KYMCO PEOPLE S 125, PEOPLE S 200, PEOPLE S 50 Service Manual
KYMCO
SERVICE MANUAL
PEOPLE S 50/125/200
4T STROKE
KYMCO
Overseas Sales Division
Overseas Service Department
PEOPLE S 4T
By KWANG YANG Motor Co., Ltd.
First Edition, JUL 2005
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4122-LCD2/3/4-S00
PEOPLE S 4T
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO People S
50/125/200 4 STROKE.
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 higher
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 6 through 11 give
instructions for disassembly, assembly
and adjustment of engine parts.
Section 12 is the removal/ installation
of chassis. Section 14 states the
testing and measuring methods of
electrical equipment. Section 18
provides the maintenance instructions
of the exhaust emission control
system.
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.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
12
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
13
BATTERY/CHARGING SYSTEM
A.C. GENERATOR
14
IGNITION SYSTEM
15
STARTING SYSTEM
16
LIGHTS/
INSTRUMENTS
SWITCHES
17
E/M
EXHAUST EMISSION CONTROL
SYSTEM
18
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
ELECTRICAL EQUIPMENT
ENGINE
1
. GENERAL INFORMATION
1-1
PEOPLE S 4T
1
GENERAL INFORMATION
ENGINE FRAME VIN SERIAL NUMBER................................................................. 1-2
SPECIFICATIONS (50 CC)....................................................................................... 1-3
SERVICE PRECAUTIONS ....................................................................................... 1-6
TORQUE VALUES ................................................................................................... 1-8
TOOLS...................................................................................................................... 1-9
LUBRICATION POINTS.........................................................................................1-10
CABLE & HARNESS ROUTING ............................................................................1-12
WIRING DIAGRAM.................................................................................................1-17
TROUBLESHOOTING............................................................................................1-20
1
1
. GENERAL INFORMATION
1-2
PEOPLE S 4T
Location of Engine Serial Numbe
r
Location of Frame Serial Numbe
r
ENGINE FRAME VEHICLE IDENTIFICATION SERIAL NUMBER
1
. GENERAL INFORMATION
1-3
PEOPLE S 4T
Ignition System
Transmis-
sion Gear
Reduction
Gear
SPECIFICATIONS
Name & Model No. PEOPLE S 50
Overall length (mm) 2010
Overall width (mm) 720
Overall height (mm) 1300
Wheel base (mm) 1360
Engine type O.H.C.
Displacement (cc) 49.5
Fuel Used
92# nonleaded
gasoline
Front wheel 42
Net weight (kg) Rear wheel 60
Total 102
Front wheel 43
Gross weight(kg) Rear wheel 66
Total 109
Front wheel 100/80-16 50P
Rear wheel 110/70-16 52P
Ground clearance (mm) 150
Perform- Braking distance (m) 4.4 (30km/h)
ance Min. turning radius
(m)
1.9
Starting system
Starting motor &
kick starter
Type
OHC air cooled 4-
cycle
Cylinder arrangement Single cylinder
Co m b u s t i on c h a m b e r t y p e Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 39x 41.4
Compression ratio 11:1
Compression pressure
(kg/cm²)
18
Max. output (kw/rpm) 2.98/7500
Max. torque (N m/rpm) 3.82/7000
Intake Open 3°
Close 11°
timing Exhaust Open -9°
Close 19°
Intake 0.04
(co l d ) (m m ) Exhaust 0.04
Idle speed (rpm) 1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.85 liter
Exchanging
capacity
0.7 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element
Fuel capacity 6.7 liters
Type CVK
Piston dia. (mm) 17
Venturi dia.(mm) 16 equivalent
Throttle type Butterfly type
Type CDI
Ignition timing 13°~28°BTDC/2100rp
Contact breaker Non-contact point type
Spark plug NGK C7HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V6AH
Clutch Type Dry multi-disc clutch
Type Non-stage
transmission
Operation
Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.895~3.113
ratio 2nd 14.69
Front Caster angle 25°
Axle Trail length
Tire pressure Front 1.75
(kg/cm²) Rear 2.00 (2.25)
Turning Left 45°
angle Right 45°
Brake system Front Disk brake
type Rear Drum brake
Suspension Front Telescope
type Rear Swing arm
Shock absorber Front Telescope
type Rear Swing arm
Frame type Steel pipe
Tires
En
g
ine
Lubrication
S
y
stem
Fuel System
Carburetor
Electrical Equipment
Power Drive System
Moving Device
Damping
Device
1
. GENERAL INFORMATION
1-4
PEOPLE S 4T
Ignition System
Transmis-
sion Gear
Reduction
Gear
SPECIFICATIONS
Name & Model No. PEOPLE S 125
Overall length (mm) 2010
Overall width (mm) 720
Overall height (mm) 1300
Wheel base (mm) 1350
Engine type O.H.C.
Displacement (cc) 125
Fuel Used
92# nonleaded
gasoline
Front wheel 45
Net weight (kg) Rear wheel 71
Total 116
Front wheel 46
Gross weight(kg) Rear wheel 76
Total 122
Front wheel 100/80-16 50P
Rear wheel 120/80-16 60P
Ground clearance (mm) 150
Perform- Braking distance (m) 7.9 (40km/h)
ance Min. turning radius
(m)
1.9
Starting system
Starting motor &
kick starter
Type
OHC air cooled 4-
cycle
Cylinder arrangement Single cylinder
Co m b u s t i on c h a m b e r t y p e Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 52.4 x 57.8
Compression ratio 9.3:1
Compression pressure
(kg/cm²)
15
Max. output (kw/rpm) 7.59/7500
Max. torque (N m/rpm) 10.36/6750
Intake Open -3°
Close +32°
timing Exhaust Open +33°
Close -2.5°
Intake 0.12
(co l d ) (m m ) Exhaust 0.12
Idle speed (rpm) 1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.91 liter
Exchanging
capacity
0.81 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element
Fuel capacity 6.8 liters
Type VE
Piston dia. (mm) 24
Venturi dia.(mm) 22.1 equivalent
Throttle type Butterfly type
Type CDI
Ignition timing 15°~28°BTDC/1700rp
Contact breaker Non-contact point type
Spark plug NGK C7HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V6AH
Clutch Type Dry multi-disc clutch
Type Non-stage
transmission
Operation
Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.86~2.64
ratio 2nd 10.87
Front Caster angle 25°
Axle Trail length
Tire pressure Front 1.75
(kg/cm²) Rear 2.00 (2.25)
Turning Left 45°
angle Right 45°
Brake system Front Disk brake
type Rear Drum brake
Suspension Front Telescope
type Rear Swing arm
Shock absorber Front Telescope
type Rear Swing arm
Frame type Steel pipe
Tires
En
g
ine
Lubrication
S
y
stem
Fuel System
Carburetor
Electrical Equipment
Power Drive System
Moving Device
Damping
Device
1
. GENERAL INFORMATION
1-5
PEOPLE S 4T
Ignition System
Transmis-
sion Gear
Reduction
Gear
Damping
Device
SPECIFICATIONS
Name & Model No. PEOPLE S 200
Overall length (mm) 2010
Overall width (mm) 720
Overall height (mm) 1300
Wheel base (mm) 1350
Engine type O.H.C.
Displacement (cc) 163
Fuel Used
92# nonleaded
gasoline
Front wheel 45
Net weight (kg) Rear wheel 71
Total 116
Front wheel 46
Gross weight(kg) Rear wheel 76
Total 122
Front wheel 100/80-16 50P
Rear wheel 120/80-16 60P
Ground clearance (mm) 150
Perform- Braking distance (m) 7.9 (40km/h)
ance Min. turning radius
(m)
1.9
Starting system
Starting motor &
kick starter
Type
OHC air cooled 4-
cycle
Cylinder arrangement Single cylinder
Co m b u s t i on c h a m b e r t y p e Semi-sphere
Valve arrangement O.H.C., chain drive
Bore x stroke (mm) 60 x 57.8
Compression ratio 9.5:1
Compression pressure
(kg/cm²)
15
Max. output (kw/rpm) 8.27/7000
Max. torque (N m/rpm) 12.6/5500
Intake Open -3°
Close +32°
timing Exhaust Open +33°
Close -2.5°
Intake 0.12
(co l d ) (m m ) Exhaust 0.12
Idle speed (rpm) 1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.91 liter
Exchanging
capacity
0.81 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element
Fuel capacity 6.8 liters
Type VE
Piston dia. (mm) 24
Venturi dia.(mm) 22.1 equivalent
Throttle type Butterfly type
Type CDI
Ignition timing 15°~28°BTDC/1700rp
Contact breaker Non-contact point type
Spark plug NGK C7HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V6AH
Clutch Type Dry multi-disc clutch
Type Non-stage
transmission
Operation
Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.86~2.64
ratio 2nd 10.87
Front Caster angle 25°
Axle Trail length
Tire pressure Front 1.75
(kg/cm²) Rear 2.00 (2.25)
Turning Left 45°
angle Right 45°
Brake system Front Disk brake
type Rear Drum brake
Suspension Front Telescope
type Rear Swing arm
Shock absorber Front Telescope
type Rear Swing arm
Frame type Steel pipe
Tires
En
g
ine
Lubrication
S
y
stem
Fuel System
Carburetor
Electrical Equipment
Power Drive System
Moving Device
1
. GENERAL INFORMATION
1-6
PEOPLE S 4T
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.
After reassembly, check all parts for proper
tightening and operation.
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.
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.
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.
1
. GENERAL INFORMATION
1-7
PEOPLE S 4T
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
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 protecting 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 or
squeeze the wires.
After routing, check that the wire harnesses
are not twisted or kinked.
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 not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
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
Engine Oil
Grease
Gear Oil
Special
＊
1
. GENERAL INFORMATION
1-8
PEOPLE S 4T
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45～0.6
0.8～1.2
1.8～2.5
3.0～4.0
5.0～6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35～0.5
0.7～1.1
1.0～1.4
2.0～3.0
3.5～4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler joint lock nut
Cylinder head nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Drive face seal cover bolt
Starter clutch cap bolt
Drive face nut
Spark plug
Starter clutch lock nut
Cam chain tensioner screw
2
4
1
2
4
2
1
1
1
1
3
3
1
1
1
1
8
8
30
8
8
5
6
8
12
12
4
6
12
10
22
6
0.9
0.9
1.5
2.2
2.0
0.9
1.0
1.3
5.5
5.5
0.3
1.2
5.5
1.2
9.5
0.4
Double end bolt
Double end bolt
Apply oil to
threads
Left hand threads
FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper mount
bolt
Rear shock absorber lower mount bolt
Speedometer cable set screw
Front shock absorber tube bolt
Front shock absorber upper mount bolt
Front shock absorber lower mount bolt
Front shock absorber hex bolt
Rear shock absorber lower joint lock nut
1
1
1
1
1
1
1
2
2
1
1
10
12
14
10
8
5
5
8
8
8
8
12.0
6.0
12.0
4.0
2.5
0.45
0.45
0.1
1.8
3.0
3.5
U-nut
U-nut
U-nut
Apply locking agent
1
. GENERAL INFORMATION
1-9
PEOPLE S 4T
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
FLYWHEEL PULLER
LOCK NUT SOCKET WRENCH
TAPPET ADJUSTER
OIL SEAL & BEARING INSTALL
FLYWHEEL HOLDER
BEARING PULLER
BEARING PULLER
BEARING PULLER
BEARING PULLER
BUSHING REMOVER
FLYWHEEL HOLDER
LONG SOCKET WRENCH
CLUTCH SPRING COMPERESSOR
CRANKSHAFT PROTECTOR
CRANKSHAF BEARING PULLER
BUSHING REMOVER
LONG SOCKET WRENCH
CUSHION ASSEMBLEN &
DISASSEMBLE TOOL
RACE CONE INSTALL
TOOL BOOX
E002
E009
E012
E014
E017
E008
E018
E020
E031
E019
E021
E022
E027
E029
E030
E032
F002
F004
F005
E033
14-8
16-7
3-5
11-4,12-5
9-3,14-10
10-4
10-4
10-4
13-0
9-3,9-13
9-8
11-0
6-0
12-5
13-0
12-16
1
. GENERAL INFORMATION
1-10
PEOPLE S 4T
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft right side oil seal
Crankshaft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SE, SF or SG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads Thread locking agent
A.C. generator connector
Transmission case breather tube
Adhesive
1
. GENERAL INFORMATION
1-11
PEOPLE S 4T
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Seat Lock
Rear Wheel Bearings
Grease
Front Brake Cable/
Speedometer
Cable/ Throttle
Cable
Main Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot
Engine Oil
Grease
Grease
Grease
Grease
Front Brake Leve
r
Pivot
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease
1
. GENERAL INFORMATION
1-12
PEOPLE S 4T
CABLE & HARNESS ROUTING
Throttle Cable
Regulator/
Rectifier
Front Brake
Fluid Tube
Speedometer Cable
Horn
Instrument Cable
Ignition Switch
C.D.I. unit
1
. GENERAL INFORMATION
1-13
PEOPLE S 4T
Throttle Cable
C.D.I. unit
Wire Harness
Front Brake Fluid Tube
Rear Brake Cable
Throttle Cable
1
. GENERAL INFORMATION
1-14
PEOPLE S 4T
Wire Harness
Fuse
Battery (+) Cable
Battery (-) Cable
Ignition Switch
Regulator/
Rectifier
Speedometer Cable
1
. GENERAL INFORMATION
1-15
PEOPLE S 4T
Fuel Valve Vacuum Tube
Throttle Cable
Vacuum Tee
Fuel Tube
Ignition Coil
A
uto Bystarte
r
Crankcase Breather Tube
Ground
A
.C.
Generator
Wire
T.P.S.
Starter Relay
A
ir Injection
Cut-off Valve
1
. GENERAL INFORMATION
1-16
PEOPLE S 4T
Throttle Cable
Fuel Tube
Carbureto
r
A
uto Bystarter Wire
Starter Moto
r
A
uto Bystarte
r
Fuel Vapor Tube
Fuel Unit
Crankcase
Breather Tube
Vacuum Tee
Starter Relay
1
. GENERAL INFORMATION
1-17
PEOPLE S 4T
WIRING DIAGRAM(50cc)
1
. GENERAL INFORMATION
1-18
PEOPLE S 4T
WIRING DIAGRAM
1
. GENERAL INFORMATION
1-19
PEOPLE S 4T
WIRING DIAGRAM (always light)
1
. GENERAL INFORMATION
1-20
PEOPLE S 4T
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel tank cap breather
hole
Clogged fuel filter
Clogged fuel strainer
Faulty auto fuel valve
Faulty charging system
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Worn cylinder, piston and piston
rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Faulty auto bystarter
Air leaking through intake pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw
Flooded carburetor
Faulty auto bystarter
Throttle valve excessively open
Check if fuel reaches
carburetor by loosening
drain screw
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Inspection/Adjustment
Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder
compression
Start engine by following normal starting
procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does not
reach carburetor
Wet spark plug
Dry spark plug
1
. GENERAL INFORMATION
1-21
PEOPLE S 4T
ENGINE LACKS POWER
Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather
hole
Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston
diaphragm
Faulty auto fuel valve
Faulty CDI unit
Faulty pulser coil
Improper valve clearance
adjustment
Worn valve seat (valve stem too
protruding
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing
Clogged carburetor jets
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too early
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early
Start engine and
accelerate lightly for
observation
Inspection/Adjustment
Symptom
Probable Cause
Engine speed
Correct timin
g
Engine speed does
not increase
sufficiently
Incorrect timin
g
Check ignition timing
(using a timing light)
Test cylinder
compression
Check carburetor for
clogging
Rapidly accelerate or
run at hi
g
h speed
Remove spark plug and
inspect
Check if engine
overheats
Check valve clearance
Correct
Incorrect
Normal
com
p
ression
Abnormal
compression
Remove oil dipstick and
check oil level and
Remove cylinder head
oil pipe bolt and inspect
Engine overheats
Engine does not
overheats
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not
Incorrect or
contaminated
Valve train lubricated
properly
Valve train not
lubricated properly
Engine does not knock
Engine knocks
Not clogged
Clogged
1
. GENERAL INFORMATION
1-22
PEOPLE S 4T
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
The woodruff key in the
crankshaft is not fixed position.
Mixture too rich (turn screw out)
Mixture too lean (turn screw in)
Deteriorated O-ring
Carburetor is not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Faulty air cut-off valve
Damaged vacuum tube
Clogged or damaged air vent
hole
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
g
round
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check air cut-off valve
Check carburetor
gasket for air leaks
Check carburetor pilot
screw adjustment
Correct timing
Incorrect timing
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter-
mittent spark
Good
Faulty
Incorrectly adjusted
1
. GENERAL INFORMATION
1-23
PEOPLE S 4T
POOR PERFORMANCE (AT HIGH SPEED)
Faulty 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
Clogged Fuel tank cap breather
hole
Faulty auto fuel valve
Clean and unclog
Cam timing gear aligning marks
not aligned
Faulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jets
for clogging
Check fuel pump for
fuel supply
Correct timing
Incorrect timing
Check valve spring
tension
Fuel flows freely
Fuel flow restricted
Correct
Incorrect
Not clogged
Clogged
Correctly adjusted
Incorrectly adjusted
Not weakened
Weak spring
Check valve timing
Check carburetor pilot
screw adjustment
1
. GENERAL INFORMATION
1-24
PEOPLE S 4T
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead battery
Faulty battery
Faulty A.C. generator coil
Broken yellow wire
Loose connector
Broken red wire
Faulty regulator/rectifier
Poorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and test
limit voltage of battery
terminals
Connect battery (+) wire
to regulator/rectifier
coupler red wire and
battery (-) wire to engine
g
round and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Battery has voltage
with ignition switch
“ON”
Normal
Voltage does not
Battery has no
voltage with ignition
switch “ON”
Resistance too high
Normal voltage No voltage
Measure resistance
between AC generator
coil terminals
Normal
Abnormal
Check regulator/rectifier
coupler for loose
connection
Normal
Abnormal
Connect battery (+) wire
to regulator/rectifier
coupler green wire and
battery (-) wire to engine
g
round and test voltage
Check regulator/rectifier
coupler for loose
connection
1
. GENERAL INFORMATION
1-25
PEOPLE S 4T
NO SPARK AT SPARK PLUG
Faulty spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switch
Weak battery
Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler
cFaulty CDI unit
cFaulty ignition coil
Replace with a new
spark plug and inspect
again
Check CDI unit coupler
for looseness
Inspection/Adjustment Symptom
Probable Cause
Normal
Normal
Normal
Abnormal
Normal
Abnormal
Abnormal
Measure resistance
between terminals of
CDI unit coupler
Check related parts
Check ignition coil with
the CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Normal
Abnormal
Check spark plug cap
and high-tension wire
for looseness
Check CDI unit with the
CDI unit tester
2
. EXHAUST MUFFLER/FRAME COVERS
2-0
PEOPLE S 4T
2
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
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
2
. EXHAUST MUFFLER/FRAME COVERS
2-1
PEOPLE S 4T
SCHEMATIC DRAWING
Loading...