KYMCO People GT 200i Service Manual

People GT 200i

By KWANG YANG Motor Co., Ltd.

1st Edition, July 2010

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T300-LGE6-A2

People GT 200i

PREFACE

This Service Manual describes the technical features and servicing procedures for the KYMCO People GT 300i.

Section 1 contains the precautions for all operations stated in this manual. Read them carefully before any operation is started.

Section 2 is the removal/installation procedures for the frame covers which are subject to removal/installation frequency during maintenance and servicing operations.

Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.

Sections 5 to 12 give instructions for disassembly, assembly and adjustment of engine parts. Section 13 is the AFI system. Section 14 to 15 is the removal/ installation of chassis. Section 16 to 19 states the testing and measuring methods of electrical equipment.

Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPT.

EDUCATION SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1 EXHAUST MUFFLER/FRAME

COVERS

INSPECTION/ADJUSTMENT 3 LUBRICATION SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 DRIVE AND DRIVEN PULLEYS/V-

BELT

FINAL REDUCTION 9 A.C. GENERATOR/STARTER

CLUTCH

CRANKCASE/CRANKSHAFT 11 COOLING SYSTEM 12 FUEL INJECTION SYSTEM

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM 16 IGNITION SYSTEM 17 STARTING SYSTEM 18 LIGHTS SWITCHES / FUEL PUMP 19

The information and contents included in this manual may be different from the motorcycle in case specifications are changed.

CHASSIS

ELE

TRI

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

People GT 200i

________________________________________________________________________________

GENERAL INFORMATION

________________________________________________________________________________

SERIAL NUMBER------------------------------------------------------------------------------------1-1 SPECIFICATION -------------------------------------------------------------------------------------1-2 SERVICE PRECAUTIONS-------------------------------------------------------------------------1-5 TORQUE VALUES-----------------------------------------------------------------------------------1-9 SPECIAL TOOLS----------------------------------------------------------------------------------- 1-10 LUBRICATION POINTS -------------------------------------------------------------------------- 1-11 CABLE & HARNESS ROUTING-------------------------------------------------------------------

1-13

TROUBLESHOOTING ---------------------------------------------------------------------------- 1-14

1. GENERAL INFORMATION

1-1

People GT 200i

SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

1. GENERAL INFORMATION

1-2

People GT 200i

SPECIFICATIONS

Name People GT 200i Model No. BF40AA Overall length 2130 mm Overall width 750 mm Overall height 1280 mm Wheel base 1450 mm Engine type 4 s t r o k e O . H . C . Displacement 205 cc Fuel Used 92# nonleaded

gasoline

Front wheel

Rear wheel

Total

171.5

Front wheel

Rear wheel

149

Total

246

Ground clearance (mm)

150

Braking distance (m)

7.9m / 40 km/hr

Min. turning radius (mm) R/L

2250/2170

Engine part

Starting system Starting motor Type

Gasoline 4-cycle

Cylinder arrangement Single cylinde

Combustion chamber type Semi-sphere Valve arrangement O.H.C.-4V Bore x stroke (mm) φ66 * 60 Compression ratio 10.3:1

Compression pressure (kg/cm²-rpm)

16-570 rpm

Max. output (ps/rpm) 20.6 / 8000 Max. torque (kg-m/rpm) 2.03 / 6500

Open -5° BTDC Close 32° BTDC Open 34° BTDC Close 5° BTDC

Intake

0.10

Exhaust

0.10

Idle speed (rpm) 1600±100 rpm Cooling Type Liquid cooling

Lubrication type

Forced pressure &

wet sump

Oil pump type Inner/outer roto

Oil filter type Full-flow filtration Oil capacity 1.5 liter Exch a n g i n g c a p a c i t y 1.3 liter

Fi injection system

Air cleaner type & No Paper element, wet Fuel capacity 9 liters

Brand Keihin Throttle Body

Butterfly type

Venturi diameter (mm)

Fuel pump pressure

3.0 bar

Electrical system

Ignition type ECU Ignition timing

ECU control Spark plug CR7E (NGK) Spark plug gap 0.6～0.7mm Battery Capacity 12V12AH

Transmission system

Clutch type Dry multi-disc Transmission type

CVT

Operation type Auto centrifugal

Reduction gear type Two-stage reduction

Primary 2.24~0.72

Final 7.222

Moving device

Tire type Tubeless

Front wheel

110/70-16

Rear wheel 140/70-16

Front wheel 1.75

Rear wheel 2.25 (with

passenger)

Wheel material Aluminium

Left 45°±5

Right 45°±5 Front Disk brake

Rear Disk brake

Damping Device

Front

Telescope

Rear Swing arm

Front 110 mm

Shock absorber stroke

Rear 100 mm

Curb weight

(kg)

Max. weight

(kg)

Intake Timing

Exhaust Timing

Valve

clearance

Reduction ratio

Tire spec.

Tire pressure

(kg/cm²)

Turning angle

Brake type

Suspension t

1. GENERAL INFORMATION

1-3

People GT 200i

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure to

use special tools for removal and installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil before reassembly.

 Apply or add designated greases and

lubricants to the specified lubrication points.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-) terminal

before operation.

 When using a spanner or other tools,

make

sure not to damage the motorcycle surface.

 After operation, check all connecting points,

fasteners, and lines for proper connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

 If the fuse

is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.

1. GENERAL INFORMATION

1-4

People GT 200i

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock on

the connector shall be released before operation.

 Hold the connector body when

connecting

or disconnecting it.

 Do not pull the connector wire.

 Check if any connector terminal is

bending,

protruding or loose.

 The connector

shall be inserted

completely.

 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.

 Check

the double connector cover for

proper coverage and installation.

 Insert the terminal completely.  Check the

terminal cover for proper

coverage.

 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.

 After

clamping, check each wire to make

sure it is secure.

Confirm Capacity

1. GENERAL INFORMATION

1-5

People GT 200i

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness

to make sure that it is not interfering with any moving or sliding parts.

 When

fixing the wire harnesses, do not make it contact the parts that will generate high heat.

 Route wire

harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid

the

projected ends of bolts and screws.

 Route

harnesses so they are neither

pulled tight nor have excessive slack.

 Protect

wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.

 When rubber protector cover is used to

protect the

wire harnesses, it shall be

installed securely.

 Do not break the sheath of wire.  If

a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it.

 When installing other parts, do not press

squeeze the wires.

 After

routing, check that the wire harnesses

are not twisted or kinked.

Do not pull too tight！

No Contact

Do not press or squeeze the wire

1. GENERAL INFORMATION

1-6

People GT 200i

 Wire harnesses routed along with

handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.

 When

a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the

rust with sand paper or equivalent

before connecting.

Do you understand the instrument？

Remove Rust！

1. GENERAL INFORMATION

1-7

People GT 200i

 Symbols:

The following symbols represent the servicing methods and cautions included in this service manual.

: Apply engine oil to the

specified points. (Use designated engine oil for lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil

Grease

Gear Oil

＊

1. GENERAL INFORMATION

1-8

People GT 200i

TORQUE VALUES

1. GENERAL INFORMATION

1-9

People GT 200i

TORQUE VALUES FRAME

1. GENERAL INFORMATION

1-10

People GT 200i

SPECIAL TOOLS

Tool Name Tool No. Performance Photo

Flywheel Puller A120E00003 A.C. generator flywheel removal

Tappet Adjuster A120E00012 Tappet adjustment

Oil Seal & Bearing Installer

A120E00014 Oil seal & bearing installing

Flywheel Holder A120E00021 A.C. generator flywheel holding

#41 Nut & Fitting A120E00028 Clutch disassembly & assembly

Thread Protector A120E00029 Protecting the crankshaft’s

thread

Valve Cotter Installer A120E00051 Valve cotter installation

Clutch Spring Compressor

A120E00053 Clutch disassembly & assembly

Shaft Collar Puller A120E00088 Bearing crankcase removal

Shaft Collar Driver A120E00091 Bearing crankcase removal

Shaft Collar Installer A120E00092 Bearing crankcase installation

Bearing Puller A120E00093 Bearing removal

Lock Nut Socket Wrench A120F00002 Steering stem removal or

installation

Electric Repair Kit A120F00032 Fuel injection system diagnosis

1. GENERAL INFORMATION

1-11

People GT 200i

LUBRICATION POINTS FRAME

The following is the lubrication points for the frame. Use grease for parts not listed. Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise and damage the durability of the motorcycle.

Grease

Front wheel axle &nut

Rear wheel axle &nut

Grease

Side stand pivot

& Main stand pivot

1. GENERAL INFORMATION

1-12

People GT 200i

CABLE & HARNESS ROUTING

Tilt Switch

Ignition Switch

ECU

Horn

Winker Relay

Hi Beam Relay

Lo Beam Relay

ECU Relay

Fuel Pump Relay

Tilt Switch

1. GENERAL INFORMATION

1-13

People GT 200i

Oil Controller

Tilt Switch

Front Brake Hose

1. GENERAL INFORMATION

1-14

People GT 200i

ISCThrottle Body

TPS

Injector

MAP Sensor

1. GENERAL INFORMATION

1-15

People GT 200i

Regulator/Rectifier

Ignition Coil

Fuel Pump

1. GENERAL INFORMATION

1-16

People GT 200i

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Possible cause

1. Check for operation of the fuel pump Abnormal  Faulty fuel pump

Normal

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Perform spark test Weak or no spark  Faulty spark plug

 Fouled spark plug  Faulty ECU

Good spark  Broken or shorted spark plug wire

 Faulty ignition switch  Faulty ignition pulse generator  Loose or disconnected spark plug

wire

5. Test cylinder compression Low compression  Valve stuck open

 Worn cylinder and piston ring  Damaged cylinder head gasket

Compression normal  Seized valve

 Improper valve timing

6. Starting following normal procedure Engine start  Intake pipe leaking but stops  Improper ignition timing (Faulty

ignition coil or ignition pulse generator)

Engine does not start  Fuel contaminated

7. Remove and inspect spark plug Wet plug  Throttle valve open

 Clogged air cleaner

1. GENERAL INFORMATION

1-17

People GT 200i

ENGINE LACKS POWER

Possible cause

1. Raise wheel off the ground Wheels do not  Brake dragging

and spin by hand spin freely  Worn or damaged wheel bearing

Wheel spins freely

2. Check tire pressure Pressure low  Faulty tire valve

 Punctured tire

Pressure normal

3. Accelerate lightly Engine speed does  Air cleaner dirty

not increase  Restricted fuel flow

 Clogged muffler

Engine speed increase  Pinched fuel tank breather

4. Check ignition timing Incorrect  Faulty ECU

 Faulty ignition pulse generator

Correct

5. Test cylinder compression Incorrect  Valve stuck open

 W

orn cylinder and piston rings

 Leaking head gasket

Normal  Improper valve timing

6. Inspect fuel flow Abnormal  Faulty pressure regulator

Normal

7. Inspect the fuel injector Abnormal  Faulty injector

Normal

8. Remove spark plug Fouled or discolored  Faulty spark plug

Not fouled or discolored

1. GENERAL INFORMATION

1-18

People GT 200i

Possible cause

9. Check oil level and condition Incorrect  Oil level too high

 Oil level too low  Contaminated oil

Correct

10. Remove cylinder head cover Valve train not  Clogged oil

and inspect lubrication lubricated properly  Clogged oil control orifice

Valve train lubricated properly

11. Check for engine overheating Overheating  Fan motor not working

 Excessive carbon build-up in

combustion chamber

 Use of poor quality fuel

Not overheating  Wrong type of fuel

 Drive and driven pulleys/clutch

slipping

12. Accelerate or run at high Engine knocks  Worn piston and cylinder

speed  Worn type of fuel

 Excessive carbon build-up in

combustion chamber

 Ignition timing to advanced (faulty

ECU)

Engine does not knock  Lean fuel mixture

1. GENERAL INFORMATION

1-19

People GT 200i

POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause

1. Check ignition timing Incorrect  Improper ignition timing

Correct

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Check for leaks in the intake pipe Leaking  Loose insulator clamp

 Damage insulator

No leak

5. Perform spark test Weak or intermittent spark  Faulty the spark plug

 Faulty carbon or wet fouled spark

plug

 Faulty ECU  Faulty ignition coil  Faulty ignition pulse generator  Faulty ignition switch  Loose or disconnected spark plug

wires

Good spark

1. GENERAL INFORMATION

1-20

People GT 200i

POOR PERFORMANCE AT HIGH SPEED

Possible cause

1. Check ignition timing Incorrect  Faulty ECU

Correct

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Check valve timing Incorrect  Camshaft not installed properly

Correct

5. Check valve spring Weak  Faulty valve spring

Not weak

POOR HANDLING

Possible cause

1. If steering is heavy  Steering stem adjusting nut too

tight

 Damaged steering head bearings

2. If either wheel is wobbling  Excessive wheel bearing play

 Bent rim  Improper installed wheel hub  Swing arm pivot bearing

excessively worn

 Bent frame

3. If the motorcycle pulled to one side  Faulty the shock absorber

 Front and rear wheel not aligned  Bent fork  Bent swing arm  Bent axle

2. EXHAUST MUFFLER/FRAME COVERS

2-0

People GT 200i

________________________________________________________________________________

EXHAUST MUFFLER/FRAME COVERS

________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------------------------------ 2-1 SERVICE INFORMATION ---------------------------------------------------------------------- 2-2 TROUBLESHOOTING--------------------------------------------------------------------------- 2-2 FRAME COVERS REMOVAL------------------------------------------------------------------ 2-3 EXHAUST MUFFLER REMOVAL ------------------------------------------------------------ 2-6

2. EXHAUST MUFFLER/FRAME COVERS

2-1

People GT 200i

SCHEMATIC DRAWING

2. EXHAUST MUFFLER/FRAME COVERS

2-2

People GT 200i

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.

• Make sure to route cables and harnesses according to the Cable & Harness Routing.

TORQUE VALUES

Exhaust muffler lock bolt 35 N-m Exhaust muffler joint lock nut 20 N-m

TROUBLESHOOTING

Noisy exhaust muffler

• Damaged exhaust muffler

• Exhaust muffler joint air leaks

Lack of power

• Caved exhaust muffler

• Clogged exhaust muffler

• Exhaust muffler air leaks

2. EXHAUST MUFFLER/FRAME COVERS

2-3

People GT 200i

FRAME COVERS REMOVAL REAR CARRIER

Remove the met-in box. First remove the eight nuts attaching the metin box. Remove the met-in box.

Remove the four bolts attaching the rear carrier. Remove the rear carrier.

FRAME BODY COVER REMOVAL

Remove the two nuts attaching the rear protective cover. Remove the rear protective cover.

Remove the center cover. Remove the body cover.

Nuts

Carrie

Protective Cove

Nuts

Body Cove

CenterCove

2. EXHAUST MUFFLER/FRAME COVERS

2-4

People GT 200i

FLOOR-FOOT REMOVAL

Remove the screws attaching the right and left side cov

ers. Remove the right and left side covers by pulling them outward.

Disconnect the battery wire. Remove the battery.

Remove the floor mat. Remove the center cover. (Ö2-3) Remove the four bolts attaching the floorboard. Remove the floorboard. The installation sequence is the reverse of removal.

LEG SHIELD REMOVAL

Remove the met-in box. Remove the body cover. Remove the floorboard. Remove the front upper cover. Remove the screws attaching the leg shield low. Disconnect the leg shield low with the cowl under cover.

The installation sequence is the reverse of removal.

Screws

Side Cove

Bolts

Leg Shield Low

Screws

Battery

Battery Wire

Floorboard

2. EXHAUST MUFFLER/FRAME COVERS

2-5

People GT 200i

WINDSHIELD REMOVAL

Remove the two bolts attaching the front windshield. Remove the windshield cover. Remove the windshield.

HANDLEBAR COVER REMOVAL

First remove the two bolts attaching the windshield. Remove the two screws and four bolts attaching the handlebar rear cover. Remove the handlebar rear cover. The installation sequence is the reverse of removal.

Remove the two screws attaching the handlebar cover Remove the handlebar cover. The installation sequence is the reverse of removal.

BOTTOM COVER REMOVAL

Remove the four bolts attaching the bottom cov

er.

Remove the bottom cover.

Bottom Cove

Bolts

Handlebar Cove

Screws

Windshield

2. EXHAUST MUFFLER/FRAME COVERS

2-6

People GT 200i

EXHAUST MUFFLER REMOVAL

Remove three lock nuts from joint in the exhaust muffler. Remove the exhaust muffler two lock bolts to remove the exhaust muffler. Remove the exhaust muffler joint packing collar. The installation sequence is the reverse of removal.

Torque:

Exhaust muffler lock bolt 35 N-m Exhaust muffler joint lock nut 20 N-m

Lock Bolts

Lock Nut

+ 189 hidden pages

KYMCO People GT 200i Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual