PEUGEOT Vivacity User Manual
Motor FB-0-1-2-4
GB
WORKSHOP MANUAL 50 cm3
CONTENTS
ENGINE PART
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
CYCLE PART
Designation Page
- Contents, ..............................................................1
- Main characteristics, ............................................ 2
- Maintenance plan,................................................ 3
- Putting into service, ..............................................4
- Tightening torques, ...............................................5
- Disc brake...........................................................14
RECOMMENDATIONS
Designation Page
- Spark plug.............................................................2
- Fuel ...................................................................... 4
- Separate lubrication..............................................4
- Relay unit ............................................................. 4
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
ELECTRIC EQUIPMENT
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
1
TECHNICAL DA TAS
Main spécifications
ENGINE MARKING
Number
Type
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 : .......................................................1 10 °
- 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 P A350
- 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
XXXXXXXX
FB2
Frame
IDENTIFICA TION MARK
Identification
plate
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 t anks full : ...................................88kg
T ransmission
- Clutch : .................................... centrifugai, automatic type
- Primary réduction gear : ........................ by a ribbed V-beit
- Life of belt :...................................................... 1 0 000 km
- Reducer equipped with 2 gearsets.
2
Trekker - Squab
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»)
MAINTENANCE
MAINTENANCE PLAN
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.
500 km or 3 mois
PLAN B
5000 km or 2500 km* 10000 km or 5000 km*
PLAN CPLAN A
CHECK :
Idle speed adjustment XXX
Throttle XXX
Oil pump control XXX
Functioning of the electric equipment XXX
Front and rear brake control XXX
Fuel pipes XXX
Oil pipes XXX
Front brake fluid pipes XXX
State and pressure of tyres X
State, pressure and wear of tyres XX
Brake fluid level XXX
Level of battery electrolyte XXX
Tightening of nuts and bolts XXX
REPLACE :
Relay unit oil XX
Spark plug XX
Filter element of the intake silencer XX
Front brake pads (if necessary) X
Rear brake linings (if necessary) XX
Drive pulley rollers (if necessary) XX
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 XXX
* reforced maintenance
Trekker - Squab
3
INSTRUCTIONS FOR MAKING OPERATIONAL
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:
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.
Capacity : ..........................................................1.3 litres.
- Fill up the oil tank with semi-synthetic engine oil for 2stroke engines with separate lubrication,
- T ype TC (API standard), type TSC3 (ASTM standard), -
- T ype FC (JASO st andard) or a synthetic oil.
PEUGEOT MOTOCYCLES recommends :
.......................................ESSO : 2T Special performance
.........................................................ESSO : 2T Synthetic
6. Checks before delivery to the
customer:
- In particular , check the tightening of the Wheel nut s ... -
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.
4
Trekker - Squab
Engine
TIGHTENING TORQUES AND SPECIAL TOOLS
TIGHTENING TORQUES SPECIAL TOOLS
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
- 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
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
Trekker - Squab
5
REMOVAL
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 cooling
systern
- Remove the two parts of the fan
covers (4 screws).
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.
Fitting of engine on service
cradle
64765
- Place the engine onto the adapter
752026
- Place the assembly on the cradle
mount 64765 clamped in a vice
752026
- Remove the 4 fastening screws of
the fan and remove the fan.
750806
68007
- 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.
6
- Remove the coil assembly and the
sensor.
Trekker - Squab
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.
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 primary
drive system
You do not have to remove of the kick
starter arm when removing the
crankcase cover.
- Loosen and remove the 1 1 fastening
screws of the cover.
- Remove the cover with both locating
dowls.
- Adjustment: see page N° 14
Rernoval of the starter
motor
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.
- Remove the starter drive assembly
from the starter motor.
- Hold the starter ring gear with the
tool 752370.
752370
- 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.
Trekker - Squab
7
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