Table of Contents
Advertisement
Advertisement
Table of Contents
Related Manuals for Peugeot Motorcycles JetForce 50 cc 2002
Summary of Contents for Peugeot Motorcycles JetForce 50 cc 2002
- Page 1 SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL...
-
Page 2: Table Of Contents
CONTENTS CONTENTS CONTENTS............................2 CHARACTERISTICS......................... 5 Engine................................5 Capacities ............................... 5 Chassis markings............................5 Engine markings............................. 5 Frame................................6 Dimensions and weight ..........................6 Tyres................................6 SERVICE SCHEDULE AND COMMISSIONING ................. 7 Check................................7 Change................................7 Check and lubricate ............................7 Reading the ECU fault codes ......................... - Page 3 CONTENTS Removal of the storage compartment (50 and 125 cc) Procedure 2............23 Removal of the shield)(50 and 125 cc) Procedure 3................... 23 Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4 ........25 Removal of the rear light / storage compartment trim (50 and 125 cc) ............25 FRAME ...............................
- Page 4 CONTENTS Removal of the engine temperature sensor ....................48 Removal of the fuel injector......................... 49 Removal of the oil pressure switch ......................49 Removal of the throttle unit.......................... 49 Removal of the fuel pump / of the fuel gauge....................51 Removal of the starter motor........................
-
Page 5: Characteristics
CHARACTERISTICS CHARACTERISTICS Engine 50 cc 125 cc Single cylinder 2-stroke direct Single cylinder 4-stroke indirect Type injection injection Cooling Liquid Bore x stroke 39.9 x 39.8 mm 57 x 48.9 mm Cubic capacity 49.9 cc 124.8 cc Max. power 3.6 kW at 7500 rpm 9.2 kW at 8750 rpm output Max. -
Page 6: Frame
CHARACTERISTICS Frame 50 cc 125 cc Frame Direct Perimetric Frame Front suspension Ø 32 mm telescopic fork Ø 36 mm telescopic fork Travel 85 mm 95 mm Rear suspension Central shock absorber Travel 95 mm 90 mm Dimensions and weight Overall length 1914 mm 1918 mm... -
Page 7: Service Schedule And Commissioning
SERVICE SCHEDULE AND COMMISSIONING SERVICE SCHEDULE AND COMMISSIONING Heavy duty servicing is for vehicles used under “harsh” conditions: door-to-door deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C. Service operations 500 kms Every 5000 kms Every 10000 kms or 1 months or 12 months... -
Page 8: Special Important Points
SPECIAL IMPORTANT POINTS SPECIAL IMPORTANT POINTS Oil and fuel This engine is designed to run on 95 or 98 unleaded fuel only Never run the machine with a petrol/oil mixture. The oil used for the separate lubrication system is « Esso 2T Spécial » or « Esso 2T Spécial anti- fumée »... -
Page 9: Tightening Torques
TIGHTENING TORQUES TIGHTENING TORQUES Body panels Front mudguard 0.8 to 1.2 mdaN Handlebar cover 0.2 to 0.4 m.daN Front legshields 0.2 to 0.4 m.daN Rear shield 0.2 to 0.4 m.daN Bottom panel 0.2 to 0.4 m.daN Footboard 0.4 to 0.6 m.daN Saddle storage compartment 0.4 to 0.6 m.daN Rear panels... -
Page 10: Special Tools
SPECIAL TOOLS SPECIAL TOOLS Tool N° Description Used with 755990 Diagnostic tool update software 68994 Torque wrench 8 extension Nm to 54 Nm 752235 adapter 752236 755996 hose clamp 750539 Tie-wrap pliers 756017 petrol injection power supply harness 752235 1/2 extension 69802 or 753977 756715 Tank gauge spanner... -
Page 11: Instrument Cluster
INSTRUMENT CLUSTER INSTRUMENT CLUSTER Instrument cluster description 1. Multi-function display 2. Rev counter 3. Speedometer 4. Engine temperature gauge 5. Control button 6. Injection system diagnostic warning light 7. Transponder immobiliser dissuasion light 8. ABS/PBS system diagnostic warning light (125 cc) 9. -
Page 12: Description Of The Multi-Function Display
INSTRUMENT CLUSTER Description of the multi-function display 13. Tripmeter (total or daily) 14. Tripmeter display 15. Type of unit used by the tripmeter 16. Clock 17. Maintenance indicator (spanner symbol) 18. Fuel gauge MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS Setting and function change operations can only be carried out if the machine is stationary (engine not running) This is for safety reasons. -
Page 13: Changing The Distance Unit
INSTRUMENT CLUSTER Changing the distance unit Changing the distance unit (km or miles) is as follows: - Ignition off, hold down the control button (5) and turn on the ignition, the distance unit flashes - Select the unit by briefly pressing the control button, the distance unit changes from “km” to “miles” or inversely. -
Page 14: Maintenance Function
INSTRUMENT CLUSTER Maintenance function Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service After servicing the machine, erase the spanner symbol as follows: - Ignition off, hold down the button (5) and turn on the ignition, the spanner symbol flashes - Release the control button - Press the button again for at least 5 seconds, the spanner symbol goes off Fuel gauge self-diagnostic... -
Page 15: Control Cable And Harness Routings
CONTROL CABLE AND HARNESS ROUTINGS CONTROL CABLE AND HARNESS ROUTINGS ABS/PBS panel 1. Main harness 2. Throttle control 3. Transponder antenna 4. Speed sensor 5. Brake light switch 6. ABS/PBS brake module reservoir feed pipe 7. Rear brake pipe 8. Right master cylinder to module brake pipe 9. -
Page 16: Right-Hand Side 50 Cc
CONTROL CABLE AND HARNESS ROUTINGS Right-hand side 50 cc 1. Main harness 2. Throttle cable (50 cc) 3. Transponder antenna 4. Speed sensor 5. Front brake pipe 6. Rear brake pipe 7. Fuel feed pipe Page : 16... -
Page 17: Left-Hand Side 125 Cc
CONTROL CABLE AND HARNESS ROUTINGS Left-hand side 125 cc 1. Main harness 2. Throttle cable (125 cc) 3. Rear brake pipe 4. Fuel supply pipe 5. Air pressure slave pipe 6. Fuel overflow pipe Page : 17... -
Page 18: Rear Right
CONTROL CABLE AND HARNESS ROUTINGS Rear right 1. Main harness Rear centre 1. Main harness Page : 18... -
Page 19: Location Of Components
LOCATION OF COMPONENTS LOCATION OF COMPONENTS 50 cc 1. Injection ECU 11. Oil pump 2. Throttle unit 12. Diagnostic light 3. Engine position and speed sensor 13. Diagnostic plug 4. Temperature sensor 14. Air compressor 5. Battery 15. Fuses 6. Fuel injector 16. -
Page 20: 125 Cc
LOCATION OF COMPONENTS 125 cc 1. Injection ECU 12. Diagnostic light 2. Throttle unit 13. Diagnostic plug 3. Engine position and speed sensor 14. Fuel pump relay, ABS/PBS, lighting, 25A 4. Temperature sensor fuse 5. Air pressure and air temperature sensor 15. -
Page 21: Body
BODY BODY Location of body components (50 and 125 cc) Body component sequence of disassembly (50 and 125 cc) LEGSHIELD TOP FOOTBOARDS RIDER SADDLE PASSENGER PANEL (11) SADDLE AND GRAB HANDLE (15) WIND FRONT LOWER TUNNELS STORAGE BATTERY COVER DEFLECTOR* AND LEGSHIELDS COMPARTMENT (16) -
Page 22: Removal Of Front Lower Legshields (50 And 125 Cc) Procedure 1
BODY Removal of front lower legshields (50 and 125 cc) Procedure 1 - Remove the ignition key - Remove the front upper legshield (1) (3 screws) - Disconnect the lighting and direction indicator connections - Remove the front lower left legshield (2) (3 screws), including the 2 fixing it to the RH legshield (3) - Remove the front lower RH legshield (3... -
Page 23: Removal Of The Storage Compartment (50 And 125 Cc) Procedure 2
BODY Removal of the storage compartment (50 and 125 cc) Procedure 2 - Open the saddle (1) - Remove the saddle strut upper securing nut - Remove the saddle (1) (2 nuts) - Remove the storage compartment (3) (6 nuts) Removal of the shield)(50 and 125 cc) Procedure 3 - Remove the front lower legshields (see... - Page 24 BODY - Remove the tunnels (4) (3 screws each) by unclipping starting at the rear upper part - Remove the bottom panels (5) (3 screws) Page : 24...
-
Page 25: Removal Of The Rear Cover Assembly And Mudflap (50 And 125 Cc) Procedure 4
BODY - Remove the rear shield (6) (3 screws) including 1 screw next to the filler cap Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4 - Remove the storage compartment (see procedure 2) - Remove the ignition key - Remove the passenger seat (2 bolts) - Remove the rear handle (3 nuts) - Remove the rear cover (1) 8 fixing screws... -
Page 26: Frame
FRAME FRAME Removal of the rear frame (50 cc) - Remove the rear cover assembly (see procedure - Remove the battery cover - Disconnect and remove the battery - Unclip the battery bracket harness without disconnecting the components - Remove the battery bracket (1) - Remove the 2 storage compartment (2) trim pieces - Remove the regulator (3), the oil pump (4) -
Page 27: Removal Of The Frame (50 Cc)
FRAME Removal of the frame (50 cc) This method is used only when changing the main frame, with the removal of several assemblies When changing the frame due to an accident, the method must be completed by the repair or replacement of damaged items - Remove the passenger seat - Remove the battery cover... - Page 28 FRAME - Disconnect the fuel tank sender unit return pipe - Using tool part number 755996 clamp the fuel supply hose between the tank and the fuel pump - Remove the fuel tank - Remove the saddle pivot - Remove the high voltage coil - Remove the shock absorber upper mount - Remove the swingarm to frame mount - Pull back the power unit...
-
Page 29: Miscellaneous Operations
MISCELLANEOUS OPERATIONS MISCELLANEOUS OPERATIONS Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc) - Remove the rear cover assembly (see procedure - Unclip the harness from the battery bracket without disconnecting the components - Remove the battery cover - Disconnect and remove the battery - Remove the battery bracket... -
Page 30: Removal Of The Radiator / Radiator Bracket (50 And 125 Cc)
MISCELLANEOUS OPERATIONS Removal of the radiator / radiator bracket (50 and 125 cc) - Remove the front lower legshields (see procedure 1) - Remove the rear shield panel (see procedure - Remove the fork guard (1) 2 fixing bolts without removing the guard - Remove the mudguard (2) - Drain off the coolant - Disconnect the radiator cooling system 4... -
Page 31: Removal Of The Fuel Gauge (50 Cc)
MISCELLANEOUS OPERATIONS Removal of the fuel gauge (50 cc) - Remove the storage compartment (see procedure 2) - Remove the tank cover panel (5 screws) - Remove the saddle pivot bracket (2 nuts) - Disconnect the fuel gauge (1) - Disconnect the return and vent pipes (2) from the sender unit - Unscrew and remove the fuel sender unit and its seal using plug wrench part number 756716... -
Page 32: Removal Of The Strainer (50 Cc)
MISCELLANEOUS OPERATIONS Removal of the strainer (50 cc) - Remove the storage compartment (see procedure 2) - Remove the tank cover panel (5 screws) - Remove the saddle pivot bracket (2 nuts) - Remove the footboard and the left tunnel - Disconnect the fuel gauge (1) - Disconnect the vent pipe (2) from the sender unit and put into a container in order to drain the... -
Page 33: Removal Of The Fuel Tank Filler Ring (50 And 125 Cc)
MISCELLANEOUS OPERATIONS Removal of the fuel tank filler ring (50 and 125 cc) - Remove the storage compartment (see procedure 2) - Remove the tank filler cap (3 screws) - Remove the filler cap trim - Remove the tank cover panel (5 screws) - Remove the tank filler ring (1) (3 screws) Note: Mark the fitting position of the filler ring on the tank... -
Page 34: Removal Of The Central Shock Absorber / From The Swingarm (50 And 125 Cc)
MISCELLANEOUS OPERATIONS - Remove the tank upper fixing bolts (6) - Remove the tank to frame 2 fixing brackets - Remove the tank with the fixing lugs, the fuel pump, the feed hoses and the cap Removal of the central shock absorber / from the swingarm (50 and 125 cc) - Remove the storage compartment (see procedure 2) -
Page 35: Removal Of The Radiator Deflector (50 Cc)
MISCELLANEOUS OPERATIONS Removal of the radiator deflector (50 cc) - Remove the footboards (4 screws) - Remove the tunnels (4 screws) - Remove the bottom panels (7 bis) - Unclip the deflector (1) from the radiator bracket and pull it downwards Removal of the braking limiter (50 cc) - Remove the footboards (4 screws) - Remove the tunnels (4 screws) -
Page 36: Working On The Engine Without Removing The Engine (50 Cc)
WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc) Removal of the inlet coupling and valves - Remove the transmission cover strip (1 screw) - Remove the air filter housing (2 screws) - Disconnect the throttle cable (1) from the throttle unit - Disconnect the throttle unit (2) -
Page 37: To Remove The Cylinder Head Procedure 5
WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE To remove the cylinder head Procedure 5 - Remove the footboards (4 screws) - Remove the tunnels (4 screws) - Remove the bottom panels (7 bis) - Disconnect the lower pump from the coolant pump to drain the cooling system - Disconnect the coolant pipes from the cylinder head and cylinder... -
Page 38: Removal Of The Temperature Sensor
WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE Removal of the temperature sensor - Remove the storage compartment (see procedure 2) - Disconnect the temperature sensor (1) - Remove the sensor Note: Refit a sensor quickly to prevent loss of coolant Removal of the air compressor - Remove the transmission cover strip (1 screw) -
Page 39: Special Work And Procedures Without Removing The Engine
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc) Important: Wash the power unit - Remove the footboards (4 screws) - Remove the tunnels (4 screws) - Remove the bottom panels (7 bis) - Disconnect the fuel injector (1) - Remove the 2 bolts from the injection... -
Page 40: Removal Of The Injection Manifold (50 Cc)
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Removal of the injection manifold (50 cc) Important: Wash the power unit - Carry out the procedure used to lower the pressure in the fuel system (see instruction 6) - Remove the clips from the 3 hoses (each time these clips are removed they must be changed for new genuine parts - Disconnect the 2 fuel pipes (1) -
Page 41: Removal Of The Thermostat (50 Cc)
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Important: Put the injector in the holder tool P/N 755986 until ready for refitting Note: The injector may only be removed for a short instant from its housing in the cylinder head, as the air injector has a Teflon seal which expands if it is not held compressed Reassembly: Re-assemble in the reverse order to dismantling... -
Page 42: Removal Of The Ecu (50 And 125 Cc)
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Removal of the ECU (50 and 125 cc) - Remove the storage compartment (see procedure 2) - Remove the ignition key - Remove the ECU two fixing nuts - Remove and disconnect the ECU (1) Important: If the ECU is changed, the throttle unit must be initialised with the diagnostic tool (refer to diagnostic tool user documentation for... -
Page 43: Removal Of The Oil Pump (50 Cc)
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE Removal of the oil pump (50 cc) - Remove the storage compartment (see procedure 2) - Disconnect the engine casing separate lubrication pipe - Disconnect the oil pump (1) - Remove the oil pump fixing bolt - Disconnect the oil inlet pipe (2) from the pump - Remove the oil pump... -
Page 44: Electricity
ELECTRICITY ELECTRICITY Removal of the instrument cluster (50 and 125 cc) - Remove the front upper legshield (3 screws) - Remove the screen (depending on version) - Remove the handlebar front cover (6 bolts) - Remove the handlebar rear cover and instrument cluster (1) assembly (3 bolts) - Disconnect the instrument cluster (2) - Remove the instrument cluster (4 bolts) -
Page 45: Removal Of The Starter Motor And/Or Lighting Relay (50 And 125 Cc) And/Or The Fuel Pump And/Or Abs/Pbs System Relay (125 Cc)
ELECTRICITY Removal of the starter motor and/or lighting relay (50 and 125 cc) and/or the fuel pump and/or ABS/PBS system relay (125 cc) - Remove the rear cover assembly (see procedure - Remove the relay concerned - lighting relay (1) (50 and 125 cc) and fuel pump relay (125 c) - starter motor relay (2) (50 cc) (on the 125 cc the relay is on the other side... -
Page 46: Removal Of The Transponder Antenna (50 And 125 Cc)
ELECTRICITY Removal of the transponder antenna (50 and 125 cc) - Remove the front lower legshields (see procedure 1) - Remove the rear shield panel (see procedure - Unclip the antenna (1) from the steering lock - Disconnect the antenna from the transponder module - Remove the antenna from the transponder Removal of the starter motor (50 cc) -
Page 47: Engine Removal
ENGINE REMOVAL ENGINE REMOVAL Removal of the 50 cc engine Important: Wash the power unit - Remove the storage compartment - Remove the passenger seat - Remove the battery cover - Disconnect the battery - Remove the 2 footboards - Remove the 2 tunnels - Remove the lower panel - Remove the transmission cover strip - Remove the air filter unit... -
Page 48: 125 Cc Specific Miscellaneous Work
125 cc SPECIFIC MISCELLANEOUS WORK 125 cc SPECIFIC MISCELLANEOUS WORK Removal of the idle valve - Disconnect the battery - Disconnect the fuel injector (1) - Disconnect the idle valve (2) - Disconnect the idle valve two hoses (3) - Remove the idle valve (4) Removal of the thermostat - Remove the storage compartment (see procedure 2) -
Page 49: Removal Of The Fuel Injector
125 cc SPECIFIC MISCELLANEOUS WORK Removal of the fuel injector - Remove the storage compartment (see procedure 2) - Disconnect the battery - Disconnect the fuel injector (1) - Disconnect the fuel feed hose (2) (1 clip, to be changed each time it is removed) - Remove the fuel injector (3) (1 bolt) Inspection: Connect the diagnostic tool and check there are no fault codes, erase them if... - Page 50 125 cc SPECIFIC MISCELLANEOUS WORK - Disconnect the throttle unit and the idle valve - Remove the throttle cable - Remove the throttle unit with the idle valve (1 clip, to be changed each time it is removed) Important: If the throttle unit is changed it must be initialised with the diagnostic tool (refer to the diagnostic tool user documentation for the injection engine)
-
Page 51: Removal Of The Fuel Pump / Of The Fuel Gauge
125 cc SPECIFIC MISCELLANEOUS WORK Removal of the fuel pump / of the fuel gauge - Remove the storage compartment (see procedure 2) - Remove the tank cover panel (5 screws) - Remove the saddle pivot bracket (1) (2 nuts) - Remove the ignition key - Disconnect the fuel gauge (2) - Disconnect the fuel gauge (3) -
Page 52: Removal Of The Starter Motor
125 cc SPECIFIC MISCELLANEOUS WORK Reassembly: Re-assemble in the reverse order to dismantling - Tighten the fuel pump using the plug wrench P/N 756716 in order to position the arrow (A) between the marks (B) on the tank - Fit the fuel gauge with a new seal using the gauge wrench P/N 756715 Inspection: Connect the diagnostic tool and... -
Page 53: Removal Of The Rear Brake Pads Or Caliper
125 cc SPECIFIC MISCELLANEOUS WORK Removal of the rear brake pads or caliper - Remove the pad 2 fixing pins - Remove the caliper 2 fixing bolts - Pull the caliper onto the disc to release the pads (1) - Remove the brake pads Note: After removing the pads, the caliper may be removed from the brake disc. -
Page 54: Removal Of The Engine Mounting Twin Linkrod
125 cc SPECIFIC MISCELLANEOUS WORK Removal of the engine mounting twin linkrod - Remove the storage compartment (see procedure 2) - Remove the left-hand footboard and tunnel - Disconnect the battery - Disconnect the oil vapour return pipe to the air filter - Disconnect the atmospheric pressure sensor - Remove the air filter unit... -
Page 55: Method Of Fitting The Engine Mounting Twin Linkrod
125 cc SPECIFIC MISCELLANEOUS WORK Method of fitting the engine mounting twin linkrod - Fit the 2 rubber bump stops (1) to the frame - Fit the twin linkrod (2) to the frame taking care it lines up with the rubber bump stops - Fit the twin linkrod upper fixing pins (3) - Fit the twin linkrod lower fixing pin (4) Page : 55... -
Page 56: Removal Of The Motor-Driven Fan Heat Switch
125 cc SPECIFIC MISCELLANEOUS WORK Removal of the motor-driven fan heat switch - Remove the front lower legshields (see procedure 1) - Remove the rear shield panel (see procedure - Remove the fork guard (1) 2 fixing bolts without removing the guard - Remove the mudguard (2) - Drain off the coolant - Disconnect the heat switch (1) -
Page 57: 125 Cc Specific Work Requiring Engine Removal
125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL 125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL Removal of the power unit Procedure 8 - Remove the storage compartment - Remove the left-hand footboard and tunnel - Disconnect the battery - Disconnect the oil vapour return pipe to the air filter - Disconnect the atmospheric pressure sensor - Remove the air filter unit... -
Page 58: Removal Of The Engine Procedure 9
125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL Removal of the engine Procedure 9 - Remove the power unit (see procedure 8) - Remove the complete exhaust system - Remove the inlet coupling and the throttle unit - Remove the suspension arm - Remove the wheel hub assembly - Remove the stand Removal of the rocker cover, setting the... - Page 60 RECOMMENDS REF: 756739 For reasons of continuous improvement, Peugeot Motocycles reserves the right to modify, delete or add any part number quoted DC/PS/ATR printed in EU 02/2002 (photos non-contractual)