Peugeot 50cc Horizontal Cylinder Iae Engine Full Service & Repair Manual

WORKSHOP MANUAL 50 cm3 Motor FB-0-1-2-4 GB

Trekker - Squab CONTENTS ENGINE PART CYCLE PART RECOMMENDATIONS ELECTRIC EQUIPMENT 1 Designation Page - Contents, ............................................................. 1 - Main characteristics, ............................................ 2 - Maintenance plan, ................................................ 3 - Putting into service, ............................................. 4 - Special tools, ........................................................ 5 - Tightening torques ............................................... 5 Dismantling Designtation Page - Removing the engine from the vehicle, ............... 6 - Placing the engine on the support, ...................... 6 - Removing the cooling system, ............................. 6 - Removing the flywheel, ........................................ 6 - Removing the oil pump, ....................................... 7 - Removing the starter motor, ................................. 7 - Removing the carburettor and choke, ................. 7 - Removing the intake valve and connecting part, . 7 - Removing the complete primary drive assy, ........ 7 - Removing the kick starter system, ....................... 8 - Removing the relay unit, ...................................... 8 - Removing the cylinder head, ............................... 8 - Removing the cylinder piston assy, ...................... 9 - Removing the RH housing, .................................. 9 - Removing the crankshaft from the LH housing, .. 9 - Replacing the crankshaft bearings and seals,.. .... 9 - Checking the crankshaft ...................................... 9 Refitting Designation Page - Refitting the crankshaft, ..................................... 10 - Closing the engine housings, ............................. 10 - Refitting the piston, ............................................ 10 - Refitting the cylinder, ......................................... 11 - Refitting the cylinder head, ................................ 11 - Refitting the relay unit, ........................................ 11 - Refitting the kick starter system, ........................ 12 - Checking the driven pulley clutch, ..................... 12 - Checking the drive pulley variator, ..................... 12 - Refitting the primary drive, ................................. 12 - Refitting the intake valve and connecting part, .. 13 - Refitting the carburettor, .................................... 13 - Refitting the starter motor, ................................. 13 - Refitting the oil pump and setting, ..................... 14 - Refitting the flywheel, ......................................... 14 - Refitting the cooling system ............................... 14 Designation Page - Contents, .............................................................. 1 - Main characteristics, ............................................ 2 - Maintenance plan, ................................................ 3 - Putting into service, .............................................. 4 - Tightening torques, ............................................... 5 - Disc brake ........................................................... 14 Designation Page - Spark plug ............................................................. 2 - Fuel ...................................................................... 4 - Separate lubrication .............................................. 4 - Relay unit ............................................................. 4 Designation Page - Electronic ignition, ............................................... 15 - Circuits supplied with alternative current, ........... 15 . lighting, ............................................................. 15 . choke, .............................................................. 16 - Resistance check of stator, ................................ 16 - Circuits supplied with direct current, .................. 17 . battery charge, ................................................. 17 . fuel gauge, ........................................................ 18 . oil gauge, ......................................................... 18 . horn, .................................................................. 18 . indicators, .......................................................... 18 . starter motor circuits, ....................................... 19 - Functional diagrams for electric circuits,. 20 and 21 - Key to electric circuits ........................................ 22

Trekker - Squab TECHNICAL DATAS Frame ENGINE MARKING XXXXXXXX FB2 Number Type Main spécifications 2 IDENTIFICATION MARK Identification plate FB2 ENGINE Forced-air cooled 2 stroke engine : - Bore and stroke : ................................................ 40 x 39.1 - Cylinder capacity : ............................................. 49.13cm3 - Compression ratio : ................................................... 6.6:1 - Maximum power (ISO) : .......................................... 3.1 kw Distribution : - Exhaust port : ........................................................... 160c° - Scavenging port : ....................................................... 110° - Air intake : ..................................... by reed valve induction - Ignition : ....................... CDI (capacitive-discharge ignition) - Spark advance : ....................................... 13° before TDC - Spark plug ................................................... Resistive 5KÙ ..................................................................... NGK - BR7HS .................................................................. EYQUEM R 850 ................................................................. BOSCH WR4AC - spark plug gap : ..................................................... 0.6mm Carburettor : .......................................... GURTNER PA350 - Idling speed : .................................... 1800 rpm ± 1 00 rpm - Initial position of the pilot air adjusting screw : - Anticlockwise rotation : ..................................... 1/2 to 13/4 - Needle with 3 levels : .................................. clips at the top - Main jet : ........................................................................ 74 Flywheel magneto : - Number of poles : ............................................................ 6 - Power : .......................................................... 2500t = 55w ........................................................................ 5000t = 85w Starter.motor : .................................................... MITSUBA ................................................................ 2000w SM10 129 ................................................................. 1500w SM10254 Oil pump : .............................................................. MIKUNI flow 24cm3 ± 1.7cm3 / hour at 3800 rpm, wide open throttle. 1CM3 = 0.031 cubic inch Transmission - Clutch : .................................... centrifugai, automatic type - Primary réduction gear : ........................ by a ribbed V-beit - Life of belt : ...................................................... 1 0 000 km - Reducer equipped with 2 gearsets. Identification : VGAS1A . . . . . . . . . . . - Front tyre : ...................................................... 120/90 x 10 - Rear tyre : ...................................................... 130/90 x 10 Pressure : - Front : .................................................................... 1,3 bar - Rear : .................................................................... 1,6 bar Capacities - Fuel tank : .............................................................. 6 litres - Oil tank : .............................................................. 1.3 litres - Transmission case : ............................................ 0.12 litre - Under-seat storage compartment : ............................. 3 kg Dimensions - Overall length : .................................................... 1760mm - Overail width : ........................................................ 670mm Excluding rear view mirror : Overall height : ...................................................... 1110mm Excluding rear view mirror : Wheelbase : .......................................................... 1250mm Weight - Complete vehicle dry weight : .................................... 82kg - Vehicie weight with tanks full : ................................... 88kg Markings 49cc - Left hand casing (under the starter motor) - Cylinder head (front right) - Cylinder (exhaust flange left hand side) - Intake pipe (on the front «49»)

Trekker - Squab MAINTENANCE PLAN C PLAN A PLAN B 500 km or 3 mois 5000 km or 2500 km* 10000 km or 5000 km* * reforced maintenance 3 Depending on how the scooter is used, it is recommended to apply either - The normal maintenance plan or - The reinforced maintenance plan. The normal maintenance plan includes: - Visit at 500 km or 3 months Plan A - Periodic maintenance every 5000 km Plan B - Periodic maintenance every 10000 km Plan C The reinforced maintenance plan includes: - Visit at 500 km Plan A - Periodic maintenance every 2500 km Plan B - Periodic maintenance every 5000 km Plan C The reinforced maintenance is intended for vehicles used in so-called “severe” conditions: door to door sales, intensive urban use (courrier), short journeys engine cold, areas with dusty atmospheres, frequent use of vehicles at an ambient temperature above 30°C. CHECK : Idle speed adjustment X X X Throttle X X X Oil pump control X X X Functioning of the electric equipment X X X Front and rear brake control X X X Fuel pipes X X X Oil pipes X X X Front brake fluid pipes X X X State and pressure of tyres X State, pressure and wear of tyres X X Brake fluid level X X X Level of battery electrolyte X X X Tightening of nuts and bolts X X X REPLACE : Relay unit oil X X Spark plug X X Filter element of the intake silencer X X Front brake pads (if necessary) X Rear brake linings (if necessary) X X Drive pulley rollers (if necessary) X X Transmission belt X CHECK AND UNCLOG Piston X Cylinder head X Exhaust port X CHECK AND LUBRICATE Driven pulley : movable driven face and needle bearing X Drive pulley : movable drive face and rollers X Kick : driven gear and link ring X CLEAN AND ADJUST Carburettor X VEHICLE TEST Road test X X X MAINTENANCE PLAN

Trekker - Squab INSTRUCTIONS FOR MAKING OPERATIONAL 4 1. Preparation of the battery (dry charged) - Remove the battery. - Remove the six cell caps and the breather tube cap. - Fill the battery with électrolyte up to the level marked UPPER LEVEL (35% sulphuric acid 1.28 g/CM3), Ref : ........................................................... 1 litre : 752740 ................................................................ 5 litres : 752741 - Leave the battery to settle for half an hour. Top up the level if necessary. - Charge the battery for 1 to 2 hours with a current of 400m.A (0.4A). - Replace the battery and connect the breather tube. - Connect up the red positive leads to the battery positive terminal, then the green negative lead to the battery earth terminal. - From then on, the battery can be topped up if necessary, using distilled water only. 2. Fuel Capacity : .............................................................. 6 litres - Conventional 4-star petrol. - Lead free petrol 98 octanes. 3. Separate lubrication: Capacity : .......................................................... 1.3 litres. - Fill up the oil tank with semi-synthetic engine oil for 2- stroke engines with separate lubrication, - Type TC (API standard), type TSC3 (ASTM standard), - - Type FC (JASO standard) or a synthetic oil. PEUGEOT MOTOCYCLES recommends : ....................................... ESSO : 2T Special performance ......................................................... ESSO : 2T Synthetic 4. Putting fuel and oil circuits into opération: - Put one litre of fuel mixture with 4% oil into the fuel tank. - Fill up the oil tank. - Start the engine: make sure that the oil circuit is completely primed. Remove the oil bleed screw from the pump to allow air in the circuit to escape. When a continuons stream of oil issues from this hole, replace the bleed screw with its fiber washer. For this : disconnect the oil intake hose to the carburettor and check that it drips, frequency depending on the engine’s speed. - Top up the fuel tank with pure 4 star petrol. 5. Checking the oil level in the transmission case: - Unscrew and remove the oil filler hole screw A and make sure that the oil level is flush with the level of the filling hole. The vehicle must be positioned on its stand and on a level surface. Esso Oil SAE 80 W 90 REF : .................................................................... 753009 capacity 0. 1 2 litre A = 1.2m.daN. 6. Checks before delivery to the customer: - In particular, check the tightening of the Wheel nuts ... - front : .................................................................... 6m daN - rear : .............................................................. 1Om daN - Check the tightness of the nuts and bolts. - Check brake adjustment and eff iciency. - Cold tyre pressure: FRONT - pressure : ......................................................... 1.3 bar - size : .......................................................... 120/90 x 10 REAR - pressure : ......................................................... 1.6 bar - size : .......................................................... 130/90 x 10 - Make sure all lights and signals operate correctly (taillight, turnsignals, stop light, horn), and various warning lights. - vehicle road test.

Trekker - Squab TIGHTENING TORQUES AND SPECIAL TOOLS TIGHTENING TORQUES SPECIAL TOOLS 5 Engine Assembly screws for : - Housings : ........................................................ 1m.daN - Covers : ............................................................ 1m.daN - Intake connecting part : .................................... 1m.daN - Starter motor : .................................................. 1m.daN - Stator : .............................................................. 1m.daN - Sensor : ............................................................ 1m.daN - Fan : ................................................................. 1m.daN - Carburettor : .................................................. 0.8m.daN - Oil pump : ...................................................... 0.8m.daN - Cylinder head : .............................................. 1.2m.daN - Drive pulley : ..................................................... 4m.daN - Driven pulley : ................................................ 4.5m.daN - Rotor : .............................................................. 4m.daN - Oil plug : ........................................................ 1.2m.daN - Spark plug : ...................................................... 2m.daN Frame - Front wheel axis nut : ........................................ 6m.daN - Rear wheel nut : ............................................. 10m.da N - Engine joint on rod : ........................................... 6m.daN - Rod joint on chassis : ..................................... 2.2m.daN - Rear shock absorber upper fixation : .............. 1.6m.daN - Rear shock absorber lower fixation : .............. 1.6m.daN - Exhaust nuts on cylinder : .............................. 1.6m.daN - Handlebar nut : .................................................. 4m.daN - Steering lock nut : .............................................. 7m.daN Standard - Screw and nut ø 5mm : ...................... 0.45 to 0.6m.daN - Screw and nut ø 6mm : ........................ 0.8 to 1.2m.daN - Screw and nut ø 8mm : ........................ 1.8 to 2.5m.daN - Screw and nut ø 1Omm : ........................... 3 to 4m.daN - Screw and nut ø 12mm : ............................ 5 to 6m.daN - Service cradle mount ............................................... 64765 - Adjustable adapter for engine service cradle ......... 752026 - Flywheel holder ....................................................... 68570 - Snap ring pliers ..................................................... 752000 - Protective end, small model for flywheel magneto remover .................................................................................. 68007 - Puiler tool ................................................................ 64706 - Crankshaft end protector ......................................... 69098 - Shouldered centring tool .......................................... 64710 - Screw on torque handle ........................................... 69104 - Compresser tool, ail types of clutch ....................... 752127 - Tubular socket wrench 39 ..................................... 752361 - Adjustable pin type face wrench ............................ 752237 - Set of half sheils 0 52 .............................................. 64709 - Puiler tool .............................................................. 750807 - Support washer ..................................................... 750808 - Surface plate 250 x 160 x 50 ................................. 750541 - Comparator (adapts to pattern plate accessory ..... 750969 - Torque wrench + extension + reducer ..................... 69802 - Flywheel puller supplied with 68007 protector ....... 750806 - Blooking tool .......................................................... 752370 - Pliers for circlips ...................................................... 69117 - Spindle .................................................................. 750069 - Steering tools ........................................................ 752948

Trekker - Squab REMOVAL 6 64765 752026 68 007 750806 Removal of the engine - Remove : - All side casings - Disconnect : - Fuel line from the carburettor, - Fuel tap vacuum hose, - Oil pump control cable - Throttle control cable, - Oil iniet piping at the pump (large hose) - Radio interference suppressor cap - Rear brake control cable Disconnect : - The wiring harness on the frame’s right tube: located at the outlet of the Flywheel magneto (under the foot board), choke, starter motor. Remove : - The lower anchor bolt of the shock absorber and the front anchor pin of the engine. Removal of the flywheel magneto - Block the rotor using a notch type pin 752237. - Remove the nut (right-hand thread). - Fit the crankshaft end protector 68007 onto the end of the crankshaft. - Screw the flywheel puller tool 750806 onto the rotor and tighten the centre bolt until the rotor comes away. - Remove the 2 fastening screws of the sensor, as well as the 2 fastening screws of the stator plate. - Remove the coil assembly and the sensor. Removal of cooling systern - Remove the two parts of the fan covers (4 screws). - Remove the 4 fastening screws of the fan and remove the fan. Fitting of engine on service cradle - Place the engine onto the adapter 752026 - Place the assembly on the cradle mount 64765 clamped in a vice

Trekker - Squab 752370 7 REMOVAL Removal of the oil pump - Unclip the oil inlet pipe to the carburettor. - Unscrew the 2 hex head socket screws. - Remove the oil pump and the control flange. - Remove the 2 square fastening nuts Q from their housings. - Remove the flexible washer lodged between the pump and the shaft bearing of the oil pump. - Adjustment: see page N° 14 Rernoval of the starter motor - Free the wire harness from the support bracket. - Remove the 2 fastening screws and washers from the starter motor and pull out together with «0» ring seal. Removal of the carburettor / choke assembly - Take off the 2 fastening screws from the carburettor and remover the carburettor / choke assembly, as well as the isothermal spacer. Removal of the reed valve and intake pipe - Unscrew and remove the 4 fastening screws. - Remove the intake pipe, the gasket, the reed valve assembly and the second gasket. Removal of the primary drive system You do not have to remove of the kick starter arm when removing the crankcase cover. - Loosen and remove the 11 fastening screws of the cover. - Remove the cover with both locating dowls. - Remove the starter drive assembly from the starter motor. - Hold the starter ring gear with the tool 752370.

Trekker - Squab REMOVAL 8 752237 Rdl 12,35x19,75x1 Make careful note of where this tool comes level with the starter ring gear plate of the starter motor in order to make sure, when refitting, that the pressure plate fits correcte into the grooves of the crankshaft. - Loosen the fastening nut (right-hand thread) of the gear plate of the drive pulley. - Remove the nut, washer and plate. - Remove the belt. - Remove the drive pulley assembly (variable speed drive) and the washer on the engine housing side (12,35 X 19,75 X 1). - Block the clutch drum with the flywheel pinch bolt no.68570 or the adjustable pin type face wrench 752237. - Loosen the screw, remove the drum and the clutch driven pulley assembly. Removal of the kick starter system - Actuate the kick starter spindle with your thumb and remove the drive ratchet and its washer. - Remove the kickstarter lever. Using snipe-nosed pliers (ref. 69117), take off the circlips, the washer, then remove the kick starter toothed section, the pull-back spring and the bushing. Removing the cylinder head - Unscrew in a crosswise order the 4 screws securing the cylinder head and cylinder block assembly. - Remove the cylinder head and gasket. Dismantling the transmission case After draining the transmission case: - Remove the 5 screws securing the cover. - Remove the cover with the drive shaft (or input shaft), the gasket and both locating dowls. - Removal of the drive shaft (or input shaft) from the transmission cover is done using a mallet. - Remove the thrust washer from the counter shaft (14.3x26xO.5). - Drain the transmission case completely before removing the final shaft (or output shaft) in order to avoid contamining brake linings. - Pull out the final shaft (output shaft). - Pull out the countershaft as well as its friction washers (1 4.3 x 26 x 0.5) and flexible washer (1 4 x 22 x 1.5).

Trekker - Squab REMOVAL 9 750807 64706 752168 69098 Removing the cylinder and piston - Remove the cylinder and cylinder-to- crankcase gasket. - Pack the crankcase mouth with clean cloth or paper. - Lean the engine to the left and take out the wrist pin’s RH snap ring. - Push the wrist pin from the left to the right; this opération does not require use of a strap. - Take out the needie bearing race. Opening the crankcase - Remove the 6 screws securing the RH crankcase half. - Fit the crankshaft end protector 68007 onto the end of the crankshaft. - Position the puller tool 750807 onto the crankcase half. - Turn the inner thrust bolt of tool 750807 until the crankcase halves split Hold the connecting rod so that it does not knock against the crankcase halves. - Remove the RH half casing. - Remove the gasket and both locating dowls. Remove the drive shaft of the oil pump and its locating bush. Changing the bearings and seals - Heat the crankcase halves evenly to 90° so that they expand. The bearings will drop out, drive out the seals. - Fit the new bearings while the crankcase halves are still warm. - Fit the oil seals in place. - The oil seal on the drive pulley side should fit flush with the crankcase, the lips being on the fl.ywheel housing side. The seal on the flywheel side should be approximately 9mm in. Note: If the crankshaft bearings remain on the crankshaft; use the puller tool 64706 with the half shells 64709 (diam = 52) to remove them. Do not forget to fit the crankshaft end protector 69098 onto the ends of the crankshaft. Removing the crankshaft assembly - Fit the crankshaft end protector 69098 onto the end of the crankshaft. -Fit puller tool 647706 with the plate 752168 onto the crankcase. - Secure the plate to the crankcage by tightening the 4 screws. - Withdraw the crankshaft by turning the inner thrust bolt of tool 64706. Checking the crankshaft assembly - The maximum side play of the conrod big end should not exceed: 0.5mm. - Check crankshaft alignement as shown in the drawing (surface plate 750541, comparator 750969 The values measured at the ends should not exceed 0.12mm.

Peugeot 50cc Horizontal Cylinder Iae Engine Full Service & Repair Manual

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