Page 1
Sales division
Technical network leadership
TECHNICAL TRAINING
-
50 CC. 2 STROKE
P/N.VIVA3.001.01/2008.GB V1
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Sales division
Technical network leaders hi p
Reproduction or translation, even partial, is forbidden without the written consent of P eugeot Motocycles
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TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS . ... .......................................... .......................................... .............................................1
PRESENTATION OF THE MACHINE............................................................................................................... 2
PRODUCT HIGHLIGHTS ....... .......................................... .... ... ... ... .......................................... .... ......................3
CHARACTERISTICS......................................................................................................................................... 4
ENGINE .............................................................................................................................................................5
Lubrication/Ignition.....................................................................................................................................6
Oil pump control unit..................................................................................................................................7
Electric oil pump.........................................................................................................................................7
Exhaust......................................................................................................................................................7
Petrol circuits..............................................................................................................................................8
Vacuum pump............................................................................................................................................8
Carburettor.................................................................................................................................................9
Pollutant emission control system............................................................................................................10
CYCLE PART ................... .......................................... ... ... .......................................... .... ... . ............................. 11
Chassis....................................................................................................................................................11
Dimensions and weight.......... ... ... .......................................... .... .......................................... .. ..................11
Brakes......................................................................................................................................................12
BODY PANELS ...............................................................................................................................................13
Description...............................................................................................................................................13
Body component sequence of disassembly.............................................................................................14
INSTRUMENT PANEL. ...................................................................................................................................15
Outside temperature gauge .....................................................................................................................15
Diagnostic. ...............................................................................................................................................15
LOCATION OF COMPONENTS...................................................................................................................... 16
WIRING DIAGRAM........ ... .......................................... .......................................... ...........................................17
Allumage/Commande de pompe à huile. (ACPH)....................................................................................17
SERVICE SCHEDULE AND COMMISSIONING.............................................................................................18
SPECIAL TOOLS ............................................................................................................................................20
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
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PRESENTATION OF THE MACHINE
PRESENTATION OF THE MACHINE
- The segment on which the Vivacity has been marketed since it was launched (1998) has
considerably changed over the last three years, further to the arrival of a great number of competing
vehicles on West European markets.
- The segment of (compact/basic) scooters accounts for a considerable share of the overall 50 cc
scooter market, 38% on average in Europe, that is to say 142000 units. It was esp ecially developed
on Southern markets where attractive prices and the aspect of utility are essential purchasing
factors.
Customer profiling.
• No driving license.
• Traffic and parking problem.
• Used instead of a 2nd car.
Our offer.
- The new Vivacity is an original vehicle which is modern and essential and which shall be a front
runner on the 2 -wheeler market thanks to 4 key success factors:
• A structured graceful design which is modern and status enhancing: The overall outline of
the vehicle gives a feeling of riding stability and sturdiness.. Its slender shape enhanced by an
aerodynamically-slick and structured profile, as well as the clever layout of its headlights make it
an elegant vehicle..
• Optimized practical features: Its harmoniously proportioned outline perfectly inegrates the
exceptional storage capacity of a scooter of such a category: Although it is compact, it features
ideal riding stability and many storage arrangements..
• Considering the wide variety of features offered, its very attractive price is lower than the curre nt
Vivacity..
• A very complete lineup is soon available.
2
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Page 5
PRODUCT HIGHLIGHTS
PRODUCT HIGHLIGHTS
Modernism.
Exhaust muffler trim.
3 spoke aluminium rims.
Built-in deflector offered as
standard equipment
Blue retro-lit instrument panel.
New horizontal engine.
Design.
Mini GT look (aerodynamically-
slick front outline in comparison
with capacious back which is
more familiar and attractive).
Its styling features emphasizes
the spirit of the brand
(aestheticism, dynamism and
innovation).
High quality finish.
Price.
Knock-down price for a
maximum of funtional features.
Cheap price and cost effective.
Compactness.
Optimized overall dimensions.
Well thought out seat height.
Record roominess.
Fuel efficiency.
8.5 l fuel tank
Record storage capacity with
35 l of total usable volume
Ergonomics.
Optimized Floor panel-to-seat
distance.
Ergonomic riding position.
Well dimensioned dual seat
Protective front body panel.
Low centre of gravity.
Functional features.
Clever storage arrangements.
Front and underseat storage
compartment.
Utility hanger.
Flat floor panel.
12 V plug offered as standard
equipment.
Optional parcel carrier and top
case.
Riding comfort and safety.
Aluminium passenger grab
handle.
Kickstand offered as standard
equipment.
Built-in footrests.
12" wheels.
Flat floor panel.
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CHARACTERISTICS
CHARACTERISTICS
Marking
Type 2-stroke single-cylinder. Horizontal cylinder
Cooling
By a circulation of forced air by means of a turbine on the
flywheel magneto
Bore x stroke 39.9 x 39.8 mm
Cubic capacity 49.9 cc
Max. power output 3 kW at 7000 rpm
Max. torque rating 4 Nm at 5800 rpm
Fuel supply PZ Ø12 carburettor
Lubrication
Separate lubrication by an electric pump driven by the Oil Pump
Control Ignition Unit
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Spark plug NGK BPR7HS
Magneto flywheel 80W
Exhaust Catalytic
Standards Euro2
4
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Page 7
ENGINE
2-stroke single-cylinder. Air cooling.
Cast iron cylinder.
Direct intake via valves into the crankcase.
Cast aluminium alloy engine crankcase.
ENGINE
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ENGINE
DELL'ORTO
Lubrication/Ignition.
- Separate lubrication by an electric pump driven by the Oil Pump Control Ignition Unit.
- 1.3 l tank capacity.
45
40
50
8
30
20
25
20
10
10
mph
0
km/h
F
30
60
40
70
50
80
°
C
km
E
IP
TR
ACPH
9
1
4
2
6
1. Oil tank.
2. Electric oil pump.
3. Carburettor.
4. Oil pump control unit.
5. Ignition sensor.
7
L
EL
LEVE
LEV
ER
UPPER
LOW
-
5
3
R
6. HT coil.
7. Battery.
8. Oil level indicator.
9. Low oil level and oil pump electric
diagnostic warning light.
6
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Page 9
Oil pump control unit.
H
CP
A
Electric oil pump.
ENGINE
By processing the data received by the ignition
sensor, the control unit provides the following
funstions:
- Ignition.
- Calculated quantity of injected oil.
- Diagnostic of the system by lighting the oil
warning light on the instrument panel.
The oil pump which is governed by the control
unit sends oil to the carburettor's venturi.
The flow depends on the engine's running
speed.
Exhaust.
1. Exhaust pipe.
2. Catalyser cone.
3. Catalytic block.
4. Heat insulation.
5. Injected air intake.
4
3
2
5
1
NC
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ENGINE
Petrol circuits.
4
3
R
1
2
1. Fuel tank.
2. Petrol filter.
Vacuum pump.
1
NC
3. Vacuum pump.
4. Carburettor.
Functioning.
Under the effect of pulses, the diaphragm (1)
pumps in and out the fuel by means of reed
valves (2) and (3).
3
4
Safety.
When the ball (4) lifts, fuel can flow into the
pump when the needle valve closes inside the
carburettor or when there is a boost pressure at
the fuel pump outlet.
2
NC
8
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Page 11
Carburettor.
ENGINE
9
1
2
4
7
1. Piston.
2. Needle.
3. Idle jet.
4. Venturi.
5. Main jet.
6. Float and needle.
7. Idle screw.
8. Mixture screw.
9. Petrol filter.
8
6
5
3
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ENGINE
Pollutant emission control system.
Pulsair.
Catalytic exhaust
1
R
3
4
2
10
1. Silencer.
2. Primary filter.
3. Pulsair reed valve.
4. Catalytic block.
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CYCLE PART
Chassis.
Front suspension
CYCLE PART
Chassis Steel tube
32 mm Ø telescopic front fork
Oil capacity: 85 cc
Travel: 75 mm
Rear suspension
Combined spring and hydraulically-damped shock absorber
Travel: 65 mm
Front tyre 120/70 - 12
Rear tyre 120/70 - 12
Front tyre pressure 1.8 bars
Rear tyre pressure 2 bars
Dimensions and weight.
Length 1923 mm
Width 670 mm
Height (without rear-view mirrors) 1170 mm
Saddle height 786 mm
Wheelbase 1337 mm
Weight 95 kg
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CYCLE PART
Brakes.
Single disc type, hydraulic control
Disc diameter and thickness: 200 mm- 3.5 mm
Front brake
cable-controlled, single cam drum type
Brake drum diameter: 110 mm
Brake lining thickness: 4 mm
12
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Cable controlled rear brake
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BODY PANELS
NC
Description.
BODY PANELS
2
1
3
4
8
6
7
1. Handlebar front fairing
2. Handlebar rear fairing
3. Tool compartiment cover
4. Front storage compartment
5. Rear shield
6. Front mudguard
7. Front wheel
10
14
9
5
11
8. Front shield panels
9. Saddle and storage compartment
10.Central panel
11.Footboard
12.Grab handle
13.Rear panels
14.Bottom panel
12
13
13
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Page 16
BODY PANELS
Body component sequence of disassembly.
1*
2
6*
3*
4
5*
14*
9*
10
12*
7*
1. Handlebar front fairing
2. Handlebar rear fairing
3. Tool compartiment cover
4. Front storage compartment
5. Rear shield
6. Front mudguard
7. Front wheel
* : This item may be removed on its own
8
11
8. Front shield panels
9. Saddle and storage compartment
10.Central panel
11.Footboard
12.Grab handle
13.Rear panels
14.Bottom panel
13
14
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Page 17
INSTRUMENT PANEL.
-
45
40
mph
km/h
50
30
60
40
70
50
80
20
30
20
25
10
10
0
INSTRUMENT PANEL.
If the low oil warning light (1) goes on or blinks, it
means that the function of the engine's lubrication
system is faulty.
F
C°
E
km
TRIP
Goes on if the temperature is lower than 3 °C
1
Outside temperature gauge
Outside temperature sensor.
Checking values:
- 45°C 4.912 kΩ.
- 20°C 12.09 kΩ.
- 0°C 27.28 kΩ.
- -10°C 42.45 kΩ.
Diagnostic.
Note: The light comes on when the ignition is turned on to check it is operational and comes
off as soon as the engine starts if there is no incident.
The engine is running :
1. If the low oil warning light (1) flashes or ramains lit, replenish the oil tank.
2. If the low oil warning light flashes or remains lit, with the correct oil level function, carry out the
trouble-shooting method. (See manual and method N°26 page 9).
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LOCATION OF COMPONENTS
NC
LOCATION OF COMPONENTS
7
2
-
14
EL
V
L
E
E
L
V
R
LE
PE
R
P
E
U
W
O
L
11
4
6
1
12
8
9
5
3
10
13
1. Oil pump control unit.
2. Battery.
3. Magneto flywheel.
4. Oil level indicator.
5. Oil pump.
6. HT coil.
7. Low oil level warning light.
8. Regulator.
9. Starter motor relay.
10.Fuel gauge.
11.Horn.
12.Outside temperature sensor.
13.Speed sensor.
14.Fuses
16
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Page 19
WIRING DIAGRAM
Ignition/Oil pump cable. (ACPH)
WIRING DIAGRAM
VE
4
ON
2
VEL
UPPER LE
LOWER LEVEL
-
OFF
3636
3165
VE
NR
VE
45
40
50
30
20
25
20
10
10
0
F
30
60
40
70
50
mph
80
km/h
C°
km
E
TRIP
BA-BE
JN-NR
8735
7,5A
VE
RGRG
8
1
7
BA-NR
RG-BA
62 41
RS
JN-BE
BA-BE
VE
6
1. Oil pump control unit.
2. Battery.
3. Ignition sensor.
4. Ignition switch.
5
3
5. Oil pump.
6. Oil level indicator.
7. Low oil level warning light.
8. Ignition coil.
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SERVICE SCHEDULE AND COMMISSIONING
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing applies to vehicles used under rugged operating conditions: door-to-door
deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient
temperature over 30°C.
Heavy duty servicing 500 kms
Check.
Service operations
1000 kms or
1 months
Every
5000 kms
Every
2500 kms
Every
10000 kms
Every
5000 kms
Every
20000 kms
Every
10000 kms
Throttle cable play C C C C
Steering column play C C C C
Operation of electrical equipment C C C C
Condition of front and rear brake hydraulic
controls
CCCC
Condition of petrol pipes C C C C
Condition of oil pipes C C C C
Tyre condition, pressure and wear C C C C
Condition of the front suspension C C C C
Condition of the rear suspension C C C C
Brake fluid level C C C C
Battery electrolyte level * C C C C
Tightness of nuts and bolts C C C C
Change.
Spark plug R R
Filter element C R R
Front brake pads # C C C
Rear brake linings # C C C
Drive pulley bearings and guides # C C
Transmission belt R
Petrol filter C
Relay box oil R C
Brake fluid Once every 2 years
C: Check.
N: Clean.
R: Change.
G: Check and lubricate.
*Depending on equipment.
# Change if necessary.
18
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Page 21
SERVICE SCHEDULE AND COMMISSIONING
Service operations
Heavy duty servicing 500 kms
Check and lubricate.
Driven pulley: Moving flange and needle
bush.
1000 kms or
1 months
Every
5000 kms
Every
2500 kms
Every
10000 kms
Every
5000 kms
Every
20000 kms
Every
10000 kms
GG
Drive pulley/Movable face G G
Test machine.
On road CCCC
C: Check.
N: Clean.
R: Change.
G: Check and lubricate.
*Depending on equipment.
# Change if necessary.
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SPECIAL TOOLS
SPECIAL TOOLS
Tool N° Designation
Casing
64706
extractor and
opening tool
Shouldered
64710
centering
tool
64765
Engine
mount
Used
with
754006
750069
Tool N° Designation
750539
64706 750808
755982 752000
Tie-wrap
pliers
Thrust
washer
Piston circlip
pliers
Used
with
64706
Protective
68007
end-piece
755985 752127
small model
Protective
69098
end-piece
64706 752237
large model
69104 Pin nut 750069 754006
750069
Pin Ø10
pitch 125
69104 755585
Clutch
compression
tool
Adjustable
pin wrench
Modified
casing
opening
plate
Bearing
extractor tool
756725
67706
20
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Page 23
SPECIAL TOOLS
Tool N° Designation
Engine
755982
mount
adapter
755983
755985
Casing
opening tool
Flywheel
puller
Used
with
Tool N° Designation
Crank
64765 756668
assembly lip
seal tool
68007 756725
38 mm pipe
wrench
68007 757860 Steering tool
Used
with
752127
755996 Hose clamp
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