PEUGEOT Speedfight 2 Owner'S Manual Download Page 20

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Summary of Contents for Speedfight 2

Page 1: ...yfirst Page 0 11 Daily pre ride checks Engineoil levelcheck Page 0 12 Coolant level check liquid cooledengines Page 0 12 Brakefluid levelcheck Page 0 13 Fuel check Paae 0 13 Suspensionand steering checks Page 0 13 Tyre checks Page 0 14 Legal and safety checks Pane 0 14 MAINTENANCE Routine maintenance and servicing Modelspecificationsand service schedules Page 1 2 Routinemaintenanceand servicing pr...

Page 2: ...Transmission Page 2C 1 Coolingsystem liquid cooled engines Page 3 1 Fueland exhaust systems Page 4 1 Ignitionsvstems Pane 5 1 Chassis components Frame and suspension Page 6 1 Bodywork Page 7 1 Brakes wheels andtvres Pane 8 1 Electricalsystem Page 9 1 Wiring diagrams Page 9 20 REFERENCE Conversionfactors Page REF4 Fault Finding Page REF02 Index Page REF Q ...

Page 3: ...ook a leap of faith with its first car actually a tricycle powered by a steam engine From this inauspicious start The lOOcc Speedfight2 they designed a four wheeler the following year which used a Panhard produced Daimler 565 cc V twin engine Cooled by water circulatinginthe frame tubes it weighed 500 kg and produced 1hp at 1000 rpm Top speed was littlemorethan stationary The type 3 car of 1891 in...

Page 4: ...n the Franco Swiss border Beaulieu Mandeure is home to the Peugeot Motocycles assembly plant Here tubes are bent into frames electrical wire is made into looms silencers are fabricated bodyworkand chassis are paintedand largely home produced components are assembled by the workforce of over 1000 people Approximately 60 of the machines produced are for export with the remainder consumed by the home...

Page 5: ...ccounts for 570 000 machines a year together with Spain Germany France and Hollandthe total tops a million Peugeot leads markets in France Finland Belgium Holland and Denmark and is aggressively pursuing the German and Italian markets where it established subsidiaries in 1997 Despite stiff competition from Piaggio Aprilia and Malaguti Peugeot see the Italian market as the key to its greatest expan...

Page 6: ... theearlierX Race as optional equipment Acknowledgements Our thanks are due to Three Cross staff of Three Cross Motorcycles Ltd for the for supplying the colour spark plug condition Motorcycles Ltd of Wimborne Dorset and to provision of technical literature and advice photos and Draper Tools Ltd for some of the Andy Legg who supplied the scooters and to Graham Sanderson who wrote the workshop tool...

Page 7: ... Urban Black 50 cc Nov 1999 Speedfight Prost 50 LCD and LCDP 50 cc Nov 1998 Trekker Streetboard 50 cc Nov 1999 Speedfight Prost 100 100cc May 1999 Trekker Metal X 50 cc Nov2001 Speedfight X Team 50 cc May 1999 Trekker Metal X 100 100cc 2002 Speedfight 50 LBDand LBDP 50 cc Nov 1999 TKR Street Zone 50 cc 2003 Speedfight 50 B and BP 50 cc Nov 1999 TKRWRC206 50cc 2003 Speedfight Prost 50 50 cc Nov 199...

Page 8: ...vised to black Torero Red and Acid Green and the Boa lock became an optional extra The Metal X variant was introduced in November 2001 featuring revised body styling a separate front mudguard mounted directly above the wheel motorcycle style handlebarsand a digital instrument display An ignition immobiliser and Boa lock were fitted as standard equipment Available in either graphite blue or graphit...

Page 9: ...idGreen was introducedforthe50cc models and the colour range for the 100 cc models was revised to Pulsar Blue Black and Technium Grey At the same time air cooled models previously designated M P and B P were redesignated N P and liquid cooled models previously designated LCDP and LBDP were redesignated LNDP 2002 models were designated E P and LEDP The Silver Sport colour option was introduced in 2...

Page 10: ... by an electrical short circuit by two metal surfaces contactingeach other by careless use of tools or even by static electricity built up in your body under certain conditions can ignite petrol vapour which in a confined space is highly explosive Never use petrol as a cleaning solvent Use an approvedsafety solvent The battery Never cause a spark or allow a naked light near the vehicle s battery I...

Page 11: ...ap when the engine is hot It is good practice to cover the cap with a heavy cloth and turn the cap slowly anti clockwise If you hear a hissing sound indicating that there is stillpressure in the system wait until it stops then continue turning the cap until it can be removed Beforeyou start Make sure you have a supply of coolant available a mixtureof 50 distilledwater and 50 Procor 3000 anti freez...

Page 12: ...ly with cold water Bike care l The fluid in the hydraulic reservoir will drop slightlyas the brakepads wear down l If the reservoir requires repeated topping up this is an indication of a fluid leak somewhere in the system which should be investigatedimmediately l Check for signs of fluid leakage from the brake hoses and components if found rectify immediately l check the operation of the brake be...

Page 13: ...es that tread depth must be at least 1 mm over 3 4 of the tread breadthall the way around the tyre with no bald patches Many riders however consider 2 mm tread depth minimum to be a safer limit Note that UK law for machines of 50 cc and under only requires that the original tyre tread is visible although in the interest of safety owners may wish to apply the above limit l Manytyres now incorporate...

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Page 15: ...play Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relay box oil capacity Brakefluid Coolant 49 cc single cylinder liquid cooledtwo stroke Variablespeedautomatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarrn and single shock 180mm disc 110mmdrum 120nox 12 140nOx 12 FL1 VGAS1B 1225mm 1730 mm 700 mm 1155mm 90 kg 7 2 litres NGK BR7HS 0 6 m...

Page 16: ...adlight brakelight and horn check Idlespeed check and adjust Kickstart gear and spindle bush check Nutsand bolts tightness check Oil pump cable check and adjust Rear drum brakecam check and lubricate Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttle cable check and adjust Relay box oil level check Variator pulleyand rollers check and lubricate Wheels andtyres chec...

Page 17: ...d minimumthickness Throttle twistgrip freepiay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relay box oil capacity Brakefluid Coolant 49 cc single cylinder liquid cooledtwo stroke Variable speedautomatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarm and single shock 180 rnm disc 180mm disc 120nox 12 140 70x 12 FL1 VGAS1B 1225mm 1730mm 700 mm 1155 mm 90 kg 7 2 litr...

Page 18: ... change Fuelsystem check Headlight brakelight and horn check Idlespeed check and adjust Kickstart gear and spindle bush check Nutsand bolts tightness check Oil pump cable check and adjust Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttle cable check and adjust Relay box oil level check Variator pulleyand rollers check and lubricate Wheels andtyres check The brakef...

Page 19: ...repressure Reartyrepressure Disc brake pad minimumthickness Rear drum brake leverfreeplay Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relay box oil capacity Brakefluid 50 cc singlecylinder air cooledtwo stroke Variable speedautomatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarm and single shock 180mm disc 110mmdrum 120nox 12 130i70x 1...

Page 20: ...ck Engineoil filter change Fuelsystem check Headlight brake lightand horn check Idlespeed check and adjust Kickstartgear and spindle bush check Nutsand bolts tightnesscheck Oil pumpcable check and adjust Reardrum brakecam check and lubricate Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttlecable check and adjust Relay box oil level check Variator pulley and roller...

Page 21: ...ressure Disc brake pad minimumthickness Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relayboxoilcapacity Brakefluid Coolant 49 cc single cylinder liquid cooledtwo stroke Variable speed automatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarrn and single shock 180 rnrndisc 180 rnm disc 120 70x 12 140 70x 12 130 70x 12 FL1 VGASlB 1225 mm 1...

Page 22: ...oil filter renew Fuelsystem check Headlight brakelight and hom check Idlespeed check and adjust Kickstart gear and spindle bush check Nuts and bolts tightness check Oil pumpcable check and adjust Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttle cable check and adjust Relay box oil level check Variator pulleyand rollers check and lubricate Wheels andtyres check Th...

Page 23: ...ap Idlespeed Fronttyrepressure Reartyrepressure Disc brake pad minimumthickness Rear drum brake lever freeplay Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relayboxoilcapacity Brakefluid 50 cc single cylinder air cooledtwo stroke Variable speed automatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarm and single shock 180 mm disc 110 mm d...

Page 24: ...l system check Engineoil filter renew Fuelsystem check Headlight brake lightand horn check Idlespeed check and adjust Kickstartgear and spindle bush check Nutsand bolts tightnesscheck Oil pump cable check and adjust Reardrum brake cam check and lubricate Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttlecable check and adjust Relay box oil level check Variator pull...

Page 25: ...ed Fronttyrepressure Reartyrepressure Disc brake pad minlmumthickness Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relay box oil capacity Brakefluid 49 cc single cylinder air cooledtwo stroke Variable speed automatic belt driven Capacitor discharge ignition CDI Leading link monolever Swingarm and single shock 180 mm disc 180 mm disc 120no x 12 140nOx 12 FB4 VGASlA 1...

Page 26: ...l filter renew Fuelsystem check Headlight brakelight and horn check Idlespeed check and adjust Kickstart gear and spindle bush check Nuts and bolts tightness check Oil pumpcable check and adjust Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttle cable check and adjust Relay box oil level check Variator pulleyand rollers check and lubricate Wheels andtyres check The...

Page 27: ...pe Normaluse Frequent stopktart riding Spark plug electrodegap ldlespeed Fronttyre pressure Reartyrepressure Disc brake pad minimumthickness Throttle twistgrip freeplay Fuel Engineoil Engineoiltankcapacity Relayboxoil Relayboxoilcapacity Brakefluid 100cc single cylinder air cooledtwo stroke Variable speedautomatic belt driven Capacitor discharge ignition CDI Leadinglink monolever Swingarmand singl...

Page 28: ...ebelt renew Engineoil system check Engineoil filter renew Fuelsystem check Headlight brake lightand hom check Idlespeed check and adjust Kickstartgear and spindle bush check Nutsand bolts tightnesscheck Oil pumpcable check and adjust Stand check and lubricate Spark plug gap check and adjust Spark plug renew Throttlecable checkand adjust Relaybox oil level check Variator pulley and rollers check an...

Page 29: ...caps and fill each cell to the upper level mark with distilledwater see illustration Do not use tap water and do not overfill The cell holes are quite small so it may help to use a clean plastic squeeze bottle with a small spout to add the water Install the battery cell caps tightening them securely then install the battery seeChapter 9 Maintenance fme battery 3 On mach nes fitted with a sealed ba...

Page 30: ...pect along the length of the outer cable for splits and kinks and the ends of the inner cable for frays and replace it with a new one if necessary seeChapter 8 4 If there are no signs of damage lubricate the cable see Step 7 If the cable is still stiff after lubrication replaceit with a new one see Chapter 8 5 If the handlebar lever and brakecable are in good condition check the operation of the b...

Page 31: ...asily from fully closed to fully open with the handlebars turned at various angles The twistgrip should returnautomatically from fully open to fully closedwhen released 2 If the throttle sticks this is probably due to a cable fault Removethe cable and lubricate it see Chapter4 3 With the throttle operating smoothly check for a small amount of freeplay in the cable measured in terms of the amount o...

Page 32: ...ngine oil system will ensure that any problems are discovered and remediedbeforethe engine is damaged 2 Check the engine oil level see Daily pre ride checks 3 Check the operation of the oil level warning light in the instrument cluster The light should come on temporarily when the ignition is first turned on as a check of the warning circuit and then extinguish If the light stays on the oil level ...

Page 33: ...speaking all 100 cc models and 50 cc models manufacturedbefore 2000 are fitted with a cable operated pump all other models are fitted with a centrifugal pump A quick visual check will confirm which pump is fitted to your machine 1 Ensure the throttle twistgrip rotates easily from fully closedto fully open with the handle bars turned at various angles and check the cable freeplay with the Specifica...

Page 34: ...f stop and go riding Placethe machine on its stand and make sure the rear wheel is clear of the ground A Warning Do not allow exhaust gases to buildupinthe work area either perform the check outside or use an exhaust gas extraction system 3 No tachometer is fitted as standard equip mentto enable the idlespeed to be compared with that specified However it is sufficient to ensure that at idle the en...

Page 35: ...ht hand side to access the hoses 4 If the electrodes are not excessively worn place beforeinstallingthe plug seeillustration Look for cracks abrasions and if thedepositscan beeasily removedwith 6 Since the cylinder head is made of and other damage Squeeze the hoses at a wire brush the plug can be re gapped and aluminium which is soft and easily damaged various points They should feel firm yet re u...

Page 36: ...light aim with the machine on level ground with the fuel tank half full and with an assistant sitting on the seat If the bike is usually ridden with a passenger on the back have a second assistantto do this 2 Adjustment is made by tuming the adjuster screw clockwise to move the beam up and anti clockwiseto move it down The adjuster screw is located on the underside of the headlight panel on Speedf...

Page 37: ...002 the oil levelplug was deletedfrom the casing itisnotnecessaryto change the oil during the life of the scooter except in the event of relay box overhaul The levelcan howeverbe checkedifdesiredwhen the drive belt cover is removedfor inspection of the belt and rollers see Section 24 with the cover removed the relay box oil levelplug is accessible 1 Support the machine in an upright position on it...

Page 38: ...iring engineremoval 3 Oil pump removal inspection installationand bleeding 13 Piston removal inspectionand installation 9 Pistonrings inspectionand installation 10 Pulsegeneratorcoil assembly removaland installation see Chapter5 Recommendedrunning in procedure 16 Spark pluggap check and adjustment see Chapter 1 Starter motor removaland installation see Chapter9 Starter pinionassembly removal inspe...

Page 39: ... mounting bolts 100cc FB6engine General Type Capacity Bore Stroke Compressionratio Piston Pistondiameter measured25 mm downfrom lower ring groove at 90 to pistonpinaxis Standard Pistonpindiameter Piston rings Ringend gap installed Standard Servicelimit max Connecting rod Small end insidediameter Big endsideclearance Crankshaft Runout ma Diameterat main bearings Torque settings Alternator rotor nut...

Page 40: ...poses such as separating the crankcase halves Precision measuringtools are required for inspecting parts to determine if they must be renewed Alternatively a Peugeot dealer will handle the inspection of parts and offer advice concerning reconditioning and replacement As a general rule time is the primary cost of an overhaul so it does not pay to installworn or substandardparts 8 As a final note to...

Page 41: ...ldbe avoldedbecause of the risk of fire 2 When clean and dry arrangethe unit on the workbench leaving suitable clear area for working Gather a selection of small containers and plastic bags so that parts can be grouped together in an easily identifiable manner Some paper and a pen should be on hand to permit notes to be made and labels attached where necessary A supply of clean rag is also require...

Page 42: ...rn to the torque setting specified at the beginningof this Chapter 7 12 lnstallthe new gasket with the raised section arrowed uppermost 14 lnstall the spark plug then fit the engine cowling making sure it locates correctly against the fan cowling see illustration 7 2a 15 lnstall the remaining components in the reverseorder of removal 8 Cylinder removal insp and installatic Note This procedurecan b...

Page 43: ...ress and feed each ring into the bore as the cylinder is lowered taking care that the ring end gaps remain correctly aligned with the pins see illustration Do not use force if the cylinder appearsto be stuck as the piston and or ringswill be damaged 13 When the piston is correctly installed in the cylinder check that the base gasket has not been displaced see illustration 9 3b then push out the pi...

Page 44: ...o Chapter 4 for carburation checks and Chapter 5 for ignition checks 11 Check the piston to bore clearance by 9 4 Removethe small end bearing 9 1 1 Measurethe piston at 90 to the piston pin axis 9 13a Check for freeplay betweenthe 9 13b Measuring the piston pinwhere it piston and the piston pin runs in the piston measuringthe cylinder bore see Section 8 and the piston diameter Measure the piston 2...

Page 45: ...llustration 3 If the gap is larger or smallerthan specified check to make sure that you have the correct rings before proceeding 4 If the gap is larger than specified it is likely the cylinder bore is worn If the gap is too 10 2 Measuring installed ring end gap 10 6 Ring locating pins arrowed are on the rear face of the piston 10 7 Fit the lower ring expander first 10 8 followed by the lower and t...

Page 46: ...oil inlet hose from the oil tank to the union on the pump and detach the hose see illustration Clamp the hose and secure it in an upright position to minimise oil loss Release the clip securingthe oil outlet hoseto the union on the pump and detach the hose Wrap clean plastic bags around the hose ends to prevent dirt entering the system Note The inlet andoutlet hosesare protected from the exhaustpi...

Page 47: ...the ignition switch is OFF Disconnect the oil outlet hose from the carburettor and crank the engine with the kickstarteruntil oil without any air mixed with it flows out the hose then reconnect the hose and secure it with the clip Alternatively fill an auxiliaw fuel tank with a 2 petrol two stroke 12 If removed install the two nuts on the underside of the pump mounting see illustration 13 8 13 Ins...

Page 48: ...ed Apply steadypressure with the tools describedand heat the bearinghousings with a hot air gun Do not try and separate the halves by leveringagainst the mating surfaces as they are easily scored and will not seal correctlyafterwards Do not strike the ends of the crankshaft with a hammer as damage to the end threads or the shaft itself will result 6 Remove the oil pump drive shaft and the shaft bu...

Page 49: ...e housings for the main bearings see illustration 14 16 If a bearing outer race has spun in its housing the inside of the housing will be damaged A bearing locking compound can be used to fix the outer race in place on reassembly if the damage is not too severe 18 The crank assembly should give many thousands of miles of service The most likely problemsto occur will be worn main bearings or a worn...

Page 50: ...ing of this Chapter If the crankshaft is worn it must be renewed Evidence of extreme heat such as discoloration or blueing indicates that lubrication failure has occurred Be sure to check the oil pump and lubrication system beforereassemblingthe engine I I 14 26 Check crankshaft runout at pointsA B C and D 26 Place the crank assembly on V blocks and check the crankshaft runout at either end usinga...

Page 51: ...at the bearing housing in the crankcase with a hot air gun before fitting the crank assembly see illustration Note Avoid applyingdirect heat onto the crankshaft 14 29e Heating the crankcase with a hot oilseal air gun 30 Wipe the mating surfaces of both crankcase halves with a rag soaked in a suitable solvent and fit the dowels and new gasket to the left hand half see illustration 31 Now fit the ri...

Page 52: ...l pump drive gears are correctly engaged 36 Installall other assemblies in the reverse order of removal 5 If the engine proves reluctant to start remove the spark plug and check that it has not becomewet and oily If it has clean it and try again If the engine refuses to start go through the fault finding charts at the end of this manualto identifythe problem unning ir i Recomr procedi nendedr Ire ...

Page 53: ...ationand bleeding 12 Piston removal inspectionand installation 9 Pistonrings inspectionand installation 10 Pulse generator coil assembly removal and installation see Chapter 5 Recommendedrunning in procedure 15 Spark pluggap check and adjustment see Chapter 1 Starter motor removal and installation see Chapter 9 Starter pinion assembly removal inspectionand installation 11 Degrees of difficulty Spe...

Page 54: ...ernal parts to the specifications of a new engine This may requirefitting new piston rings and crankcase seals or after a high mileage renewing the crankshaftand connecting rod assembly The end result should be a like new engine that will give as many trouble free miles as the original 6 Before beginningthe engine overhaul read through the related proceduresto familiarise yourself with the scope a...

Page 55: ...ecified at the beginningof this Chapter Make sure all wires cables and hoses are correctly routed and connected and secured by any clips or ties Fillthe coolingsystem see Chapter 3 Bleed the oil pump see Chapter 2A Section 13 and check the adjustment of the oil pumpcable where fitted seeChapter 1 Check the operation of the rear brake before ridingthe machine see Chapter 8 iassembl ssembly general ...

Page 56: ...ead and cylinder for signs of leakage which could indicatethat the head is warped 13 Using a precision straight edge check the head mating surface for warpage Check vertically horizontally and diagonally across the head making four checks in all see Chapter 2A 14 Ensure that the thermostat bypass passageis clear see illustration 7 8 Temperature sender A and coolant 7 14 Thermostat bypass passage m...

Page 57: ...ter 2A Take care that no residualcoolant the cylinder water jacket spills into the lankcase opening If the cylinder is stuck tap round the joint face betweenthe cylinder and e crankcasewith asoft facedmalletto free it Xn t attemptto free the cylinder by insertinga screwdriver between it and the crankcase m ll damage the sealing surfaces When the zylinder is partway removed stuff a clean rag nto th...

Page 58: ...9 3 The remainderof the procedureis the same asfor air cooled models Referto Chapter 2A Section 14for details tial start up after werhaul 1 Make sure the oil tank is at least partly full and the pump is correctly adjusted see Chapter 1 and bled of air see Chapter 2A Section 13 2 Make sure there is fuel inthe tank 3 With the ignition OFF operate the kickstart a couple of times to check that the eng...

Page 59: ... C Q C m 2 E m E E E E E E E E E E E E E E E E E E E E E E E E E E E E E X E Z q z z z z z z z aD C C l W W W 7 Q W Q Q a D r r 7 O N 0 O I n O O N N O r m o n b r w C o C m 2 V c U z 0 C a ...

Page 60: ...t for the air cooling duct and removethe duct Inspectthe duct filter element If it is dirty the element should be washed in soapy water and refitted when dry If the element is damaged or has deteriorated replaceit with a new one 5 On Vivacity 50 models with a composite cover check the condition of the rubber stop for the kickstart quadrant inside the cover If the stop is damaged or excessively wor...

Page 61: ... washer if fitted from the kickstart shaft on the outside of the cover see illustrations 5 Ease the kickstart shaft out of the cover and releasethetension onthe kickstartreturnspring Unhook the spring from the kickstart quadrant and removethe shaft seeillusbation 6 Note how the return spring locates inside the cover and removethe spring and kickstart bush see illustrations 7 Clean all the componen...

Page 62: ...eth engage in notch arrowed 4 3b then remove the outer half of the pulley tension until the quadrant can be butted against the stop on the insideof the case see illustration Ensure the shaft is pressed all the way into the case then install the washer if fitted and circlip see illustrations 3 4a and 3 4b 12 Fit the kickstart lever in the rest position and tighten the pinch bolt securely Operate th...

Page 63: ...ankshaft see illustration 7 To disassemble the variator remove the three screws or bolts and lift off the cover On models fitted with greased rollers removethe O ring and discard it as a new one must be fitted on reassembly see illustrations 8 On restricted 50 cc machines lift out the restrictor plate see illustration 9 Lift out the ramp plate noting how it fits and removethe ramp guides then lift...

Page 64: ...Renewthe pulley half if it isdamaged Installation 15 Fit the rollers into the variator body see illustration 4 9 If applicable lubricate the rollers and the ramps with high melting point grease before installation Note Too much grease in the variator will make it run out of balanceandcause vibration 16 Check that the ramp guides are correctly fitted on the ramp plate and install the plate see illu...

Page 65: ...ts on the pulleysor the pulleysrunningout of alignment should be investigated Note Drive belts are not interchangeable between different models in the Peugeot range Always specify the year andmodel ofyour scooter when buyinga new belt Ifin doubt check thepart numbermarked on the belt with a Peugeotdealer 3 Oil or grease inside the casing will contaminate the belt and prevent it gripping the pulley...

Page 66: ...o the nut see illustrations 6 Fit a strap wrench around the clutch shoes to holdthe assembly while the nut is undone then release the spring pressure by undoing the clamp see illustration 7 Remove the clutch then remove the spring seat the spring and the centre sleeve see illustrations 8 Two O rings are fitted to the pulley outer half see illustration Peugeot do not list the O rings as separate it...

Page 67: ...n the hub of the pulley inner half with molybdenum disulphide grease and install the clutch and pulley assembly on the input shaft Install the clutchdrum ensuringthe splines align with the shaft andfit the new centre nutfingertight Use the method employed on removal to prevent the clutch turning and tighten the centre nut to the specified torque setting Note Donot usea threadlockingcompoundon the ...

Page 68: ...ed 6 The input shaft is a press fit in its bearing only remove the shaft if a new one is being fitted or if a new bearing or seal is being fitted Support the cover on blocks of wood and drive the shaft out using a soft faced mallet on the clutch end If the shaft is being reused fit the clutch centre nut to protect the threads The pinion is an integral part of the shaft 7 8 Check the pinion teeth A...

Page 69: ... and drive the bearing out with a is clean and dry then apply a few drops of oil bearing driver or suitably sized socket from 7 13 Lever out the old oil seal inside and check that it turns smoothly If it the seal side see illustration Install the new grates or rattles it is worn and must be bearing with a bearing driver or socket large replaced with a new one see Steps 15 to 16 enough to contact t...

Page 70: ...Smear the inside of the output shaft oil seal with grease then install the cover and relay shafts into the case taking care not to damage the output shaft seal as the shaft is pushed through it see illustration 7 3b Ensure the dowels locate correctly and install the cover bolts Tighten the bolts evenly and in a criss cross pattern to the torque setting specified at the beginningof this Chapter 21 ...

Page 71: ...led by the passingair then through the water pump and back to the engine where the cycle is repeated A thermostat is fitted in the cylinder headto prevent the coolant flowing to the radiator when the engine is cold therefore accelerating the speed at which the engine reaches normal operating temperature A coolant temperature sender mounted in the cylinder head is connectedto the temperature gauge ...

Page 72: ... then reconnect the hose and secure it with the clip see illustration 2 3b Flushing 5 Flush the system with clean tap water by connecting a garden hose to the lower radiator hose and back filling the system Allow the water to run through the system until it is clear and flows cleanly out of the detached hose If the radiator is extremely corroded it should be renewed 6 Attach the coolant hoses to t...

Page 73: ... is defective and must be renewed Replacement 4 Refer to Chapter 9 for instrument cluster removal and installation Note The temperature gauge is an integral part of the instrument cluster and cannot be obtainedas a separateitem Temperature gauge sender Check 5 Disconnect the battery negative ve lead then disconnect the sender wiring connector see illustration 3 2 Using a continuity tester check fo...

Page 74: ...apter 28 THERMOMETER THERMOSTAT u 4 4 Set up for testing the thermostat Section 7 On completion refill the cooling ln tallation system as describedin Section2 4 Installation is the reverse of removal Make sure the hoses are correctly installed and 5 Coolantreservoir secured with their clips On completion refill removaland installatic the reservoir with the proper coolant mixture see Daily re ride ...

Page 75: ...al components are not available for the pump if it is leaking coolant a new unit must be fitted Note Leaks leave tell tale scale deposits or coolant stains Ensure the coolant is leaking from inside the pump and not froma hose connectionor damagedhose Removal 3 Drain the coolant and leave the hoses detached from the pump see Section 2 4 Undothe pump mounting bolts and remove the bolts and the guide...

Page 76: ...new ones Installation 5 Slide the clips onto the hose first then work the hose all the way onto its unions as indicated by the index marks seeillustration If the hose is difficult to push e ofki nit water or alternatively a lit water can be used 8s a lubrica nor tle soapy I nt 6 Rotate the hose on its unions to settle it in positionbefore slidingthe clips intoplace and tighteningthem securely see ...

Page 77: ...heck thejets fitted to your machine before orderingnewparts Fuel Fueltype Unleaded petrol gasoline min95 octane Tank capacity Speedfightmodels 7 2 litres 50 cc Trekker models 6 0 litres 100cc Trekker models 7 2 litres Vivacity models 6 0 litres Automatic choke mechanism Choke unit resistance 1996to 2003 models Gurtner approx 36 ohms 20 C 1997to 2003 models Dell Orto approx 5 2 ohms 20 C Choke resi...

Page 78: ...service procedures are considered routine maintenance items and for that reasonare included in Chapter 1 Precautions Warning Petrol gasoline is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance is present If you spill any fue...

Page 79: ... the tap must be replaced with a new one Removal 7 Disconnect the fuel and vacuum hoses from the carburettorand place the free end of the fuel hose in a suitable container below the level of fuel in the tank Create a vacuum in the vacuum hoseand drain the tank If the tap is blocked remove the tank to drain the fuel see Section3 8 Loosentheclipsecuringthetap andwithdraw the tap assembly see illustr...

Page 80: ... by the rear wheel contacting the ground ensure that the scooter is on its stand and i f necessary place a support under the stand to prevent the rear wheel contacting the ground 1 Idle fuel air mixture is set using the pilot screw see illustrations Adjustment of the pilot screw is not normally necessary and should only be performed if the engine is running roughly stalls continually or when fitti...

Page 81: ...choke unit 6 2a Fixings for air filter housing on Speedfight 6 3a Fixingfor air intake duct on Speedfight resistance between the terminal on the resistor side of the connector and earth ground If the result is not as specifiedat the beginning of this Chapter the resistor is probably faulty 8 Carburettor overhaul general information 1 Poor engine performance hesitation hard starting stalling floodi...

Page 82: ...seoil loss and wrap a clean plastic bag aroundthe end of the hoseto prevent dirt enteringthe system 6 Detach the fuel hose from the carburettor see illustration Note There will be a small amount of residual fuel in the hose but fuel should not leak from the hose once this has drained If fuel continues to leak from the hose check the operation of the fuel tap see Section2 7 Position a suitable cont...

Page 83: ...ounting sleeve gasket and discard it as a new one must be fitted on reassembly see illustrations 4 On a Gurtner carburettor undo the screw retaining the float pin and remove the float and pin see illustrations If loose remove the pin from the float On a Dell Orto carburettor carefully withdraw the float pin and removethe float see illustration 5 Remove the float valve noting how it fits onto the t...

Page 84: ...n Note Record the screw s current setting by counting the numberof tums requiredto removeit 9 The pilot screw can be removed if required but note that its setting will be disturbed see Haynes Hint Unscrew and remove the pilot screw along with its spring seeSection5 To record the pilot screw s c u m n t setting turnitinuntil rt seats lightly counting the m number of tums necessary to achieve this t...

Page 85: ...ettor top from the cable the cable elbow and remove the carburettor top see illustrations The needleis retained in the slide by a spring strip withdraw the spring strip and lift the needle out of the slide see illustration Note the position of the needle clip see illustration 11 On a Dell Orto carburettor to remove the throttle slide and needle from the throttle cable compress the slide spring and...

Page 86: ... sure the needle valve enters its seat On a Gurtner carburettor install the pin and secure it with the retaining screw see illustration 10 4a On a Dell Ortocarburettor installthe pin seeillustration 10 4 6 Fit a new gasket either to the carburettor body or the float chamber as applicable makingsure it is seated properly in its groove seeillustrations 10 3b and 10 3 lnstallthe chamber onto the carb...

Page 87: ...ssembly remove the upper or front handlebar cover front panel floor panel and storage compartment see Chapter 7 If required remove the exhaust system see Section 15 12 On liquid cooled models undo the radiator mounting bolts and displace the radiator and coolant reservoir assembly secure it to the machine with cable ties while removing and installing the throttle cable see Chapter3 13 Release the ...

Page 88: ... the problem 6 Check that the stopper plate retaining screwsaretight do not disassemblethe valve unnecessarily as individual components are not available Installation 7 Ensure that the mating surfaces between the crankcase the reed valve and the inlet manifoldare clean and perfectly smooth 8 Install a new gasket on the crankcase see illustration The reed valve will only fit one way round so ensure...

Page 89: ...n the jointing surfaces of the dlaust remove the bolts and lift the system away removed heck around the welded patch on manifold and cylinder port Smear the gasket from the machine see illustration the exhaust for gas leaks i with grease to hold it in place while fitting the 5 On 100 CC machines loosen the nuts and requires a number of modifications to the exhaust bolts securing the exhaust to the...

Page 90: ... system controlled by signals from All models are fitted with a fully transistorised electronic ignition system which due to its lack of mechanical parts is totally maintenance free The system comprisesthe alternatorrotorand sourcecoil pulse generator coil CDI unit and ignition HT coil referto the wiring diagrams at the end of Chapter 9 for details The ignition trigger which is on the outside surf...

Page 91: ... usedon this system 4 Spark plug resistance can be checked with a multimeter Remove the plug and clean the electrodes seeChapter 1 Set the multimeter to the K ohms scale and connect the meter probes to the terminal at the top of the plug and the central electrode see illustration If the reading is not within the range shown in the Specifications the plug is defective and must be replaced with a ne...

Page 92: ...and General lnfonnation check Note The AEC 400 ignition system has a separate immobiliser the ACI 100 ignition system has a combined CDI unit and immobiliser 1 The system comprises a security coded ignition key with integral transponder the immobiliserand transponder aerial When the key is inserted into the ignition switch the security code is transmitted from the key to the immobiliservia the aer...

Page 93: ...oil on the basic CDI system or ACI 100 system set the multimeter to the ohms x 100 scale and connect the meter probes between the yellow blue wire terminal in the connectorand earth ground see illustration 8 To check the pulse generator coil on the AEC 400 system set the multimeter to the ohms x 100 scale and connect the meter probes betweenthe black wire terminal in the connectorand earth ground ...

Page 94: ...earinglocknut 20W fork oil upsidedown telescopic forks 1 All models are fitted with a stand which bolts onto the bottomof the engine 2 Fra insp d repair All models are fitted with a tubular and pressedsteel one pieceframe The engineandtransmission unit is linkedto theframe bya pivotingsilentblockassemblyat the front and by the rear shock absorber 1 The frame should not require attention making the...

Page 95: ...aulty it should be renewed see Section 9 Check that the shock mountingboltsaretight 4 On models with telescopic forks inspect the area around the dust seal for signs of grease or oil leakage then carefully lever off the dust seal using a flat bladed screwdriver and inspect the area beneath it see illustration If corrosion due to the ingress of water is evident the seals where fitted must be renewe...

Page 96: ...ear of the handlebar making sure no strain is placed on the hydraulic hose see Chapter 8 Keep the master cylinder reservoir upright to prevent air entering the system Note Some models are fitted with hydraulically operated front and rear brakes on others only the front brake is hydraulically operated 9 Removethe left handgrip peel the grip off the end of the bar or if necessary cut it off 10 On Sp...

Page 97: ...orwards and backwards see illustration Any looseness in the steering head bearings will be felt as front to rear movement of the suspension Note On models with monolever front suspension grasp the suspensionlegbehindthe wheel at either end of the monoleverarmpivot bolt for this test 5 If play is felt in the bearings adjust them as follows 6 Displacethe handlebars seeSection 5 7 Some early models a...

Page 98: ...er 8 and remove the front wheel and the brake caliper On Speedfight models if required removethe front mudguard and the wheel hub OnVivacity models remove the front mudguard On Speedfight 2 Furious and Metal X Furious models ensure the lower endof the speedometercable isdetachedfrom thefront suspension see Chapter 9 2 Removethe handlebars see Section 5 On Speedfight 2 Furious and Metal X Furious m...

Page 99: ...beenremoved 4 The outer races are an interferencefit inthe frame and can be tapped from positionwith a suitable drift seeillustration Tap firmly and evenly around each race to ensure that it is driven out squarely It may prove advan tageousto curve the end of the drift slightlyto improveaccess 5 Alternatively the races can be pulled out using a slide hammer with internal expanding extractor 6 The ...

Page 100: ...early models the monolever arm pivot bolt pivots on rubber bushesin the bottom of the suspension leg on later models the bolt pivots on a pair of bearings Before separating the arm from the suspension leg check the condition of the bushes or bearings by moving the arm laterally against the suspensionleg If any play is felt between the arm and the leg the bushes or bearings must be renewed Also mov...

Page 101: ...erollerbearing to tap evenly around the outer race of the ball bearing see illustrations The bearing spacer will come out with the bearing The bearing should be almost silent when spun If it grates or rattles it should be renewed 12 Clean the needle roller bearing with a suitable solvent and dry it with compressed air lnspect the surface of the rollersfor wear and pitting Apply a few drops of clea...

Page 102: ...rdis fitted 23 lnstall the bolt for the caliper bracket torque arm in the suspension leg from the right hand side then install the arm washer and new nut see illustration 9 4 Tighten the nut sufficiently to allow final alignment of the torque arm when the caliper bracket is installed 24 lnstall the lower end of the shock absorber inthe bracketon the monolever arm then install the bolt and mudguard...

Page 103: ... ones it is good practice to renew the dust seals when the forks are disassembled Reassembly 40 Installthe compressionlimitingcone 41 Lubricate the new oil seal with fork oil p of the ct it wher lace 8 oil seal a presslnl 42 Once the seal is installed fit the circlip makingsure it iscorrectly located in itsgroove 43 Check that both plugs are in the ends of the spring then insert the spring into th...

Page 104: ...these models are outwardly similar to the Trekker forks However fork action is controlled by an hydraulic cartridge in the left hand tube and a spring in the right hand tube and the forks are maintenance free If the fork action is suspect consult a Peugeot dealer If the fork is damaged a new fork assembly will have to be fitted To remove the fork first remove the steering stem see Section7 10 Rear...

Page 105: ... the front half of the handlebar switch housing and is retainedby a nut 2 To remove the mirror on early models pull back the lowerend of the boot on the stem to expose the top of the fixing see illustration Counterholdthe fixing and undothe nut then withdraw the mirror from the switch housing On later models with carbon look mirrors remove the plug from the top of the bracket then counterhold the ...

Page 106: ...er from the footrest bracket and slide the footrest out of the bracket Note the bush inside the footrest pivot hole Seat 1 To remove the seat insert the ignition key into the seat lock and turn it anti clockwise This will release the catch on the rear underside of the seat base see illustration Swingthe seat upright 2 Theseat isretainedbythe hingeat thefront of theseat base seeillustration Support...

Page 107: ...vethe collars see illustration Refit the tank caps 11 The storage compartment is retained by three or four flange nuts as applicable see illustration Undo the nuts then lift the compartment and seat assembly off the machine see illustration Note On Trekker models the storage compartment is retained by two of the rear cowling screws in addition to the nuts see illustration 12 Installation is the re...

Page 108: ...ill have to be renewed lubricant liquid soap or mounting grommets will assist the lugs to engage without the needfor unduepressure Inthe case of damage to the body panels it is usually necessary to remove the broken panel and replace it with a new or used one There are however some shops that specialise in plastic welding so it may be worthwhile seeking the advice of one of these specialists befor...

Page 109: ...t 1variants have a one piece front headlight panel with no grille or separate front panel The front body panels were redesigned for the Speedfight 2 models If required the headlightpanel can be removed with the front panelattachedto it Onair cooledSpeedfight2 variants the grillewas blankedoff 8 Undothe four screws in the kick panel see illustration 9 Undo the two screws on the lower front edge of ...

Page 110: ...et at the rear left hand side of the mudguard see illustration 20 Undo the screws securing the mudguard bracket to the monolever arm and removethe mudguardand bracket see illustration 6 19 21 If required undo the screws securing the bracket to the mudguard 22 lnstallation is the reverse of removal Ensure the U clips are in place and tighten all fixings securely Note The rear right hand side mudgua...

Page 111: ... see Section5 and undothe screwsjoining the two side panels above the battery compartment seeillustration 35 Undo the two screws securing the side panel to the floor panel and the two screws securing the side panel to the rear cowling then removethe panel see illustration 36 lnstallation is the reverse of removal Ensure the U clips are in place on the floor panel and rear cowlingfixing points Floo...

Page 112: ...oints for the side panels see illustration Connect the wiring for the rear light unit and check the operation of the tail light and brake light Rear mudguard 47 Remove the rear cowling and disconnect the wiring connectors for the rear turn signals and where fitted the number plate light see illustrations 48 If a Boa lock isfitted undothe two screws 6 48a Undo the two screws 6 48b and lift off the ...

Page 113: ...ethat all the connectorsare secure and 58 The headlight unit is retained in the panel check the operation of the instruments and by three screws undo the screws and remove 52 The spoiler is retained by three screws turn signals see illustration Undo the screws to detach the unit see illustration the spoiler Trekker TKR and Metal X Furious models Handlebarcovers 53 The rear cover is retained by fiv...

Page 114: ...nd installation 15 Tyres general informationandfitting 17 Tyres pressure tread depthandcondition see Daily pre ride checks Wheels general check see Chapter 1 Wheel bearings check and renewal 16 Wheels alignment check 13 Wheels inspectionand repair 12 Degrees of difficulty Specifications Disc brake Fluidtype Padminimumthickness Disc thickness Standard Servicelimit s u m f o r Vw6 expecienced DN sui...

Page 115: ...see illustration If either pad is worn down to or beyond the service limit is fouled with oil or grease or heavily scored or damaged both pads must be renewed Note Itisnotpossible to degreasethe friction material if the pads are contaminatedin any way they mustbe renewed 4 If the pads are in good condition clean them carefully using a fine wire brushwhich is completely free of oil and greaseto rem...

Page 116: ...g washers as new ones must be usedon installation Inspection 5 Clean the exterior of the caliper with denatured alcohol or brake system cleaner Inspect the caliper for signs of damage especially around the mounting lugs and the bleed screw and renew it if necessary If 3 4 Unscrew the bolt to detach the hose 3 5 Fluid leaks indicate a failed seal hydraulicfluid is leakingfrom aroundthe edge on remo...

Page 117: ...er is secure Unscrew the master cylinder clamp bolts and remove the back of the clamp see illustration Position the assembly clear of the handlebar making sure no strain is placed on the brake hose and the brake light switch wiring Keep the fluid reservoir upright to prevent air enteringthe hydraulic system 3 If the master cylinder is being removed disconnect the brake light switch wiring connecto...

Page 118: ...g components see illustration 7 Check that the fittings align correctly then install the banjo bolts using new sealing washers on both sides of the fittings see illustration 5 4 Tighten the banjo bolts securely 8 Flush the old brake fluid from the system refillwith new DOT4 brake fluid and bleedthe air from the system see Section8 9 Check the operation of the brakes before ridingthe scooter 8 Brak...

Page 119: ...taching the hose With the hose attached the valve can then be opened andclosedwithan open endedspanner 14 Open the bleed valve and carefully inject fluid into the system until the level in the reservoir is up to the half way mark on the inspection window Tighten the bleed valve disconnectthe hoseand refit the dust cap 15 Operate the brake lever carefully several times to bring the pads into contac...

Page 120: ...the shoes first lubricatethe cam and the pivot post with a smear of copper grease and hook the springs into the shoes Positionthe shoes in a V on the cam and pivot post then fold them down into position Operate the brake arm to check that the cam and shoes work correctly 14 Installthe wheel and test the operation of the brake before ridingthe scooter 10 Rea renc r drum brakecable wal 8 1 Removethe...

Page 121: ...l will have to be renewed Never attempt to repaira damaged cast alloywheel 13 Wheels alignment cnecK 1 Misalignment of the wheels can cause strange and potentially serious handling problems and will most likely be due to bent frame or suspension components as the result of an accident If the frame or suspension are at fault repair by a frame specialist or replacement with new parts are the only op...

Page 122: ...e wheel see above On Speedfight 2 Furious models remove the screw securing the lower end of the speedometer cable to the caliper bracket and disconnectthe cable see illustration 5 Have an assistant apply the front brake then loosen the hub nut see illustration Undo the brake caliper mounting bolts and slide the caliper off the disc see Section 3 Note Do not operate the brakeleverwhile the caliperi...

Page 123: ...e axle bearings sleeves and speedometerdrive with grease Ensurethe dust cap is installedonthe caliper bracket beforeslidingthe bracket onto the axle 14 15 Disconnect the speedometer cable 14 16a Remove the axle nut and washer 14 16b Note how the speedometer gearbox A locates against the fork slider 9 Ensure the plain washer is installed inside the speedometer gearbox before sliding the hub onto th...

Page 124: ...inst the corresponding section on the inside of the fork Slidethe axle in carefully from the right hand side ensuring Speedfight models wheel the fork legs and wheel remain in alignment t lt i s not possible to remove the rear 21 Installthe as her and axle nut and tighten on its own with the exhaustsystem in place If the nut to the torque setting specified at the the exhaust system hasbeenremoved ...

Page 125: ...n assistant applythe rear brake then loosen the hub nut Undothe brake caliper mounting bolts and slide the caliper off the disc see Section 6 Note Do not operate the brake lever while the caliper is off the disc 10 Unscrew the hub nut and remove the nut and washer then draw the hub assembly off the axle see illustration 11 lnspect the splines on the axle and on the inside of the hub for wear and d...

Page 126: ... same procedure 7 Thoroughly clean the hub with a suitable solvent and inspect the bearing seats for scoring and wear If the seats are damaged consult a Peugeot dealer before reassembling the wheel 8 Installa new bearing intoitsseat inone side of the hub with the marked or sealed side facing outwards Using the old bearing a bearing driver or a socket large enough to contact the outer race of the b...

Page 127: ...s fitted in the rear wheel or the rear hub Refer to Chapter 2C for renewal of the rear axleloutputshaft bearings in the transmissionrelay box 1 The wheels ftted to all models are designed to taketubelesstyres only Tyre sizes are given inthe Servicespecifications in Chapter 1 2 Refer to Daily pre ride checks at the beginningof this manualfor tyre maintenance Fitting new tyres 3 When selecting new t...

Page 128: ...atorlrectifier check and replacement 32 Speedometer cable check and replacement 17 Starter motor disassembly inspectionand reassembly 27 Starter motor removal and installation 26 Starter relay check and replacement 25 Tail brake light bulb test and replacement 9 Tail light unit removal and installation 10 Turn signal bulbs test and replacement 14 Turn signalassembly removal and installation 15 Tur...

Page 129: ... the component to both the battery and the frame To aid in locating a problem in any electrical circuit refer to the 2 6a A test light 2 6b or buzzer can be used for simple voltage checks WiringDiagramsat the end of this Chapter 2 Beforetackling any troublesome electrical circuit first study the wiring diagram thoroughly to get a complete picture of what makes up that individual circuit Trouble sp...

Page 130: ... the battery strap or displace the strap and lift the battery from its holder seeillustrations 4 Before installation clean the battery terminals terminal screws nuts and lead ends with a wire brush knife or steel wool to ensure a good electricalconnection 5 Installthe battery then reconnectthe leads connecting the positive ve lead first and secure the battery strap kept to a minlmum by jelly to th...

Page 131: ...its holderto check it visually see illustration 2 A blown fuse is easily identified by a break in the element see illustration The fuse is clearly marked with its rating and must only be replaced by a fuse of the correct rating see Specifications at the beginning of this Chapter It is advisable to carry a spare fuse on the scooter at all times A Warning Never put ina fuse of a higher rating or bri...

Page 132: ... none of the turn signals work check the turn signal circuit see Section 13 Instrument cluster lights Note On Speedfight 2 Furious and Metal X Furious models the warning lights are illuminatedby LEOS Ifa light fails to work and the fault cannot be traced to a wiring or component failure the instrument cluster will have to be replacedwith a new one 19 If one light fails to work check the bulb and t...

Page 133: ... the bulbholder out of its socket 7 6b and pull the bulb out of the holder from corrosion jhen installthe connector 3 Onall other models twistthe bulbholderanti clockwise and draw it out of the headlight unit then pushthe bulb in and twist it anti clockwise to release it from the holder see illustrations Check that the contacts inside the bulbholder are clean and free from corrosion then fit the n...

Page 134: ...et and twist it anti clockwiseto remove it see illustration 3 Check the socket terminals for corrosion and clean them if necessary see illustration Line up the pins of the new bulb with the slots in the socket then push the bulb in and turn it clockwise until it locks into place Note The pins on the bulb are offset so it can only be installed one way It is a good idea to use a paper towel or dry c...

Page 135: ...see Section 30 2 Most turn signal problems are the result of a failed bulb or corroded socket This is especially true when the turn signals function properly in one direction but not in the other Check the bulbsand the sockets see Section 14 Also check the operation of the turn signal switch see Section 22 and the turn signalwarning light see Section 18 3 If the bulbs and sockets are good test the...

Page 136: ...he turn signal lens and lift off the lens noting how it fits see illustrations Where fitted unclip the bulb cover then push the bulb into the socket and turn it anti clockwise to remove it 6 Check that the contacts inside the socket are clean and free from corrosion Line up the pins on the bulb body with the slots in the socket then push the bulb in and turn it clockwise until it locks into place ...

Page 137: ...nit see illustration 8 Installationis the reverseof removal 9 The rear turn signals are integral with the rear light unit seeSection 10 16 Instrumentcluster check removal and installation P Check 1 Special instruments are required to check the operation of the speedometer If it is believed to be faulty first check the operation of the speedometer cable see Section 17 then take the scooter to a Peu...

Page 138: ...the cable does not rotate the cable or the speedometer gearbox is damaged or broken 4 Unscrew the knurled ring and disconnect the lower end of the cable from the speedometer gearbox to check the inner cable see illustration Remove the front wheel on Trekker and Vivacity models and the front wheel hub assembly and caliper bracket on Speedfight models to check the speedometergearbox see Chapter 8 Re...

Page 139: ...d don t work in a garage where a naturalgas type appliance is present I fyou spill any fuel on your skin rinse it off immediately with soap and water When you perform any kindof work on the fuel system wear safety glasses and have a fire extinguisher suitable for a class B type fire flammable liquids on hand Fuel gauge Check 1 Remove the storage compartment to access the top of the fuel tank see C...

Page 140: ...r 20 5 Measuring resistance in the oil level sensor 3 Disconnect the wiring connector from the top of the sensor see illustration With the ignition switched on check for voltage at the black wire terminal inthe connector If there is no voltage check the wiring between the connector and the ignition switch see Wiring Diagrams at the end of this Chapter 4 To test the sensor remove it from the oil ta...

Page 141: ... checks 3 Remove the handlebar covers and front or headlight panel as necessary to trace the wiring from the switch in question back to its connector see Chapter 7 Disconnect the relevant wiring connector see illustrations 4 Check for continuity between the terminals of the switch wiring with the switch in the various positions e g switch off no continuity switch on continuity referringto the Wiri...

Page 142: ...the horn and tighten the mounting bolt securely Connect the wiring connectors and test the horn 25 Starter relay check and renewal Check 1 If the starter circuit is faulty first check the fuse see Section 5 Also check that the 25 4 Measuring the starter relay secondary resistance 24 1 and Vivacity models 25 2 Pull the starter relay out of its socket next to the battery battery is fully charged see...

Page 143: ...times depending on the nature of the fault the startermotor can be repaired 1 Removethe starter motor see Section 26 2 Undo the screws securing the housing to the end cover and draw the housing off leavingthe armaturein place in the cover see illustration 3 Carefully lift the housing seal off over the armature see illustration 4 Withdraw the armature from the cover notingany shims or washers on ei...

Page 144: ...y result if short circuitsoccur 4 If a multimeter is not available the job of checking the charging system should be left to a Peugeotdealer leal output tes 29 Chargingsystem P 1 If the charging system of the machine is thought to be faulty perform the following checks Leakage test 2 Disconnect the battery negative ve terminal 3 Set the multimeter to the Amps function and connect its negative ve p...

Page 145: ...his Chapter see illustration 3 5 To removethe rotor from the crankshaft it is 5 If the readings obtained differ greatly from Note This procedure can be cam ed out with necessary to first protect the end of the shaft those given particularly if the meter indicates the engine in the frame use either the Peugeot service tool Pt No Removal 1 Disconnect the battery negative ve terminal 2 Removethe bell...

Page 146: ...the floor panel seeChapter 7 The regulatorlrectifier is mounted on a bracket 31 8a Two bolts A secure the pulse generator B 31 8 Alternator stator is secured by two bolts arrowed forward of the battery holder see illustration 2 Disconnect the battery negative ve terminal Set a multimeterto theohms x 1scale and connect the meter probes to the green wire terminal in the regulatorlrectifier wiring co...

Page 147: ...9 20 Wiring diagrams ...

Page 148: ...Wiring diagrams 9 21 iiiZl ...

Page 149: ...9 22 Wiring diagrams ...

Page 150: ... forceper square inch psi Ibf in2 Ib in2 psi Ibf in2 Ibiin Kilopascals kPa x 0 0 1 Kilograms forceper square x 98 1 Kilopascals kPa centimetre kgf cm2 kg cm Millibar mbar x 100 Pascals Pa x 0 0 1 Millibar mbar Millibar mbar x 0 0145 Pounds forceper square inch x 68 947 Millibar mbar psi Ibf in2 Ib in Millibar mbar x 0 75 Millimetresof mercury mmHg x 1 333 Millibar mbar Millibar mbar x 0 401 Inches...

Page 151: ... 9 IJ Batteryvoltage low Check and recharge battery Chapter 9 Starter motor defective Make sure the wiring to the starter is secure Make sure the starter relay clicks when the start button is pushed If the relay clicks then the fault is in the wiring or motor Starter relay faulty Check it Chapter 9 Starter switch on handlebarnot contacting The contactscouldbe wet corrodedor dirty Disassembleand cl...

Page 152: ...tonring lands Pistonrenewal is necessary Chapter2 Cylinderhead gasket damaged If a head is allowedto become loose or if excessive carbon build upon the pistoncrownand combustion chamber causes extremely high compression the head gasket may leak Renew the gasket Chapter2 Cylinderheadwarped This is caused by overheating or improperlytightened head bolts Machine shop resurfacingor head renewal is nec...

Page 153: ...ttor Chapter4 Air filter clogged poorlysealed or missing Chapter 1 Air filter housingor duct poorly sealed Look for cracks holesor looseclamps or screws and replaceor repairdefective parts Carburettor inlet manifold loose Check for cracks breaks damaged gasketsor looseclamps Compressionlow Spark plug loose Removethe plugand inspect its threads Reinstall andtightensecurely Chapter 1 Cylinderhead no...

Page 154: ...wom unevenly Chapter2C Clutchpulleyor variator pulley out of alignment Chapter2C Bent or damaged transmissionshaft ChapterX IJ Loose clutch nut or variator nut Chapter2C Air filter housingor duct poorly sealed Lookfor cracks holesor looseclamps or screws and renew or repairdefective parts Carburettor inlet manifold loose Check for cracks breaks damaged gasketsor looseclamps Compressiontoo hlgh Car...

Page 155: ...mponent failure Enginemountingbolts loose Tighten all engine unit mounting bolts Chapter2A or 28 Crankshaft bearingsworn Chapter2A or 28 lubrication enew damaged parts Chapter 2 7 Abnormal frame and suspension noise Front end noise Brake noise Steering head bearingslooseor damaged Clickswhen braking Squealcaused by dust on brakepadsor shoes Usuallyfound in Check and adjust or renew as necessary Ch...

Page 156: ...d out by high pressure car washes Disassemblesteering headand repack bearings Chapter6 Steering stem bent Caused by an accident Renew the steering stem don t try to straightenit Chapter 6 Front tyre air pressuretoo low Daily pre ride checks Handlebar shakes or vibrates excessively Tyres wom Daily pre ride checks Suspension componentsworn Renew worn parts Chapter6 Wheel rim s warped or damaged Insp...

Page 157: ...oil or grease etc Fit new shoes Clean drum thoroughly with brakecleaner Chapter 8 Brake lever arm incorrectly positioned or cam excessively worn Chapter8 Brakes drag Cable incorrectly adjusted or requires lubrication Check cable Chapter 1 Shoe returnsprings broken Chapter8 Lever action roughor lever stuck Check pivot and lubricate Chapter 8 Lever arm or cam binds Caused by inad9quate lubrication o...

Page 158: ...ence platelight 9 8 ratings 9 2 sidelight 9 6 taillbrake light 9 7 turn signal 9 9 Cables oil pump 1 29 1 30 rear drum brake 1027 807 speedometer 9 1 1 throttle 1 28 4 1 0 Caliper disc brake 8 2 8 4 Carburettor cleaning 1 31 disassekbly cleaningand inspection 4 7 heater 4 1 2 overhaul 4 5 reassembly 4 1 0 removal and installation 4 6 specifications 3 1 CDI unit 5 4 Charging system 9 17 Choke mecha...

Page 159: ...lcheck 0 13 1 2 7 levers 1 26 8 7 master cylinder 8 4 hose 1027 805 pads 1 27 8 2 Front mudguard Speedfight 7 6 Trekker 7 1 0 Vivacity 7 1 3 Front panel Speedfight 7 5 Vivacity 7 1 3 Front side panels Speedfight 7 6 Front suspension check 6 2 forks 6 9 6 10 6 1 1 monolever 6 7 specifications 6 1 Front wheel 8 9 8 1 3 Fuelsystem carburettor 1031 405 to 4 1 2 choke mechanism 4 5 fuel filter 4 3 fuel...

Page 160: ...peedfight 7 8 Trekker 7 1 1 Vivacity 7 1 5 Oil front forks 6 1 Oilfilter 1 3 0 Oil levelcheck engine 0 1 2 Oil levelcheck relaybox 1 3 4 Oil levelsensor 9 1 3 Oil pump cable adjustment and systemcheck 1 29 1 30 removal inspection installationand bleeding 2 A 9 28 6 Oil tank 4 4 Pads dlsc brake 1 27 8 2 8 4 Passengerfootrests 7 1 Piston removal inspectionand installation 2A 6 28 5 rings 2A 8 28 6 P...

Page 161: ...pinion assembly 2A 9 2B 6 Starter relay 9 1 5 Steering check 0 1 3 fault finding R E F REF07 head bearings 604 606 stem 6 5 Storagecornpamnent 7 2 Suspension check 0 13 6 2 fault finding REF 6 REF07 front forks 6 9 6 10 6 11 front monolever 6 7 rear shock absorber 6 1 1 rear silentblockassembly 6 1 1 specifications 6 1 Tail light bulb 9 7 check 9 5 unit 9 7 Tap andtank fuel 4 3 Temperature gauge a...

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PEUGEOT Speedfight 2, Owner'S Manual

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