PDF Workshop Repair Manual Peugeot Vivacity 50cc 100cc (1999-2005) - 8 MB
This digital workshop manual provides comprehensive repair and maintenance information for the Peugeot Vivacity 50cc and 100cc scooters manufactured between 1999 and 2005.
It includes detailed instructions, wiring diagrams, and specifications for all major systems.
Whether you're performing routine service or a complete engine overhaul, this manual is the ultimate guide for any owner or mechanic.
Keep your scooter running like new with this essential resource.
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--- Page 1 ---
Contents
LIVING WITH YOUR SCOOTER
Introduction
The Peuaeot Storv Paae 04
.
Acknowledgements Page 0.7
About this manual Page 0.7
Identification numbers Pane 0.8
Buying spare parts Page 0.9
Model development Page 0.9
Safety first! Page 0.11
Daily (pre-ride checks)
Engine oil level check Page 0.12
Coolant level check (liquid-cooled engines) Page 0.12
Brake fluid level check Page 0.13
Fuel check Paae 0.13
Suspension and steering checks Page 0.13
Tyre checks Page 0.14
Legal and safety checks Pane 0.14
MAINTENANCE
Routine maintenance and servicing
Model specifications and service schedules Page 1.2
Routine maintenance and servicing procedures Page 1.26
--- Page 3 ---
0.12 Daily (pre-ride) checks
Note: The daily @re-ride) checks outlined in your owner's manual covers those items which should be inspected on a daily basis.
Engine oil level check
Before you start: The correct oil: earliest opportunity. However, do not rely on
/ Make sure you have a supply of the correct Modern engines place great demarde nn the oil waming light to tell you that the oil tank
oil available. their oil. It is very importantt that the c eeds topping up. Get into the habit of
/ Support the machine in an upright position oil for your bike is used. hecking the oil level in the oil tank regularly,
whilst checking the level. Make sure it is on Always top up with a goo(j quality oil of the S1uch as at the same time as you fill up with fuel.
level ground. specified type. Peugeot specify a enmi- " U S , , ,
1 If the engine is run without oil, even for a
synthetic, JASO FC SAE20 oil for two- stroke s hort time, engine damage and very soon
engines with separate lubric:ation. engine seiziIre will occur. It is advised that a
If the oil level waming light: comes
.. .
on the oil bottle of t\ivo-stroke oil is carried in the
tank requires topping up immediately or at tho c'torage compartment for such emergencies.
Remove the filler cap to check the oil If the level is low, top the tank up with the
1 level; it should be up to the bottom of the 2recommended oil, then fit the filler cap
filler neck when full. securely.
Coolant level check (liquid-cooled models)
Warning: DO NOT leave open Before you start: Bike care:
containers of coolant about, as it Use only the specified coolant mixture. It is
/Make sure you have a supply of coolant
is poisonous. important that anti-freeze is used in the
available (a mixture of 50% distilled water and
50% Procor 3000 anti-freeze is needed). system all year round, and not just in the
Warning: Do not remove the winter. Do not top-up the system with water
Peugeot state that other anti-freeze products
reservoir cap when the engine is only, as the coolant will become too diluted.
will not mix with Procor 3000. If you are in any
hot. It is good practice to cover Do not overfill the reservoir tank, which is
doubt about the type of coolant already in the
the cap with a heavy cloth and turn the cap located behind the front panel on all models.
system, it is advised that you drain and flush
slowly anti-clockwise. If you hear a hissing The coolant level should be just below the
the cooling system (see Chapter 3) and refill
sound (indicating that there is still pressure bottom of the filler neck. Any surplus should
with the specified coolant mixture.
in the system), wait until it stops, then be siphoned or drained off to prevent the
/Always check the coolant level when the
continue turning the cap until it can be possibility of it being expelled.
engine is cold.
removed. If the coolant level falls steadily, check the
/ Support the machine in an upright position
whilst checking the level. Make sure it is on system for leaks (see Chapter 1). If no leaks
level ground. are found and the level continues to fall, it is
recommended that the machine is taken to a
Peugeot dealer for a pressure test.
Undo the screws securing the front panel Unscrew the reservoir cap - see Warning Top-up if necessary with the specified
1and remove the panel. 2above. The reservoir should be at least
half full.
3coolant mixture.
--- Page 4 ---
1.8 Model specifications and service schedules
Speedfight 2 50 LCDPILBDPILNDPILEDP,X-Team 50 LNDP,
X-Race 50 LNDP, WRC 206 50, Furious
Model identification
Engine .................................................. 49 cc single cylinder liquid-cooled two-stroke
Transmission ............................................. Variable speed automatic, belt driven
Ignition .................................................. Capacitor discharge ignition (CDI)
Frontsuspension ......................................... Leading link monolever
Rearsuspension .......................................... Swingarrn and single shock
Frontbrake .............................................. 180 rnrn disc
Rearbrake ............................................... 180 rnm disc
Fronttyresize ............................................ 120/70 x 12
Rear tyre size
2000to2002models ..................................... 140/70x 12
2003to2005models ..................................... 130/70x 12
Engineno.suffix .......................................... FL1
Frame no. prefix .......................................... VGASl B
Wheelbase ............................................... 1225 mm
Overalllength ............................................ 1730 mm
Overall width (excl. mirrors) ................................. 700 mm
Overall height (excl. mirrors) ................................ 1155 mm
Weight(dry) .............................................. 90 kg
Fueltankcapacity ......................................... 7.2 litres
Servicing specifications and lubricants
Sparkplug type ........................................... NGK BR7HS
Spark plug electrode gap ................................... 0.6 mm
Idlespeed ............................................... 1500 rpm
Fronttyrepressure ........................................ 19 psi (1.3 Bar)
Reartyrepressure ........................................ 23 psi (1.6 Bar)
Disc brake pad minimum thickness .......................... 1.5 mm
Throttle twistgrip freeplay .................................. 2to5mm
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded petrol (gasoline) min 95 octane
Engineoil ................................................ JASO FC, SAE 20 semi-synthetic
Engineoiltankcapacity .................................... 1.3 litres
Relayboxoil ............................................. 80W-90 scooter gear oil
Relayboxoilcapacity ..................................... 120 ml
Brakefluid ............................................... DOT 4
Coolant ................................................. 50% distilled water and 50% Procor 3000 anti-freeze is needed).
Peugeot state that other anti-freeze products will not mix with
Procor 3000.
--- Page 5 ---
1.28 Routine maintenance and servicing procedures
8.1 Check brake pad wear at the underside of the caliper 9.1 Rear drum brake wear indicator (A) and index mark (B)
material wear can be checked by looking at adjusted to compensate, the indicator moves for a small amount of freeplay in the cable,
the underside of the caliper (see illustration). closer to the index mark on the casing. To measured in terms of the amount of twistgrip
Alternatively, displace the caliper (see Chap- check the extent of brake wear, have an rotation before the throttle opens, and
ter 8)to check the amount of wear. assistant apply the brake firmly; if the compare the amount to the Specifications at
2 If the amount of friction material remaining indicator aligns with the index mark, the brake the beginning of this Chapter (see
on the pads is below 1.5 mm, new pads must shoes must be replaced with new ones (see illustration).
be fitted. Chapter 8). 4 If there is insufficient or excessive freeplay,
Warning: Brake pads often wear a t loosen the locknut on the cable adjuster, then
A different rates. I f there i s any
doubt about the condition o f either
o f the pads in a caliper, remove the caliper
4" nrottle cable -
~ c and
k adjustmenl &% turn the adjuster until the specified amount of
freeplay is evident, then retighten the locknut
(see illustration). If the adjuster has reached
and check. Brake failure will result i f the its limit of adjustment, replace the cable with a
friction material wears away completely. new one (see Chapter 4).
3 Refer to Chapter 8 for details of pad 5 Start the engine and check the idle speed. If
removal, inspection and replacement. All models the idle speed is too high, this could be due to
1 Ensure the throttle twistgrip rotates easily incorrect adjustment of the cable. Loosen the
from fully closed to fully open with the locknut and turn the adjuster in - if the idle
9 Brake sFn@a- handlebars turned at various angles. The speed falls as you do, there is insufficient
check twistgrip should return automatically from fully freeplay in the cable. Reset the adjuster (see
open to fully closed when released. Step 4). Note: The idle speed should not
2 If the throttle sticks, this is probably due to change as the handlebars are turned. I f i t
1 The rear drum brake is equipped with a a cable fault. Remove the cable and lubricate does, the throttle cable is routed incorrectly.
wear indicator (see illustration). it (see Chapter 4). Rectify the problem before riding the scooter
2 As the brake shoes wear and the cable is 3 With the throttle operating smoothly, check (see Chapter 4).
I -
10.3 Throttle cable freeplay is measured in terms of twistgrip 10.4 Throttle cable locknut (A) and adjuster (B)
rotation
--- Page 6 ---
2A.4 Air-cooled two-stroke engine
5.14 Remove the bolts securing the rear shock (A) and the 7.2a The engine cowling is secured by a bolt on the cooling fan
frame (B) to the engine unit cowling.. .
caliper, then temporarily refit the rear wheel cleaner. A high flash-point solvent, such as Remove the oil pump (see Section 13)
(see Chapter 8). Unclip the brake hose from paraffin can be used, or better still, a Remove the reed valve (see Chapter 4)
the underside of the drive belt casing (see proprietary engine degreaser such as Gunk. Remove the starter motor (see Chapter 9)
.
illustration 5.12) Use an old paintbrush to work the solvent into Separate the crankcase halves (see
14 Check that all wiring, cables and hoses are the various recesses of the engine casings. Section 14)
clear of the engine/transmission unit. With the Take care to exclude solvent or water from the
aid of an assistant, support the weight of the electrical components and inlet and exhaust Reassembly
machine on the rear grab handle. Remove the ports. 6 Reassembly is accomplished by reversing
bolt securing the rear shock absorber to the Warning: The use o f petrol the general disassembly sequence.
transmission casing, then remove the front
engine mounting bolt and lift the frame away
from the engine/transmission unit (see
A (gasoline) as a cleaning agent
should be avolded because of the
risk of fire.
i" +
7 Cylinder head -
"' ..-- -.w *-. sg
illustration). 2 When clean and dry, arrange the unit on the removal, inspecti
15 If required, remove the stand (see Chap- workbench, leaving suitable clear area for and installation
ter 6) and the rear wheel (see Chapter 8). working. Gather a selection of small
containers and plastic bags so that parts can Note: This procedure can be camed out with
Installation be grouped together in an easily identifiable the engine in the frame. If the engine has been
16 Installation is the reverse of removal, manner. Some paper and a pen should be on removed, ignore the steps that do not apply.
noting the following points: hand to permit notes to be made and labels Caution: The engine must be completely
Make sure no wires, cables or hoses attached where necessary. A supply of clean cool before beginning this procedure or the
become trapped between the engine and the rag is also required. cylinder head may become warped.
frame when installingthe engine. 3 Before commencing work, read through the
appropriate section so that some idea of the
Removal
Tighten the engine mounting bolts to the
torque settings specified at the beginning of necessary procedure can be gained. When 1 Remove the body panels as necessary
this Chapter. removing components it should be noted that according to model (see Chapter 7).
Make sure all wires, cables and hoses are great force is seldom required, unless 2 Pull the spark plug cap off the spark plug,
correctly routed and connected, and secured specified. In many cases, a component's then remove the bolts securing the engine
by any clips or ties. reluctance to be removed is indicative of an cowling and remove the cowling, noting how
Bleed the oil pump (see Section 13) and -
incorrect approach or removal method if in it fits (see illustrations).
check the adjustment of the oil pump cable any doubt, re-check with the text. 3 Remove the spark plug, then unscrew the
where fitted (see Chapter 1). 4 When disassembling the engine, keep
Check the operation of the rear brake 'mated' parts that have been in contact with
before riding the machine (see Chapter 8). each other during engine operation together.
These 'mated' parts must be reused or
renewed as an assembly.
6 Disassembly and 5 Complete engine disassembly should be
reassembly - done in the following general order with
general infonnatiorI reference to the appropriate Sections. Refer
to Chapter 2C for details of transmission
components disassembly.
Disassembly Remove the cooling fan (see Section 11)
1 Before disassembling the engine, the Remove the alternator (see Chapter 9)
external surfaces of the unit should be Remove the variator (see Chapter 2C)
thoroughly cleaned and degreased. This will Remove the cylinder head (see Section 7)
prevent contamination of the engine intemals, Remove the cylinder (see Section 8) 7.2b .. .a bolt on the left-hand side front
and will also make working a lot easier and Remove the piston (see Section 9) of the cowling . . .
--- Page 7 ---
2A.14 Air-cooled two-stroke engine
: : : : ;L
TOGETHER
qg
.
14.29b Installing the crankshaft with the
Peugeot service tools
Nz~Y
WASHER
WELD
M I 0 x 1.25mm
PITCH NUT
THREADED 40mm DIAMETER
H32761 ROD STEEL TUBE
14.29~Installing the crankshaft with the
home-made tool 14.29d Details of the home-made tool for installing the crankshaft
two-stroke oil, then, if the main bearing is in the 30 Wipe the mating surfaces of both
crankcase half, pull the crank assembly into crankcase halves with a rag soaked in a
place ensuring the connecting rod is aligned suitable solvent and fit the dowels and new
with the crankcase mouth. Peugeot produce gasket to the left-hand half (see illustration).
five individual service tools (Pt. Nos. 752168, 31 Now fit the right-hand crankcase half.
64706,750069,64710 and 69104)to do this Lubricate the shaft, seal and bearing with the
(see illustration). Alternatively, use the set-up specified two-stroke oil, then, if the main
shown (see illustrations). If the main bearing is bearing is in the crankcase half, press the
on the crankshaft, heat the bearing housing in crankcase half into place. Peugeot produce
the crankcase with a hot air gun before fitting five individual service tools (Pt. Nos. 750808,
the crank assembly (see illustration). Note: 64706,750069,64710 and 69104)to do this
Avoid applying direct heat onto the crankshaft (see illustration). Alternatively, place a thick
oil seal. washer over the centre of the crankcase to
14.29e Heating the crankcase with a hot
air gun
14.30 Install the crankcase dowels (A) and gasket (B) 14.31 Installing the right-hand crankcase half with the Peugeot
service tools
--- Page 8 ---
Transmission 2 0 3
3.3 Kickstart lever rest position 3.43 Remove the circlip .. . 3.4b . . .and washer from the kickstart
shaft
3.5 Release the tension in the spring and 3.6a Unhook the spring from the post 3.6b . . .and remove the kickstart bush
unhook it from the quadrant (arrowed) ...
F a r and that the lever returns to its proper 2 Pull the engaging pinion out of its recess in 6 Note how the return spring locates inside
3:position afterwards. Fit the bracket over the cover, noting how the spring locates (see the cover and remove the spring and kickstart
-o rear brake cable or hose and secure it to illustration 2.3). Remove the washer from bush (see illustrations).
-o underside of the drive belt cover with the behind the pinion. 7 Clean all the components with a suitable
Zccw . 3 Note the rest position of the kickstart lever, solvent.
then undo the lever pinch bolt and pull the
lever off the shaft (see illustration). Inspection
3 Kickstart mechanism - 4 Remove the circlip and washer (if fitted) 8 Check the dogs on the end of the engaging
removal, inspection from the kickstart shaft on the outside of the pinion and the corresponding dogs on the
and installation cover (see illustrations). kickstart driven gear (see illustrations).
5 Ease the kickstart shaft out of the cover and lnspect the teeth on the engaging pinion and
release the tension on the kickstart return spring. the teeth on the kickstart quadrant (see
Removal Unhook the spring from the kickstart quadrant illustrations). Check the shafts of the
Semove the drive belt cover (see Section 2). and remove the shaft (see illusbation). engaging pinion and the kickstart quadrant,
3.8a Inspect the dogs (A) and teeth (B) on the engaging pinion 3.8b Inspect the dogs on the kickstart driven gear (arrowed)
--- Page 9 ---
Chapter 3
Cooling system (liquid-cooled engine)
Refer to Chapter 1 for model identification details
Contents
Coolant hoses - removal and installation ..................... 8 General information ...................................... 1
Coolant level check .................. .see Daily (pre-ride) checks -
Radiator removal and installation .......................... 6
Coolant reservoir - removal and installation ................... 5 Temperature gauge and sender - check and replacement . . . . . . . . 3
Cooling system checks ..........................see Chapter 1 Thermostat - removal, check and installation .................. 4
Cooling system - draining, flushing and refilling ................ 2 Water pump - check, removal and installation ................. 7
Degrees of difficulty
Easy,suWfa
novicewithl i i
experience
$ F~eas~,suW
g for beginnerwith
$ mexpeknce
$ D M a l s s u ~'%~ V a y ~
suitable for competent \experienced DIY
$ mechanic
a
$ a p o ~ i $
1
suitableforexpertDIY s?
\
Specifications
Coolant
Typeandmixture .......................................... 50% distilled water and 50% Procor 3000 anti-freeze is needed.
Peugeot state that other anti-freeze products will not mix with
Procor 3000.
Temperature sender
Resistance
@20°C ................................................ 1.91 to 2.58 K-ohms
@90°C ............................... . . . . . . . . . . . . . . . . . 92 to 124 ohms
Torque settings
Water pump mounting bolts ................
- - -
prevent the coolant flowing to the radiator attracted by its sweet smell and may drink
General informatiion when the engine is cold, therefore it. Check with the local authorities about
accelerating the speed at which the engine disposing of used antifreeze. Many
reaches normal operating temperature. A communities will have collection centres
coolant temperature sender mounted in the which will see that antifmze is disposed of
The cooling system uses a watedantifreeze cylinder head is connected to the temperature safely. Antifreeze is also combustible, so
coolant to cany excess energy away from the gauge on the instrument panel. don't store it near open flames.
Warning: Do not remove the
engine in the form of heat. The coolant is
contained within a water jacket inside the
cylinder and cylinder head which is connected
to the radiator and the water pump by the
A reservoir cap when the engine is
hot. Scalding hot coolant and
steam may be blown out under pressure,
Caution: At all times use the specified type
of antifreeze, and always mix i t with
distilled water in the correct proportion.
The antifreeze contains corrosion
coolant hoses. which could cause serious injury. inhibitors which are essential to avoid
Coolant heated by the engine is circulated Warning: Do not allow antifreeze damage to the cooling system. A lack of
by thermo-syphonic action, and the action of
the pump, to the radiator. It flows across the
radiator core, where it is cooled by the
A to come in contact with your skin
or painted or plastic surfaces of
the scooter. Rinse off any spills immediately
these inhibitors could lead to a build-up of
corrosion which would block the coolant
passages, resulting in overheating and
passing air, then through the water pump and with plenty of water. Antifreeze is highly severe engine damage. Distilled water
back to the engine where the cycle is toxic if ingested. Never leave antifreeze must be used as opposed to tap water to
repeated. lying around in an open container or in avoid a build-up of scale which would also
A thermostat is fitted in the cylinder head to puddles on the floor; children and pets are block the passages.
--- Page 11 ---
Fuel and exhaust systems 4.5
6 Air filter housing -
removal and installation
Removal
1 Remove the cover from the air filter housing
and remove the filter element (see Chapter 1).
2 Unscrew the bolts securing the air filter
housing to the transmission casing and
manoeuvre the housing away, noting how it
fits (see illustrations).