13. FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 25013________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________FUEL SYSTEM/CARBURETOR/FUEL PUMP________________________________________________________________________________FUEL SYSTEM-------------------------------------------------------------------------------------13- 1SCHEMATIC DRAWING-------------------------------------------------------------------------13- 2OPERATION OF CARBURETOR JETS-----------------------------------------------------13- 3SERVICE INFORMATION-----------------------------------------------------------------------13- 5CARBURETOR REMOVAL ---------------------------------------------------------------------13- 7VACUUM CHAMBER DISASSEMBLY-------------------------------------------------------13- 7FLOAT CHAMBER DISASSEMBLY ----------------------------------------------------------13- 9AUTO BYSTARTER INSPECTION/REMOVAL--------------------------------------------13- 11AIR CUT-OFF VALVE (A.C.V.) ----------------------------------------------------------------13- 12AUTO BYSTARTER INSTALLATION --------------------------------------------------------13- 14FLOAT CHAMBER ASSEMBLY ---------------------------------------------------------------13- 15FLOAT LEVEL INSPECTION ------------------------------------------------------------------13- 16VACUUM CHAMBER ASSEMBLY------------------------------------------------------------13- 16CARBURETOR INSTALLATION --------------------------------------------------------------13- 17FUEL PUMP REMOVAL/DISASSEMBLY---------------------------------------------------13- 18FUEL PUMP INSPECTION ---------------------------------------------------------------------13- 19FUEL PUMP ASSEMBLY -----------------------------------------------------------------------13- 19FUEL PUMP INSTALLATION ------------------------------------------------------------------13- 20FUEL TANK REMOVAL -------------------------------------------------------------------------13-201313-0

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL SYSTEM13-1

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250SCHEMATIC DRAWING13-2

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250OPERATION OF CARBURETOR JETS1. LOW SPEED Air Venturi (slightly opened throttle valve)Low Speed Air Inlet Fuel in Float Chamber Slow Jet---------------------- Low Speed Small Jet Holes2.MIDDLE SPEED Air Venturi (halfway opened throttle valve)High Speed Air Jet Fuel in Float Chamber Main JetMain Jet (The slow jet also works.)Air Bleed Holes Mixture…….Air Bleed Holes Mixture…….Low & Middle Speed Supplementary Device:Vacuum TubeLow Speed Air JetACVVacuum DiaphragmAirPilot ScrewMain JetBypass JetSlow Jet13-3Low & Middle Speed Supplementary Fuel Inlets

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL PUMPCONSTRUCTION:The fuel pump adopted for this model is a fuel pump which utilizes the positive and negativepulsating pressures produced by the engine crankcase to control the oil pump diaphragms anddeliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.FUEL PUMP CONSTRUCTIONLower CoverBig SpringOutlet ValveVacuum-typeSpringBodyWasher Comp ValveSpringUpper CoverInlet13-4

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250SERVICE INFORMATIONGENERAL INSTRUCTIONS• When working with gasoline, keep away from sparks and flames.• Note the locations of O-rings when disassembling and replace them with new ones duringassembly.• Before float chamber disassembly, drain the residual gasoline from the float chamber.• Do not try to disassemble the auto bystarter.• When assembling the vacuum chamber and air cut-off valve, be careful not to damage thediaphragms.• All cables, fuel lines and wires must be routed and secured at correct locations.• When removing the fuel tank, keep sparks and flames away from the working area.• When removing the fuel tank, the remaining fuel in the tank must be lower than ½ of the fuel tankcapacity to avoid gasoline overflowing.• Fuel tank capacity: 8.0 litersSPECIFICATIONSPEOPLE 250 PEOPLE S 250Type CVK CVKSize of bore (mm) 30 30Main jet NO 108# 104#Pilot screw opening 2½ ± ½ 1¼± ¾Piston diameter (mm) 28.8 26Idle speed 1700 1600Throttle type Butterfly type Butterfly typeFuel pump output 33cc/1800rpm/10 Seconds 33cc/1800rpm/10 SecondsSPECIAL TOOLSFloat level gaugeFuel unit remover13-5

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250TROUBLESHOOTINGEngine does not start• No fuel in tank• Restricted fuel line• Too much fuel getting to cylinder• Clogged air cleaner• Contaminated fuel• Faulty fuel pumpEngine idles roughly, stalls or runs poorly• Incorrect idle speed• Rich mixture• Lean mixture• Clogged air cleaner• Intake air leak• Contaminated fuel• Faulty air-cut off valve• Damaged vacuum tube and connectors• Damaged carburetor insulatorThrottle does not open fully, so engine stalls• Damaged vacuum piston diaphragm• Clogged diaphragm holeLean mixture• Clogged fuel jets• Clogged fuel tank cap breather hole• Clogged fuel filter• Bent, kinked or restricted fuel line• Faulty float valve• Float level too low• Faulty fuel pump or insufficient outputRich mixture• Auto bystarter valve opens excessively• Faulty float valve• Float level too high• Clogged air jets• Auto bystarter valve set plate installed inthe wrong groove•Clogged air cleanerEngine is hard to start• No fuel in tank• Restricted fuel line• Clogged fuel strainer• Faulty fuel pump• Broken or clogged vacuum tube• Faulty or clogged charcoal canisterLean mixture• Clogged charcoal canister• Bent, kinked or restricted fuel line• Clogged fuel strainer• Float level too low13-6

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250CARBURETOR REMOVALT.P.SAuto BystarterFuel TubeRemove the met-in box.Disconnect the fuel tube at the carburetor.Disconnect the auto bystarter wire.Disconnect the throttle position sensor wire.T.P.S WireAuto Bystarter WireDisconnect the heater carburetion wirecouplerLoosen the throttle cable adjusting nut andlock nut, and disconnect the throttle cablefrom the carburetor.Loosen the air cleaner connecting tube bandand carburetor intake manifold band and thenremove the carburetor.Air Cleaner ConnectingTube BandIntake Manifold BandThrottle CableHeater CarburetionWire CouplerVACUUM CHAMBER DISASSEMBLYLoosen the drain screw and drain the fuelfrom the float chamber.13-7Drain Screw

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250Remove the two vacuum chamber coverscrews and the cover.ScrewsVacuum Chamber CoverRemove the compression spring and vacuumpiston.SpringVacuum PistonRemove the needle holder, spring and jetneedle from the piston.• Be careful not to damage the vacuumpiston diaphragm.DiaphragmVacuum PistonVACUUM PISTON INSPECTIONInspect the vacuum piston and jet needle forwear or damage.Inspect the diaphragm for deterioration andtears.Needle HolderJet Needle13-8

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FLOAT CHAMBER DISASSEMBLYRemove the three float chamber screws andthe float chamber.Float ChamberScrewsRemove the float pin, float and float valve.FloatFloat ValveFloat PinFloat ValveFLOAT VALVE INSPECTIONInspect the float valve seat contact area forwear.Float Valve Seat13-9

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250JETS/SCREWS REMOVAL• Before removing the pilot screw, turnthe pilot screw clockwise until it seatslightly and record the rotating turns.Do not force the pilot screw against itsseat to avoid seat damage.Pilot Screw (P.S.)Remove the main jet, needle jet holder andneedle jet.Remove the slow jet.Main JetSlow JetClean the removed the main jet, needle jetholder, needle jet and slow jet with detergentoil. • Be sure to use clean detergent oil.Needle JetSlow JetPilot ScrewNeedle Jet HolderMain Jet13-10

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250AUTO BYSTARTER INSPECTION /REMOVALAUTO BYSTARTER INSPECTIONMeasure the resistance between the autobystarter wire terminals.Resistance: 14-20Ω (10 minutesminimum after stopping the engine)If the reading is not within the limit, replacethe auto bystarter with a new one.Connect a hose to the fuel enriching circuit ofthe carburetor. Connect the auto bystartergreen/black wire to the positive (+) terminal ofa battery and black/white wire to the negative(-) terminal. Wait 5 minutes and blow thehose with mouth. If the passage is blocked,the auto bystarter is normal.Disconnect the auto bystarter from the battery.Wait 30 minutes and blow the hose withmouth.. If air can be blown into the hose,the auto bystarter is normal.B/WG/BHoseAUTO BYSTARTER REMOVALRemove the one set plate screw and set plateand then remove the auto bystarter from thecarburetor body.Auto BystarterScrews13-11Set Plate

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250AUTO BYSTARTER INSPECTIONCheck the auto bystarter valve and needle fornicks, wear or damage.If any faulty part is found, replace the autobystarter with a new one.Bystarter NeedleBystarter ValveAIR CUT-OFF VALVE (A.C.V.)A.C.V. REMOVALRemove the two screws and the air cut-offvalve cover.Air Cut-off Valve CoverScrewsRemove the spring, diaphragm and O-rings.Inspect the diaphragm and spring for wear ordamage.DiaphragmCoverSpring13-12

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250CARBURETOR BODY CLEANINGBlow compressed air through all passages ofthe carburetor body. • Make sure that no fuel jet is clogged.Install the O-ring onto the air-cut-off valvebody securely.• Install the O-ring with the flat facetoward the valve body side.O-ringInstall the diaphragm, spring, and cover.CoverSpringDiaphragmInstall and tighten the two screws attachingthe air cut-off valve cover.Connect the hose.Screws13-13

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250ACCELERATING PUMPDISASSEMBLYRemove the two accelerating pump coverscrews and accelerating pump cover.Remove the spring and accelerating pumpdiaphragm.ScrewsINSPECTIONInspect the accelerating pump diaphragm forcracks, damage or deterioration. Replace ifnecessary.Assemble the accelerating pump in thereverse order of disassembly.DiaphragmCoverO-ringSpringAUTO BYSTARTER INSTALLATIONInstall the auto bystarter and set plate.Install and tighten the two screws.• Insert the auto bystarter into thecarburetor body until it bottoms andposition the set plate into the uppergroove in the bystarter.• Install the set plate with its round facefacing down.Auto BystarterScrews13-14

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FLOAT CHAMBER ASSEMBLYInstall the main jet.Install the slow jet.Slow JetMain JetInstall the pilot screw.• Be sure to record the rotating turnswhen it is removed.Pilot ScrewInstall the float valve, float and float pin.FloatFloat ValveFloat Pin13-15

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FLOAT LEVEL INSPECTIONMeasure the float level at the location of themain jet (just contacting the float valve).Float Level: 18.5±1.0mm: 18±1.0mm(PEOPLE S 250)Replace the float if the level is incorrect.Check the operation of the float and thenreinstall the float chamber.FloatVACUUM CHAMBER ASSEMBLYFirst install the jet needle and spring into thevacuum chamber and then install the needleholder.Vacuum PistonNeedle HolderJet NeedleInstall the vacuum piston into the carburetorbody.Install the spring.Install the vacuum chamber cover and tightenit with the two screws. • Be careful not to let the diaphragm slip.• If the diaphragm cannot be positionedcorrectly because of expansion, dry thediaphragm before installation.Vacuum PistonSpringDiaphragm13-16

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250Check the heater with battery.If the heater is getting hot, means the heaterwithout problem, otherwise the heater has tobe changed.HeaterCARBURETOR INSTALLATIONTighten the drain screw.Install the carburetor onto the intake manifoldand tighten the band.Install the air cleaner connecting tube andtighten the band.Connect the throttle cable to the carburetor.Connect the heater carburetion wire coupler.After connecting the throttle cable, adjustthe throttle grip free play to 2~6mm.Air Cleaner ConnectingTube BandThrottle CableIntake Manifold BandHeater CarburetionWire CouplerConnect the auto bystarter wire.Connect the fuel tube and vacuum tube to thecarburetor.Connect the throttle position sensor wire.Perform the following inspections andadjustments:•Throttle grip free play (3-3)•Idle speed (3-6)Install the seat, met-in box and frame bodycover.T.P.ST.P.S WireAuto BystarterFuel TubeAuto Bystarter Wire13-17

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL PUMP REMOVALRemove met-in box and carrier.Remove the body cover, center cover andrear fender cover A.Disconnect the fuel pump inlet, outlet andvacuum tubes.Remove the two fuel pump attaching nuts andthe fuel pump.Outlet TubeVacuum TubeNutsInlet TubeFUEL PUMP DISASSEMBLYRemove the four fuel pump body screws.InletScrewsVacuum TubeOutletDisassemble the fuel pump.13-18

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL PUMP INSPECTIONInspect the fuel pump diaphragms A and B fordamage.Inspect each gasket for damage.DiaphragmGasketsInspect the suction valve, outlet valve andrelief valve in the fuel pump body for damage,cracks or foreign matters.OutletRelief ValveSuction ValveSpringOutlet ValveInletSpringFUEL PUMP ASSEMBLYAssemble the fuel pump in the reverse orderof disassembly.• During assembly, be sure to install thegaskets and diaphragms properly toavoid damage.• Do not allow any foreign matter to enterthe fuel pump during assembly.Dowel PinsFuel Pump BodyDowel Pin Holes13-19

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL PUMP INSTALLATIONInstall the fuel pump and secure it with thetwo nuts.Connect the fuel pump inlet, outlet andvacuum tubes.Install the met-in box and carrier.Install the body cover, center cover and rearfender A.Outlet TubeVacuum TubeNutsInlet TubeMeasure the fuel pump output.Start the engine and disconnect the fueloutlet tube and place a clean container underthe tube to check the fuel output.Output: 33cc/1800rpm/10 seconds .Outlet TubeFuel PumpContainerFUEL TANK REMOVALRemove the floor board. (2-7)Remove four nuts at the tank shield andremove the tank shield.Tank ShieldNuts13-20

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250Disconnect the fuel unit wire connector.Remove the fuel tube between the fuel tankand the fuel filler.Disconnect the fuel vapor tube.Disconnect the fuel tube between the fueltank and fuel strainer.Fuel Unit Wire ConnectorTube to Fuel FillerTube to Fuel StrainerFuel Vapor TubeRemove the four bolts on the fuel tank.Remove the fuel tank.BoltsBoltsThe installation sequence is the reverse ofremoval.13-21

13. FUEL SYSTEM/CARBURETOR/FUEL PUMP/ FUEL TANKPEOPLE/PEOPLE S 250FUEL STRAINER REMOVALRemove the right side cover.Remove the fuel strainer from the fuel line.Fuel StrainerINSPECTIONInspect if the fuel strainer is clogged andclean it with compressed air.When removing the fuel strainer, do notallow flames or sparks near the workingarea and drain the residual gasoline intoa container.INSTALLATIONInstall the fuel strainer with its arrow marktoward the fuel pump.Fuel Strainer13-22