KYMCO People GT 200i Manual de usuario

People GT 200i

By KWANG YANG Motor Co., Ltd.

1st Edition, July 2010

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T300-LGE6-A2

People GT 200i

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO People

GT 300i.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules

and service information for each part,

starting from periodic maintenance.

Sections 5 to 12 give instructions for

disassembly, assembly and

adjustment of engine parts. Section 13

is the AFI system. Section 14 to 15 is

the removal/ installation of chassis.

Section 16 to 19 states the testing and

measuring methods of electrical

equipment.

Most sections start with an assembly

or system illustration and

troubleshooting for the section. The

subsequent pages give detailed

procedures for the section.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPT.

EDUCATION SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1

EXHAUST MUFFLER/FRAME

COVERS 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

ENGINE REMOVAL/INSTALLATION 5

CYLINDER HEAD/VALVES 6

CYLINDER/PISTON 7

DRIVE AND DRIVEN PULLEYS/V-

BELT 8

FINAL REDUCTION 9

A.C. GENERATOR/STARTER

CLUTCH 10

CRANKCASE/CRANKSHAFT 11

COOLING SYSTEM 12

FUEL INJECTION SYSTEM 13

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER` 15

BATTERY/CHARGING SYSTEM 16

IGNITION SYSTEM 17

STARTING SYSTEM 18

LIGHTS SWITCHES / FUEL PUMP 19

The information and contents

included in this manual may be

different from the motorcycle in case

specifications are changed.

CHASSIS ELE

TRI

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

People GT 200i

________________________________________________________________________________

GENERAL INFORMATION

________________________________________________________________________________

SERIAL NUMBER------------------------------------------------------------------------------------1-1

SPECIFICATION -------------------------------------------------------------------------------------1-2

SERVICE PRECAUTIONS-------------------------------------------------------------------------1-5

TORQUE VALUES-----------------------------------------------------------------------------------1-9

SPECIAL TOOLS----------------------------------------------------------------------------------- 1-10

LUBRICATION POINTS -------------------------------------------------------------------------- 1-11

CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-13

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

1. GENERAL INFORMATION

1-1

People GT 200i

SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

1. GENERAL INFORMATION

1-2

People GT 200i

SPECIFICATIONS

Name People GT 200i

Model No. BF40AA

Overall length 2130 mm

Overall width 750 mm

Overall height 1280 mm

Wheel base 1450 mm

Engine type 4stroke O.H.C.

Displacement 205 cc

Fuel Used 92# nonleaded

gasoline

Front wheel

Rear wheel

Total 171.5

Front wheel 97

Rear wheel 149

Total 246

Ground clearance (mm) 150

Braking distance (m) 7.9m / 40 km/hr

Min. turning radius (mm) R/L 2250/2170

Engine part

Starting system Starting motor

Type Gasoline 4-cycle

Cylinder arrangement Sin

le c

linde

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.-4V

Bore x stroke (mm) φ66 * 60

Compression ratio 10.3:1

Compression pressure

(kg/cm²-rpm) 16-570 rpm

Max. output (ps/rpm) 20.6 / 8000

Max. torque (kg-m/rpm) 2.03 / 6500

Open -5° BTDC

Close 32° BTDC

Open 34° BTDC

Close 5° BTDC

Intake 0.10

Exhaust 0.10

Idle speed (rpm) 1600±100 rpm

Cooling Type Liquid cooling

Lubrication type Forced

ressure &

wet sump

Oil pump type Inner/outer roto

Oil filter type Full-flow filtration

Oil capacity 1.5 liter

Exchanging capacity 1.3 liter

Fi injection system

Air cleaner type & No Paper element, wet

Fuel capacity 9 liters

Brand Keihin

Throttle Body Butterfly type

Venturi diameter (mm) 32

Fuel pump pressure 3.0 bar

Electrical system

Ignition type ECU

Ignition timing ECU control

Spark plug CR7E (NGK)

Spark plug gap 0.6～0.7mm

Battery Capacity 12V12AH

Transmission system

Clutch type Dry multi-disc

Transmission type CVT

Operation type Auto centrifugal

Reduction gear type Two-stage reduction

Primary 2.24~0.72

Final 7.222

Moving device

Tire type Tubeless

Front wheel 110/70-16

Rear wheel 140/70-16

Front wheel 1.75

Rear wheel 2.25 (with

passenger)

Wheel material Aluminium

Left 45°±5

Right 45°±5

Front Disk brake

Rear Disk brake

Damping Device

Front Telescope

Rear Swing arm

Front 110 mm

Shock absorber

stroke Rear 100 mm

Curb weight

(kg)

Max. weight

(kg)

Intake Timing

Exhaust

Timing

Valve

clearance

Reduction ratio

Tire spec.

Tire pressure

(kg/cm²)

Turning angle

Brake type

Suspension

1. GENERAL INFORMATION

1-3

People GT 200i

SERVICE PRECAUTIONS

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

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

Apply or add designated greases and

lubricants to the specified lubrication points.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points,

fasteners, and lines for proper connection

and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

1. GENERAL INFORMATION

1-4

People GT 200i

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

After clamping, check each wire to make

sure it is secure.

Confirm

Capacity

1. GENERAL INFORMATION

1-5

People GT 200i

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts that will generate

high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

Route harnesses so they are neither

pulled tight nor have excessive slack.

Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

When rubber protector cover is used to

protect the wire harnesses, it shall be

installed securely.

Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape or

replace it.

When installing other parts, do not press or

squeeze the wires.

After routing, check that the wire harnesses

are not twisted or kinked.

Do not pull

too tight！

No Contact

Do not press or

squeeze the wire

1. GENERAL INFORMATION

1-6

People GT 200i

Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or surrounding parts in all steering

positions.

When a testing device is used, make sure

to understand the operating methods

thoroughly and operate according to the

operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Do you understand

the instrument？

Remove Rust！

1. GENERAL INFORMATION

1-7

People GT 200i

Symbols:

The following symbols represent the

servicing methods and cautions included in

this service manual.

: Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

:Caution

:Warning

Special

Engine Oil

Grease

Gear Oil

＊

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