KICK STARTER SERVICE INFORMATION 9 2 MS OU EO OE UNG 9 2 LEFI CRANKCASE COVER 9 3 DRIVE cinere E E 9 3 CLUICH DREVEN PULJIE ue vue X aU 9 7 e 9 14 9 DRIVE AND DRIVEN PULLEYS KYMCO KICKSTARTER PEOPLE 125 150 9 1 9 DRIVE AND DRIVEN PULLEYS dC KYMCO KICK STARTER PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed e Avoid getting grease and oil on the drive bel
52. dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 1 GENERAL INFORMATION ENGINE FRAME VIN SERIAL NUMBER 1 2 SPECIFICATIONS 125 CC ee 1 3 SPECIFICATIONS 150 CC ee 1 4 SERVICE PRECAUTIONS wisscscsssssssssscsssssssssssssssssscssssssssssssssssssesssesees 1 5 TORQUE VALUES lt 1 7 1 8 LUBRICATION 1 9 CABLE amp HARNESS ROUTING wussssssscsssssssssscsscssssssssssssssssssssseseees 1 11 WIRING DIAGRAM tt 1 16 WIRING DIAGRAM SG ee 1 17 TROUBLESHOOTING unccssssssssssssssssssscsssssssssssscssssssssssssssssssssssssssssseees 1 18 1 1 GQ KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER BA3 1000710 Vehicle Identification Serial Number 1 2 dO KYMCO 1l GENERAL INFORMATION PEOPLE 125 150 SPECIFICATIONS 6 8 liters Overallwidth mm 690 Type VE Wheel base mm 1335 CDI Spark plug gap 0 6 0 7mm 12V6AH 181 Dry multi disc clutch Operation Automatic centrifugal type 100 80 16 56P Reduction Perform Braking distance m 4 4 30km h ance ratio 10 98 5 on 1013TmdTB UIo S S UOUS STUISUBL 1290 reor uois uononpoy Min turning radius m 2 starting motor amp UI9 S S 1904 piuouidmbg 014991 starting system Pw Gaude 29 5 Axle Tmillngh Tire pressure kg cm 2 00
53. e Gear Shaft Needle Bearing Clutch Body uox Si Fm ei 5 Spring Roller dO KYMCO 16 STARTING SYSTEM PEOPLE 125 150 Measure the clutch cover O D Service Limit 27 94mm replace if over Clutch Cover Starter Idle Gea 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 1f below I Clutch Body 2 Starter Drive Gear Needle Bearing Clutch Cover Lock Nut Cap Bolt 16 8 16 STARTING SYSTEM ASSEMBLY Install the springs plungers and rollers onto the clutch body Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body Apply locking agent to the threads of the clutch cover bolts and tighten them 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 Universal Holder o Note that the lock nut is left threaded Install the right crankcase cover 54 7 16 9 RE 1 k i gt e dO KYMCO PEOPLE 125 150 1 Clutch Cover ic KYMC
54. e 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 the 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 12 12 FRONT WHEEL FRONT BRAKE O 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 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 the 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 5kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system FRONT SHOCK ABSORBER
55. e 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 180cc 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 free play 10 20mm TIRE PRESSURE M m s O O TIRE SIZE Front 80 80 16 45 Rear 100 80 16 56P TORQUE VALUES Front axle nut 6 0kg m Rear axle nut 11 0kg m 3 1 dO 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 if necessary A Adjust C Clean R Replace Tighten Whichever Regular Service Mileage km comes first gt 9 4000 6000 8000 9000 10000 Engine oil motorcyce 300km Engine oil filter C C screen 300km ri eese Replace at every 3000km Sparkplug o o Clean at every 2000km replace if necessary messes rp ppt re 2717 suspension LI il oT Seesen 1 e n the interest of safety we recommend these items
56. e 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 INSTALLATION The assembly and installation sequence 15 the reverse of removal Ya cket dO KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 DISASSEMBLY Remove the screws to disassemble the instruments 17 9 KYMCO T ECHNICAL INFORMATION Model ALL MODEL For EURO 2 Date 8 JAN 04 Subject KYMCO Clean Air System For EURO 2 NO KTI 04002 KYMCO Clean Air System For EURO 2 The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely When the spent fuel charge is released into the exhaust system it is still hot enough to burn The system allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as changing a significant portion of the poisonous carbon monoxide into harmless carbon dioxide Secondary Air Suction System Diagram 4 stroke Air cleaner Carburetor Fresh air Inlet pipe Vacuum tube 2 debe Secondary air pipe ie L Air suction valve Fresh air 1 2 KYMCO T ECHNICAL INFORMATION Model ALL MODEL For EURO 2 Date 8 JAN 04 Subject KYMCO Clean Air S
57. e with a clean towel to prevent foreign matters from entering e Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm e 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 pilot screw is 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 e A tachometer must be used when adjusting the engine speed e Turn the pilot screw in or out slowly to obtain the highest engine speed SPECIFICATIONS Item Identification number 052 54 Float level mm SPECIAL TOOL Float level gauge 5 2 FUEL SYSTEM TROUBLESHOOTING Engine is hard to start e No spark at plug e Compression too low e No fuel to carburetor Clogged fuel filter Restricted fuel line Faulty float valve Incorrectly adjusted float level Engine flooded with fuel Clogged air cleaner Fuel overflowing e ntake air leak e Contaminated fuel e Faulty auto bystarter e Clogged idle system or auto bystarter passages Rich mixture e Faulty auto bystarter e Faulty float valve e Float level too high e Clogged air jets e Dirty air cleaner e Flooded carburetor Backfiring at deceleration e Faulty air cut off va
58. 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 KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 IGNITION TIMING Timing Hole Cap The CDI unit is not adjustable If the ig nition timing is incorrect check the ig nition system gt 15 6 Remove the rear right side cover Remove the timing hole cap Check the ignition timing with a timing light When the engine 15 running at idle speed the ignition timing 15 correct if the F mark 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 fly wheel CYLINDER COMPRESSION Warm up the engine before compression test Remove the met in box and frame center cover c2 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 15 low check for the fol lowing Leaky valves Valve clearance to small Leaking cylinder head gasket Pi
59. esistance 20 Yellow Green 0 1 1 00 T Charging coil resistance 20 C 0 2 1 20 Single phase half wave SCR Regulator Rectifier Lighting 12 0 14 0V 5000rpm Electric tester tachometer Resistor 4 0 6 00 14 2 Limit voltage 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR TORQUE VALUES Pulser coil bolt 0 5kg m Coil lock bolt 0 9kg m Flywheel nut 5 5kg m Cooling fan bolt 0 9kg m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power e Dead battery e Disconnected battery cable e Fuse burned out e Faulty ignition switch Low power e Weak battery connector e Loose battery connection e Charging system failure e Faulty regulator rectifier Charging indicator light does not come on e Dead battery e Faulty charging indicator e Faulty indicator light bulb Charging indicator light does not go out e Faulty battery e Faulty charging indicator e Faulty regulator rectifier 14 3 PEOPLE 125 150 Intermittent power e Loose battery cable connection e Loose charging system connection e Loose connection or short circuit in lighting system Charging system failure e Loose broken or short circuit wire or e Faulty regulator rectifier e Faulty A C generator 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 BATTERY REMOVAL Remove the frame cover screw
60. evels of top middle and bottom at 90 to the piston pin in 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 Limits True Roundness 0 05mm repair or replace if over Cylindricity 0 05mm repair or replace if over Middle Bottom dO KYMCO 8 CYLINDER PISTON PEOPLE 125 150 Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if over Measure the connecting rod small end I D Service Limit 15 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring e Be careful not to damage or break the piston and piston rings e All rings should be installed with the markings facing up e After installing the rings they should rotate freely without sticking Second side Rail Oil Ring side Rail ZA Second 8 7 dO KYMCO 8 CYLINDER PISTON PEOPLE 125 150 PISTON INSTALLATION Remove any gasket remnant from the crankcase surface X Be careful not to drop foreign matters into the crankcase Install the piston piston pin an
61. ff valve Remove the two screws to remove the air cut off valve cover spring and vacuum diaphragm ASSEMBLY Install the vacuum diaphragm onto the carburetor Install the spring and air cut off valve cover and then tighten the two screws e Be sure to set the vacuum diaphragm lip into the groove on the carburetor e When installing the air cut off valve cover make sure that the vacuum diaphragm 15 properly installed VACUUM CHAMBER DISASSEMBLY Remove the two vacuum chamber cover screws and the cover Remove the spring and vacuum diaphragm piston KYMCO PEOPLE 125 150 Spring ll ei Diaphragm Air Cut off valve Screws over m r Ll gt 1 dH T i 54 I LN Ti Im IT 4 Pu n T m 1 1 e T ELI i 1 i EE NU V3 Vacuum Chamber Cover Spring Vacuum Diaphragm Piston 5 6 KYMCO FUEL SYSTEM PEOPLE 125 150 Push the needle holder in and turn it left to Install remove the needle holder Remove the spring and jet needle from the piston careful not damage vacuum diaphragm INSPECTION Inspect the needle for stepped wear Inspect the vacuum piston for wear or damage Inspect the diaphragm for deterioration and tears Vacuum Diaphragm ASSEMBLY Install the vacuum piston d
62. ghten the clutch outer nut Torque 5 5kg m Special Flywheel Holder Install the drive belt Install the drive pulley face starting ratchet and drive face nut When installing 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 9 13 dO KYMCO PEOPLE 125 150 Clutch Spring Compressor Er Clutch Driven Pulley Clutch Outer Flvwheel Holder Starting Ratchet Drive Pulley bw b Universal Holder 9 DRIVE AND DRIVEN PULLEYS KICK STARTER KICK STARTER REMOVAL Remove the left crankcase cover c 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 PEOPLE 125 1
63. gine and oil line e Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After the oil pump 15 installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm Inner rotor to outer rotor clearance oR Oil pump Outer rotor to pump body clearance P 02 Rotor end to pump body clearance 0 05 0 10 TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption e Oil level too low e Oil leaks e Clogged oil filter or oil passages e Worn or poorly installed piston rings e Not use the specified oil e Worn valve guide or seal 4 2 4 LUBRICATION SYSTEM GQ KYMCO PEOPLE 125 150 ENGINE OIL OIL FILTER OIL LEVEL X e Place the motorcycle upright on level ground for engine oil level check e Run the engine for 2 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 1s 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
64. hain guide Install the cylinder head CAMSHAFT HOLDER ASSEMBLY Install the exhaust valve rocker arm to the mark side of the camshaft holder Install the intake valve rocker arm and the rocker arm shafts Align the cutout on the front end the intake valve rocker arm shaft with the bolt of the camshaft holder e Align the cross cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder KYMCO 7 CYLINDER HEAD VALVES PEOPLE 125 150 CAMSHAFT INSTALLATION ms DR eM Turn the flywheel so that the 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 Li 1 F gt J 1 i Fur v p cylinder head EV 71 7 JN Install the cam chain over the camshaft gear 7 4 7 4 V 1 Round Hole Punch Marks _Dowel Pins Install dowel pins Camshaft Holder Install the camshaft holder washers and nuts ANN on the cylinder head Tighten the four cylinder head nuts and two bolts Torque Cylinder head nut 2 0kg m e Apply engine oil to the threads of the cylinder head nuts e Diagonally tighten the cylinder head nuts in
65. iaphragm 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 e Be careful not to damage the diaphragm e Hold the vacuum piston while tightening the vacuum chamber cover Vacuum Diaphragm Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber 5 7 5 FUEL SYSTEM KYMCO PEOPLE 125 150 Remove the float pin float and float valve INSPECTION Inspect the float valve and valve seat for damage or clogging Inspect the float valve and valve seat contact area for stepped wear or contamination Worn or contaminated float valve and valve seat must be replaced because it will result in float level too high due to incomplete airtightness Remove the main jet needle jet holder needle jet slow jet and pilot screw e Be careful not to damage the fuel jets and pilot screw e 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 e Do not force the pilot screw against its seat to avoid seat damage 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 K Also remove and clean the vacuum chamber and air cut off valve
66. ive new bearings into the 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 y left crankcase Install the countershaft and gear into the left crankcase Install the washer onto the countershaft Install the dowel pins and a new gasket Countershaft Drive Shaft 10 5 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 gt 13 3 Install the rear brake cable 13 5 Bolts Oil Check Bolt Hole m Oil Filler After installation fill the transmission case with the specified oil 3 7 e Place the motorcycle on its main stand on level ground e Check the oil sealing washer for wear or damage Specified Gear Oil KYMCO SIGMA GEAR OIL SAE 90 Y Xx 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 dO KYMCO 11 CRANK
67. k ELEC EE CEC EE EE CEC EC EE CEC ECDC CEC EE EEC EC EE EEC EC EE EECEC ET EECEC EE EC EEC EE ECE EC EE EEE EC EE ECE EEE aulty air cut off valve Damaged vacuum tube logged or damaged air vent hole 1 20 1 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED BARRARA AAAA R ARAARA RAR ARRA RAR AAAA Check ignition timing Check carburetor pilot Screw adjustment Check fuel pump for fuel supply Inspection Adjustment Fuel flows freely Fuel flow restricted Check carburetor jets clogging j Check valve spring tension dO KYMCO PEOPLE 125 150 Probable Cause aulty CDI unit Faulty pulser coil The woodruff key in the crankshaft is not fix position Improperly adjusted valve clearance Worn valve seat Empty fuel tank Clogged fuel tube or filter logged Fuel tank cap breather ole Faulty auto fuel valve Clean and unclog Cam sd gear aligning marks not aligne Faulty spring 1 21 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause Start engine and test limit VO tage of gt terminals Normal voltage Voltage does not Dead battery increase Faulty battery Measure resistance between AC generator mss
68. ke cam Torque 1 0kg m Install the brake arm return spring Brake Arm Brake Cable Y 45 Install the brake arm pin 5 4 PF Connect the brake cable and install the adjusting nut a Install the rear wheel gt 13 3 Adjust the rear brake lever free play 3 8 REAR SHOCK ABSORBER REMOVAL Remove the frame body cover 222 Remove air cleaner case 45 13 Bolt 13 5 13 REAR WHEEL REAR BRAKE O KYMCO _ REAR SUSPENSION PEOPLE 125 150 Remove the 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 AC GENERATOR PEOPLE 125 150 BATTERY CHARGING SYSTEM A C GENERATOR CHARGING SYSIENUL AA UT 14 1 SERVICE INFORMA TION ssssssssscessessssnssesnesescssas
69. l advance 27 BTDC 5 000 100rpm Ignition coil resistance 20C Secondary Pulser coil resistance 20 C Ignition coil primary side max voltage Pulser coil max voltage TESTING INSTRUMENT Kowa Electric Tester 15 2 dO KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 TROUBLESHOOTING High voltage too low No high voltage e Weak battery or low engine speed e Faulty ignition switch e Loose ignition system connection e Faulty CDI unit e Faulty CDI unit e Poorly connected or broken CDI ground wire e Faulty ignition coil eDead battery or faulty regulator rectifier e Faulty pulser coil e Faulty ignition coil connector Normal high voltage but no spark at plug e Faulty pulser coil e Faulty spark plug e Electric leakage in ignition secondary circuit e Faulty ignition coil Good spark at plug but engine would not start e Faulty CDI unit or incorrect ignition timing e Improperly tightened A C generator flywheel 15 3 15 IGNITION SYSTEM PEOPLE 125 150 CDI UNIT INSPECTION Remove the front cover screws Disconnect the CDI coupler and remove the CDI unit Measure the resistance between the terminals using the electric tester e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester e n this table Needle swings then ret
70. ll be incorrect In this case check the dry battery e The Kowa tester readings are 100 times the actual values Be careful during testing Replace the regulator rectifier 1f the readings are not within the specifications in the table KYMCO PEOPLE 125 150 Regulator Rectifier Unit White 0 2K 6k o Yellow c l ce fixas e v Green M 14 6 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 A C GENERATOR CHARGING NNNM Charging Coil Wire White COIL Ep meme 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 1 2Q at 20 C _ Replace the generator charging coil if Lighting Coil Wire Yellow the reading is not within the specifications EEE E XN RES A C GENERATOR LIGHTING ES 558 Qi COIL 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 0 2 1 20 20 Replace the A C generator lighting coil if the reading 1s n
71. lutch driven pulley gt 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 KYMCO 10 FINAL REDUCTION PEOPLE 125 150 Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Countershaft Bearing Drive Shaft Bearing Check the transmission case cover bearings E for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Countershaft Bearing Countershaft Bearing BEARING REPLACEMENT N TRANSMISSION CASE COVER Remove the transmission case cover bearings using a bearing remover Remove the final shaft oil seal M M Oil Seal Drive new bearings into the transmission case cover 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 Dr
72. lve e Lean mixture in idle system dO KYMCO PEOPLE 125 150 Misfiring during acceleration e Faulty ignition system e ean mixture Engine idles roughly stalls or runs poorly e Clogged fuel system e Ignition malfunction e Rich or lean mixture e Contaminated fuel e ntake air leak e ncorrect idle speed e ncorrectly adjusted pilot screw e Clogged idle system or auto bystarter passages e Incorrectly adjusted float level Lean mixture e Clogged fuel jets e Faulty float valve e Float level too low e Clogged fuel system e ntake air leak e Faulty vacuum piston e Faulty throttle KYMCO FUEL SYSTEM PEOPLE 125 150 CARBURETOR REMOVAL LLL Remove frame body cover c2 Disconnect the auto bystarter wire connector Loosen the drain screw and drain the 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 hp d Intake Manifold Air Cleaner omnes Band Tube Band Throttle Cable AUTO BYSTARTER ig OPERATION INSPECTION p Measure the resistance between the auto 4 ET bystarter wire terminals Resistance 50 max 10 minutes minimum after s
73. nevenly binds or has vertical movement adjust the steering stem ball race 2212 15 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness 15 found gt 1 11 3 9 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE 1 7Skg cm 1 75kg em 2 00kg cm 225kg cm TIRE SIZE Front 80 80 16 45 Rear 100 80 16 56 Check the front axle nut for looseness Check the rear axle nut for looseness 1 ew If the axle nuts are loose tighten them to the Front Axle Nut specified torques Torques Front 6 0kg m Rear 11 0kg m b 3 10 dO KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 LUBRICATION SYSTEM SERVICEJNEORMATION 4 2 0 1 0 5676 NN 4 2 1 NL 6 1 MIPM MM 4 3 I INL BI 4 3 4 LUBRICATION SYSTEM PEOPLE 125 150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump 4 1 dO KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed in the frame e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the en
74. ns RESISTANCES Unit Float G Y W 26 38 450 550 The installation sequence is the reverse of removal e nstall the fuel unit by aligning the groove on the fuel unit with the tab on the fuel tank AUTO BYSTARTER AUTO BYSTARTER INSPECTION Remove the rear right side cover c2 Disconnect the auto bystarter wire connector Measure the resistance between the yellow and green black wire terminals Resistance 100 max T Perform this operation when the engine is cold RESISTOR INSPECTION Remove the front cover 222 Disconnect the green black and green wires and measuring the resistance between the wire terminals Resistance 50 max If the needle remains at it indicates that the resistor 1s faulty and must be replaced 1 7 A Auto Bystarter Connector 17 7 dO KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 INSTRUMENTS BULB REPLACEMENT Remove front cover 52 Remove the bulb socket and replace the bulb The installation sequence is the reverse of removal Bulb Socket Dimmer Fuel Gauge Wires Speedometer CablePassing Wires i INSTRUMENTS REPLACEMENT Remove handlebar front cover 52 Remove the handlebar rear cover 222 Disconnect the right and left handlebar switches wire couplers Disconnect the speedometer cable Remove the instrument bulb sockets Disconnect the three fuel gauge wires Remov
75. nt cover c2 Remove the two screws attaching the headlight Remove the headlight unit Remove adjust the headlight beam bolt The installation sequence is the reverse of removal After installation adjust the headlight beam 53 9 Bolt FRONT TURN SIGNAL LIGHT Remove the turn signal bulb shell screw 222 Remove the front turn signal bulb socket and replace the bulb The installation sequence is the reverse of removal Position Light Shell POSITION LIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the bulb shell screw The installation sequence is the reverse of removal Turn Signal Bulb Shell 17 3 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 IGNITION SWITCH _ uad INSPECTION Remove the front cover 2 4 Disconnect the ignition switch wire coupler Check for continuity between the wire terminals od oo Red Gren Black 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 52 4 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals a ws Te 17 4 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 1
76. ody cover 2 2 Turn the ignition switch ON and the starter relay 15 normal if you hear a click when the starter button 1s depressed If there 1s no click sound e nspect the starter relay voltage e nspect the starter relay ground circuit e 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 1s fully applied If the battery has no voltage inspect the stop switch continuity and cable 16 5 dO 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 1s 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 15 normal if there 15 continuity Ei Motor Cable INSTALLATION Connect starter motor cable c
77. ol box Remove 2 the ignition switch decorative ring Remove 8 1 2 the six screws that combine the front cover with the front tool box Remove 8 2 4 the two screws attaching the front cover Remove the front tool box 9 HANDLEBAR COVER REMOVAL Remove the handlebar front cover bolt Remove 9 1 2 the two screws attaching the handlebar rear cover Disconnect the headlight wire connector and remove the handlebar front cover Remove 3 the bolt attaching the handlebar rear cover Remove 9 2 two screws inside the handlebar rear cover 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 to remove the exhaust muffler Remove the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m PEOPLE 125 150 2 6 iC KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 INSPECTION ADJUSTMENT SERVICE eio iqq rr prairies 3 1 MAINTENANCE SCHEDULE orri aro 3 2 L8 810 3 3 THROTTLE OPERATION
78. onnector Qus 2 7 properly install the waterproof rubber jacket e E Check the O ring for wear or damage and s 2 S c replace if necessary 2 Apply grease to O ring and install the f awe o Starter motor Tighten the two mounting bolts o The starter motor cable connector must be installed properly STARTER CLUTCH REMOVAL Remove the A C generator gt 14 7 Remove the right crankcase cover 4 3 16 STARTING SYSTEM Remove the starter clutch lock nut Lock Nut Wrench Universal Holder 6 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 1s 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 CLUTCH BODY DISASSEMBLY Remove the rollers plungers and springs from the clutch body Inspect the clutch body for wear or damage and replace if necessary Inspect each roller and plunger for wear or damage and check for weak spring Replace if necessary 16 7 dO KYMCO PEOPLE 125 150 Starter Idl
79. ot within the specifications RESISTOR INSPECTION Remove the front cover 2 4 Measure the resistance between the resistor lead and engine ground Resistances 30W7 5Q 7 0 8 00 5W5 0Q 4 0 6 00 x Resistor Fan Cover n A C GENERATOR REMOVAL Remove the rear right side cover 222 Remove the four bolts attaching the cooling fan cover to remove the fan cover lt gt 7 EA ee 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 Hold flywheel with an universal holder Remove the flywheel nut Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Special Flywheel Puller Ne Flywheel Puller Remove the A C generator wire connector nus iH Et g j 75 L is E s i T E Generator Wire Connector 14 8 14 SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 Remove the A C generator wire set plate _ 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 INSTALLATION Flywheel p Woodruff Key 5 5kg Cooling Fan 0 5kg m_ p
80. piston rings Leaking cylinder head gasket Improper valve timing Clogged carburetor jets Fouled spark plug Incorrect heat range plug Oil level too high Oil level too low Oil not changed Clogged oil pipe Faulty oil pump Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Excessive carbon build up in combustion chamber Poor quality fuel lutch slipping Mixture too lean Ignition timing too early 1 19 dO KYMCO 1 GENERAL INFORMATION PEOPLE 125 150 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing Correct timing Incorrect timing The woodruff key in the crankshaft is not fixed position Check carburetor pilot Screw adjustment ixture too rich turn screw Correctly adjusted Incorrectly adjusted out ixture too lean turn screw in Check carburetor gasket air leaks FPP gt Deteriorated O ring Carburetor 15 securely Damaged insulator rubber Broken vacuum tube Remove spark plug and Install it into spark plug to test spark L connecting 1t to engine ground Faulty or fouled spark plug Faulty CDI unit Faulty A C generator Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch Weak or inter mittent spar
81. r 12 4 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 FRONT WHEEL BEARING _ _ Remove the side collar and dust seal NBN E 7 4 1 Jj P 7 LAT mo WO Li i amp 3 a z 0 E 1 gt 1 a 1 1 t M Pel T gt I 5 4 i 7 EE te r 2 ywp p E D RISE pm d i Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub BEARING REPLACEMENT Remove the front wheel bearings and distance collar 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 e Drive in the bearing squarely with the sealed end facing out Driver handle A Driver Handie A 12 5 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION PEOPLE 125 150 Apply grease to a new dust seal lip and install _ dust seal Install the side collar
82. r 1s needed to measure or test the electric equipment e Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment e 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 eFaulty auto bystarter e Faulty ignition switch e Faulty auto bystarter resistor e Fuse burned out e Poorly connected or broken wire e Weak battery e Clogged carburetor e Burned bulb e Faulty switch e Faulty horn e Poorly connected broken or shorted wire Fuel gauge pointer does not register Fuel gauge pointer does not move correctly e Faulty fuel gauge e Faulty fuel gauge e Faulty fuel unit e Faulty fuel unit e Poorly connected broken or shorted wire e Faulty fuel unit float 17 2 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES PEOPLE 125 150 HEADLIGHT Bulb Socket BULB REPLACEMENT XC Remove the handlebar front cover c2 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 handlebar fro
83. r mount bolt 4 0kg m Rear shock absorber lower mount bolt 2 5kg m Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m Brake arm bolt 1 0kg m TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Brake not adjusted properly e Faulty tire e Worn brake linings e Axle not tightened properly e Worn brake shoes at cam contacting area Soft rear shock absorber e Worn brake cam e Weak shock absorber spring e Worn brake drum e Faulty damper 13 2 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEOPLE 125 150 REAR WHEEL a 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 Rear Nut 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
84. rew Outer Rotor Pump Body Outer Kotor GQ KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 ASSEMBLY Inner Rotor Install the outer rotor inner rotor and pump shaft into the pump body Screw X Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin Install the pump cover by aligning the hole in the cover with the dowel pin 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 oil pump with the arrow 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 KYMCO 4 LUBRICATION SYSTEM PEOPLE 125 150 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 MN 725 Oil Separator Cover Starter Idle Gear Starter Clutch Install the starter idle gear and starter clutch 47722 27 16 9 Install the gasket dowel pins Install the right crankcase cover and tighten the nine bolts Torque 0 9kg m Diagonally tighten the bolts 2 3 times 4 7 iC KYMCO 5 FUEL SYSTEM PEOPLE 125 150
85. ring play 11 2 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 the crankcase gasket surface Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces 11 3 11 CRANKCASE CRANKSHAET PEOPLE 125 150 Remove the oil seal from the right crankcase Check the oil seal lip for wear or deterioration The installation sequence is the reverse of removal CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 55mm replace if over 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 4 KYMCO 11 CRANKCASE CRANKSHAFT PEOPLE 125 150 Install the dowel pins and a new gasket onto Gasket the left crankcase Place the right crankcase over the crankshaft and onto the left crankcase Tighten the two crankcase attaching bolts Torque 0 9kg m Crankcase Bolts 11 S 12 FRONT WHEEL FRONT BRAKE KYMCO ___ SUSPENSION PEOPLE125159 FRONT WHEEL FRONT BRAKE FRONT SUSP
86. rive plate Install the retainer plate and secure with the circlips rmi Circlip CLUTCH DRIVEN PULLEY ASSEMBLY Clean the driven pulley faces and remove any grease from them Install the oil seal onto the moveable driven face Apply grease to the O rings and install them onto the moveable driven 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 Movable Driven Face Remove any excessive grease sure to clean the driven face off any grease Set the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor 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 KICK STARTER Compress the clutch spring compressor and install the drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 5kg m sure to use clutch spring compressor to avoid spring damage Special Clutch Spring Compressor INSTALLATION Install the clutch driven pulley onto the drive shaft Keep grease off the drive shaft Install the clutch outer Hold the clutch outer with the flywheel holder Install and ti
87. s Open the cover and remove the battery cover screw First disconnect the battery negative cable and then the positive cable X When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence is 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 X 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 flames sparks away from charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery to avoid explosion e Charge the battery according to the e Quick charging should only be done in an emergency e Measure the voltage 30 minutes after the battery 1s charged Charging current Standard 0 7A Quick 3 0 Charging time Standard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min 14 4 14
88. se or engine oil to the valve guide movable parts valve arm and camshaft sliding surface for initial lubrication e The camshaft is lubricated by engine oil through the cylinder head engine oil passages Clean the oil passages before assembling the cylinder head e After disassembly clean the removed parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Standard mm Service Limit mm N ow om EX Cylinder head compression pressure 13 kg cm Cylinder head warpage 29 7064 29 803 Camshaft cam height 29 4251 29 4388 29 15 29 05 10 000 10 015 10 10 Valve rocker arm I D EN 10 00 10 015 10 10 Valve seat width Valve stem O D Valve guide I D Valve stem to guide mE 0 10 0 037 0 08 0030 0057 7 CYLINDER HEAD VALVES dO KYMCO PEOPLE 125 150 TORQUE VALUES Cylinder head nut 2 0kg m Valve clearance adjusting nut 0 8kg m TROUBLESHOOTING Apply engine oil to threads Apply engine oil to threads e The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed e Compression too low Compression too low e Incorrect valve clearance adjustment e Burned or bend valves e Incorrect valve timing
89. should be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 FUEL LINE Fuel Filter Remove met in box c2 Check the fuel lines and replace any parts which show signs of deterioration damage or leakage X 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 Play 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 Adjusting Nut 3 3 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 AIR CLEANER Screws _ AIR CLEANER REPLACEMENT Remove the rear side covers c2 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 15 ex cessively dirty or damaged Air Case Cover Air Cleaner Element CHANGE INTERVAL More freq
90. some symptoms can be found If there 15 a short circuit inside the battery no voltage 15 produced on the battery terminals If the rectifier would not operate the voltage will become too high and shorten the battery service life e If a battery is not used for a long time it will discharge by itself and should be recharged every 3 months e A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life e Inspect the charging system according to the sequence specified in the Troubleshooting e 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 e t is not necessary to check the MF battery electrolyte or fill with distilled water e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done in an emergency e Remove the battery from the motorcycle for charging e When replacing the battery do not use a traditional battery e When charging check the voltage with an voltmeter SPECIFICATIONS Capacity Model 12V 6AH Voltage Fully charged 13 1V Battery 20C Undercharged 12 3V Charging current STD 0 7A Quick 3 0A Charging time STD 5 10hr Quick 30min Generator Lighting coil r
91. ssccesssesscssasesscessesssees 14 2 TROUBLESHOOTING 14 3 BATTER E 14 4 CHARGING SYSTEM Pr 14 5 REGULATORREC FIER eeescee cee eeeveeteseevesvevi Sees 14 6 A C GENERATOR CHARGING CO1L 14 7 A C GENERATOR LIGHTING COIL 14 7 RESIS TOR INSPEC TION 14 7 AC GENERATOR 14 7 14 0 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 Re gulator Rectifier Resistors SS E n Battery A C Generator CHARGING CIRCUIT Rectifier Battery Handlebar I2V6AH switches 14 1 14 BATTERY CHARGING SYSTEM KYMCO A C GENERATOR PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid 15 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 e The battery can be charged and discharged repeatedly If a discharged battery is not used for long time its service life will be shortened Generally the capacity of a battery will decrease after it is used for 2 3 years A capacity decreased battery will resume its voltage after it 15 recharged but its voltage decreases suddenly and then increases when a load is added e When a battery 15 overcharged
92. steel balls contact each other closely Check that the steering stem rotates E uM freely without vertical play Top Cone Race Top Cone Race Lock Nut Wrench 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 gt 12 15 Steering Stem Lock Nut Wrench Bolt HANDLEBAR INSTALLATION Install handlebar onto steering stem tube and then install and tighten the bolt Torque 4 5kg m Install the front wheel gt 12 6 Install the brake levers 12 15 Install the handlebar covers 12 17 13 REAR WHEEL REAR BRAKE KYMCO ___ REAR SUSPENSION PEOPLE1257150 REAR WHEEL REAR BRAKE REAR SUSPENSION SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 2 REAR VV 13 3 UN 13 4 REAR SHOCK ABSORBER 13 5 ADJUSTABLE REAR CUSHION c eere eere eee eene eee enano 13 6 13 0 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEOPLE 125 150 13 1 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e During servicing keep oil or grease off the brake drum and brake linings SPECIFICATIONS Standard mm Service Limit mm Rear wheel Axial 2 0 so TORQUE VALUES Rear axle nut 11 0 13 0kg m Rear shock absorber uppe
93. ston 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 Compression Gauge 3 6 dO KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 FINAL REDUCTION GEAR OIL 22 Oil Check Bolt OIL LEVEL CHECK f Place the motorcycle on its main stand on level ground for oil level check Stop the engine and remove the oil check bolt The oil level shall be at the oil check bolt hole If the oil level 1s low add the recommended oil to the proper level Recommended Oil GEAR OIL VISCOSITY SAE90 Oil Check Bolt Hole _ Install the oil check bolt D Make sure that the sealing washer is in good condition D 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 15 in good condition Fill with the recommended oil Sealing Washer 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 c 9 3 Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new if ne cessary and in accordance with the Mainte AD EL nance Schedule Du cet 3 7 dO KYMCO 3 I
94. system before riding SPECIFICATIONS lem Standard mm Service Limit mm Axle shaft runout 02 Front wheel Redal 29 _ Axa 20 Front brake lining thickness 55 275 Front shock absorber spring free length 260 252 Brake disk thickness 3255 30 Brkediskrumou 2 0 005 Brake master cylinder ID 12700 12743 1275 Brake master cylinder piston O D 1265771264 _ 1264 Brake caliper piston O D 33910 33934 33901 Brake caliper cylinder LD 3390339909 3401 TORQUE VALUES Steering stem bolt 4 07 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 nut 6 0kg m Brake master cylinder bolt 1 0 1 4kg 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 e Excessively tightened steering stem top cone race e Broken steering balls e nsufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e Bent front fork e Bent front axle or uneven tire Poor brake performance e Incorrectly adjusted brake e Worn brake linings e Cont
95. t and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS Drive face collar O D 23 960 23 974 Cuteh ining thickness 5 _ Driven face spring freelength _ ie7 o o TOROUE VALUES Drive face nut 5 5kg m Clutch outer nut 5 5kg m SPECIAL TOOLS Universal holder 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 e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Broken driven face spring e Fouled drive face Engine stalls or motorcycle creeps e Broken clutch weight spring 9 2 9 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER PEOPLE 125 150 LEFT CRANKCASE COVER x 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 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
96. table Ifthe ignition timing 1s 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 the engine 15 running at 1700rpm the ignition timing 15 correct if the mark aligns with the index mark within 3 Ignition Timing 13 BTDC 1700rpm 15 6 dO KYMCO 16 STARTING SYSTEM PEOPLE 125 150 SERVICE INFORMATION ee 16 2 TROUBLESHOOTING 16 2 STARTER MOTOR eee 16 3 STARTER RELAY te 16 5 STARTER 16 6 16 0 16 STARTING SYSTEM KYMCO Starter Button PEOPLE 125 150 E 7 Starter Relay STARTING CIRCUIT Starter Motor R Fuse1SA Ignition Switch Starter Button Starter Motor Y R starter Relay Battery 12V6AH Front Stop Switch 16 1 dO KYMCO 16 STARTING SYSTEM PEOPLE 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed e For the starter clutch removal refer to Section 4 SPECIFICATIONS standard mm service Limit mm Starter motor brush length 12 5 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
97. topping the engine If the reading 15 not within the limit replace the auto bystarter with a new one FUEL SYSTEM KYMCO PEOPLE 125 150 Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter yellow wire to the positive terminal of a battery and green wire to the negative terminal Wait 5 minutes and blow the hose with mouth or vacuum pump If the passage 15 blocked the auto bystarter 15 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 1s normal REMOVAL Remove the set plate screws and set plate Remove the auto bystarter from the carburetor AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part is found replace the auto bystarter as a set INSTALLATION Insert the auto bystarter into the carburetor body until it bottoms Position the set plate into the groove in the auto bystarter and tighten the screws X e Be sure to install the auto bystarter and set plate properly e nstall the set plate with its bottom face facing down 5 5 Vacuum Pump Set Plate Screws Bystarter Valve Bystarter Needle arter Screws W y Auto Byst 5 FUEL SYSTEM AIR CUT OFF VALVE DISASSEMBLY Disconnect the vacuum tube from the air cut o
98. ttery the positive terminal must be connected first E 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 E After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation PEOPLE 125 150 B Hold the connector body when connecting or disconnecting it Do not pull the connector wire Check if any connector terminal 15 bending protruding or loose B connector shall be inserted completely B If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal 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 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 harnesses B After clamping check each wire to make sure it 1S secure Do not squeeze wires against the weld or its clamp E After clamping check each harness
99. uent replacement is required when riding in unusually dusty or rainy areas e The air cleaner element has viscous type paper element Do not clean it with compressed air e Be sure to install the air cleaner ele ment 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 brush Specified Spark Plug NGK C7HSA Measure the spark plug gap Spark Plug Gap 0 6 0 7mm Cracks X When installing first screw in the spark Damage plug by hand and then tighten it with a spark plug wrench Washer De formation Gap Wear and Fouling Deposit 0 6mm 0 7mm KYMCO 3 INSPECTION ADJUSTMENT PEOPLE 125 150 VALVE CLEARANCE Cylinder Head Cover Inspect and adjust valve clearance while the engine is cold below 35 Remove the center cover 52 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 e Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED X e The
100. unding parts in all steering positions Special l Use special tool When a testing device is used make sure to understand the operating methods Caution thoroughly and operate according to the operating instructions Be careful not to drop any parts V Warning B When rust 15 found on a terminal remove the rust with sand paper or equivalent before connecting B Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind 1 6 dO KYMCO 1l GENERAL INFORMATION PEOPLE 125 150 TORQUE VALUES STANDARD TORQUE VALUES Torque kg m Torque kg m 5mm bolt nut 5mm screw 6mm bolt nut 6mm screw SH bolt Smm bolt nut l 6mm flange bolt nut 10mm bolt nut amm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Cylinder head bolt A Double end bolt Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Drive face seal cover bolt Starter clutch cap bolt Drive face nut Spark plug Starter clutch lock nut Cam chain tensioner screw NO Double end bolt Apply oil to threads Left hand threads e 02 U Steering stem lock nut Front axle nut Rear axle nut Rear
101. urns indicates that there is a charging current applied to a condenser The needle will then remain at co unless the condenser is discharged Unit KQ Probe Black Black Blue G Ds Blue Yellow Yellow ix Black 150 280 20 30 Blue Blue Yellow Black Yellow Black Blue 15 4 dO KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 IGNITION COIL REMOVAL Remove the frame body cover 222 Remove the spark plug cap Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil INSPECTION CONTINUITY TEST This test 1s to inspect the continuity of ignition coil Measure the resistance between the ignition coil primary coil terminals Resistance 0 1 1 00 20 Measure the secondary coil resistances with and without the spark plug cap Resistances with plug cap 7 12 0 20 without plug cap 2 4 0 20 Correctly operate the tester following the manufacturer s instructions 15 5 GQ KYMCO 15 IGNITION SYSTEM PEOPLE 125 150 PULSER COIL INSPECTION This test is performed with the stator installed in the engine Remove the frame body cover 222 Disconnect the A C generator connector Measure the pulser coil resistance between the blue yellow and green wire terminals Resistance 70 1300 20 Refer to page 14 7 for the A C generator removal IGNITION TIMING INSPECTION The CDI unit is not adjus
102. would not turn Lack of power e Fuse burned out e Weak battery e Weak battery e Loose wire or connection e Faulty ignition switch e Foreign matter stuck in starter motor e Faulty starter clutch or gear e Faulty front or rear stop switch e Faulty starter relay Starter motor rotates but engine does e Poorly connected broken or shorted wire not start e Faulty starter motor e Faulty starter clutch e Starter motor rotates reversely e Weak battery 16 2 16 STARTING SYSTEM 16 3 STARTER MOTOR REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly 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 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 dO KYMCO PEOPLE 125 150 Motor Case Case Screws Commutator KYMCO 1
103. ystem For EURO 2 NO KTI 04002 Secondary Air Suction System Diagram 2 stroke Secondary air hose lt Fresh air Cylinder The spent fuel charge Catalytic converter 2 4C KYMCO PEOPLE 125 150 1 GENERAL INFORMATION WIRING DIAGRAM

Service Manual - Kymco Spare Parts

Contents

Download Pdf Manuals

Related Search

Related Contents