PEUGEOT Jet C-Tech, Jet C-Tech 307 WRC Workshop Manual
Sales division
Technical network leadership
WORKSHOP MANUAL
-
Sales division
Technical network leadership
Reproduction or translat ion, even partial, is forbi dden without the written co nsent of Peugeot Motocyc les
TABLE OF CONTENTS
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
TABLE OF CONTENTS . ... ....................................... ... ... ... .... ... ....................................... ... ... ... ... ....................... 1
CHARACTERISTICS......................................................................................................................................... 3
Engine........................................................................................................................................................3
Capacities. .................................................................................................................................................3
Chassis......................................................................................................................................................4
Dimensions and weight................................................. ... ... ... .... ... ....................................... ......................4
Tyres. .........................................................................................................................................................4
Chassis markings.......................................................................................................................................4
Engine marking..........................................................................................................................................4
SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 5
Check.........................................................................................................................................................5
Change. .....................................................................................................................................................5
Check and lubricate. ..................................................................................................................................6
Clean and adjust.............................................................. ....................................... ... ... ... . .........................6
Test machine..............................................................................................................................................6
Battery preparation (Except battery without maintenance)*. .....................................................................7
Checks before handing over to the customer.............................................................................................7
SPECIAL IMPORTANT POINTS....................................................................................................................... 8
Oil and fuel.................................................................................................................................................8
Starting up after overhauling the engine....................................................................................................8
TIGHTENING TORQUES ................................. .... ... ... ... ... .......................................... .... ... ................................ 9
Body panels. ..............................................................................................................................................9
Cycle part...................................................................................................................................................9
Standard. ...................................................................................................................................................9
SPECIAL TOOLS ............................................................................................................................................ 10
LOCATION OF COMPONENTS...................................................................................................................... 11
BODY PANELS ............................................................................................................................................... 12
Removal of the front shield panel.............................................................................................................12
Removal of front lower shield panels. ......................................................................................................12
Removing the footboard and the LH tunnel. ....... ............................................................................. ........12
Removal of the storage compartment......................................................................................................13
Removal of the rear cover assembly and mudflap...................................................................................14
Removal of the header tank.....................................................................................................................14
ELECTRIC COMPONENTS ............................................................................................................................ 15
Removal of the blinker unit.......................................................................................................................15
TABLE OF CONTENTS
2
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Removal of the ignition module................................................................................................................15
Removal of the headlight bulbs................................................................................................................15
Removal of the horn.................................................................................................................................16
Removal of the oil pump control unit........................................................................................................16
Removal of the regulator..........................................................................................................................16
Removal of the engine temperature sensor.............................................................................................16
Removal of the oil pump. .........................................................................................................................16
Removal of the high tension coil..............................................................................................................17
PETROL CIRCUITS.........................................................................................................................................18
Removal of the fuel tank filter...................................................................................................................18
Removal of the fuel pump........................................................................................................................18
Removal of the carburettor.......................................................................................................................19
Procedure to position the carburettor.......................................................................................................20
Removal of the inlet coupling and valves.................................................................................................21
Removal of the inlet coupling and valves.................................................................................................21
Removal of the throttle valve....................................................................................................................21
WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE.............................................................22
Removal of the air pump..........................................................................................................................22
Removal of the cylinder / piston...............................................................................................................22
Removal of the water pump.....................................................................................................................23
MISCELLANEOUS OPERATIONS ................................................................................................................. 24
Removal of the rear brake pad.................................................................................................................24
CHARACTERISTICS
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Engine.
Capacities.
Jet C-Tech 307 WRC
Type. 2-stroke single-cylinder.
Cooling. Liquid.
Bore x stroke. 39.9 x 39.8 mm.
Cubic capacity. 49.9 cc.
Max. power output. 3.6 kW at 7300 rpm.
Max. torque rating. 7000 rpm.
Fuel supply. Carburettor Gurtner PY15.
Lubrication. Electric oil pump.
Transmission. By 2 variable pulleys and V-type belt.
Clutch. Centrifugal automatic.
Spark plug. NGK CR7EB.
Exhaust. Catalytic.
Fuel tank. 7.8 l 95 or 98 lead-free.
Oil tank.
1.2 l.
Semi synthetic for 2 stroke engines with separate oiling.
Relay box. 0.12 l SAE 80W90 life lubricated.
Coolant.
1.4 l.
Peugeot coolant part number 754614.
Fork. 0.12 l per tube (Esso Univis 46 or Agip H Lift 46).
CHARACTERISTICS
4
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Chassis.
Dimensions and weight.
Tyres.
Jet C-Tech 307 WRC
Chassis. Steel wrap-round frame (Direct Perimetric Frame)
Front suspension. Ø32 mm telescopic fork.
Travel. 85 mm.
Rear suspension. Central shock absorber.
Travel. 95 mm.
Overall length.
1915 mm.
Width at handlebar.
720 mm.
Height (without rear-view
mirrors)
1165 mm.
Wheelbase.
1340 mm.
Saddle height.
820 mm. 810 mm.
Unladen weight.
114 kg.
Front wheel rim. 12 inch aluminium alloy. 13 inch aluminium alloy.
Front tyre. 120/70 - 12. 130/60 - 13.
Front tyre pressure. 1.6 bars. 2.2 bars.
Rear wheel rim. 12 inch aluminium alloy. 13 inch aluminium alloy.
Rear tyre. 130/70 - 12. 130/60 - 13.
Rear tyre pressure. 1.8 bars. 2.2 bars.
Chassis markings. Engine marking.
1. VIN number.
- Manufacturer's plate located under the
saddle.
2. Engine number.
*
xxxxxxxxxx
*
1
XXXXXXXXXX
XXX
2
SERVICE SCHEDULE AND COMMISSIONING
5
Reproduction or translation, even partial, is 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.
* Depending on equipment.
# Change if necessary.
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.
Idle setting. X X X
Throttle cable play. X X X
Steering column play. X X X
Operation of electrical equipment. X X X
Condition of front and rear brak e hydraulic controls *. X X X
Condition of petrol 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
Tightness of nuts and bolts. X X X
Change.
Spark plug. X X
Intake silencer. X
Front brake pads #. X X
Rear brake pads #. X X
Drive pulley bearings and guides #. X X
Transmission belt. X
Brake fluid and coolant. Once every 2 years
Petrol filter. X
SERVICE SCHEDULE AND COMMISSIONING
6
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
* Depending on equipment.
# Change if necessary.
Service operations.
500 kms or
1months.
Every
5000 kms or
12 months.
Every
10000 kms.
Heavy duty servicing. 500 kms.
Every
2500 kms.
Every
5000 kms.
Check and lubricate.
Driven pulley: Moving flange and needle bush. X
Kick lever boss/Kick starter control shaft. X X
Clean and adjust
Carburettor X
Test machine.
On road. X X X
SERVICE SCHEDULE AND COMMISSIONING
7
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Battery preparation (Except battery without maintenance)*.
Remove the battery.
Remove the 6 filler caps and the vent plug.
Fill with electrolyte to the level marked "UPPER LEVEL".
Electrolyte: (35% sulfuric acid = 1.28 g/cm
3
)
1 litre can P/N 752740.
5 litre can P/N 752741.
Leave the battery to stand for around half an hour.
Top up if necessary.
Charge the battery for at least 2 hours with a current of 0.4A.
Refit the battery and connect the vapour vent pipe.
Connect the red wire lug to the battery's + terminal, and the green wire lug to the battery's - terminal.
Then, the battery level should be topped up if necessary, after fully charging, using distilled water only.
Checks before handing over to the customer.
Check the wheel nuts are tight.
Check nuts and bolts are tight.
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 with the machine.
* Depending on equipment.
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