Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for PEUGEOT Speedfight3
Summary of Contents for PEUGEOT Speedfight3
- Page 1 Direction commerciale Animation technique réseau WORKSHOP MANUAL...
- Page 2 Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
-
Page 3: Table Of Contents
TIGHTENING TORQUES ..........................13 Engine part ..............................13 Body panels .............................13 Cycle part..............................14 Standard ..............................14 SPECIAL TOOLS ............................15 LOCATION OF COMPONENTS........................16 CONTROL CABLE AND HARNESS ROUTINGS................... 17 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 4 Removal of the fork ..........................41 Replacing the steering head cups......................42 Removal of the fork tubes ........................43 The fork and its components........................43 Installing the fork............................44 Steering system tightening method......................44 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 5 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 power unit ........................53 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 6: Products Danger Symbols Used
Used batteries. collection point. People's safety can be seriously affected if Compulsory Operation that can be the recommendations are not fully gloves dangerous for people. respected. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 7 Indicate the specific procedures that shall New part Use a new part. be followed in order not to damage the vehicle. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 8: Characteristics
Minimum grade: API GL4 Fuel tank 8 l 95 or 98 lead-free 1.1 l Oil tank Semi-synthetic API TC JASO FC oil 2T 1.3 l Cooling system Fluid PEUGEOT Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 9: Chassis
13 inch aluminium alloy Front tyre 130/60 - 13 Front tyre pressure 1.8 bars Rear wheel rim 13 inch aluminium alloy Rear tyre 130/60 - 13 Rear tyre pressure 2 bars Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 10: Brakes
196 mm - 3.5 mm thickness Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking (1) number and manufacturer's plate Engine number (2) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 11: Service Schedule And Commissioning
Overall operation. Road test. V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment. a. Depending on model Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 12: Service Operations
The need to remove carbon may be determined by checking the quantity of carbon in the cylinder exhaust port. V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 13: Battery Preparation (Except Battery Without Maintenance)
Check brake adjustment and efficiency. Check the tyre pressures cold. Check operation of the lights, flashers, horn, and brake light. Check the different warning lights work. Carry out a road test. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 14: Special Important Points
The light comes on when the ignition is turned on to check it is operational and comes off as soon as the engine starts if there is no incident. When starting the engine hot or cold do not accelerate. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 15: Tightening Torques
1 to 2 Nm Floor panel 4 to 8 Nm Saddle storage compartment 4 to 8 Nm Rear panels 1 to 2 Nm Grab handle 20 to 25 Nm Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 16: Cycle Part
Nut and bolt 6 mm diameter 10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm Nut and bolt 12 mm diameter 55 Nm Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 17: Special Tools
756725 752127 wrench tool Adjustable 752237 757860 Steering tool pin wrench Steeing head Steeing head 753726 757990 cup push tool cup push tool (*) New or modified tool. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 18: Location Of Components
3. Ignition sensor 10. Fuel gauge 4. Oil level indicator 11. Horn 5. Oil pump 12. Speed sensor 6. HT coil 13. Fuses 7. Low oil level warning light Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 19: Control Cable And Harness Routings
6. Left indicator power harness C. The rear brake control (9) must run 7. Saddle opening control through the bar attached to the crankcase 8. Throttle control 9. Rear brake control cable Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 20: Body Panels
13. Bottom panel 5. Front lower legshields 14. Grab handle 6. Rear shield 15. Rear mudguard 7. Front mudguard 16. Mudguard 8. Front wheel 9. Saddle and storage compartment Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 21: Body Component Sequence Of Disassembly
6. Rear shield 15. Rear mudguard 7. Front mudguard 16. Mudguard 8. Front wheel 17. Fork 9. Saddle and storage compartment * This item may be removed on its own. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 22: Removal Of 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 23: Removal Of The Rear Cover Assembly And Mudflap
- Disconnect the taillight. - Remove the splash guard. • 4 plastic screws. - Remove the taillight. • 4 plastic screws. - Separate the 2 fairings (1). • 2 plastic screws. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 24: Removal Of Handlebar Fairing
- Remove the handlebar front cover. • 6 plastic screws. - Disconnect the instrument cluster. - Remove the handlebar rear cover and instrument cluster assembly. • 4 plastic screws. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 25: Removal Of The Front Top Shield Panel
- 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 26: Removal Of Front Lower Shield Panels
- 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 27: Removal Of The Under Body Panel
- 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 28: Service Operations
- Lubricate the air filter with a special purpose oil for air filters and squeeze out the excess oil. - Fit the air filter. - Fit the gasket (2). - Install the air filter cover. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 29: Brake Inspection
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 30: Rear Brake
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 31: Checking The Brake Fluid Level
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 32: Rear Brake Linings
- Disconnect the air hose from the exhaust (1). - Remove the 2 screws fastening the mudguard (2). - Remove the exhaust (3 screw). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 33 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 34 - Install the exhaust. Use a new exhaust gasket. • Exhaust to cylinder mounting nut: Tightening torque: 15 Nm. • Exhaust to casing mounting bolt: Tightening torque: 22 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 35: Transmission
- Remove the fixed flange nut and washer. - Remove the fixed flange. 752237 Tightening torque: 40 Nm. - Remove the belt (1). - Remove the drive pulley (2) together with the guide hud. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 36 - 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 grease). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 37: Checking The Drive Belt
SERVICE OPERATIONS Checking the drive belt Measure the width of the belt (A). Minimum width: 15.5 mm. Make sure the belt is not cracked. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 38: Checking The Clutch Linings
- 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 pulley, lubricate the needle bearing (3). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 39: Removal Of The Fuel Filter
- Disconnect the lower pump from the coolant pump to drain the cooling system (1). - Connect the lower hose to the water pump. Fit the clamp collar with the "ears" downwards. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 40 - 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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 41: Steering / Fork
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 42 - 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 43: Removal Of The Fork
• The nut. • the rubber washer. • The nut. • The dust cover. • The upper cone. - Remove the fork. - Remove the caged ball bearings. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 44: Replacing The Steering Head Cups
- 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 45: Removal Of The Fork Tubes
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 46: Installing The Fork
- Fit and finger tighten the nut (7) so that its notches are aligned with those of the nut. - Fit the lock washer (8) in the notches of the 2 nuts. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 47 STEERING / FORK - Install the steering locknut -9) and tighten it. Tightening torque: 70 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 48: Electric Components
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 49: Changing The Oil Pump
N° 28). Removal of the high tension coil - Remove the storage compartment. See: Procedure 1. page 20. - Disconnect and remove the high voltage coil (1) (1 screw). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 50: Fuel System
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 51: Removal Of The Float, Needle Valve And Jets
(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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 52 - 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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
-
Page 53: Removal Of The Engine Speed Adjuster Screw And Mixture Control Screw
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 54: The Carburettor And Its Components
9. Float chamber gasket. 10. Float pin screw. 11. Float. 12. Float pin. 13. Needle valve. 14. Idle jet. 15. Main jet. 16. Venturi. 17. Idle screw. 18. Mixture screw. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 55: Power Unit
• The fuel inlet pipe (7). • The oil supply hose (8). • The vacuum pressure hose (9). • Disconnect the cylinder head hose (10). • The pulsair reed valve hose (11). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 56 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 57 POWER UNIT - Lift the rear of the machine. - Remove the power propulsion unit from the frame. - Remove the covers from the power unit. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 60 P/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)