PEUGEOT Vivacity Workshop Manual Download

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Sales division
Technical network leadership

WORKSHOP MANUAL

Workshop manual

Technical network leadership

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

Summary of Contents for Vivacity

Page 1: ...es division Technical network leadership WORKSHOP MANUAL Workshop manual Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

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Page 3: ...sions and weight 6 Tyres 6 Brakes 6 SERVICE SCHEDULE AND COMMISSIONING 7 To be checked at each service 7 Service operations 7 Battery preparation Except battery without maintenance 8 Installing the battery vent hose 8 New machine preparation 8 SPECIAL IMPORTANT POINTS 9 Oil and fuel 9 Starting up after overhauling the engine 9 TIGHTENING TORQUES 10 Engine part 10 Body panels 10 Cycle part 11 Stand...

Page 4: ...oval of the spark plug 23 Replacing the air filter 23 Front brake pads 24 Replacing the brake pads 24 Checking the brake fluid level 25 Rear brake linings 26 Transmission 29 Checking the drive belt 31 Checking the clutch linings 31 Replacing the clutch lining assembly 32 Removal of the fuel filter 33 MISCELLANEOUS OPERATIONS 34 Removal of the fork 34 Replacing the bearings of the steering system 3...

Page 5: ...ty glasses and 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 garbage cans sinks or nature The ideal solution is to bring this product to your nearest household waste recy...

Page 6: ...ge 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 pa...

Page 7: ... 700 rpm Fuel supply Carburettor PZØ12 Lubrication Separate lubrication by an electric pump driven by the Oil Pump Control Ignition Unit Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust Catalytic Starter motor By kick starter or electric starter Spark plug NGK BPR7HS Electrode gap 0 6 mm Magneto flywheel 90 W Relay box oil 0 12 l SAE 80W90 Minimum grade API G...

Page 8: ... wheel rim 12 inch aluminium alloy Front tyre 120 70 12 Front tyre pressure 1 8 bars Rear wheel rim 12 inch aluminium alloy Rear tyre 120 70 12 Rear tyre pressure 2 bars Front brake Single disc type hydraulic control Disc diameter and thickness 200 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 num...

Page 9: ... brake hydraulic controls V V V V Brake fluid level V V V V Front brake pad wear V V V V Rear brake lining wear V V V V Condition of petrol pipes V V V V Condition of oil pipes V V V V Tyre condition pressure and wear V V V V Condition of the front suspension Condition of the rear suspension C C C C Battery electrolyte level Battery charge C C C C Tightness of nuts and bolts V V V V Headlight heig...

Page 10: ...pour 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 vent hose After being disconnected from the battery the vent hose must be routed through the 2 holders located in the rear splash guard...

Page 11: ...lace 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 sparks 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 ac...

Page 12: ...on cover 10 Nm Relay box cover 10 Nm Stator 10 Nm Engine speed sensor 5 Nm Rotor 40 Nm Turbine 7 Nm Starter motor 10 Nm Spark plug 20 Nm Cylinder head 12 Nm Inlet manifold 10 Nm Crankcase 10 Nm Front mudguard 8 to 10 Nm Handlebar cover 2 to 4 Nm Front shield panel 2 to 4 Nm Rear shield 2 to 4 Nm Bottom panel 2 to 4 Nm Floor panel 6 to 8 Nm Saddle storage compartment 8 to 10 Nm Rear panels 6 to 8 N...

Page 13: ...ock absorber top mount 45 Nm Shock absorber bottom mount 22 Nm Exhaust to cylinder mounting nut 15 Nm Exhaust to casing mounting bolt 20 Nm Upper cone in 2 operations 40 23 Nm Upper cone locknut Hand tightened Steering locknut 70 Nm Front brake caliper 25 Nm Front brake disc 22 Nm Handle bar 25 Nm Nut and bolt 5 mm diameter 5 Nm Nut and bolt 6 mm diameter 10 Nm Nut and bolt 8 mm diameter 22 Nm Nut...

Page 14: ...06 750069 750539 Tie wrap pliers 64710 Shouldered centering tool 64706 750808 Thrust washer 64706 64765 Engine mount 755982 752000 Piston circlip pliers 68007 Protective end piece small model 755985 752127 Clutch compression tool 756725 69098 Protective end piece large model 64706 752237 Adjustable pin wrench 69104 Pin nut 750069 753726 Steeinghead cup push tool 750069 Pin Ø10 pitch 125 69104 7540...

Page 15: ...fied tool Tool N Designation Used with Tool N Designation Used with 755585 Bearing extractor tool 756668 Crank assembly lip seal tool 755982 Engine mount adapter 64765 756725 38 mm pipe wrench 752127 755983 Casing opening tool 68007 757860 Steering tool 755985 Flywheel puller 68007 757990 Steeinghead cup push tool 755996 Hose clamp ...

Page 16: ...cles LOCATION OF COMPONENTS 1 Oil pump control unit 2 Battery 3 Ignition sensor 4 Oil level indicator 5 Oil pump 6 HT coil 7 Low oil level warning light 8 Regulator 9 Starter motor relay 10 Fuel gauge 11 Horn 12 Outside temperature sensor 13 Speed sensor 5 11 1 2 9 8 6 7 3 4 14 10 12 13 UP PE R LE VE L LO W ER LE VE L N C NC ...

Page 17: ...body components Description 1 Handlebar front fairing 2 Handlebar rear fairing 3 Tool compartiment cover 4 Front storage compartment 5 Rear shield 6 Front mudguard 7 Front wheel 8 Front shield panel 9 Saddle and storage compartment 10 Central panel 11 Footboard 12 Grab handle 13 Rear panels 14 Bottom panel N C 12 1 2 14 7 13 3 4 8 9 6 5 11 10 ...

Page 18: ...embly 1 Handlebar front fairing 2 Handlebar rear fairing 3 Tool compartiment cover 4 Front storage compartment 5 Rear shield 6 Front mudguard 7 Front wheel 8 Front shield panel 9 Saddle and storage compartment 10 Central panel 11 Footboard 12 Grab handle 13 Rear panels 14 Bottom panel This item may be removed on its own 5 10 14 13 12 9 8 7 2 1 6 11 3 4 ...

Page 19: ...val of the rear storage compartment Procedure 1 Lift the saddle Remove the storage compartment 8 screw Disconnect the accessory plug Removal of the rear cover assembly and mudflap Procedure 2 Remove the rear storage compartment See Procedure 1 page 17 Remove the grab handle 3 screw 1 Remove the central cover panel 5 screw 1 ...

Page 20: ...on or translation even partial is forbidden without the written consent of Peugeot Motocycles Remove the rear cover assembly 5 screw 3 Disconnect the taillights Remove the splash guard 6 screw Separate the 3 fairings 4 3 3 4 4 ...

Page 21: ...consent of Peugeot Motocycles Removal of the front storage compartment Procedure 3 Remove the storage compartment lid 5 screw Remove the storage compartment 11 screw Disconnect the horn Removal of the rear shield panel Procedure 4 Remove the 4 upper screws that secure the rear shield panel ...

Page 22: ...ld panel Remove the rear shield panel Removal of the front shield panel Remove the front storage compartment See Procedure 3 page 19 Remove the rear shield panel See Procedure 4 page 19 Remove the wheel spindle nut When re installing use a new nut Remove the front wheel Remove the front mudguard 1 4 screw Remove the 5 screws that secure the front shield panel 1 N ...

Page 23: ...emove the 6 screws that secure the front shield panel Unclip the mud splash guard from the front leg shield panel Remove the front shield panel Removal of the footboard Procedure 5 Remove the rear storage compartment See Procedure 1 page 17 Remove the central cover panel 5 screw Remove the rear shield panel See Procedure 4 page 19 Remove the bottom panel 14 screw Remove the footboard 4 screw ...

Page 24: ... without the written consent of Peugeot Motocycles Removal of the instrument cluster Remove the handlebar front cover 6 screw Disconnect the instrument cluster Remove the handlebar rear cover and instrument cluster assembly 4 screw Remove the instrument cluster 4 screw ...

Page 25: ...r 1 Remove the spark plug Essential precautions When re installing srew in the spark plug a few turns by hand Tighten the spark plug Tightening torque 20 Nm Replacing the air filter Remove the air filter cover 5 bolts and its seal Remove the air filter 1 Clean inside the air filter box Lubricate the air filter with a special purpose oil for air filters and squeeze out the excess oil Fit the air fi...

Page 26: ...1 5 mm Replacing the brake pads Remove the calliper 2 screw Tightening torque 25 Nm Straighten the retainer in order to release the 2 pins 1 Remove the 2 spindles 2 Remove the brake pads 3 and the anti vibration plates 4 When refitting the brake pads push the pistons all the way into their housing When re installing use a new pin retainer After refitting actuate the brake levers several times to b...

Page 27: ...ition 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 Maximum brake fluid level B Minimum brake fluid level Remove the handlebar front cover 6 screw Remove the cover and the diaphragm from the master cylinder 2 screw Add brake fluid until it reaches the maximum level A B ...

Page 28: ...r and check the position of the wear mark on the cam tierod A in relation to the mark B on the engine housing If the cam tierod mark is lined up or passes the wear mark on the engine housing the brake lining must be replaced Disassembly Disconnect the air hose from the exhaust 1 Remove the exhaust holder plate 2 2 screw Remove the exhaust 2 screws and 2 nuts B A 1 2 ...

Page 29: ...ten consent of Peugeot Motocycles Remove the wheel spindle nut and washer 3 Remove the rear wheel When re installing use a new nut Remove the brake linings 4 Remove the adjusting nut the barrel 5 and the brake control cable 6 Remove the brake arm 7 the brake cam 8 and the spring 3 N 5 7 8 6 4 ...

Page 30: ...e brake cam and pin Install the grake linings Install the spring 9 Install the brake control cable the barrel and the adjusting nut 5 Install the wheel Tightening torque 100 Nm Measure the free travel of the rear brake control lever Ajust the lever free travel using the adjusting nut B Brake control free travel 10 to 20 mm Install the exhaust Use a new exhaust gasket Exhaust to cylinder mounting n...

Page 31: ... Motocycles Transmission Lift the air filter box to reach the transmission cover 2 screw A Remove the transmission cover 5 screw Hold the fixed flange with tool P N 752237 Remove the fixed flange nut and washer Remove the fixed flange Remove the belt Remove the drive pulley 1 together with the guide hud A 752237 1 ...

Page 32: ...nd drive pulley assembly Checking the drive pulley Remove the bump stop 2 3 vis 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 When refitting respect the way the rollers are installed Grease the moving flange bore lightly high temperature greas...

Page 33: ...g the drive belt Measure the width of the belt A Minimum width 15 5 mm Make sure the belt is not cracked Checking the clutch linings Using the depth calliper measure the thickness of the clutch linings Mini thickness 1 mm Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear A A B ...

Page 34: ...eplacing 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 756725 Slacken tool P N 752127 Remove the clutch lining assembly 2 When re installing the driven pulley lubricate the needle bearing 3 752127 1 3 2 ...

Page 35: ...compartment See Procedure 1 page 17 Remove the central cover panel 5 screw Remove the RH under body panel 9 screw Put a hose clamp P N 755996 on the fuel inlet hose 1 Disconnect the fuel supply hose 2 Remove the fuel filter 3 When re installing respect the direction of installation of the filter shown by the arrow which indicates in which direction the fuel flows 755996 1 2 3 ...

Page 36: ...new nut Tightening torque 10 Nm Suspend or immobilize the machine securely Remove the front mudguard Remove the front brake caliper from the fork tube Tightening torque 10 Nm Remove the front wheel When re installing use a new nut Tightening torque 10 Nm 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 steeri...

Page 37: ... forbidden without the written consent of Peugeot Motocycles Using a drift remove the steering head cups Using a chisel pry the steering head cup off by pressing the tool behind the dust cover Reassembly Install the following new parts The dust cover 1 The fork cone 2 2 1 ...

Page 38: ...753726 fit a new upper cup into the steering tube Using push tool P N 757990 fit a lower cup into the steering tube Grease the cup bearing races Install new caged ball bearings 3 Fit the fork into the steering column Install the upper cone 4 Install the dust cover 5 Fit and tighten the nut 6 Tightening torque 40 Nm Loosen and re tighten the nut Tightening torque 23 Nm 753726 3 3 4 5 6 ...

Page 39: ... the written consent of Peugeot Motocycles Install the rubber washer 4 Fit and finger tighten the nut 5 so that its notches are aligned with those of the nut Fit the lock washer 6 in the notches of the 2 nuts Install the steering head locknut and tighten it 7 Tightening torque 70 Nm 4 5 6 7 ...

Page 40: ...p P N 755996 on the fuel inlet hose 1 Disconnect the 2 fuel pipes Disconnect the vacuum hose 2 Remove the fuel pump Removal of the fuel gauge Remove the rear storage compartment See Procedure 1 page 17 Remove the central cover panel 5 screw Remove the tank filler ring 1 Disconnect the fuel gauge 2 Remove the fuel gauge 4 screw Remove the rubber gasket When re installing use a new gasket Removal of...

Page 41: ...uction or translation even partial is forbidden without the written consent of Peugeot Motocycles Put a hose clamp P N 755996 on the fuel inlet hose 1 Disconnect the fuel supply hose Disconnect the fuel gauge Remove the fuel tank 755996 ...

Page 42: ...l supply hose 2 The oil supply hose 3 Disconnect the electric choke 4 Remove the intake silencer 1 collar and 2 screws Remove the carburettor 1 clip to be changed each time it is removed Remove the valve Take out the throttle control cable 5 by compressing the spring using the throttle valve 6 Dismantle the valve equipped with its needle spring and carburettor chamber cap Dismantle the needle 7 by...

Page 43: ...ent of Peugeot Motocycles Remove the fuel filter 9 Locate the position of the choke 10 and then remove it Removal of the float needle valve and jets Remove the chamber 4 screw Remove the paper gasket 11 Loosen the float pin clamping screw 12 Remove the float 13 with its pin and needle valve A 9 10 12 13 11 ...

Page 44: ...he needle valve seat A Removal of the engine speed adjuster screw and mixture control screw Turn clockwise the engine speed adjuster screw 17 and mixture control screw 18 while counting the number of turns until they are screwed home When re fitting this operation allows you to put them back to their initial adjutment position Do not turn the screws home forcefully Remove the idle screw and the mi...

Page 45: ... tool which can damage the ducts of these items Reassembly Fit the jet spray nozzle 16 Fit the main jet 15 Fit the idle adjuster screw 14 Place the needle valve in the grooves of the float 2 Fit the pin into the float Install the float on the carburettor body while fitting the needle valve into its recess Position the pin in its recess Fit and tighten the screw C that secures the float pin Install...

Page 46: ...er components and if necessary when starting the engine readjust according to the values indicated on the technical data card 6 Piston 7 Needle 8 Clips 9 Petrol filter 10 Choke 11 Float chamber gasket 12 Float pin screw 13 Float and needle 14 Idle jet 15 Main jet 16 Venturi 17 Idle screw 18 Mixture screw 1 2 9 7 4 6 8 5 3 10 6 7 17 18 14 15 13 16 8 11 12 ...

Page 47: ...of the cylinder head cylinder and piston see the workshop manual 50cc engine Horizontal cylinder 757806 Disconnect the battery Remove the rear cover assembly See Procedure 2 page 17 Disconnect The magneto 1 The starter motor 2 The suppressor 3 The choke 4 Disconnect The throttle control 5 The fuel supply hose 6 The oil supply hose 7 The vacuum pressure hose 8 The pulsair reed valve hose 9 The rear...

Page 48: ...the written consent of Peugeot Motocycles Suspend the rear of the machine Remove the shock absorber upper mount 10 Tightening torque 45 Nm Remove the linkrod to frame pin nut 11 Tightening torque 60 Nm When re installing use a new nut Remove the linkrod to frame connecting pin 12 10 11 N 12 ...

Page 49: ...LLANEOUS OPERATIONS 47 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Lift the rear of the machine Remove the power propulsion unit from the frame 15 ...

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Page 52: ... MA0003GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC PS APV Printed in the E U 06 2008 non contractual pictures ...

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