PEUGEOT JETFORCE 50CC 125CC Full Service & Repair Manual

SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL

CONTENTS Page : 2 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 ......................................................................................................................... 7 Test machine................................................................................................................................................... 7 SPECIAL IMPORTANT POINTS .................................................................................................... 8 Oil and fuel ..................................................................................................................................................... 8 Starting up after overhauling the engine ........................................................................................................ 8 Electricity ....................................................................................................................................................... 8 Special features............................................................................................................................................... 8 TIGHTENING TORQUES ................................................................................................................. 9 Body panels .................................................................................................................................................... 9 Frame .............................................................................................................................................................. 9 Standard .......................................................................................................................................................... 9 SPECIAL TOOLS ............................................................................................................................. 10 INSTRUMENT CLUSTER............................................................................................................... 11 Instrument cluster description ...................................................................................................................... 11 Description of the multi-function display .................................................................................................... 12 MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS................................................ 12 Changing from the total distance display to the daily display ..................................................................... 12 Changing the distance unit ........................................................................................................................... 13 Setting the clock ........................................................................................................................................... 13 Maintenance function ................................................................................................................................... 14 Fuel gauge self-diagnostic ............................................................................................................................ 14 CONTROL CABLE AND HARNESS ROUTINGS....................................................................... 15 ABS/PBS panel ............................................................................................................................................ 15 Conventional braking panel.......................................................................................................................... 15 Right-hand side 50 cc ................................................................................................................................... 16 Left-hand side 125 cc ................................................................................................................................... 17 Rear right ...................................................................................................................................................... 18 Rear centre.................................................................................................................................................... 18 LOCATION OF COMPONENTS.................................................................................................... 19 50 cc ............................................................................................................................................................. 19 125 cc ........................................................................................................................................................... 20 BODY .................................................................................................................................................. 21 Location of body components (50 and 125 cc) ............................................................................................ 21 Body component sequence of disassembly (50 and 125 cc) ........................................................................ 21 Removal of front lower legshields (50 and 125 cc) Procedure 1............................................................... 22 Removal of the headlight and sidelight assemblies (50 and 125 cc)............................................................ 22 Method for fitting the lower legshield bracket (50 and 125 cc) ................................................................... 22

CONTENTS Page : 3 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 ............................................................................................................................................... 26 Removal of the rear frame (50 cc)................................................................................................................ 26 Removal of the frame (50 cc) ....................................................................................................................... 27 MISCELLANEOUS OPERATIONS ............................................................................................... 29 Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc)......................... 29 To remove the oil filter (50 cc) .................................................................................................................... 29 To remove the header tank (50 and 125 cc) ................................................................................................. 29 Removal of the radiator / radiator bracket (50 and 125 cc).......................................................................... 30 Removal of the fuel gauge (50 cc) ............................................................................................................... 31 Removal of the strainer (50 cc) .................................................................................................................... 32 Removal of the fuel tank filler ring (50 and 125 cc) .................................................................................... 33 Removal of the fuel tank (50 cc) .................................................................................................................. 33 Removal of the central shock absorber / from the swingarm (50 and 125 cc) ............................................. 34 Removal of the radiator deflector (50 cc) .................................................................................................... 35 Removal of the braking limiter (50 cc) ........................................................................................................ 35 Removal of the saddle strut (50 and 125 cc) ................................................................................................ 35 WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc) .................... 36 Removal of the inlet coupling and valves .................................................................................................... 36 To remove the cylinder head Procedure 5 .................................................................................................. 37 Removal of the cylinder / piston .................................................................................................................. 37 Removal of the temperature sensor .............................................................................................................. 38 Removal of the air compressor ..................................................................................................................... 38 SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE ................. 39 Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc) ........................................................ 39 Procedure for bleeding the fuel circuit Procedure 7 (50 and 125 cc)......................................................... 39 Removal of the injection manifold (50 cc) ................................................................................................... 40 Removal of the air injector (50 cc) ............................................................................................................... 40 Removal of the thermostat (50 cc) ............................................................................................................... 41 Removal of the ECU (50 and 125 cc) .......................................................................................................... 42 Removal of the throttle unit (50 cc) ............................................................................................................. 42 Removal of the oil pump (50 cc) .................................................................................................................. 43 Removal of the fuel gauge (50 cc) ............................................................................................................... 43 ELECTRICITY.................................................................................................................................. 44 Removal of the instrument cluster (50 and 125 cc)...................................................................................... 44 Removal of the voltage regulator and saddle actuator (50 and 125 cc) ....................................................... 44 Removal of the battery cover, battery, fuses (50 and 125 cc) ...................................................................... 44 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) ................................................................................................................... 45 Removal of the high tension coil (50 and 125 cc) ........................................................................................ 45 Removal of the horn, immobiliser module (50 and 125 cc) ......................................................................... 45 Removal of the transponder antenna (50 and 125 cc) .................................................................................. 46 Removal of the starter motor (50 cc)............................................................................................................ 46 ENGINE REMOVAL ........................................................................................................................ 47 Removal of the 50 cc engine ........................................................................................................................ 47 125 cc SPECIFIC MISCELLANEOUS WORK ............................................................................. 48 Removal of the idle valve............................................................................................................................. 48 Removal of the thermostat ........................................................................................................................... 48

CONTENTS Page : 4 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 ........................................................................................................................ 52 Removal of the rear brake pads or caliper .................................................................................................... 53 Removal of the suspension arm.................................................................................................................... 53 Removal of the engine mounting twin linkrod............................................................................................. 54 Method of fitting the engine mounting twin linkrod .................................................................................... 55 Removal of the motor-driven fan heat switch .............................................................................................. 56 Removal of the motor-driven fan ................................................................................................................. 56 125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL .................................................. 57 Removal of the power unit Procedure 8 ..................................................................................................... 57 Removal of the engine Procedure 9 ............................................................................................................ 58 Removal of the rocker cover, setting the rockers, removal of the camshaft, removal of the rockers .......... 58 Removal of the cylinder head, removal of the cylinder and/or piston, removal of the cylinder head or base gasket, removal of the timing chain, setting the timing ....................................................................... 58 Removal of the connecting rod and/or LH bearing and/or changing the casings ........................................ 58

CHARACTERISTICS Page : 5 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles CHARACTERISTICS Engine 50 cc 125 cc Type Single cylinder 2-stroke direct injection Single cylinder 4-stroke indirect 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 output 3.6 kW at 7500 rpm 9.2 kW at 8750 rpm Max. torque at 6500 rpm 7250 rpm Fuel system Direct electronic injection (TSDI) Indirect electronic injection (EFI) Lubrication Electric oil pump Trochoidal pump Transmission 2 variable pulleys and Vee belt Clutch Centrifugal automatic Spark plug NGK CPR8E NGK CR7EB Exhaust Catalytic Non-catalytic Capacities Fuel tank 8 litres 95 or 98 lead-free Oil tank 1.2 litres semi-synthetic (API TC) Engine oil 1.25 litres SAE 10W40 Relay box oil 0.12 litres SAE 80W90 Life lubricated Coolant* 1.3 l 1.6 l Fork 125 cc by tube Esso Univis 46 or Agip H Lift 46 190 cc by tube Esso Univis 46 or Agip H Lift 46 * Peugeot coolant part number 754614 Chassis markings 1 – VIN number and manufacturer’s plate Engine markings 2 – Engine number

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 Width at handlebar 740 mm Height with rear view mirror 1260 mm 1279 mm Wheelbase 1314 mm 1369 mm Ground clearance 137 mm 112 mm Saddle height: 820 mm 845 mm Unladen weight 115 kg 149 kg Tyres Front wheel 13-inch alloy Front tyre 130/60 - 13 Front tyre pressure 2 bar 2 bar Rear wheel 13-inch alloy Rear tyre 130/60 - 13 140/60 - 13 Rear tyre pressure 2.2 bar 2.2 bar Page : 6 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles

SERVICE SCHEDULE AND COMMISSIONING Page : 7 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 or 1 months Every 5000 kms or 12 months Every 10000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Check Throttle cable play X X X Steering column play X X X Operation of electrical equipment X X X Condition of front and rear brake hydraulic controls X X X Condition of fuel pipes X X X Condition of oil pipes X X X Tyre pressures X Tyre condition, pressure and wear X X Brake fluid level X X X Battery electrolyte level * X X X Coolant level X X X Engine oil level X Tightness of nuts and bolts X X X Change Spark plug X X Inlet silencer/air filter** Front brake pads# X Rear brake pads *# X Drive pulley bearings and guides # X X Transmission belt X Engine oil (+ clean strainer) X Engine oil filter X Brake fluid and coolant** Check and lubricate Driven pulley: moving flange and needle bush X Drive pulley: moving flange and rollers* X Reading the ECU fault codes Injection and ABS/PBS system* X X X Test machine On road X X X * depending on equipment # if necessary ** every 20000 km for the 50 cc (10000 if harsh use servicing) and every 40000 for the 125 cc (20000 km if harsh use servicing)

SPECIAL IMPORTANT POINTS Page : 8 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 » recommended by the manufacturer Starting up after overhauling the engine The oil circuit bleed system (50 cc) must be checked with the diagnostic tool, the fuel pump bleeds itself automatically when the ignition is turned on Starting should not be with a 2-stroke mixture, as the fuel pump and injectors are not designed to operate with oil. When starting the engine hot or cold do not accelerate Check the coolant level in the header tank After road-testing the machine, check there are no fault codes left in the ECUs (read with diagnostic tool) Electricity All components of the electrical system are powered with 12 volts DC. The battery must not be disconnected while the engine is running and the voltage must be at least 8.5 volts for the ECU to function and enable engine starting To avoid any risk of forgetting to turn off the ignition after opening the saddle, the ignition key should be removed after each job Special features After changing the injection ECU or the throttle, the initialisation procedure must be carried out with the diagnostic tool The ECU has a diagnostic function which via the instrument cluster Led or the diagnostic tool, enables reading of the faults in the memory The fuel inlet and injection manifold return pipes must only be replaced by genuine service parts. The fuel pressure of 8 bars requires special pipes. The fuel pipes must be changed if they show signs of wear, cracks, etc. The clips are specific, they must always be changed each time they are removed and replaced with new genuine parts clips Note: Before carrying out any work, leave the engine to cool for a minimum of 2 hours. Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a clear and well-ventilated area.

TIGHTENING TORQUES Page : 9 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 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 0.2 to 0.4 m.daN Grab handle 2 to 2.5 m.daN Rear mudguard 0.2 to 0.4 m.daN Frame Front wheel spindle 6 to 7 m.daN Rear wheel bolt 8.5 to 9.5 m.daN Rear wheel spindle nut 10 to 12 m.daN Linkrod to engine pivot 4.3 to 5 m.daN Linkrod to swingarm 4.3 to 5 m.daN Engine-upper linkrod pivot 4.3 to 5 m.daN Shock absorber top mount 2.4 to 2.6 m.daN Shock absorber bottom mount 2.4 to 2.6 m.daN Front and rear frame mounting nut 2 to 2.5 m.daN Exhaust to cylinder mounting nut 1.5 to 1.8 m.daN Exhaust to cylinder head mounting nut (125 cc) 1.5 to 1.8 m daN Exhaust to casing mounting bolt 2 to 2.5 m.daN Upper cone (in 2 operations) 3.8/2.3 mdaN Upper cone locknut Tighten manually Steering locknut 7 to 8 m.daN Front brake caliper 2.5 to 3.5 m.daN Rear brake caliper 2 to 2.5 m.daN Front disc brake 0.9 to 1 m.daN Rear disc brake 0.9 to 1 m.daN Handlebar 2.5 to 3.5 mdaN Standard Nut and bolt 5 mm diameter 0.5 m.daN Nut and bolt 6 mm diameter 1 m.daN Nut and bolt 8 mm diameter 2.2 m.daN Nut and bolt 10 mm diameter 3.5 m.daN Nut and bolt 12 mm diameter 5.5 m.daN

SPECIAL TOOLS Page : 10 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles SPECIAL TOOLS . Tool N° Description Used with 68994 Torque wrench 8 Nm to 54 Nm extension 752235 adapter 752236 750539 Tie-wrap pliers 752235 1/2 extension 69802 or 753977 752236 1/2-3/8 adapter 69802 or 753978 753977 Torque wrench 30 Nm to 150 Nm extension 752235 adapter 752237 754086 Steering tool 755806 Cartridge France 755878 755807 Cartridge Export 755878 755878 Diagnostic tool (game boy colour) 755806 755807 755990 Diagnostic tool update software 755996 hose clamp 756017 petrol injection power supply harness 756715 Tank gauge spanner 756449 ABS/PBS interface cable for diagnostic tool 755878 755806 755807 756575 Piston locking fork 756716 Tank ring spanner 756607 Fork seal fitting tool 125 cc 756608 Fork seal fitting tool 50 cc

PEUGEOT JETFORCE 50CC 125CC Full Service & Repair Manual

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