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

• Coverage: Covers the KYMCO People GT 300i, model BF60AA, as documented in the March 2010 first-edition factory service publication, document code T300-LGE5-A2.
• Engine repair: Covers maintenance and inspection, engine removal and installation, cylinder-head and valve work, camshaft/timing service, cylinder/piston inspection, crankcase separation, crankshaft checks, lubrication, and cooling-system repair.
• CVT and driveline: Details the left crankcase cover, drive and driven pulleys, V-belt, clutch, final reduction, A.C. generator, flywheel, starter clutch, and engine-hanger procedures.
• Fuel-injection diagnosis: Includes CELP blink-code and DTC checks without a scan tool, DTC reset, TPS/ISC reset, no-start fault isolation, live-data analysis, and KYMCO FI diagnostic-tool instructions 3620A-LEB2-E00.
• Chassis and electrical: Addresses steering, front and rear wheels, hydraulic disc brakes, forks, shocks, battery/charging, ignition, starting, lights, switches, fuel pump, and side-stand interlock testing.
• Documentation depth: A 221-page PDF in the original A4 layout, with 11 major mechanical assembly schematics/exploded views, system diagrams, troubleshooting charts, torque and service-limit tables, lubrication points, cable/harness routing, and special-tool codes.

Exact Model and Repair Scope

This manual is tied to the People GT 300i BF60AA, not a generic 300cc KYMCO scooter. Its specifications identify the 298.9 cc liquid-cooled OHC four-valve single-cylinder engine, Keihin throttle body, ECU-controlled ignition, CVT, and two-stage final reduction. The fuel-injection chapter also identifies the LGE5 designation used in the diagnostic-tool screens.

The manual states which jobs can be done with the engine still in the frame. Cylinder-head and valve work, cylinder and piston service, CVT and clutch work, final-reduction service, and A.C. generator/starter-clutch repair are documented as in-frame operations. Crankcase separation requires engine removal, and the cooling chapter treats water-pump service as an engine-out job. That distinction helps a technician plan support equipment, coolant draining, and access before a teardown begins.

Periodic service pages cover the maintenance schedule, throttle operation, engine oil and filter, coolant, air cleaner, spark plug, valve clearance, compression testing, and final-reduction oil. They also address the drive belt, brakes, clutch-shoe wear, suspension, fasteners, tires, steering, and side-stand ignition cut-off.

Internal engine chapters add camshaft removal and installation, cylinder-head disassembly and assembly, valve and guide inspection, piston and ring inspection, crankshaft checks, oil-pump service, flywheel removal, and starter-clutch service. Factory torque data, wear limits, clearances, electrical values, and fluid specifications are placed with the relevant assembly.

EFI, No-Start, and Electrical Testing

The fuel-injection section combines component locations with full diagnostic coverage. It provides an injection-system diagram, troubleshooting for hard starting and poor running, CELP failure-code interpretation, a DTC list, memory reset, and TPS/ISC reset after related throttle-body or ECU work.

Fuel-pump and cut-off-relay checks are followed by tests for the tilt switch, ECU, injector, water-temperature sensor, and O2 sensor. The throttle-body pages cover MAP, ISC, TPS, and the diagnostic connector.

The KYMCO diagnostic-tool pages cover ECU identification, DTC reading and clearing, live-data analysis, and reset functions. Live-data screens include engine speed, battery voltage, throttle position, intake and atmospheric pressure, and temperature inputs. They also show injector duration, ignition advance, O2 information, and ISC values. A separate no-start section and manual troubleshooting procedure support fault isolation when the dedicated tool is not available.

Electrical repair coverage is divided into practical systems. Charging-system pages cover the battery, regulator/rectifier, and A.C. generator; ignition and starting chapters address the coil, spark plug, tilt switch, starter motor, and starter relay. Separate procedures cover lighting, brake-light and handlebar switches, the auxiliary outlet, fuel pump, and side-stand switch. The charging circuit, ignition-system layout, and starting circuit show the related test points and connections.

Schematics, Tools, and Shop Cautions

The manual's major diagrams include the cylinder-head/valve schematic, CVT assembly view, cooling-system schematic, front brake/fork schematic, injection-system diagram, and charging circuit. Additional pages provide cable and harness routing, component-location views, and system layouts for ignition and starting.

Special-tool references are identified by factory code, including the flywheel puller E003, tappet adjuster E012, oil-seal and bearing installer E014, flywheel holder E021, and steering lock-nut wrench F002. These references matter when a repair calls for controlled pulling, holding, bearing installation, or steering-stem work rather than improvised methods.

Several manual-specific repair traps are called out. Frame-cover joint claws can be damaged when panels are forced; oil or grease on the CVT belt and pulley faces can cause drive slip; and disconnecting ECU or charging-system connectors with the ignition on can damage electronic components. Fuel-system work includes pressure-relief precautions, while the brake chapters warn against contaminating friction surfaces or painted and plastic parts with brake fluid.

This is a factory service manual rather than a complete illustrated parts catalog. The exploded schematics support assembly identification and repair work, but they do not replace a full OEM parts fiche. Electrical coverage is system-specific, with layouts and circuits for the covered systems rather than a separate full-vehicle wiring-diagram supplement.