PEUGEOT Jet C-Tech Workshop Manual Download

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TABLE OF CONTENTS

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

Removal of the ignition module................................................................................................................15

Removal of the headlight bulbs. ...............................................................................................................15

Removal of the horn.................................................................................................................................16

Removal of the oil pump control unit........................................................................................................16

Removal of the regulator. .........................................................................................................................16

Removal of the engine temperature sensor. ............................................................................................16

Removal of the oil pump. .........................................................................................................................16

Removal of the high tension coil. .............................................................................................................17

PETROL CIRCUITS......................................................................................................................................... 18

Removal of the fuel tank filter...................................................................................................................18

Removal of the fuel pump. .......................................................................................................................18

Removal of the carburettor.......................................................................................................................19

Procedure to position the carburettor. ......................................................................................................20

Removal of the inlet coupling and valves. ................................................................................................21

Removal of the throttle valve....................................................................................................................21

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE ............................................................. 22

Removal of the air pump. .........................................................................................................................22

Removal of the cylinder / piston. ..............................................................................................................22

Removal of the water pump. ....................................................................................................................23

MISCELLANEOUS OPERATIONS ................................................................................................................. 24

Removal of the rear brake pad.................................................................................................................24

Summary of Contents for Jet C-Tech

Page 1: ...Sales division Technical network leadership WORKSHOP MANUAL ...

Page 2: ...Sales division Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Page 3: ...ttery preparation Except battery without maintenance 7 Checks before handing over to the customer 7 SPECIAL IMPORTANT POINTS 8 Oil and fuel 8 Starting up after overhauling the engine 8 TIGHTENING TORQUES 9 Body panels 9 Cycle part 9 Standard 9 SPECIAL TOOLS 10 LOCATION OF COMPONENTS 11 BODY PANELS 12 Removal of the front shield panel 12 Removal of front lower shield panels 12 Removing the footboar...

Page 4: ...l of the oil pump 16 Removal of the high tension coil 17 PETROL CIRCUITS 18 Removal of the fuel tank filter 18 Removal of the fuel pump 18 Removal of the carburettor 19 Procedure to position the carburettor 20 Removal of the inlet coupling and valves 21 Removal of the inlet coupling and valves 21 Removal of the throttle valve 21 WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE 22 Removal of the a...

Page 5: ...ut 3 6 kW at 7300 rpm Max torque rating 7000 rpm Fuel supply Carburettor Gurtner PY15 Lubrication Electric oil pump Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Spark plug NGK CR7EB Exhaust Catalytic Fuel tank 7 8 l 95 or 98 lead free Oil tank 1 2 l Semi synthetic for 2 stroke engines with separate oiling Relay box 0 12 l SAE 80W90 life lubricated Coolant 1 4 l P...

Page 6: ...1915 mm Width at handlebar 720 mm Height without rear view mirrors 1165 mm Wheelbase 1340 mm Saddle height 820 mm 810 mm Unladen weight 114 kg Front wheel rim 12 inch aluminium alloy 13 inch aluminium alloy Front tyre 120 70 12 130 60 13 Front tyre pressure 1 6 bars 2 2 bars Rear wheel rim 12 inch aluminium alloy 13 inch aluminium alloy Rear tyre 130 70 12 130 60 13 Rear tyre pressure 1 8 bars 2 2...

Page 7: ...hs Every 10000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Check Idle setting X X X Throttle cable play X X X Steering column play X X X Operation of electrical equipment X X X Condition of front and rear brake hydraulic controls X X X Condition of petrol pipes X X X Condition of oil pipes X X X Tyre pressures X Tyre condition pressure and wear X X Brake fluid level X X X Batter...

Page 8: ...ing on equipment Change if necessary Service operations 500 kms or 1 months Every 5000 kms or 12 months Every 10000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Check and lubricate Driven pulley Moving flange and needle bush X Kick lever boss Kick starter control shaft X X Clean and adjust Carburettor X Test machine On road X X X ...

Page 9: ...ecessary Charge the battery for at least 2 hours with a current of 0 4A Refit the battery and connect the vapour vent pipe Connect the red wire lug to the battery s terminal and the green wire lug to the battery s terminal Then the battery level should be topped up if necessary after fully charging using distilled water only Checks before handing over to the customer Check the wheel nuts are tight...

Page 10: ...operties Should it be changed replace it with a genuine pipe Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Work in a clear and well ventilated area Before carrying out any work leave the engine to cool for at least 2 hours Starting up after overhauling the engine The oil pump must be drained in accordance with the recommended procedures When ...

Page 11: ...rod to engine pivot 4 5 m daN Linkrod to swingarm 4 5 m daN Engine upper linkrod pivot 4 5 m daN Shock absorber top mount 2 5 m daN Shock absorber bottom mount 2 5 m daN Front and rear frame mounting nut 2 2 m daN Exhaust to cylinder mounting nut 1 5 m daN Exhaust to casing mounting bolt 2 2 m daN Upper cone in 2 operations 3 8 2 3 m daN Upper cone locknut Hand tightened Steering locknut 7 5 m daN...

Page 12: ...OOLS Tool N Designation Used with Tool N Designation Used with 068994 Torque wrench 8 N m to 54 N m 752235 752236 753977 Torque wrench 30 N m to 150 N m 752235 752236 750539 Tie wrap pliers 755996 Hose clamp 752235 1 2 extension 68994 or 753977 756575 Piston locking fork 752236 1 2 3 8 adapter 68994 or 753977 757860 Steering tool ...

Page 13: ...1 Oil pump control unit 2 Battery 3 Ignition sensor 4 CDI unit 5 Oil level indicator 6 Oil pump 7 HT coil 8 Low oil level warning light 9 STOP light 10 Regulator 11 Starter motor relay 12 Flasher unit 13 Horn 14 Engine temperature sensor 15 7 5 A fuse 16 Air pump 7 10 6 11 2 5 4 12 3 1 15 16 8 9 13 14 12V 25A UP PE R LE VE L LO W ER LE VE L STOP N C N C ...

Page 14: ...ocedure 2 Remove the front lower left shield panel 1 3 screws including the 2 fixing it to the RH shield panel Remove the front lower RH shield panel 3 screw Removing the footboard and the LH tunnel Procedure 3 Remove the 2 screws that hold the LH footboard 1 Unclip the outer part of the footboard starting at the rear Unclip the footboard from the frame bottom Raise the footboard by levering on th...

Page 15: ...dden without the written consent of Peugeot Motocycles Remove the LH tunnel 2 by releasing it from the rear upper part Carry out the same operation for the RH side Removal of the storage compartment Procedure 4 Lift the saddle Remove the storage compartment 6 nuts 2 ...

Page 16: ... cover 8 fixing screws Disconnect the tail light and the turnsignal lights Remove the rear cover assembly unclip the rear cover from the storage compartment trim fed one side of the panel under the battery bracket pull the cover clear by turning it on the same side Removal of the header tank Remove the front upper shield panel see procedure 1 Removal of front lower shield panels see procedure 2 Em...

Page 17: ...emoval of the blinker unit Removal of the ignition module Remove the front upper shield panel see procedure 1 Disconnect and remove the blinker unit 1 Disconnect and remove the ignition module 2 Removal of the headlight bulbs Remove the bulbs 3 The bulbs are held in the headlight by means of a plate which is locked by turning it to the right 2 1 3 ...

Page 18: ...moval of front lower shield panels see procedure 2 Remove the horn 1 When refitting locate the header tank positioning pins A and the window B in the rear shield and in the radiator bracket Removal of the oil pump control unit Removal of the regulator Removal of the engine temperature sensor Removal of the oil pump Remove the storage compartment see procedure 4 Remove Control unit 1 Regulator 2 1 ...

Page 19: ...itten consent of Peugeot Motocycles Oil pump 3 The temperature sensor 4 Refit a sensor quickly to prevent loss of coolant Removal of the high tension coil Remove the footboard and the left tunnel see procedure 3 Disconnect the coil 1 and the spark plug lead Remove the high tension coil 4 3 1 ...

Page 20: ...rocedure 3 Empty the fuel tank by disconnecting a hose Loosen the fuel filter collar 1 Remove the fuel filter Clean or change the filter according to the maintenance recommendations Removal of the fuel pump Remove the footboard and the left tunnel see procedure 3 Put a hose clamp P N 755996 on the fuel inlet hose 1 Disconnect the 2 fuel hoses 1 and 3 Disconnect the vacuum hose 2 Remove the fuel pu...

Page 21: ...the rear mudguard 1 3 screws 1 of which is also used for the air filter Disconnect the air pipe from tha air filter housing 2 Remove the air filter 1 click collar Disconnect the electric choke Disconnect the separate lubrication hose 1 Remove the screw that secures the carburettor chamber cap 2 Remove the carburettor and its cap and needle valve Disconnect the fuel supply hose 3 1 click collar 1 2...

Page 22: ...the carburettor by making sure its pin is correctly positioned A in the recess B provided in the intake pipe Click the collar Fit the air filter on the carburettor Fit and tighten the screw that secures the air filter to make sur it is positioned Clip theclick collar by making sure the carburettor is level Remove the air filter attachment screw Connect the lubrication and fuel supply hose Fit the ...

Page 23: ...f screw 2 Remove the 2 bolts Remove the inlet coupling Remove the reed valves and its gasket of composite materials Removal of the throttle valve Take out the throttle control cable 1 by compressing the spring using the throttle valve 2 Dismantle the valve equipped with its needle spring and carburettor chamber cap Dismantle the needle 3 by pushing it out in order to remove the clips 4 The height ...

Page 24: ...d Removal of the cylinder piston Remove the storage compartment see procedure 4 Remove the footboard and the left tunnel see procedure 3 Remove the bottom panel Disconnect the lower pump from the coolant pump to drain the cooling system Disconnect the coolant pipes from the cylinder head and cylinder Disconnect the temperature sensor Disconnect the suppressor Remove the spark plug Remove the exhau...

Page 25: ...52000 Remove the gudgeon pin Remove the piston Remove the needle bearing race from the connecting rod end When refitting the cylinder we recommend locking the piston using the fork part number 756575 in order to facilitate assembly Removal of the water pump Remove the exhaust Disconnect the lower pump from the coolant pump to drain the cooling system Disconnect the upper hose Remove the water pump...

Page 26: ... is forbidden without the written consent of Peugeot Motocycles MISCELLANEOUS OPERATIONS Removal of the rear brake pad Remove the 3 lug studs of the rear wheel Remove the caliper 2 fixing bolts Remove the caliper from the brake disc Remove the pins Remove the brake pads ...

Page 27: ......

Page 28: ... N 758073 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC APV Printed in the E U 04 2005 non contractual pictures ...

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