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CONTROL CABLE AND HARNESS ROUTINGS

17

Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles

CONTROL CABLE AND HARNESS ROUTINGS

1. Radiator hoses
2. Main harness
3. Left switch supply harness
4. Ignition switch
5. Right indicator power harness
6. Left indicator power harness
7. Saddle opening control
8. Throttle control
9. Rear brake control cable

A. The saddle opening control (7) must run

between the "ears" of the radiator hose
clamp

B. The rear brake control cable (9) must run

through the bar attached to the underbody
panel

C. The rear brake control (9) must run

through the bar attached to the crankcase

6

4

2

2

2

1

7

9

1

8

5

3

7

8

7

9

2

1

1

7

A

B

9

C

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Содержание Speedfight3 LC

Страница 1: ...Direction commerciale Animation technique réseau WORKSHOP MANUAL ...

Страница 2: ...Workshop manual Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Страница 3: ...CHEDULE AND COMMISSIONING 9 To be checked at each service 9 Service operations 10 Time required for maintenance 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 Starting up after overhauling the engine 12 TIGHTENING TORQUES 13 Engine part 13 Body panels 13 Cycle part 14 Sta...

Страница 4: ...otboard 24 Removal of the under body panel 25 SERVICE OPERATIONS 26 Removal of the spark plug 26 Replacing the air filter 26 Brake inspection 27 Replacing the brake pads 27 Front brake 27 Rear brake 28 Checking the brake fluid level 29 Rear brake linings 30 Transmission 33 Checking the drive belt 35 Checking the clutch linings 36 Replacing the clutch lining assembly 36 Removal of the fuel filter 3...

Страница 5: ...6 Removal of the fuel gauge 46 Changing the oil pump 47 Removal of the high tension coil 47 FUEL SYSTEM 48 Removal of the fuel pump 48 Removal of the carburettor 48 Removal of the throttle valve 48 Removal of the float needle valve and jets 49 Removal of the engine speed adjuster screw and mixture control screw 51 Reassembly 51 The carburettor and its components 52 POWER UNIT 53 Removal of the pow...

Страница 6: ... 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 recycling ...

Страница 7: ...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 parts...

Страница 8: ...ax torque rating 4 Nm at 5800 rpm 4 Nm at 6000 rpm Compression 6 bars 700 rpm Fuel supply Carburettor TK PZØ12 Carburettor TK PZ Ø15 Lubrication Separate lubrication by means of a DELL ORTO or MIKUNI electric pump driven by the Oil Pump Control Ignition Unit ACPH Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust With catalytic system and pulsair valve Starter ...

Страница 9: ...nt fork Ø32 mm Travel 80 mm Rear suspension Combined spring and hydraulically damped shock absorber Travel 68 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 97 kg 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 R...

Страница 10: ... hydraulic control Disc diameter and thickness 215 mm 3 5 mm Rear brake cable controlled single cam drum type Single disc type hydraulic control Disc diameter and thickness 196 mm 3 5 mm 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 B 1 E 4 0 0 M B X X X X X X X X 2 ...

Страница 11: ...rvice Steering column play V V V Wheel bearing play C C C Throttle cable play V V V Operation of electrical equipment V V V Condition of front and rear brake hydraulic controls a C C C Brake fluid level V V V Brake pad wear C C C Rear brake lining wear a C C C Condition of petrol pipes C C C Condition of oil pipes C C C Tyre condition pressure and wear C C C Condition of the front suspension Condi...

Страница 12: ...R Air filter R R Drive pulley bearings and guides R R Transmission belt R R Driven pulley caged needle bearing G G Kick starter mechanism G G Check and remove carbon Piston Cylinder head Exhaust port b N N Setting the carburettor V V Joints Central stand Brake levers G G Petrol filter R Petrol pipe R Once every 5 years Coolant R Once every 5 years Brake fluid R Once every 2 years Time required for...

Страница 13: ...nt 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 gua...

Страница 14: ...ce 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 acco...

Страница 15: ...ion cover 10 Nm Cylinder head 12 Nm Thermostat valve 10 Nm Engine temperature sensor 20 Nm Starter motor 10 Nm Clutch plate and shoes 40 Nm Water pump 10 Nm Drive pulley 40 Nm Driven pulley 45 Nm Inlet manifold 10 Nm Rotor 40 Nm Stator 10 Nm Front mudguard 8 to 10 Nm Handlebar cover 1 to 2 Nm Front shield panels 1 to 2 Nm Rear shield 4 to 8 Nm Bottom panel 1 to 2 Nm Floor panel 4 to 8 Nm Saddle st...

Страница 16: ...Shock absorber top mount 45 Nm Shock absorber bottom mount 22 Nm Exhaust to cylinder mounting nut 15 Nm Exhaust to casing mounting bolt 22 Nm Exhaust bracket 10 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 Rear brake caliper 30 Nm Rear brake disc 30 Nm Handle bar 40 Nm Nut and bolt 5 mm diameter 5 N...

Страница 17: ...PECIAL TOOLS New or modified tool Tool N Designation Used with Tool N Designation Used with 750539 Tie wrap pliers 755996 Hose clamp 752127 Clutch compression tool 756725 756725 38 mm pipe wrench 752127 752237 Adjustable pin wrench 757860 Steering tool 753726 Steeinghead cup push tool 757990 Steeinghead cup push tool ...

Страница 18: ...otocycles LOCATION OF COMPONENTS 1 Oil pump control and ignition 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 Speed sensor 13 Fuses 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 ...

Страница 19: ...on switch 5 Right indicator power harness 6 Left indicator power harness 7 Saddle opening control 8 Throttle control 9 Rear brake control cable A The saddle opening control 7 must run between the ears of the radiator hose clamp B The rear brake control cable 9 must run through the bar attached to the underbody panel C The rear brake control 9 must run through the bar attached to the crankcase 6 4 ...

Страница 20: ...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 ...

Страница 21: ...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 ...

Страница 22: ...dure 1 Lift the saddle Remove the battery cover 1 2 plastic screws Disconnect and remove the battery Remove the filler cap from the oil tank 2 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 2 3 A ...

Страница 23: ...he storage compartment See Procedure 1 page 20 Remove the lower fairing by sliding it towards the rear of the vehicle 1 Ø6 mm screw Remove the rear cover assembly 10 screw 6 plastic screws A 2 Ø5 mm screw B 2 Ø6 mm screw 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 ...

Страница 24: ...terdite sans autorisation écrite de 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 ...

Страница 25: ...he front top cover panel 3 plastic screws Remove the front upper shield panel 4 plastic screws Disconnect the lighting system connection Removal of the rear shield panel Procedure 5 Remove the handlebar fairings See Procedure 3 page 22 Remove the front upper shield panel See Procedure 4 page 23 Remove the rear shield panel 4 washer head screws Ø6 mm A 1 screwØ6 mm B B A A ...

Страница 26: ... page 23 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 Removal of the footboard Procedure 7 Remove the rear cover assembly See Procedure 2 page 21 Remove the front lower shield panels See Procedure 6 page 24 Remove the RH and LH footrest 1 2 screws e...

Страница 27: ... écrite de Peugeot Motocycles Removal of the under body panel Remove the footboard See Procedure 7 page 24 Remove the bottom panel 4 plastic screws When reassembling ensure that the radiator hoses run correctly inside the underbody A Place the rear brake control cable in the pin B B A ...

Страница 28: ... installing srew in the spark plug a few turns by hand Tighten the spark plug Tightening torque 20 Nm Air cooling Spark plug NGK BR5HS Tightening torque 12 Nm Fluid cooling system Spark plug NGK CR7EKA 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 ...

Страница 29: ...mensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Replacing the brake pads Front brake Remove the calliper 2 screw Tightening torque 45 Nm Remove the 2 spindles 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 ...

Страница 30: ...s fastening the rear wheel Loosen the brake pad pin first Remove the calliper 2 screw Tightening torque 30 Nm Remove the brake pad stop pin 2 Remove the brake pads 3 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 1 2 3 ...

Страница 31: ...ake 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 ...

Страница 32: ... the wear mark on the 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 Disassembly Remove the 2 nuts attaching the exhaust flange to the cylinder Disconnect the air hose from the exhaust 1 Remove the 2 screws fastening the mudguard 2 Remove the exhaust 3 screw B A 1 2 2 ...

Страница 33: ... washer 3 Remove the rear wheel 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 Reassembly Lubricate the brake cam spindle and fit it into the casing Fit the brake arm onto the cam and align the punched marks A Tightening torque 8 Nm 3 5 7 8 6 4 9 8 A 5 ...

Страница 34: ...cable the barrel and the adjusting nut 5 Install the wheel Tightening torque 110 Nm When re installing use a new nut 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 nut Tightening torque 15 Nm Exhaust to casing mounting bolt T...

Страница 35: ...smission 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 Tightening torque 40 Nm Remove the belt 1 Remove the drive pulley 2 together with the guide hud A 752237 2 1 ...

Страница 36: ...y assembly Tightening torque 45 Nm Checking the drive pulley Remove the bump stop 2 3 screw 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 tempe...

Страница 37: ...NS 35 Reproduction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles Checking the drive belt Measure the width of the belt A Minimum width 15 5 mm Make sure the belt is not cracked A ...

Страница 38: ...face 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 756725 Slacken tool P N 752127 Tightening torque 40 Nm Remove the clutch lining assembly 2 When re installing the driven p...

Страница 39: ...filter 2 When re installing respect the direction of installation of the filter shown by the arrow which indicates in which direction the fuel flows Draining the cooling circuit The cooling system is drained when the engine is cold Remove the storage compartment See Procedure 1 page 20 Remove the front top cover panel Remove the header tank cap Disconnect the lower pump from the coolant pump to dr...

Страница 40: ...rew 2 to remove air contained in the engine Close the bleeder screw Start the engine and accelerate in order to warm it up Stop the engine once it reaches its operating temperature Approximately 90 C Check the coolant level in the header tank If necessary add coolant in the header tank A Maximum level Check the level with the machine parked on its centre stand on level ground 2 A ...

Страница 41: ...move the front brake caliper from the fork tube 2 screw Loosen the wheel spindle clamping screw 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 Nm ...

Страница 42: ...eel 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 Line up the right fork stanchion with the end of the wheel spindle Tighten the spindle clamping screw Tightening torque 10 Nm Refit the other items in the reverse order to disassembly A N 1 ...

Страница 43: ...r 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 The nut...

Страница 44: ... 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 ...

Страница 45: ...g a circlip plier 3 Remove the fork tubes Remove the springs Remove the rubber stop When refitting lightly grease the balk rings 5 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...

Страница 46: ...teering 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 t...

Страница 47: ...STEERING FORK 45 Reproduction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles Install the steering locknut 9 and tighten it Tightening torque 70 Nm 9 ...

Страница 48: ...or Starter motor relay Remove the lower fairing by sliding it towards the rear of the vehicle 1 screw Remove Regulator 1 The starter motor relay 2 Oil pump control and ignition unit 3 Removal of the fuel gauge Remove the footboard See Procedure 7 page 24 Disconnect the fuel gauge 1 Remove the fuel gauge 4 screw Remove the rubber gasket When re installing use a new gasket 1 1 2 3 1 N ...

Страница 49: ... of the vehicle 1 screw Clamp the end of the oil tank outlet pipe using a clamp ref 755996 Disconnect the oil filter pipe 1 Disconnect the oil inlet hose from the carburettor 2 Remove the oil pump 1 screw 3 After refitting the oil pump purge the oil circuit as recommended See manual and method N 28 Removal of the high tension coil Remove the storage compartment See Procedure 1 page 20 Disconnect a...

Страница 50: ...ump 1 screw Removal of the carburettor Remove the rear storage compartment See Procedure 1 page 20 Disconnect The throttle control 1 The fuel 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 Removal of the throttle valve Take out the throttle control cable 5 by co...

Страница 51: ... Motocycles Dismantle the needle 7 by pushing it out in order to remove the clips 8 Remove the fuel filter 9 Remove the carburator warming resistor 6 Depending on model Locate the position of the choke 10 and then remove it Removal of the float needle valve and jets Remove the chamber 4 screw 7 8 A 9 10 ...

Страница 52: ...eugeot Motocycles Remove the paper gasket 11 Loosen the float pin clamping screw 12 Remove the float 13 with its pin and needle valve Remove the idle jet 14 Remove the main jet 15 Remove the jet spray nozzle 16 Check the condition of the needle valve and the needle valve seat A 12 13 11 14 15 16 A ...

Страница 53: ...turn the screws home forcefully Remove the idle screw and the mixture control screw with their spring Clean the carburettor body and its components with a cleanser P N 755700 Or use an ultrasonic cleaning tank Blow into 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 Reassembly Fit the jet spray nozzle 16 Fit the ma...

Страница 54: ...omponents and if necessary when starting the engine readjust according to the values indicated on the technical data card Idle speed Air cooling 1800 rpm Fluid cooling system 1800 rpm Mixture screw 1 tr 3 4 The carburettor and its components 2 Piston 3 Needle 4 Clips 5 Petrol filter 6 Heater element 7 Starter clamping plate 8 Choke 9 Float chamber gasket 10 Float pin screw 11 Float 12 Float pin 13...

Страница 55: ...50cc engine Cast iron cylinder Fluid cooling system Remove the storage compartment See Procedure 1 page 20 Remove the lower fairing by sliding it towards the rear of the vehicle 1 screw Drain the cooling circuit See chapter page 37 Disconnect The magneto 1 The starter motor 2 The suppressor 3 The choke 4 The temperature sensor 5 Disconnect The throttle control 6 The fuel inlet pipe 7 The oil suppl...

Страница 56: ...move the rear brake caliper 12 Temporarily reinstall the wheel Suspend the rear of the machine Remove the RH and LH footrest Remove the shock absorber upper mount 13 Tightening torque 45 Nm When re installing use a new nut Remove the linkrod to engine connecting pin 14 Tightening torque 60 Nm When re installing use a new nut 12 13 N 14 N ...

Страница 57: ... Reproduction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles Lift the rear of the machine Remove the power propulsion unit from the frame Remove the covers from the power unit ...

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Страница 60: ...N MA0008FR 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 02 2009 non contractual pictures ...

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