Kymco People GT 300i (BF60AA) 2010 Factory Service Manual (P/N T300-LGE5-A2)

This first-edition factory service manual covers the 2010 Kymco People GT 300i (BF60AA). Kwang Yang Motor Co., Ltd. issued it in March 2010 under P/N T300-LGE5-A2.

PDF Search, Bookmarks, and Print Format

Finding procedures and wiring details: Most chapters have searchable text. The maintenance chart, lubrication chapter, and some table entries and diagram labels fall outside text search. Chapter bookmarks use Italian labels. Zooming in makes the small wire codes and ECU pin numbers in the ignition circuit easier to read.

The ZIP contains one printable, English-language A4 PDF with 221 pages, including the factory cover and preface.

Engine, CVT, and Scooter Diagnostics

This selection of workshop topics highlights the main repair and diagnostic work. The manual also covers windshield and exhaust muffler removal.

• Periodic maintenance: Service schedule, engine oil and filter service, air cleaner and spark plug replacement, valve clearance adjustment, and cylinder compression testing.

• Engine repair: Engine removal and installation, cylinder head and valve service, camshaft timing, piston and ring inspection, crankcase separation, and crankshaft checks.

• CVT and final reduction: Left crankcase cover removal, drive and driven pulley service, V-belt inspection, clutch work, and service of the two-stage final reduction.

• Fuel-injection diagnosis: Dashboard CELP blink codes, diagnostic trouble code (DTC) reading and clearing, TPS/ISC reset, and live-data checks with the KYMCO FI diagnostic tool.

• Cooling system: Radiator and cap testing, thermostat inspection, water pump seal replacement, and coolant bleeding after engine installation.

• Chassis service: Steering and front fork work, wheel and bearing inspection, rear suspension service, and hydraulic disc brake caliper and master cylinder service.

• Electrical testing: Battery and charging checks, ECU-controlled ignition diagnosis, starter motor and relay tests, and lighting and switch checks.

This manual suits scooter technicians and experienced owners familiar with multimeter testing and the use of dedicated service tools.

Engine Access and Driveline Service

The cylinder head, cylinder and piston, CVT, final reduction, AC generator, and starter clutch can be serviced with the engine in the frame. Crankcase separation and water pump service require engine removal. That distinction helps you plan engine support, access, and coolant draining before teardown.

For the liquid-cooled, four-valve OHC single, the manual details valve stem and guide inspection and shows how to remove and install the oil pump as a unit. It also covers engine hanger service, throttle operation, final reduction oil, clutch shoe wear, chassis fasteners, and tire and suspension checks.

The CVT section shows how to inspect the weight rollers and replace the driven-face bearing. It also explains how oil or grease on the belt and pulley faces can cause drive slip.

EFI No-Start Diagnosis

The no-start checklist and CELP fault tables link dashboard blink codes to likely causes and symptoms. The manual identifies the Keihin throttle body as LGE5 and uses that designation for the People GT 300i in the KYMCO FI diagnostic tool (3620A-LEB2-E00) instructions.

The tool pages show ECU identification and live data for engine speed, battery voltage, throttle position, intake and atmospheric pressure, and temperature inputs. They also show injector duration, ignition advance, oxygen sensor data, and idle speed control values.

Component checks cover the fuel pump and cut-off relay, tilt switch, injector, coolant temperature and oxygen sensors, and the throttle body's MAP sensor, TPS, and idle air bypass valve (ISC). The ECU connector table maps pin functions, and the throttle body procedures explain when TPS/ISC reset is required after reinstallation.

Brake Service, Circuits, and Shop References

The brake procedures cover bleeding and master cylinder inspection. Steering work includes steering-stem race replacement, and the rear chassis section shows rear fork and shock removal.

The charging section covers regulator/rectifier, harness, and stator checks. Ignition and starting have individual circuit diagrams. Switch tests cover the brake lights, handlebar controls, auxiliary outlet, and side-stand ignition interlock.

Eleven chapter-opening mechanical overview pages illustrate assemblies such as the cylinder head and valves, CVT, cooling system, and front brake and fork. Parts identification is limited to service illustrations and individual part references. The manual also provides torque tables, wear limits, fluid specifications, lubrication points, and cable and harness routing.

The tool list identifies the flywheel puller (E003), tappet adjuster (E012), oil seal and bearing installer (E014), flywheel holder (E021), and steering locknut wrench (F002).

The manual calls out fuel pressure relief, ignition-off precautions for ECU and charging connectors, and the risk of brake fluid contaminating friction surfaces or damaging painted and plastic parts. It also warns that forcing frame covers can break their retaining claws.

Selected Valve, Cooling, and Charging Specs

The valve adjustment procedure specifies 0.10 mm for both intake and exhaust with the engine cold, below 35°C. The cooling section gives a radiator cap relief pressure of 0.9 ± 0.15 kg/cm² for the cap test.

The charging-coil check specifies 0.4–0.6 Ω at 20°C (68°F) between the yellow-wire terminals.