PEUGEOT SPEEDFIGHT 3 RS Workshop Manual Download Page 44 | Manualshive

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STEERING/FORK

42

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

The fork and its components

1. Hydraulic cartridge nut.
2. Lip seal.
3. Circlip.
4. Rubber washer.
5. Balk rings.
6. Expansion spring.
7. Fork lower tube.
8. Compression spring.
9. Rubber stop.
10. Hydraulic cartridge.
11. Stanchion.

After refitting, pump the forks several
times to eliminate the excess grease
inside the tubes.
Wipe the grease off the fork tubes.

11

4

2

1

5

6

7

9

1

10

8

5

3

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Summary of Contents for SPEEDFIGHT 3 RS

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

Page 2: ......

Page 3: ...nce 10 Battery preparation Except battery without maintenance 11 Installing the battery vapour vent hose 11 New machine preparation 11 SPECIAL IMPORTANT POINTS 12 Oil and fuel 12 TIGHTENING TORQUES 13 Engine part 13 Body panels 13 Cycle part 14 Standard 14 SPECIAL TOOLS 15 STANDARD TOOLS 15 LOCATION OF COMPONENTS 16 BODY PANELS 17 Location of body components 17 Body component sequence of disassemb...

Page 4: ...31 Installing the valve clearance 32 Idle setting 33 Brake inspection 34 Replacing the brake pads 34 Checking the brake fluid level 35 Rear brake linings 36 Disassembly 36 Reassembly 37 Removal of the fuel filter 38 STEERING FORK 39 Changing the front fork seals 39 Removal of the fork tubes 41 The fork and its components 42 Removal of the fork 43 Replacing the steering head cups 44 Installing the ...

Page 5: ... of the carburettor 50 Removal of the throttle valve 50 Removal of the float needle valve and jets 51 Removal of the mixture screw 52 Removal of the pick up pump 53 Removal of the pick up pump suction valve 53 Removal of the deceleration enrichment device 53 Removal of the carburetor heater 54 The carburettor and its components 54 POWER UNIT 55 Removal of the power unit 55 ...

Page 6: ...nd appropriate clothes such as a cotton overall Do not breath fumes Explosive The product can explode under certain circumstances flame heat impact friction Avoid impacts friction sparks and heat Hazardous to the environment The product affects fauna and flora Do not dump it in dustbins sinks or in the environment The ideal solution is to bring this product to your nearest household waste recyclin...

Page 7: ...age to the vehicle and in certain cases a cancellation of the warranty can be involved if the recommendations are not fully respected Note Operation that can be difficult Indicate a note which gives key information to make the procedure easier Lubricate Lubricate the parts to be assembled Indicate the specific procedures that shall be followed in order not to damage the vehicle Grease Grease the p...

Page 8: ... output 2 8 kW at 8000 rpm Max torque rating 3 5 Nm at 6500 rpm Compression 9 5 bars at 550 rpm Fuel supply Carburettor KEIHIN NCV Lubrication Pressurised wet sump lubrication Trochoid pump driven by a gear set from the crankshaft Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust With catalytic system and pulsair valve Standards Euro 3 Starter motor By kick st...

Page 9: ... fork Ø32 mm Travel 80 mm Rear suspension Combined spring and hydraulically damped shock absorber Travel 65 mm Overall length 1895 mm Width at handlebar 700 mm Height without rear view mirrors 1120 mm Wheelbase 1290 mm Saddle height 810 mm Unladen weight 100 kg Front wheel rim 13 inch aluminium alloy Front tyre 130 60 13 Front tyre pressure 1 8 bars Rear wheel rim 13 inch aluminium alloy Rear tyre...

Page 10: ... Speedfight 3 Front brake Single disc type hydraulic control Disc diameter and thickness 215 mm 3 5 mm Rear brake cable controlled single cam drum type Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking 1 number and manufacturer s plate Engine number 2 VGAV 1AAAA 0JXXX XXX 1 XXXXXX XXXXXXXXX 2 ...

Page 11: ...service Steering column play V V V V V V Wheel bearing play C C C C C C Throttle cable play V V V V V V Operation of electrical equipment V V V V V V Condition of the front brake hydraulic control V V V V V V Brake fluid level V V V V V V Front brake pad wear C C C C C C Rear brake lining wear C C C C C C Condition of petrol pipes C C C C C C Tyre condition pressure and wear C C C C C C Condition ...

Page 12: ...lley bearings and guides V C V C Transmission belt R R Driven pulley caged needle bearing G G G G Kick starter mechanism G G Valve clearances V V V V V Setting the carburettor V V Joints Central stand Brake levers G G G G Petrol filter R Engine oil clean strainer R R R R R R Relay box oil R R R R R Petrol pipe R Once every 5 years Brake fluid R Once every 2 years Time required for maintenance Code...

Page 13: ...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 Depending on equipment Installing the battery vapour vent hose After being connected to the battery the vapour vent hose must be routed through the 2 holders located in the rear splash g...

Page 14: ...re any signs of wear cracks etc The air pipe between the air pump and the exhaust is specific owing to its heat resistance properties Should it be changed replace it with a genuine pipe The clips are specific they must always be changed each time they are removed and replaced with new genuine parts clips Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or...

Page 15: ...er plug 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Crankcase 12 Nm RH casing cover 12 Nm Freewheel 90 Nm Oil pump 10 Nm Transmission cover 10 Nm Relay box cover 22 Nm Relay box drain plug 10 Nm Starter motor 10 Nm Rotor 55 Nm Turbine 10 Nm Stator 12 Nm Engine speed sensor 12 Nm Drive pulley 55 Nm Driven pulley 55 Nm Clutch plate and shoes 55 Nm Front mudguard 8 to 10 Nm Handlebar cover 1 to 2...

Page 16: ... 60 Nm Shock absorber top mount 45 Nm Shock absorber bottom mount 25 Nm Exhaust to cylinder mounting nut 15 Nm Exhaust to casing mounting bolt 30 Nm Upper cone in 2 operations 40 17 Nm Upper cone locknut Hand tightened Steering locknut 70 Nm Front brake caliper 45 Nm Front brake disc 30 Nm Fork arm 25 Nm Handle bar 40 Nm Nut and bolt 5 mm diameter 5 Nm Nut and bolt 6 mm diameter 10 Nm Nut and bolt...

Page 17: ...ool N Designation Used with 750539 Tie wrap pliers 752361 39 mm pipe wrench 752127 752127 Clutch compression tool 756725 757860 Steering tool 752237 Adjustable pin wrench 757990 Steeinghead cup push tool 753726 Steeinghead cup push tool 766062 Spark plug spanner 755996 Hose clamp Wrenches with interchangeable end fittings for valve clearance adjustment Type Marolotest P N 500140 ...

Page 18: ...Peugeot Motocycles LOCATION OF COMPONENTS 1 CDI unit 2 Battery 3 Ignition sensor 4 HT coil 5 Regulator 6 Starter motor relay 7 Starter resistor 8 Temperature control unit 9 Fuel gauge 10 Horn 11 Speed sensor 12 Fuses 13 Resistor warming carburator U PP ER LE V EL LO W ER LE V EL N C 5 11 1 2 9 8 6 7 3 4 13 10 12 ...

Page 19: ...ts Description 1 Handlebar front fairing 2 Handlebar rear fairing 3 Front top cover panel 4 Legshield top panel 5 Front lower legshields 6 Rear shield 7 Front mudguard 8 Front wheel 9 Saddle and storage compartment 10 Lower fairing 11 Rear panels 12 Footboard 13 Bottom panel 14 Grab handle 15 Rear mudguard 16 Mudguard 14 1 2 6 12 8 11 3 4 7 9 5 10 13 16 15 ...

Page 20: ...nt fairing 2 Handlebar rear fairing 3 Front top cover panel 4 Legshield top panel 5 Front lower legshields 6 Rear shield 7 Front mudguard 8 Front wheel 9 Saddle and storage compartment 10 Lower fairing 11 Rear panels 12 Footboard 13 Bottom panel 14 Grab handle 15 Rear mudguard 16 Mudguard 17 Fork This item may be removed on its own 4 3 1 8 15 14 12 17 13 16 9 7 11 10 2 6 5 ...

Page 21: ...storage compartment Procedure 1 Lift the saddle Remove the battery cover 1 2 plastic screws Disconnect and remove the battery Remove the storage compartment 4 washer head screws Ø6 mm Disconnect the accessory plug 3 When reassembling ensure that the accessory plug supply harness runs IN FRONT of the storage compartment bracket A 1 3 A ...

Page 22: ... the storage compartment See Procedure 1 page 19 Remove the lower fairing by sliding it towards the rear of the vehicle 1 screw Ø6 mm Remove the rear cover assembly 10 screw 6 plastic screws A 2 screw Ø5 mm B 2 screw Ø6 mm C Disconnect the taillight Remove the splash guard 4 plastic screws Remove the taillight 4 plastic screws Separate the 2 fairings 1 2 plastic screws A A A C B A 1 ...

Page 23: ...rbidden without the written consent of Peugeot Motocycles Removal of handlebar fairing Procedure 3 Remove the handlebar front cover 6 plastic screws Disconnect the instrument cluster Remove the handlebar rear cover and instrument cluster assembly 4 plastic screws ...

Page 24: ... 4 Remove the front top cover panel 3 plastic screws Remove the front upper shield panel 4 plastic screws Disconnect the lighting Removal of the rear shield panel Procedure 5 Remove the handlebar fairings See Procedure 3 page 21 Remove the front upper shield panel See Procedure 4 page 22 Remove the rear shield panel 4 washer head screws Ø6 mm A 1 screw Ø6 mm B B A A ...

Page 25: ... the ignition key switch trim with the mark at the bottom A Removal of front lower shield panels Procedure 6 Remove the rear shield panel See Procedure 5 page 22 Remove the front lower shield panels 3 plastic screws Disconnect the direction indicators If a direction indicator bulb is changed the indicator s other bulbs must also be systematically replaced A ...

Page 26: ...rear cover assembly See Procedure 2 page 20 Remove the front lower shield panels See Procedure 6 page 23 Remove the RH and LH footrest 1 2 screws each Remove the tank filler cap trim 2 3 screw Remove the footboard 4 washer head screws Ø6 mm A Removal of the under body panel Remove the footboard See Procedure 7 page 24 Remove the bottom panel 4 plastic screws 2 1 A A ...

Page 27: ... flat ground Remove the engine s oil filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Remove the strainer cap 3 and clean the strainer Re install the filter cap fitted with a new seal Tightening torque 15 Nm Insert the drain plug fitted with a new seal Tightening torque 20 Nm Pour the required quantity of oil corresponding to the manufacturer s standar...

Page 28: ...thout exceeding the latter Add oil if necessary Draining the relay box The gearbox must be drained when the engine is warm so that the oil will run easier Put on protective gloves Place the vehicle on its central stand on flat ground Remove the relay box filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Insert the drain plug fitted with a new seal Tight...

Page 29: ... the spark plug using tool P N 766062 Essential precautions When re installing srew in the spark plug a few turns by hand Tighten the spark plug Tightening torque 12 Nm Replacing the air filter Remove the air filter cover 7 bolts and its seal Remove the air filter 1 Clean inside the air filter box Fit a new air filter Fit the gasket 2 Install the air filter cover Check the condition of the seals a...

Page 30: ... the inlet silencer drain plug to let humidity and oil drip out 3 Transmission Remove the transmission cover 10 screw Tightening torque 10 Nm Remove the paper gasket and the two 2 centering pins Hold the fixed flange with tool P N 752237 Remove the fixed flange nut and washer Remove the fixed flange Tightening torque 55 Nm 3 752237 ...

Page 31: ... with the guide hud Lock the clutch drum with the pin wrench P N 752237 Remove the clutch drum and the clutch and drive pulley assembly Tightening torque 55 Nm Checking the drive pulley Remove the holder 3 and its 3 plastic guides Remove the moving flange 5 6 bearings 4 The bearings must be changed if they show major signs of wear The guides shall be replaced if they show signs of wear 2 1 752237 ...

Page 32: ...thout the written consent of Peugeot Motocycles When refitting respect the way the rollers are installed Grease the moving flange bore lightly high temperature grease Checking the drive belt Measure the width of the belt A Minimum width 17 2 mm Make sure the belt is not cracked A ...

Page 33: ...urface of the plates in contact with the belt does not show any cracks or signs of abnormal wear Replacing the clutch lining assembly Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 clamped in the jaws of a vice Remove nut 1 using spanner P N 752361 Slacken tool P N 752127 Tightening torque 55 Nm Remove the clutch lining assembly 2 When re installing the driven...

Page 34: ...ne by hand in the operating direction in order to bring the rocker pads on the back of the cams A Using the set of feeler gauges measure the clearance of each valve Clearances Intake 0 05 0 02 mm Exhaust 0 10 0 02 mm If the clearance is not correct adjust by means of the cam follower screw Use a wrench to adjust the valve clearance Type Marolotest P N 500140 Checking the valve clearance At the int...

Page 35: ... the storage compartment See Procedure 1 page 19 The engine must be at its operating temperature Switch off the engine Park the vehicle on its stand Check the operating clearance in the throttle Start the engine Screw or unscrew the engine speed adjuster screw 1 to alter the idle speed The rear wheel should not turn Idle speed 2000 to 2200 rpm 1 ...

Page 36: ... minimum dimensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Replacing the brake pads Remove the calliper 2 screw Tightening torque 45 Nm Remove the2 pins 1 Remove the brake pads 2 When refitting the brake pads push the pistons all the way into their housing After refitting actuate the brake levers several times to bring the brake pads against the brake disc A 1 5mm 2 1 ...

Page 37: ... brake fluid level Position the handlebars so that the master cylinder will be horizontal Check the brake fluid level and if necessary top up in the master cylinder A Remove the handlebar front cover 6 screw Remove the cover and the diaphragm from the master cylinder 1 2 screw Add brake fluid until it reaches the maximum level A MIN MAX 1 ...

Page 38: ...he cam tierod A compared to the mark B on the engine housing If the cam tierod mark is lined up with or passes the wear mark on the engine housing the brake lining must be replaced When it is no longer possible to adjust the control tension nut the brake pads are worn C Disassembly Remove the 2 nuts attaching the exhaust flange to the cylinder Disconnect the air hose from the exhaust 1 Remove the ...

Page 39: ...t and washer 2 Remove the rear wheel Remove the brake linings 3 Remove the adjusting nut the barrel 4 and the brake control cable 5 Remove the brake arm 6 the brake cam 7 and the spring Reassembly Lubricate the brake cam spindle and fit it into the casing Fit the brake arm 6 by aligning it with the brake cam axis 7 Tightening torque 8 Nm 2 4 6 7 5 3 6 7 ...

Page 40: ...st the lever free travel using the adjusting nut C Brake control free travel 10 to 20 mm Install the exhaust Use a new exhaust gasket Exhaust to cylinder mounting nut Tightening torque 15 Nm Exhaust to casing mounting bolt Tightening torque 30 Nm Removal of the fuel filter Remove the footboard See Procedure 7 page 24 Lift the fuel tank Clamp the end of the fuel inlet pipe using a clip ref 755996 D...

Page 41: ...emove the front brake caliper from the fork tube 2 screw Loosen the wheel spindle clamping screw 1 Remove the wheel spindle 2 Remove the front wheel Remove the front mudguard 4 screw Remove the screws fastening the fork stanchions 3 Remove the fork stanchions Carefully remove the lip seals using a screwdriver 4 Install new lightly lubricated lip seals Fit the fork staunchions Tightening torque 25 ...

Page 42: ...ometer drive gear assembly to the wheel drive pins Fit the wheel matching the speedometer drive gear assembly to the pin A on the fork stanchion Fit the wheel spindle and tighten When re installing use a new nut Tightening torque 65 Nm Tighten the spindle clamping screw 1 Tightening torque 10 Nm Refit the other items in the reverse order to disassembly A 1 ...

Page 43: ...Procedure 4 page 22 Turn the handlebars to the right to reveal the fork nut 1 in the hold in the mudguard Support the hydraulic cartridge cylinder and remove the nut Left side Carefully remove the lip seals using a screwdriver 2 Remove the circlip using a circlip plier 3 Remove the fork tubes Remove the springs Remove the rubber stop When refitting lightly grease the balk rings 5 1 2 3 ...

Page 44: ...nents 1 Hydraulic cartridge nut 2 Lip seal 3 Circlip 4 Rubber washer 5 Balk rings 6 Expansion spring 7 Fork lower tube 8 Compression spring 9 Rubber stop 10 Hydraulic cartridge 11 Stanchion After refitting pump the forks several times to eliminate the excess grease inside the tubes Wipe the grease off the fork tubes 11 4 2 1 5 6 7 9 1 10 8 5 3 ...

Page 45: ...end or immobilize the machine securely Remove the front brake caliper from the fork tube Tightening torque 45 Nm Remove the front wheel Tightening torque 65 Nm When re installing use a new nut Remove the front mudguard Remove the brake control cable grommet and the speed sensor located under the fork triple clamp 2 2 screw Using tool P N 757860 remove the steering locknut Remove The lock washer Th...

Page 46: ...the steering head cups Using a drift remove the steering head cups Using push tool P N 753726 fit a new upper cup into the steering tube Using push tool P N 757990 fit a lower cup into the steering tube Using a chisel pry the steering head cup off by pressing the tool behind the dust cover Install the following new parts The dust cover 3 The fork cone 4 753726 4 3 ...

Page 47: ... steering column Install new ball cage bearings 2 respect the right way of installation Install the upper cone 3 Install the dust cover 4 Fit the nut 5 Steering system tightening method Tighten the nut 5 Tightening torque 40 Nm Loosen and re tighten the nut Tightening torque 17 Nm Install the rubber washer 6 Fit and finger tighten the nut 7 so that its notches are aligned with those of the nut Fit...

Page 48: ...STEERING FORK 46 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Install the steering head locknut and tighten it 9 Tightening torque 70 Nm 9 ...

Page 49: ...tch 2 Battery 3 CDI unit 4 Spark plug socket 5 Spark plug 6 HT coil 7 Carburetor heater 8 Temperature control unit 9 Automatic starter 10 Magneto flywheel 11 Revolution counter 12 Regulator X 1000rpm 0 1 2 3 4 5 6 7 8 9 1 0 11 12 km h mph km mi TRIP 7 5A OFF ON U PP ER LE VE L LO W ER LE VE L 1 2 11 3 10 9 12 8 7 6 4 5 5 14 VE NR JN BA JN NR VE BA VE NR VE RG RG NR VE VE VE VE VE VE JN JN NR ...

Page 50: ... the carburettor heating resistor Between 10 2 and 20 2 C Disconnect the temperature control unit and take the measurements on the harness side Between the green wire and the ground 0 Between the white yellow wire and the ground Resistor warming carburator 8 5 20 Between the black wire and the ground ignition on 12 V Battery voltage Between the yellow wire and the ground engine running 13 5 V Regu...

Page 51: ... ignition on 12 V Battery voltage If the values are correct replace the ignition module If the values are incorrect check The ignition switch The harness The high voltage coil Primary 0 2 20 Secondary 5 20 The suppressor 5 k 20 The ignition sensor Between the green black wire and the ground 115 20 Fuel gauge Remove the footboard See Procedure 7 page 24 Disconnect the fuel gauge 1 Remove the fuel g...

Page 52: ...connect the vacuum hose 2 Remove the fuel pump 1 screw Removal of the carburettor Remove the storage compartment See Procedure 1 page 19 Remove the lower fairing by sliding it towards the rear of the vehicle 1 screw Disconnect The throttle control 1 The fuel inlet pipe 2 Disconnect The carburettor heating resistor 3 The choke 4 Remove the carburettor 2 Collars Removal of the throttle valve Remove ...

Page 53: ...eedle 4 Check that the membrane is in good condition The height oif the needle is factory set and cannot be modified Removal of the float needle valve and jets Remove the chamber 4 screw Remove the float chamber and its O ring Check the condition of the float chamber O ring Loosen the float pin clamping screw 2 Remove the float 3 its pin 4 and the needle valve 5 2 3 4 5 2 3 4 ...

Page 54: ...e the needle well 8 Check the condition of the needle valve and the needle valve seat A Check the condition of the float chamber O ring Removal of the mixture screw Turn clockwise the mixture control screw 1 while counting the number of turns until it is screwed home When re fitting this operation allows you to put it back to its initial adjustment position 6 7 8 A 1 ...

Page 55: ...tective rubber 2 Check the condition of the bushing and the rubber protection Remove the piston 3 Removal of the pick up pump suction valve Remove the jet Remove the spring Remove the ball Removal of the deceleration enrichment device Remove the 2 bolts that secure the cover Remove the cover Remove the spring Remove the membrane Remove the O ring Check that the membrane is in good condition Check ...

Page 56: ...nto every jet and duct of the carburettor body with compressed air Do not use any metal tool which can damage the ducts of these items Re install all the other components and if necessary when starting the engine readjust according to the values indicated on the technical data card The carburettor and its components 1 Choke 2 Piston 3 Sump 4 Float 5 Jets 6 Needle valve 7 Mixture screw 8 Pick up pu...

Page 57: ...e workshop manual 2 valve 50cc 4 stroke engine Remove the storage compartment See Procedure 1 page 19 Remove the lower fairing by sliding it towards the rear of the vehicle 1 screw Disconnect The magneto 1 The starter motor 1 The choke 1 The suppressor 2 The carburettor heater 3 Disconnect The throttle control 4 The fuel inlet pipe 5 The vacuum pressure hose 6 Pulsair The vacuum pressure hose 7 Fu...

Page 58: ...spend the rear of the machine Remove the shock absorber upper mount 9 Tightening torque 45 Nm When re installing use a new nut Remove the linkrod to engine connecting pin 10 Tightening torque 60 Nm When re installing use a new nut Remove the power propulsion unit from the frame Remove the covers from the power unit 9 10 ...

Page 59: ......

Page 60: ...N MA0014GB Peugeot Motocycles is constantly improving its vehicles It therefore reserves the right to remove modify or add any reference mentioned in this manual DC PS APV 12 2009 non contractual pictures ...

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