KYMCO People GT 300i Service Manual
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KYMCO People GT 300i Service Manual

People gt 300i
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People GT 300i
By KWANG YANG Motor Co., Ltd.
1st Edition, March 2010
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T300-LGE5-A2

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  • Page 1 People GT 300i By KWANG YANG Motor Co., Ltd. 1st Edition, March 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T300-LGE5-A2...

  • Page 2: Table Of Contents

    People GT 300i PREFACE TABLE OF CONTENTS This Service Manual describes the technical features servicing GENERAL INFORMATION procedures for the KYMCO People GT 300i. EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read...

  • Page 3: General Information

    1. GENERAL INFORMATION People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ 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...

  • Page 4: General Information

    1. GENERAL INFORMATION People GT 300i SERIAL NUMBER Location of Frame Serial Number Location of Engine Serial Number...

  • Page 5: Specification

    1. GENERAL INFORMATION People GT 300i SPECIFICATIONS Oil filter type Full-flow filtration Name People GT 300i Oil capacity 1.5 liter Model No. BF60AA Exchanging capacity 1.3 liter Overall length 2130 mm Fi injection system Overall width 750 mm Air cleaner type & No...

  • Page 6: Service Precautions

    1. GENERAL INFORMATION People GT 300i Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with...
  • Page 7 1. GENERAL INFORMATION People GT 300i Before connecting a terminal, check for After operation, terminal caps shall be damaged terminal cover or loose negative installed securely. terminal. Confirm Capacity When taking out the connector, the lock on Check the double connector cover for the connector shall be released before proper coverage and installation.
  • Page 8 1. GENERAL INFORMATION People GT 300i Protect wires and harnesses with electrical Do not squeeze wires against the weld or tape or tube if they contact a sharp edge or its clamp. corner. Do not pull too tight After clamping, check each harness to...
  • Page 9 1. GENERAL INFORMATION People GT 300i Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent surrounding parts steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
  • Page 10 1. GENERAL INFORMATION People GT 300i Symbols: following symbols represent servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) Grease : Apply grease for lubrication.

  • Page 11: Torque Values

    1. GENERAL INFORMATION People GT 300i TORQUE VALUES...
  • Page 12 1. GENERAL INFORMATION People GT 300i TORQUE VALUES FRAME...

  • Page 13: Special Tools

    1. GENERAL INFORMATION People GT 300i SPECIAL TOOLS Tool Name Tool No. Performance Photo Flywheel Puller A120E00003 A.C. generator flywheel removal Tappet Adjuster A120E00012 Tappet adjustment Oil Seal & Bearing A120E00014 Oil seal & bearing installing Installer Flywheel Holder A120E00021 A.C.

  • Page 14: Lubrication Points

    1. GENERAL INFORMATION People GT 300i 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.

  • Page 15: Cable & Harness Routing

    1. GENERAL INFORMATION People GT 300i CABLE & HARNESS ROUTING Tilt Switch Winker Relay Tilt Switch Horn Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay 1-12...
  • Page 16 1. GENERAL INFORMATION People GT 300i Oil Controller Front Brake Hose Tilt Switch 1-13...
  • Page 17 1. GENERAL INFORMATION People GT 300i MAP Sensor Throttle Body Injector 1-14...
  • Page 18 1. GENERAL INFORMATION People GT 300i Fuel Pump Ignition Coil Regulator/Rectifier 1-15...

  • Page 19: Troubleshooting

    1. GENERAL INFORMATION People GT 300i 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.
  • Page 20 1. GENERAL INFORMATION People GT 300i 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...
  • Page 21 1. GENERAL INFORMATION People GT 300i 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...
  • Page 22 1. GENERAL INFORMATION People GT 300i 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...
  • Page 23 1. GENERAL INFORMATION People GT 300i 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.

  • Page 24: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ 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...

  • Page 25: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS People GT 300i SCHEMATIC DRAWING...

  • Page 26: Service Information

    . EXHAUST MUFFLER/FRAME COVERS People GT 300i 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.

  • Page 27: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS People GT 300i Nuts FRAME COVERS REMOVAL REAR CARRIER Remove the met-in box. First remove the eight nuts attaching the met- in box. Remove the met-in box. Remove the four bolts attaching the rear Carrier Bolts carrier.
  • Page 28 . EXHAUST MUFFLER/FRAME COVERS People GT 300i Side Cover FLOOR-FOOT REMOVAL Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them outward. Screws Disconnect the battery wire. Remove the battery.
  • Page 29 . EXHAUST MUFFLER/FRAME COVERS People GT 300i WINDSHIELD REMOVAL Remove the two bolts attaching the front windshield. Remove the windshield cover. Remove the windshield. Windshield HANDLEBAR COVER REMOVAL First remove the two bolts attaching the windshield. Remove the two screws and four bolts attaching the handlebar rear cover.

  • Page 30: Exhaust Muffler Removal

    . EXHAUST MUFFLER/FRAME COVERS People GT 300i 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.

  • Page 31: Inspection/Adjustment

    3. INSPECTION/ADJUSTMENT People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION / ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION----------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE------------------------------------------------------------------- 3- 2 THROTTLE OPERATION ----------------------------------------------------------------------- 3- 3 ENGINE OIL ---------------------------------------------------------------------------------------- 3- 4 RESERVE TANK ---------------------------------------------------------------------------------- 3- 5 AIR CLEANER ------------------------------------------------------------------------------------- 3- 6...

  • Page 32: Inspection/Adjustment

    3. INSPECTION/ADJUSTMENT People GT 300i SERVICE INFORMATION GENERAL WARNING • Before 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.
  • Page 33 3. INSPECTION/ADJUSTMENT People GT 300i...

  • Page 34: Throttle Operation

    3. INSPECTION/ADJUSTMENT People GT 300i THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm Adjusting Nut Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side.

  • Page 35: Engine Oil

    3. INSPECTION/ADJUSTMENT People GT 300i ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on the level ground. Wait for 2～3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when checking the oil level.

  • Page 36: Reserve Tank

    3. INSPECTION/ADJUSTMENT People GT 300i The spring will come out when the filter cap is removed. Let the engine oil drain out. Check that the O-ring is in good condition. Spring Install a new oil filter. Make sure the rubber seal on the oil filter facing the left crankcase.

  • Page 37: Air Cleaner

    3. INSPECTION/ADJUSTMENT People GT 300i AIR CLEANER AIR FILTER REPLACEMENT Remove the body cover. Remove seven screws attaching to the air cleaner cover. Remove six screws attaching to the filter. Check the filter and replace it if it is excessively dirty or damaged.

  • Page 38: Valve Clearance

    3. INSPECTION/ADJUSTMENT People GT 300i VALVE CLEARANCE Cylinder Head Cover • Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the seat assy and luggage box. Remove the four bolts and then cylinder head cover.

  • Page 39: Final Reduction Gear Oil

    3. INSPECTION/ADJUSTMENT People GT 300i FINAL REDUCTION GEAR OIL • Place the scooter on its main stand on level ground. Remove the transmission fluid drain bolt. Remove the transmission fluid filler bolt, then slowly rotate the rear wheel to drain the fluid.

  • Page 40: Brake System

    3. INSPECTION/ADJUSTMENT People GT 300i BRAKE SYSTEM BRAKE DISK/BRAKE PAD Check the brake disk surface for scratches, unevenness or abnormal wear. Check if the brake disk runout is within the specified service limit. Check if the brake pad wear exceeds the wear indicator line.

  • Page 41: Clutch Shoe Wear

    3. INSPECTION/ADJUSTMENT People GT 300i CLUTCH SHOE WEAR Start engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep or the engine stop, check the clutch shoes for wear and replace if necessary.

  • Page 42: Nuts/Bolts/Fasteners

    3. INSPECTION/ADJUSTMENT People GT 300i NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.

  • Page 43: Side Stand

    2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your KYMCO dealer for service. 3-12...

  • Page 47: Lubrication System

    4. LUBRICATION SYSTEM People GT 300i OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right-under crankcase cover. Oil Filter Cap The spring will come out when the filter cap is removed Let the engine oil drain out. Check that the O-ring is in good condition Spring Install a new oil filter.

  • Page 50: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION People GT 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION--------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-6...
  • Page 51 5. ENGINE REMOVAL/INSTALLATION People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal.
  • Page 52 . ENGINE REMOVAL/INSTALLATION People GT 300i Throttle Body Air Cleaner Connector ENGINE REMOVAL/INSTALLATION REMOVAL Remove the air cleaner Disconnect the connector including of ISC, Throttle body, TPS, WTS, MAP sensor and injector. Disconnect the O2 sensor connector. Disconnect the throttle cables.
  • Page 53 5. ENGINE REMOVAL/INSTALLATION People GT 300i Remove the muffler. Remove the rear fork mounting bolts (1) attaching to the crankcase. Torque: 3.5 kgf-m (35 N-m) Remove the rear axle nut (2). Torque: 12.0 kgf-m (120 N-m) Remove two bolts (3) attaching to rear brake hose clamps.
  • Page 54 . ENGINE REMOVAL/INSTALLATION People GT 300i Remove the spark plug cap. Spark Plug Cap Radiator Hose Disconnect the lower radiator hose from lower radiator pipe. Remove the right and left rear cushion lower mount bolts. Torque: 4.0 kgf-m (40N-m) Mount Bolt...
  • Page 55 5. ENGINE REMOVAL/INSTALLATION People GT 300i Remove the engine mount nut and pull it out. Remove the engine from the frame. At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
  • Page 56 . ENGINE REMOVAL/INSTALLATION People GT 300i Mount Nut ENGINE HANGER REMOVAL Remove the engine mount nut and pull it out. Be careful to put the engine down. Remove the left/right engine hanger mount bolt. Remove the engine from frame. INSTALLATION Installation is in the reverse order of removal.

  • Page 57: Cylinder Head/Valves

    6. CYLINDER HEAD/VALVES People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/VALVES ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 6-1 SERVICE INFORMATION----------------------------------------------------------------------- 6- 2 TROUBLESHOOTING --------------------------------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ------------------------------------------------------ 6- 4 CAMSHAFT REMOVAL-------------------------------------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL------------------------------------------------------------------ 6- 6...

  • Page 58: Schematic Drawing

    6. CYLINDER HEAD/VALVES People GT 300i SCHEMATIC DRAWING...

  • Page 59: Service Information

    6. CYLINDER HEAD/VALVES People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

  • Page 60: Troubleshooting

    6. CYLINDER HEAD/VALVES People GT 300i TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low •...

  • Page 61: Cylinder Head Cover Removal

    6. CYLINDER HEAD/VALVES People GT 300i CYLINDER HEAD COVER REMOVAL Cylinder Head Cover Remove the met-in box. Remove the body cover and center cover. Disconnect the breather hose to air cleaner. Remove the cylinder head cover four bolts. Remove the cylinder head cover.
  • Page 62 6. CYLINDER HEAD/VALVES People GT 300i Nuts Remove four nuts attaching to the cylinder head. Remove two bolts attaching to the camshaft gear. Remove the camshaft gear from the cam chain. • Diagonally loosen the cylinder head cap nuts in 2 or 3 times.

  • Page 63: Cylinder Head Removal

    6. CYLINDER HEAD/VALVES People GT 300i Rocker Arm Remove the rocker arm with bolt as shown. CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.

  • Page 64: Cylinder Head Disassembly

    6. CYLINDER HEAD/VALVES People GT 300i Remove nuts attaching upper/lower side of cylinder head. Remove two bolts attaching to the cylinder head. Remove the cylinder head. Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Bolts Remove all gasket material from the cylinder head mating surface.

  • Page 65: Cylinder Head Assembly

    6. CYLINDER HEAD/VALVES People GT 300i VALVE STEM INSPECTION Inspect each valve for bending, burning, or abnormal stem wear. Intake valve Exhaust valve Valves Remove carbon deposits from combustion chamber. Clean off any gasket remnants from the cylinder head contact surface.

  • Page 66: Cylinder Head Installation

    6. CYLINDER HEAD/VALVES People GT 300i Dowel Pins CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket. Install the cam chain guide. • Clean the intake valve rocker arm shaft grease before installation. Gasket Cam chain guide Cylinder Head Install the cylinder head.
  • Page 67 6. CYLINDER HEAD/VALVES People GT 300i CYLINDER HEAD INSTALLATION Dowel Pins Install the dowel pins and a new cylinder head gasket. Install the cam chain guide. • Clean the intake valve rocker arm shaft grease before installation. Gasket Cam chain guide Cylinder Head Install the cylinder head.
  • Page 68 6. CYLINDER HEAD/VALVES People GT 300i Tighten the four cylinder head nuts and the Nuts four bolts between the cylinder head and cylinder. Torque: Cylinder head nuts: 3.6 kgf-m (35.3 N-m) Camshaft Gear Round hole Turn the A.C. generator flywheel so that the “T”...

  • Page 69: Cylinder Head Cover Installation

    6. CYLINDER HEAD/VALVES People GT 300i CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance. Thermostat Injector Install a new cylinder head cover O-ring and install the cylinder head cover. Be sure to install the O-ring into the groove properly. Install the inlet pipe.

  • Page 70: Cylinder/Piston

    7. CYLINDER/PISTON People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER/PISTON ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 7-1 SERVICE INFORMATION----------------------------------------------------------------------- 7-2 TROUBLESHOOTING --------------------------------------------------------------------------- 7-2 CYLINDER REMOVAL --------------------------------------------------------------------------- 7-3 PISTON REMOVAL ------------------------------------------------------------------------------- 7-3 PISTON INSTALLATION ------------------------------------------------------------------------ 7-7 CYLINDER INSTALLATION -------------------------------------------------------------------- 7-7...

  • Page 71: Schematic Drawing

    7. CYLINDER/PISTON People GT 300i SCHEMATIC DRAWING...

  • Page 72: Service Information

    7. CYLINDER/PISTON People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 73: Cylinder Removal

    7. CYLINDER/PISTON People GT 300i CYLINDER REMOVAL Cylinder Dowel Pins Remove the cylinder head. Remove the cam chain guide. Remove the cylinder. Water Hose Gasket Cam Chain Guide Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.
  • Page 74 7. CYLINDER/PISTON People GT 300i Inspect the piston, piston pin and piston rings. Remove the piston rings. Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and...
  • Page 75 7. CYLINDER/PISTON People GT 300i Measure the piston pin O.D. Service Limit: 16.994 mm replace if below Measure the piston O.D. Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 72.70mm replace if below...
  • Page 76 7. CYLINDER/PISTON People GT 300i Measure the connecting rod small end I.D. Service Limit: 15.06 mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring. • Be careful not to damage the piston and piston rings during assembly.

  • Page 77: Piston Installation

    7. CYLINDER/PISTON People GT 300i PISTON INSTALLATION Remove any gasket material from the crankcase surface. • Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip. • Position the piston “IN” mark on the intake valve side.
  • Page 78 7. CYLINDER/PISTON People GT 300i Install the cam chain guide. Gasket Dowel Pin • Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head gasket and dowel Cam Chain Guide pins. Connect the water hose to the cylinder.

  • Page 79: Drive And Driven Pulleys/V- Belt

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/V-BELT ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 8- 1 SERVICE INFORMATION----------------------------------------------------------------------- 8- 2 TROUBLESHOOTING --------------------------------------------------------------------------- 8- 2 LEFT CRANKCASE COVER ------------------------------------------------------------------- 8- 3 DRIVE PULLEY ------------------------------------------------------------------------------------ 8- 3...

  • Page 80: Drive And Driven Pulleys/V-Belt

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i SCHEMATIC DRAWING...

  • Page 81: Service Information

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS  The drive pulley, clutch and driven pulley can be serviced with the engine installed.  Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.

  • Page 82: Left Crankcase Cover

    8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i LEFT CRANKCASE COVER REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender A together. Remove the protector cover of left crankcase cover. Left Crankcase Cover Remove the bolts attaching to the left crankcase cover.
  • Page 83 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Replace a new belt at every 20,000km. • Use specified genuine parts replacement. MOVABLE DRIVE FACE ASSEMBLY Remove the pulley face, clutch outer, driven pulley and belt.
  • Page 84 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i INSPECTION Check each weight roller for wear or damage. Check the movable drive face bushing for wear or damage. ASSEMBLY...
  • Page 85 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i Install the weight rollers into the movable drive face. • The direction of all weight rolls is same. The color side is towards to clockwise. Ramp Plate Install the ramp plate.
  • Page 86 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i Clutch Spring Compressor CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Set the tool in a vise and remove the clutch drive plate nut. • Be sure to use a clutch spring compressor to avoid spring damage.
  • Page 87 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i INSPECTION Measure the driven face spring free length. Service Limit: 136 mm replace if below Outer Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.
  • Page 88 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i Press a new needle bearing into the driven face. Clips Retainer Plate CLUTCH DISASSEMBLY Remove the clips and retainer plate to disassemble the clutch. • Keep grease off the clutch linings.
  • Page 89 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i CLUTCH ASSEMBLY Clips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the clips.
  • Page 90 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i Install the movable driven face onto the driven face. Grooves Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
  • Page 91 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i INSTALLATION Install the movable drive face assembly and drive pulley collar onto the crankshaft. Drive Pulley Collar Movable Drive Face Assembly Movable Drive Face Assembly Put the drive belt on the driven pulley.
  • Page 92 8. DRIVE AND DRIVEN PULLEYS/ V-BELT People GT 300i Install the left crankcase cover. Left Crankcase Cover 8-13...

  • Page 93: Final Reduction

    9. FINAL REDUCTION People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 9-1 SERVICE INFORMATION----------------------------------------------------------------------- 9-2 TROUBLESHOOTING --------------------------------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY -------------------------------------------------------- 9-3 FINAL REDUCTION INSPECTION ----------------------------------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ------------------------------------------------------------- 9-5...

  • Page 94: Schematic Drawing

    9. FINAL REDUCTION People GT 300i SCHEMATIC DRAWING...

  • Page 95: Service Information

    9. FINAL REDUCTION People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.

  • Page 96: Final Reduction Disassembly

    9. FINAL REDUCTION People GT 300i FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear brake caliper. Remove the right rear shock absorber. Remove the rear fork. Remove the rear wheel. Remove the left crankcase cover. Remove the clutch outer/driven pulleys.
  • Page 97 9. FINAL REDUCTION People GT 300i Drive Shaft Bearing Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.

  • Page 98: Final Reduction Assembly

    9. FINAL REDUCTION People GT 300i FINAL REDUCTION ASSEMBLY Dowel Pin Install the drive shaft into the left crankcase. Put the final gear on the left crankcase. Install the countershaft and gear into the left crankcase. Install the final shaft into the final gear and transmission case.

  • Page 99: Generator/Starter Clutch

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 10-1 SERVICE INFORMATION----------------------------------------------------------------------- 10-2 TROUBLESHOOTING --------------------------------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------------------------------- 10-3 STATOR REMOVAL ------------------------------------------------------------------------------ 10-3 FLYWHEEL REMOVAL -------------------------------------------------------------------------- 10-4 STARTER CLUTCH ------------------------------------------------------------------------------ 10-4...

  • Page 100: Schematic Drawing

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i SCHEMATIC DRAWING 10-1...

  • Page 101: Service Information

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • All operations and inspections in this section can be made with the engine installed. • Should drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)

  • Page 102: Right Crankcase Cover Removal

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the water pump cover. Disconnect the water hoses from the right crankcase cover. Remove bolts attaching right crankcase cover and the cover. Water Hose...

  • Page 103: Flywheel Removal

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i Flywheel FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut and washer. Special Flywheel holder E021 Flywheel Holder Remove the flywheel with a flywheel puller. Special Flywheel puller...
  • Page 104 10. A.C. GENERATOR/STARTER CLUTCH People GT 300i Oil Separator Cover OIL PUMP REMOVAL Remove the attaching bolts and oil separator cover. Bolts Oil Pump Drive chain Cam Chain Spread the clip off and remove the oil pump driven gear, then remove the oil pump drive chain.
  • Page 105 10. A.C. GENERATOR/STARTER CLUTCH People GT 300i INSPECTION Inspect the starter driven gear for wear or damage. Measure the starter driven gear I.D. and O.D. I.D. Service Limits: I.D.: 22.15mm replace if over O.D.: 41.50mm replace if below O.D. Starter Idle Gear Inspect the starter idle gear and shaft for wear or damage.
  • Page 106 10. A.C. GENERATOR/STARTER CLUTCH People GT 300i Arrow Mark Bolts Cam Chain INSTALLATION Install oil pump and tighten two bolts. Make sure that the pump shaft rotates freely. The arrow of oil pump is upside. Install cam chain. Oil pump...

  • Page 107: Flywheel Installation

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i Starter Idle Gear Shaft Install the starter idle gear and shaft. Install the starter driven gear onto the crankshaft. Starter Driven Gear Flywheel FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel.

  • Page 108: Stator Installation

    10. A.C. GENERATOR/STARTER CLUTCH People GT 300i STATOR INSTALLATION Install the A.C. generator stator on the right Screws crankcase cover and secure it with the three bolts. Install the pulsar coil on the right crankcase cover and secure it with the two screws.

  • Page 109: Crankcase/Crankshaft

    11. CRANKCASE/CRANKSHAFT People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 11-1 SERVICE INFORMATION----------------------------------------------------------------------- 11-2 TROUBLESHOOTING --------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION------------------------------------------------------------------- 11-3 CRANKSHAFT INSPECTION ------------------------------------------------------------------ 11-4 CRANKCASE ASSEMBLY ---------------------------------------------------------------------- 11-5 11-0...

  • Page 110: Schematic Drawing

    11. CRANKCASE/CRANKSHAFT People GT 300i SCHEMATIC DRAWING 11-1...

  • Page 111: Service Information

    11. CRANKCASE/CRANKSHAFT People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to knock the crankcase forcedly to prevent damaging the mating surfaces.

  • Page 112: Crankcase Separation

    11. CRANKCASE/CRANKSHAFT People GT 300i CRANKCASE SEPARATION Remove bolts attaching left crankcase. Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. • Never use a driver to knock the crankcase mating surfaces apart.

  • Page 113: Crankshaft Inspection

    11. CRANKCASE/CRANKSHAFT People GT 300i Oil Seal Remove the oil seal from the left crankcase. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6 mm replace if over Measure the connecting rod small end I.D. Service Limit: 17.06 mm replace if over Measure the crankshaft bearing play.

  • Page 114: Crankcase Assembly

    11. CRANKCASE/CRANKSHAFT People GT 300i Left Crankcase CRANKCASE ASSEMBLY Install a new oil seal onto the left crankcase. Place the left crankcase down and install the crankshaft into the left crankcase. • Avoid damaging the oil seal. • Apply grease to the lip of the oil seal.

  • Page 115: Cooling System

    12. COOLING SYSTEM People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 12- SERVICE INFORMATION----------------------------------------------------------------------- 12- TROUBLESHOOTING --------------------------------------------------------------------------- 12- COOLING SYSTEM TESTING----------------------------------------------------------------- 12- RADIATOR ------------------------------------------------------------------------------------------ 12- WATER PUMP ------------------------------------------------------------------------------------- 12- 8 THERMOSENSOR -------------------------------------------------------------------------------- 12- 11 THERMOSTAT ------------------------------------------------------------------------------------- 12- 12...

  • Page 116: Schematic Drawing

    12. COOLING SYSTEM People GT 300i SCHEMATIC DRAWING 12-1...

  • Page 117: Service Information

    12. COOLING SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system.
  • Page 118 616cc 504cc ＊ • Use coolant of specified mixing rate 40%:60%. (The mixing rate of 448cc KYMCO SIGMA coolant concentrate + 672cc distilled water) • Do not mix coolant concentrate of different brands. • Do not drink the coolant, which is poisonous.

  • Page 119: Radiator

    12. COOLING SYSTEM People GT 300i COOLING SYSTEM TESTING Radiator Tester RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the sealing cap surface before testing.
  • Page 120 12. COOLING SYSTEM People GT 300i From: Reserve Tank From: Engine Remove the under cowl. Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins.
  • Page 121 12. COOLING SYSTEM People GT 300i Remove two bolts/nuts on the radiator. Remove the radiator. 95701-06016: Bolts 94050-06060: nuts RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator. Check fan motor by battery. 12-6...
  • Page 122 12. COOLING SYSTEM People GT 300i THERMOSTATIC SWITCH When the coolant temperature is lower than 85 ℃, the thermostatic switch OFF. When coolant temperature is over 90 ℃, the thermostatic switch ON. 37760: Thermostatic Switch RADIATOR INSTALLATION Install the fan rubber on the radiator with...

  • Page 123: Water Pump

    12. COOLING SYSTEM People GT 300i Water Pump Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 124 12. COOLING SYSTEM People GT 300i Water Pump Shaft WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly.
  • Page 125 12. COOLING SYSTEM People GT 300i Seal Washer (Porcelain) Install the dowel pins and a new gasket and Impeller then install the water pump assembly to the right crankcase cover. Tighten 12 bolts to secure the right crankcase cover. ＊...

  • Page 126: Thermosensor

    12. COOLING SYSTEM People GT 300i Thermosensor Wire THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor THERMOSENSOR INSPECTION...

  • Page 127: Thermostat

    12. COOLING SYSTEM People GT 300i THERMOSTAT THERMOSTAT REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing.

  • Page 129: Fuel Injection System

    13. FUEL INJECTION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ FUEL INJECTION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 13- 1 SPECIFICATIONS ---------------------------------------------------------- 13- 2 INJECTION SYSTEM DIAGRAM --------------------------------------- 13- 3 PARTS LOCATION -------------------------------------------------------- 13- 4 TROUBLESHOOTING----------------------------------------------------- 13- 6 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL------------------------------------------------------- 13- 7 EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE CODES-------------------------------------------------------------------------13- 8 SELF-DIAGNOSIS RESET PROCEDURE ----------------------------- 13- 9 CELP FAILURE CODES LIST------------------------------------------- 13-10...

  • Page 130: Fuel Injection System

    13. FUEL INJECTION SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.

  • Page 131: Specifications

    13. FUEL INJECTION SYSTEM People GT 300i SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number LGE5 Idle speed 1600±100 rpm Throttle grip free play 2～6 mm (1/16～1/4 in) Fuel injector resistance (at 20°C/68°F) 11.7±0.6 Fuel pump resistance Float at full position 100±3 Ω...

  • Page 132: Injection System Diagram

    13. FUEL INJECTION SYSTEM People GT 300i INJECTION SYSTEM DIAGRAM FULL NAME ABBREVIATIONS (01) Electronic control unit (02) Tilt switch (Angle detect sensor) ROLL (03) Fuel pump/Fuel level unit (04) Water temperature sensor WTS sensor (05) Crank position sensor (Pulser)

  • Page 133: Parts Location

    13. FUEL INJECTION SYSTEM People GT 300i PARTS LOCATION Winker Relay Tilt Switch Horn Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay MAP Sensor Throttle Body Injector 13-4...

  • Page 134: Troubleshooting

    13. FUEL INJECTION SYSTEM People GT 300i TROUBLESHOOTING Engine fail to start Backfiring or misfiring during acceleration • Intake manifold air leak • Ignition system malfunction • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Faulty fuel pump • Clogged fuel filter, throttle body •...

  • Page 135: Self-Diagnostic Procedures Without

    13. FUEL INJECTION SYSTEM People GT 300i SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL SELF-DIAGNOSTIC PROCEDURES It can be performed without diagnostics program. Place the scooter on its main stand. Put the side stand up and the engine stop switch is at “RUN”.

  • Page 136: Efi Self-Diagnosis Check Engine Lamp (Celp) Failure Codes

    13. FUEL INJECTION SYSTEM People GT 300i EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE CODES If more than a damaged part has occurred, the “CELP” begins blinking in order. The “CELP” denotes the failure codes. When the indicator lights for one second that For example: If the indicator blinks six times, is equal to ten.

  • Page 137: Self-Diagnosis Reset Procedure

    13. FUEL INJECTION SYSTEM People GT 300i SELF-DIAGNOSIS RESET PROCEDURE 1. Put the side stand up and engine stop switch is at “RUN”. 2. Turn the key to the ON position and wait for ten seconds. 3. Fully open the throttle and wait for ten seconds.

  • Page 138: Celp Failure Codes List

    13. FUEL INJECTION SYSTEM People GT 300i CELP FAILURE CODES LIST Failure Blinks Contents Causes Symptoms Codes ● Faulty TPS voltage range (0.3~4.5 V) ● Loose or poor connection on TPS Engine operates Sensor P0120 Faulty TPS normally ● Open or short circuit on the TPS wire ●...
  • Page 139 13. FUEL INJECTION SYSTEM People GT 300i Failure Blinks Contents Causes Symptoms Codes ● Faulty Inductive ignition coil Ω range (4.2 Ω ± 15%) Faulty ● Loose or poor connection on Engine fail to be inductive P0351 inductive ignition coil...
  • Page 140 13. FUEL INJECTION SYSTEM People GT 300i SPARK PLUG ANTI-FLOOD When have not failure code occurs and pressing starter switch repeatedly, can still not start the engine, maybe the spark plug is wet by fuel, perform the spark plug anti- flood to purge the fuel in the engine.

  • Page 141: Tps/Isc Reset

    13. FUEL INJECTION SYSTEM People GT 300i TPS/ISC RESET ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.

  • Page 142: Fuel Pump

    13. FUEL INJECTION SYSTEM People GT 300i Connector FUEL PUMP INSPECTIION Put the side stand up and the engine stop switch is at “RUN” Disconnect fuel pump/fuel unit connector. Connect the multimeter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal.
  • Page 143 13. FUEL INJECTION SYSTEM People GT 300i Fuel Pump Connector REMOVAL Disconnect the connector and fuel band from the fuel pump. Remove the six screws onto the fuel pump. Remove the fuel pump and O-ring. Hose Band INSTALLATION Replace a new O-ring on the fuel tank.

  • Page 144: Fuel Cut-Off Relay

    13. FUEL INJECTION SYSTEM People GT 300i Battery FUEL CUT-OFF RELAY INSPECTION Remove the fuel cut-off relay. Connect the ohmmeter to the fuel cut-off relay connector terminals. Connection: Black – Red/Black Connect 12 V battery with the fuel cut-off Fuel Cut-Off Relay relay connector.

  • Page 145: Tilt Switch

    13. FUEL INJECTION SYSTEM People GT 300i TILT SWITCH INSPECTION Support the scooter level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch.

  • Page 146: Electronic Control Unit (Ecu)

    13. FUEL INJECTION SYSTEM People GT 300i ELECTRIC CONTROL UNIT (ECU) REMOVAL/INSTALLATION ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when throttle body, MAP, TPS, ISC or ECU has been reinstalled.
  • Page 147 13. FUEL INJECTION SYSTEM People GT 300i INSPECTION Disconnect and remove the ECU from the frame. Check for continuity between pin 35 and 36 of the ECU side connector. There should be continuity at all times. Check for continuity between each pins 8, 9 and 24 of the ECU side connector.

  • Page 148: Fuel Injector

    13. FUEL INJECTION SYSTEM People GT 300i FUEL INJECTOR INSPECTION Disconnect the fuel injector connector. Measure the resistance between 2 pins of the fuel injector connector. Standard: 11.7±0.6 Ω (at 20°C/68°F) REMOVAL Disconnect the connector from the fuel injector. Remove the bolt of the fuel injector.
  • Page 149 13. FUEL INJECTION SYSTEM People GT 300i Groove INSTALLATION Apply the engine oil to a new O-ring. Install the fuel injector into the fuel pipe. Ensure the tab of the fuel injector inserted into the groove of the fuel pipe.

  • Page 150: Wts Sensor

    13. FUEL INJECTION SYSTEM People GT 300i MAP Sensor Throttle Body WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring.

  • Page 151: O 2 Sensor

    13. FUEL INJECTION SYSTEM People GT 300i SENSOR The O sensor issues signal to ECU when the temperature is over 350°C during the engine is working. The temperature is up to 350°C earlier than the muffler for O heater sensor. So the O sensor begins performance.

  • Page 152: Throttle Body/Map/Isc/Tps

    ● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
  • Page 153 13. FUEL INJECTION SYSTEM People GT 300i TPS INSPECTION Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector.
  • Page 154 13. FUEL INJECTION SYSTEM People GT 300i Screw/Set Plate DISASSEMBLY The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU has been reinstalled. Remove the screw and then remove the ISC and set plate.

  • Page 155: Diagnostic Tool Connector

    13. FUEL INJECTION SYSTEM People GT 300i Apply oil onto a new O-ring. When install the MAP onto the throttle body, being careful not to damage the O-ring. Always replace an O-ring with a new one. Install the set plate and tighten the screw securely.

  • Page 156: Operation Instructions

    13. FUEL INJECTION SYSTEM People GT 300i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00 13-27...
  • Page 157 13. FUEL INJECTION SYSTEM People GT 300i . FI DIAGNOSTIC TOOL This tool is developed by KYMCO and for KYMCO vehicle only. Please refer to the specification when serving this vehicle. This tool is without battery inside. The power is provided from vehicle.
  • Page 158 13. FUEL INJECTION SYSTEM People GT 300i . DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power. LGE5 is for People GT 300i A). ECU version: Including of model name, ECU number, identifications number and software version.
  • Page 159 13. FUEL INJECTION SYSTEM People GT 300i B). Press the " Down " button and then turn to the first page. LGE5 is for People GT 300i C). Press the " Enter " button to check the DTC failure code...
  • Page 160 13. FUEL INJECTION SYSTEM People GT 300i D). Press the " Enter " button E). Press the " Enter " button F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page...
  • Page 161 13. FUEL INJECTION SYSTEM People GT 300i G). Press the " UP " button H). Press the " Enter " button and then turn to the previous page with red color. I). Press the " UP " button 13-32...
  • Page 162 13. FUEL INJECTION SYSTEM People GT 300i J). Press the " Enter " button and then turn to the first page. LGE5 is for People GT 300i LGE5 is for People GT 300i 13-33...
  • Page 163 13. FUEL INJECTION SYSTEM People GT 300i . DTC CLEAR PROCEDURE ). Check the DTC LGE5 is for People GT 300i ). Press the " Enter " button LGE5 is for People GT 300i ). Choose " Load DTC "...
  • Page 164 13. FUEL INJECTION SYSTEM People GT 300i ). Press the " Enter " button and the indicator is lighting. ). Clearing DTC completed if the indicator is off. 13-35...
  • Page 165 13. FUEL INJECTION SYSTEM People GT 300i . DATA ANALYSIS PROCEDURE ). Press the " Down " twice LGE5 is for People GT 300i ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 LGE5 is for People GT 300i ).
  • Page 166 5. FUEL INJECTION SYSTEM People GT 300i . DATA ANALYSIS PROCEDURE ). Press the " Down " twice LGE5 is for People GT 300i ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 LGE5 is for People GT 300i ).
  • Page 167 5. FUEL INJECTION SYSTEM People GT 300i ). Down-page 02 The measure figures including of TPS position, Intake pressure and Intake air temperature. Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of Atmosphere pressure, Fuel Injector interval and Ignition advance timing.
  • Page 168 5. FUEL INJECTION SYSTEM People GT 300i ). Down-page 05 The measure figures including of ISC target, ISC step and ISC learn step. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of ISC motor state.
  • Page 169 5. FUEL INJECTION SYSTEM People GT 300i . Vehicle can not be started – Handling method (Steps) Preliminary Checking: 6 basic inspection 1. Is the battery with voltage (12 V or higher) 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.

  • Page 170: Manual Trouble Shooting Procedure

    5. FUEL INJECTION SYSTEM People GT 300i 六. Manual Trouble Shooting Procedure How to read DTC from speedometer? New Phase 5 Fuel Injection Engine Vehicle DTC Reading: Automatic indication – ECU upgrade version (with Oxygen sensor): Reading DTC from speedometer directly.
  • Page 171 5. FUEL INJECTION SYSTEM People GT 300i LGE5 SF : Customer : Eng. No: Production Service Mileage : Date : Date : Reason of repair: □ maintenance □ breakdown Item Memo Date Reference ECU No 39200-LGE5-E500 Hardware Ver Software Ver...
  • Page 172 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ SCHEMATIC DRAWING-------------------------------------------------------------------------14- 1 SERVICE INFORMATION-----------------------------------------------------------------------14- 2 TROUBLESHOOTING ---------------------------------------------------------------------------14- 3 STEERING HANDLEBAR -----------------------------------------------------------------------14- 4 FRONT WHEEL------------------------------------------------------------------------------------14- 5...

  • Page 173: Schematic Drawing

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...

  • Page 174: Service Information

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.

  • Page 175: Troubleshooting

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Loose front axle cone race • Broken steering balls • Bent spoke plate •...

  • Page 176: Steering Handlebar

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 2-3) Remove the front and rear brake master cylinder attaching bolts. Bolts Throttle Cable Remove the four screws attaching the right and left handlebar switches.

  • Page 177: Front Wheel

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
  • Page 178 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0 mm replace if over Axial: 2.0 mm replace if over Dust Seal Collar FRONT WHEEL BEARING Remove the side collar and dust seal.
  • Page 179 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle 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.

  • Page 180: Front Brake

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT BRAKE BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers. ( 2-3) Drain the brake fluid from the hydraulic brake system. Disconnect front stop switch wire connector. Remove the brake fluid tube bolt.
  • Page 181 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 14.05 mm Measure the brake master cylinder piston O.D. Service Limit: 13.94 mm Before assembly, inspect the 1st and 2nd rubber cups for wear.
  • Page 182 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Place the brake master cylinder on the handlebar and install the holder with the “up” “UP” Mark mark facing up. Also align the punch mark with the holder joint seam.
  • Page 183 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.

  • Page 184: Front Shock Absorber

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT SHOCK ABSORBER Upper Mount Bolts REMOVAL Remove the front cover. (  2-5) Remove the front wheel. (  15-5) Remove the front brake caliper. (  15-11) Remove the front shock absorber upper mount bolts.

  • Page 185: Steering Handlebar/Front Wheel/Front Brake/Front

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT FORK Lock Nut Wrench REMOVAL Remove the handlebar covers. ( 2-3) Remove the steering handlebar. ( 15-4) Remove the front cover. ( 2-5) Remove the front fender cover. ( 2-6) Remove the front wheel.
  • Page 186 14. STEERING HANDLEBAR/FRONT WHEEL/FRONT People GT 300i BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.

  • Page 187: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 15-1 SERVICE INFORMATION----------------------------------------------------------------------- 15-2 TROUBLESHOOTING --------------------------------------------------------------------------- 15-2 REAR BRAKE -------------------------------------------------------------------------------------- 15-3 REAR FORK ---------------------------------------------------------------------------------------- 15-4...
  • Page 188 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER People GT 300i SCHEMATIC DRAWING 15-1...
  • Page 189 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk.
  • Page 190 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER People GT 300i Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. ( 2-10) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper.
  • Page 191 15. REAR BRAKE/REAR FORK/REAR PEOPLES 300i WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts. Torque: 35 N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.
  • Page 192 15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER PEOPLES 300i Rear Brake Disk REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-10) Remove the rear brake caliper. ( 16-3) Remove the rear fork. ( 16-6) Remove the rear axle collar. Remove the rear wheel. Rear Axle Collar INSPECTION Measure the rear wheel rim runout.
  • Page 193 When adjusting rear cushion, the spring preload of rear cushions must be the same. Standard spring preload position: People GT 125i: 1st People GT 300i: 2nd A cushion adjust wrench is provided with new scooter. Wrench The rear right cushion can be adjusted directly with the wrench tool.

  • Page 194: Battery/Charging System

    . BATTERY/CHARGING SYSTEM People GT 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 16-1 CHARGING CIRCUIT ----------------------------------------------------- 16-1 SERVICE INFORMATION------------------------------------------------ 16-2 TROUBLESHOOTING----------------------------------------------------- 16-3 BATTERY CHARGING --------------------------------------------------- 16-4 CHARGING SYSTEM ----------------------------------------------------- 16-6 REGULATOR/RECTIFIER ----------------------------------------------- 16-6 16-0...

  • Page 195: Battery/Charging System

    . BATTERY/CHARGING SYSTEM People GT 300i CHARGING SYSTEM LAYOUT Battery AC Generator Regulator/Rectifier 16-1...

  • Page 196: Service Information

    . BATTERY/CHARGING SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is 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 •...

  • Page 197: Troubleshooting

    . BATTERY/CHARGING SYSTEM People GT 300i TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in • Faulty ignition switch...
  • Page 198 . BATTERY/CHARGING SYSTEM People GT 300i Terminal BATTERY REMOVAL The battery is under the floorboard. Remove the two screws attaching the battery cover. Pull battery out to expose the terminal leads. Disconnect the negative (-) terminal lead from the battery first, then disconnect the positive (+) terminal lead.

  • Page 199: Battery Charging

    . BATTERY/CHARGING SYSTEM People GT 300i BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. Turn the power ON/OFF at the charger, not at the battery terminals.

  • Page 200: Regulator/Rectifier

    . BATTERY/CHARGING SYSTEM People GT 300i REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator/rectifier connectors. Check the connectors for loose contacts of corroded terminals. Regulator/Rectifier BATTERY WIRE Measure the voltage between the Red/White wire terminal and ground.
  • Page 201 . BATTERY/CHARGING SYSTEM People GT 300i CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals. Standard: 0.4 ~ 0.6 Ω (20ºC/68ºF) Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground. There should be no continuity.

  • Page 202: Ignition System

    17. IGNITION SYSTEM People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM ________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------------------------------ 17-1 SERVICE INFORMATION----------------------------------------------------------------------- 17-2 TROUBLESHOOTING --------------------------------------------------------------------------- 17-2 SPARK PLUG -------------------------------------------------------------------------------------- 17-3 IGNITION COIL INSPECTION ----------------------------------------------------------------- 17-3 A.C. GENERATOR INSPECTION------------------------------------------------------------- 17-4 TILT SWITCH INSPECTION ------------------------------------------------------------------- 17-4...

  • Page 203: Ignition System Layout

    17. IGNITION SYSTEM People GT 300i IGNITION SYSTEM LAYOUT Ignition Coil Tilt switch Ignition Switch IGNITION CIRCUIT 17-1...

  • Page 204: Service Information

    17. IGNITION SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2.

  • Page 205: Spark Plug

    17. IGNITION SYSTEM People GT 300i Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. ( 2-6) Remove the ignition coil. Primary Coil IGNITION COIL CONTINUITY...

  • Page 206: Generator Inspection

    17. IGNITION SYSTEM People GT 300i A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Measure resistance between blue/white and green/white wire terminals.
  • Page 207 17. IGNITION SYSTEM People GT 300i REMOVAL/INSTALLATION Disconnect the connector and remove two screws, then remove tilt switch. Installation is in the reverse order of removal. Install the tilt switch with its “up” mark facing up. Tighten the mounting screws securely.

  • Page 208: Starting System

    18. STARTING SYSTEM People GT 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM ________________________________________________________________________________ STARTING SYSTEM LAYOUT ---------------------------------------------------------------- 18-1 SERVICE INFORMATION----------------------------------------------------------------------- 18-2 TROUBLESHOOTING --------------------------------------------------------------------------- 18-2 STARTER MOTOR-------------------------------------------------------------------------------- 18-3 STARTER RELAY INSPECTION-------------------------------------------------------------- 18-4 18-0...

  • Page 209: Starting System Layout

    18. STARTING SYSTEM People GT 300i STARTING SYSTEM LAYOUT Starter Relay Ignition Switch STARTING CIRCUIT 18-1...

  • Page 210: Service Information

    18. STARTING SYSTEM People GT 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.

  • Page 211: Starter Motor

    18. STARTING SYSTEM People GT 300i 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 make sure the starter motor can’t operate securely.

  • Page 212: Starter Relay Inspection

    18. STARTING SYSTEM People GT 300i Starter Motor Cable INSTALLATION Connect the starter motor cable. Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install it to the starter motor. Tighten the two mounting bolts.

  • Page 213: Lights Switches/ Fuel Pump

    19. LIGHTS SWITCHES/ FUEL PUMP People GT 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 19- 1 BULB REPLACEMENT --------------------------------------------------- 19- 3 BRAKE LIGHT SWITCH-------------------------------------------------- 19- 5 IGNITION SWITCH -------------------------------------------------------- 19- 5 RIGHT HANDLEBAR SWITCH ----------------------------------------- 19- 6...
  • Page 214 19. LIGHTS SWITCHES/ FUEL PUMP People GT 300i ELECTRICAL EQUIPMENT LAYOUT Oil Controller Winker Relay Winker Relay Tilt Switch Horn Ignition Switch ECU Relay Lo Beam Relay Hi Beam Relay Fuel Pump Relay 19-1...

  • Page 215: Service Information

    19. LIGHTS SWITCHES/ FUEL PUMP People GT 300i SERVICE INFORMATION GENERAL A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.

  • Page 216: Bulb Replacement

    19. LIGHTS SWITCHES/ FUEL PUMP People GT 300i BULB REPLACEMENT LICENECE LIGHT Disconnect the license bulb socket. Remove the bulb and replace with a new one. HEADLIGHT A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF.
  • Page 217 19. LIGHTS/METERS/SWITCHES People GT 300i FRONT TURN SIGNAL LIGHT Remove the front cover. Turn the bulb socket and then remove the front turn signal light. Push and turn the bulb counterclockwise to remove it, then replace with a new one.

  • Page 218: Brake Light Switch

    19. LIGHTS/METERS/SWITCHES People GT 300i BRAKE LIGHT SWITCH Remove the handlebar cover. Disconnect front or rear brake light switch connectors and check for continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.

  • Page 219: Right Handlebar Switch

    19. LIGHTS/METERS/SWITCHES People GT 300i Engine Stop Switch RIGHT HANDLEBAR SWITCH INSPECTION Remove the handle cover. Disconnect right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows:...

  • Page 220: Left Handlebar Switch

    19. LIGHTS/METERS/SWITCHES People GT 300i Dimmer Switch LEFT HANDLEBAR SWITCH INSPECTION Disconnect left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Horn Switch Turn Signal light Switch...

  • Page 221: Fuel Pump

    19. LIGHTS/METERS/SWITCHES People GT 300i Connector FUEL PUMP REMOVAL Remove the seat and met-in Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose. Remove the six nuts and fuel unit connectors then remove the fuel hose.
  • Page 222 19. LIGHTS/METERS/SWITCHES People GT 300i Measure resistance between Red/Black and Green wire of the fuel unit connector. Standard (at 20°C/68°F): Float at full position About 1100 Ω Float at empty position About 100 Ω 19-9...

  • Page 223: Side Stand Switch

    19. LIGHTS/METERS/SWITCHES People GT 300i Side Stand Switch SIDE STAND SWITCH INSPECTION Remove the luggage box. The side stand switch is located on the side stand. Disconnect the side stand switch connector. There should be continuity between the Yellow/Green and Green with the side stand is up.

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