PEUGEOT SpeedFight 3 Workshop Manual
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PEUGEOT SpeedFight 3 Workshop Manual

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Sales division
Technical network leadership
WORKSHOP MANUAL
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Summary of Contents for PEUGEOT SpeedFight 3

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

  • Page 3: Table Of Contents

    Removal of the rear cover assembly and mudflap ...................20 Removal of handlebar fairing ........................21 Removal of the front top shield panel.......................22 Removal of the rear shield panel ......................22 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 4 ELECTRICITY..............................47 Ignition principle schematic/Carburetor heater ..................47 Temperature control unit/Regulator/Starter motor relay/Ignition unit ............48 Checking the carburettor heating circuit....................48 Checking the ignition system ........................49 Fuel gauge ...............................49 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 5 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 Reproduction or translation, even partial, is forbidden without the written consent of 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 or translation, even partial, is forbidden without the written consent of 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 8: Characteristics

    0.7 L SAE 5W40 Crankcase Minimum grade : API SL/SJ 0.1 L SAE 80W90 Relay box Minimum grade : API GL4 Fuel tank 8 l 95 or 98 lead-free Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Chassis

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

  • Page 10: Brakes

    Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking (1) number and manufacturer's plate Engine number (2) Reproduction or translation, even partial, is forbidden without the written consent of 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 12: Service Operations

    (0.5 h = 30 min) V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 13: Battery Preparation (Except Battery Without Maintenance)

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

  • Page 14: Special Important Points

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

  • Page 16: Cycle Part

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

  • Page 17: Special Tools

    Spark plug 753726 766062 cup push tool spanner 755996 Hose clamp STANDARD TOOLS Wrenches with interchangeable end fittings for valve clearance adjustment Type : Marolotest P/N 500140 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Location Of Components

    3. Ignition sensor 10. Horn 4. HT coil 11. Speed sensor 5. Regulator 12. Fuses 6. Starter motor relay 13. Resistor warming carburator 7. Starter resistor Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Body Panels

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

  • Page 20: Body Component Sequence Of Disassembly

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

  • Page 21: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Removal Of The Rear Cover Assembly And Mudflap

    - Remove the splash guard. • 4 plastic screws. - Remove the taillight. • 4 plastic screws. - Separate the 2 fairings (1). • 2 plastic screws. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 23: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Removal Of The Front Top Shield Panel

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

  • Page 25: Removal Of Front Lower Shield Panels

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

  • Page 26: Removal Of 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 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Service Operations

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.7 l. - Start the engine and let it run for a short while. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Draining The Relay Box

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.1 l. - Fit the filler cap. Tightening torque: 10 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 29: Removal Of The Spark Plug

    - Fit a new air filter. - Fit the gasket (2). - Install the air filter cover. Check the condition of the seals and make sure they are properly positioned. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Transmission

    - Hold the fixed flange with tool P/N 752237. - Remove the fixed flange nut and washer. - Remove the fixed flange. 752237 Tightening torque: 55 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 31 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Checking The Drive Belt

    Checking the drive belt - Measure the width of the belt (A). Minimum width: 17.2 mm. - Make sure the belt is not cracked. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Checking The Clutch Linings

    - Slacken tool P/N 752127. Tightening torque: 55 Nm. - Remove the clutch lining assembly (2). - When re-installing the driven pulley, lubricate the needle bearing (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 34: Installing The Valve Clearance

    • At the intake a 0.10 mm feeler gauge shouldn't go. • At the exhaust a 0.15 mm feeler gauge shouldn't go. - On the contrary, if the fealer gauge goes, reset the clearances. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 35: Idle Setting

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

  • Page 36: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 37: Checking The Brake Fluid Level

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

  • Page 38: Rear Brake Linings

    - Remove the 2 nuts attaching the exhaust flange to the cylinder. - Disconnect the air hose from the exhaust (1). - Remove the exhaust (2 screw). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 39: 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 40: Removal Of The Fuel Filter

    - Remove the fuel 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 41: Steering/Fork

    - Carefully remove the lip seals using a screwdriver (4). - Install new lightly lubricated lip seals. - Fit the fork staunchions. Tightening torque: 25 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 42 Tightening torque: 65 Nm. - Tighten the spindle clamping screw (1). Tightening torque: 10 Nm. - Refit the other items in the reverse order to disassembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 43: Removal Of The Fork Tubes

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

  • Page 44: The Fork And Its Components

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

  • Page 45: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 46: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 47: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 48 STEERING/FORK - Install the steering head locknut and tighten it (9). Tightening torque: 70 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 49: Electricity

    8. Temperature control unit. 3. CDI unit. 9. Automatic starter. 4. Spark plug socket. 10. Magneto flywheel. 5. Spark plug. 11. Revolution counter. 6. HT coil. 12. Regulator. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 50: Temperature Control Unit/Regulator/Starter Motor Relay/Ignition Unit

    - If the values are correct, replace the temperature control unit. - If the values are incorrect, check: • The harness. • The ignition switch. ±20% • The carburettor heating resistor: 8.5 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 51: Checking The Ignition System

    - Check the resistance between the terminals depending on the upper and lower positions of the float. ±20% A. Full fuel tank: 10 ±20% B. Empty fuel tank: 95 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 52: Fuel System

    - Remove the carburettor (2 Collars). Removal of the throttle valve - Remove the chamber cap (2 screw). - Remove the spring. - Remove the needle, valve and membrane assembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 53: Removal Of The Float, Needle Valve And Jets

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

  • Page 54: Removal Of The Mixture Screw

    When re-fitting, this operation allows you to put it back to its initial adjustment position. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 55: Removal Of The Pick-Up Pump

    - Remove the spring. - Remove the membrane. - Remove the O ring. Check that the membrane is in good condition. Check the condition of the O-ring. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 56: Removal Of The Carburetor Heater

    5. Jets. 6. Needle valve. 7. Mixture screw. 8. Pick-up pump. 9. Idle screw. 10. Pick-up pump suction valve. 11. Deceleration enrichment device. 12. Carburetor heater. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 57: Power Unit

    • The vacuum pressure hose (6) (Pulsair). • The vacuum pressure hose (7) (Fuel pump). • The pulsair reed valve hose (8). • The rear brake control cable. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 58 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 60 P/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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