WO

RK

SH

OP

MA

NU

AL

50 c

m3 Motor FB-0-1-2-4

GB

Trekker - Squab

CONTENTS

ENGINE PART CYCLE PART

RECOMMENDATIONS

ELECTRIC EQUIPMENT

1

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

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

Designation Page

- Contents, .............................................................. 1- Main characteristics, ............................................ 2- Maintenance plan, ................................................ 3- Putting into service, .............................................. 4- Tightening torques, ............................................... 5- Disc brake ........................................................... 14

Designation Page

- Spark plug ............................................................. 2- Fuel ...................................................................... 4- Separate lubrication .............................................. 4- Relay unit ............................................................. 4

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

TECHNICAL DATAS

Frame

ENGINE MARKING

XXXXXXXXFB2

NumberType

Main spécifications

2

IDENTIFICATION MARK

Identificationplate

FB2 ENGINEForced-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 kwDistribution :- Exhaust port : ........................................................... 160c°- Scavenging port : ....................................................... 110°- 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 : ..................................................... 0.6mmCarburettor : .......................................... GURTNER PA350- 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 : ........................................................................ 74Flywheel magneto :- Number of poles : ............................................................ 6- Power : .......................................................... 2500t = 55w........................................................................ 5000t = 85wStarter.motor : .................................................... MITSUBA................................................................ 2000w SM10 129................................................................. 1500w SM10254Oil pump : .............................................................. MIKUNIflow 24cm3 ± 1.7cm3 / hour at 3800 rpm, wide openthrottle. 1CM3 = 0.031 cubic inch

Transmission

- Clutch : .................................... centrifugai, automatic type- Primary réduction gear : ........................ by a ribbed V-beit- Life of belt : ...................................................... 1 0 000 km- Reducer equipped with 2 gearsets.

Identification : VGAS1A . . . . . . . . . . .

- Front tyre : ...................................................... 120/90 x 10- Rear tyre : ...................................................... 130/90 x 10Pressure :- 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 : ........................................................670mmExcluding rear view mirror :Overall height : ...................................................... 1110mmExcluding rear view mirror :Wheelbase : ..........................................................1250mm

Weight

- Complete vehicle dry weight : .................................... 82kg- Vehicie weight with tanks full : ................................... 88kg

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»)

Trekker - Squab

MAINTENANCE

PLAN CPLAN A PLAN B500 km or 3 mois 5000 km or 2500 km* 10000 km or 5000 km*

* reforced maintenance

3

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 CThe 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 urbanuse (courrier), short journeys engine cold, areas with dusty atmospheres, frequent use of vehicles at an ambient temperatureabove 30°C.

CHECK :Idle speed adjustment X X XThrottle X X XOil pump control X X XFunctioning of the electric equipment X X XFront and rear brake control X X XFuel pipes X X XOil pipes X X XFront brake fluid pipes X X XState and pressure of tyres XState, pressure and wear of tyres X XBrake fluid level X X XLevel of battery electrolyte X X XTightening of nuts and bolts X X X

REPLACE :Relay unit oil X XSpark plug X XFilter element of the intake silencer X XFront brake pads (if necessary) XRear brake linings (if necessary) X XDrive pulley rollers (if necessary) X XTransmission belt X

CHECK AND UNCLOGPiston XCylinder head XExhaust port X

CHECK AND LUBRICATEDriven pulley :movable driven face and needle bearing XDrive pulley :movable drive face and rollers XKick : driven gear and link ring X

CLEAN AND ADJUSTCarburettor X

VEHICLE TESTRoad test X X X

MAINTENANCE PLAN

Trekker - Squab

INSTRUCTIONS FOR MAKING OPERATIONAL

4

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 markedUPPER 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 thelevel if necessary.- Charge the battery for 1 to 2 hours with a current of400m.A (0.4A).- Replace the battery and connect the breather tube.- Connect up the red positive leads to the battery positiveterminal, then the green negative lead to the battery earthterminal.- 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:

Capacity : .......................................................... 1.3 litres.- Fill up the oil tank with semi-synthetic engine oil for 2-stroke engines with separate lubrication,- Type TC (API standard), type TSC3 (ASTM standard), -- Type FC (JASO standard) or a synthetic oil.PEUGEOT MOTOCYCLES recommends :....................................... ESSO : 2T Special performance......................................................... ESSO : 2T Synthetic

4. Putting fuel and oil circuits intoopération:

- 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 iscompletely primed. Remove the oil bleed screw from thepump to allow air in the circuit to escape. When acontinuons stream of oil issues from this hole, replace thebleed screw with its fiber washer.For this : disconnect the oil intake hose to the carburettorand check that it drips, frequency depending on theengine’s speed.- Top up the fuel tank with pure 4 star petrol.

5. Checking the oil level in thetransmission case:

- Unscrew and remove the oil filler hole screw A andmake sure that the oil level is flush with the level of thefilling hole. The vehicle must be positioned on its standand on a level surface.Esso Oil SAE 80 W 90REF : .................................................................... 753009capacity 0. 1 2 litreA = 1.2m.daN.

6. Checks before delivery to thecustomer:

- In particular, check the tightening of the Wheel nuts ... -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 variouswarning lights.- vehicle road test.

Trekker - Squab

TIGHTENING TORQUES AND SPECIAL TOOLS

TIGHTENING TORQUES SPECIAL TOOLS

5

Engine

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

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

- 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

Trekker - Squab

REMOVAL

6

64765 752026

68007

750806

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 (largehose) - Radio interference suppressor cap - Rear brake control cable

Disconnect : - The wiring harness on the frame’sright tube: located at the outlet of theFlywheel magneto (under the footboard), choke, starter motor.

Remove : - The lower anchor bolt of the shockabsorber and the front anchor pin ofthe engine.

Removal of the flywheelmagneto

- Block the rotor using a notch type pin752237.

- Remove the nut (right-hand thread).- Fit the crankshaft end protector68007 onto the end of the crankshaft.

- Screw the flywheel puller tool 750806onto the rotor and tighten the centrebolt until the rotor comes away.- Remove the 2 fastening screws ofthe sensor, as well as the 2 fasteningscrews of the stator plate.

- Remove the coil assembly and thesensor.

Removal of coolingsystern

- Remove the two parts of the fancovers (4 screws).

- Remove the 4 fastening screws ofthe fan and remove the fan.

Fitting of engine on servicecradle

- Place the engine onto the adapter752026- Place the assembly on the cradlemount 64765 clamped in a vice

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752370

7

REMOVAL

Removal of the oil pump

- Unclip the oil inlet pipe to thecarburettor.- Unscrew the 2 hex head socketscrews.- Remove the oil pump and the controlflange.- Remove the 2 square fastening nutsQ from their housings.- Remove the flexible washer lodgedbetween the pump and the shaftbearing of the oil pump.

- Adjustment: see page N° 14

Rernoval of the startermotor

- Free the wire harness from thesupport bracket.- Remove the 2 fastening screws andwashers from the starter motor andpull out together with «0» ring seal.

Removal of thecarburettor / choke

assembly

- Take off the 2 fastening screws fromthe carburettor and remover thecarburettor / chokeassembly, as well as the isothermalspacer.

Removal of the reedvalve and intake pipe

- Unscrew and remove the 4 fasteningscrews.- Remove the intake pipe, the gasket,the reed valve assembly and thesecond gasket.

Removal of the primarydrive system

You do not have to remove of the kickstarter arm when removing thecrankcase cover.- Loosen and remove the 11 fasteningscrews of the cover.

- Remove the cover with both locatingdowls.

- Remove the starter drive assemblyfrom the starter motor.

- Hold the starter ring gear with thetool 752370.

Trekker - Squab

REMOVAL

8

752237

Rdl 12,35x19,75x1

Make careful note of where this toolcomes level with the starter ring gearplate of the starter motor in order tomake sure, when refitting, that thepressure plate fits correcte into thegrooves of the crankshaft.- Loosen the fastening nut (right-handthread) of the gear plate of the drivepulley.- Remove the nut, washer and plate.- Remove the belt.- Remove the drive pulley assembly(variable speed drive) and the washeron the engine housing side (12,35 X19,75 X 1).

- Block the clutch drum with the fly-wheel pinch bolt no.68570 or the ad-justable pin type face wrench 752237.

- Loosen the screw, remove the drumand the clutch driven pulley assembly.

Removal of the kickstarter system

- Actuate the kick starter spindle withyour thumb and remove the driveratchet and its washer.

- Remove the kickstarter lever. Usingsnipe-nosed pliers (ref. 69117), takeoff the circlips, the washer, thenremove the kick starter toothedsection, the pull-back spring and thebushing.

Removing the cylinderhead

- Unscrew in a crosswise order the 4screws securing the cylinder head andcylinder block assembly.- Remove the cylinder head andgasket.

Dismantling thetransmission case

After draining the transmission case:- Remove the 5 screws securing thecover.

- Remove the cover with the driveshaft (or input shaft), the gasket andboth locating dowls.

- Removal of the drive shaft (or inputshaft) from the transmission cover isdone using a mallet.- Remove the thrust washer from thecounter shaft (14.3x26xO.5).

- Drain the transmission casecompletely before removing the finalshaft (or output shaft) in order to avoidcontamining brake linings.- Pull out the final shaft (output shaft).

- Pull out the countershaft as well asits friction washers (1 4.3 x 26 x 0.5)and flexible washer (1 4 x 22 x 1.5).

Trekker - Squab

REMOVAL

9

750807

64706

752168

69098

Removing the cylinderand piston

- Remove the cylinder and cylinder-to-crankcase gasket.- Pack the crankcase mouth withclean cloth or paper.

- Lean the engine to the left and takeout the wrist pin’s RH snap ring.- Push the wrist pin from the left to theright; this opération does not requireuse of a strap.- Take out the needie bearing race.

Opening the crankcase

- Remove the 6 screws securing theRH crankcase half.

- Fit the crankshaft end protector68007 onto the end of the crankshaft.- Position the puller tool 750807 ontothe crankcase half.

- Turn the inner thrust bolt of tool750807 until the crankcase halvessplit Hold the connecting rod so that itdoes not knock against the crankcasehalves.- Remove the RH half casing.

- Remove the gasket and bothlocating dowls. Remove the driveshaft of the oil pump and its locatingbush.

Changing the bearingsand seals

- Heat the crankcase halves evenly to90° so that they expand. The bearingswill drop out, drive out the seals.- Fit the new bearings while thecrankcase halves are still warm.- Fit the oil seals in place.- The oil seal on the drive pulley sideshould fit flush with the crankcase, thelips being on the fl.ywheel housingside. The seal on the flywheel sideshould be approximately 9mm in.

Note:If the crankshaft bearings remain onthe crankshaft; use the puller tool64706 with the half shells 64709 (diam= 52) to remove them. Do not forgetto fit the crankshaft end protector69098 onto the ends of the crankshaft.

Removing the crankshaftassembly

- Fit the crankshaft end protector69098 onto the end of the crankshaft.

-Fit puller tool 647706 with the plate752168 onto the crankcase.

- Secure the plate to the crankcage bytightening the 4 screws.- Withdraw the crankshaft by turningthe inner thrust bolt of tool 64706.

Checking the crankshaftassembly

- The maximum side play of theconrod big end should not exceed:0.5mm.- Check crankshaft alignement asshown in the drawing (surface plate750541, comparator 750969The values measured at the endsshould not exceed 0.12mm.

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752168

750069

REFITTING

10

64706

6471069104

750808

Closing the crankcase halves

- Position both locating dowls in theLH crankcase:- Put the crankcase gasket in place(no oil, no grease).

- Position the RH crankcase and fit iton being careful not to damage the oilseal where it meets the cotter key.-Screw the extended nut 750069 ontothe end of the crankshaft.- Position the washer 750808 (50 x 29x 3mm).-Position the tool 64706.

- Position the centring tool 64710.- Turn the torque handle 69104 untilthe crankcases close completely.- Hold the crankshaft assembly steadyon the left hand side with the starterring gear.- Grease the oil pump shaft andposition the shaft / seat assembly inthe crankcase.- Make sure that the crankshaftassembly can rotate normally anddrives the oil pump shaft correctly.- Position the 6 fastening screws (3 =L 45mm, 3 = L 70mm) and tightenthem to 1 m.dan.Make sure the crankcase gasket islevel.

Lubricate the crankshaft assemblyand bearings with 2-stroke engine oil.

Refitting the engine

Assembly of the crankshaft into theleft hand crankcase:- Fit the crankshaft into the bearing.- Screw the ex tended nut 750069onto the end of the crankshaft.

- Fit tool 64706 with the plate 752168onto the extended nut and centre theassembly onto the crankcase using 4screws.- Position the centring tool 64710.

- Screw the torque handie 69104 ontothe extended nut 750069 whilekeeping the crankshaft assemblysteady. Continue turning the torquehandle until the crankshaft comes intocontact with the bearing.

Waming : do not jam the conrodcabre in the crankcase.

In order to hold the crankshaftassembly easily, use the rotorpositioned in its right hand sidewoodruff key.Make sure the crankshaft assembly iscorrectly positioned in relation to thecrankcase mouth (the middle of theconrod must correspond with the levelof the crankcase mouth).

Refitting the piston

- Check the cylinder and piston partsare a matched pair.

- Fit the needie bearing race into theconrod small end after having oiled it(2-stroke engine oil).

- Position the piston with the arrowpointing towards the exhaust port.-Push in the wrist pin.-Fit the snap rings. It is essentiel thatthey are new.

The opening of the snap ring will bepositioned at the top or at the bottom,but under nocircumstances to the side.

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REFITTING

11

côté couvercle ARBRE INTERMÉDIAIRE

rondelle souplerondelle métal

Refitting the transmissioncase

- Replace the oil seals and bearings ifnecessary by the appropriate “ heatingand drift >, method.- Check that the outlet channels areclear :

Removal of the case.

Outlet between the oil seal and therear wheel bearing.

- Fit on the countershaft: · the flexible washer 14 x 22 x 1.5 · the thrust washer 14.3 x 26 x 0.5.

Refitting the cylinder

- The parting face should be cleaned.- Lubricate the piston and the cylinderbore.- Fit a new and dry cylinder basegasket onto the cylinder.- Make sure that the piston ring endgaps are aligned with the positioningslots.- Position the cylinder and push itdown while squeezing the piston ringsbet-ween your thumb and middlefinger.- Make sure the cylinder base gasketis correctly positioned on thecrankcase using 2 threaded bolts.

Refitting the cylinder head

- Check thàt the gasket seat surfaceof the cylinder head is not damaged.-Position the 4 fastening screws ontothe cylinder head with washers.

- Position the cylinder head gasketonto the cylinder head, the raised faceupwards.- Push the cylinder head / screw /gasket assembly onto the cylinder.- Tighten the 4 screws progressivelyand in a crosswise order (L = 95mm)1.2 m.dan.

-Fit the spark plug 2m.daN.

ImportantSmear the countershaft ends withgraphite grease in order to ensureimproved lubrication when putting thevehicie into service.

- Position the countershaft.- Position the final shaft (or outputshaft) while being careful not todamage the oil seal.

If this seal is damaged, oit wîil flow tothe outside through the outiet siotlocated in the retumspring housing of the brake key; Photoopposite.

- Fit a thrust washer 14.3 x 26 x 0.5onto the countershaft;

- Position 2 locating dowls and thegasket.- Position the primary shaft (or inputshaft) into its bearing using a mallet ifnecessary.- Position the cover and secure itusing 5 screws (L = 40) 1 m.dan.

Make sure that the shafts can rotate.

Note- Fill the case with 0.12 litre of SAE80W 90 oil.- Peugeot Motocycles recommendsESSO GEAR OIL GX........ ref. 753009- Oil filler screw 1.2m.daN.

Trekker - Squab

REFITTING / FITTING

12

2

752127

752361

1

C. Refit the primarytransmission.

Fitting a variator

Warning: do not delete any piling upelement or reduce the dimensions.This would lead to a tightening of thenut on the grooves of the crankshaftassembly and not on the fixes drivenface and hence would destroy thecrankshaft assembly.

- Place the washer 12.35 x 19.75 X 1on the crankshaft assembly.- Position the variable speed drivewhile keeping the movable drivenface, the 6 rollers and the variationramp with the thrust spacer underpressure.- Fit the drive belt.- Position the start ring gear platewhile checking that it is properly fittedon the grooves of the crankshaft as-sembly, position the nut and tighten byhand.- Check that the ring is flush with thetool 752370.- Tighten the nut to 4m.da.N.

Instailing the kick starter (LHcover)

- Fit the spindle bushing and the nylonspacer (mark 1).

- Position the return spring, fit thelongest hook onto the pin on the cover.- Instail the spindle into the bushingafter lubrication.- Fit the second hook of the springonto the toothed section.- Wind the spring slightly so as toposition the kick starter spindle ontothe central rib of the cover.- Install the washer and circlips ontothe axis of the toothed section.- Position the drive ratchet:place the washer over the boss of theratchet shaft housingload the kick starter by about 1/8 of aturn in order to position the ratchet(after lubricating theshaft),position the ratchet stop in its housing.(Mark 2).

PRIMARYTRANSMISSION

A. Clutch and driven puileyassembly :

1. Dismantling:

- Hold the assembly using tool 752127in a vice and loosen the special nutwith the wrench 752361 (39) or a 34mm wrench depending on the clutch.- Remove in the followin’g order : . the clutch shoe assembly . the spring . the spring guiding sleeve . take out the three guide pins of thevariable speed drive, . separate the movable driven facefrom the fixed driven face.

2. Refitting- Check the oil seals of the movabledriven face.- Assemble the fixed and movabledriven faces.- Refit the 3 guide pins and lubricatethe ramp of the variable speed drive.- Position the sleeve having checkedthat both «0» rings are in goodcondition.- Position the spring and the clutchassembly.- Using the tool 752127, compress thespring and check that the nut istightened to 5m.daN.

B. Drive pulley - variatorassembly :

1. Dismantling- Remove the thrust spacer L = 38mmand the 3 bolts that secure thehousing and the stop (no 7 wrench).

- Remove the housing using ascrewdriver.- Remove the stop, the ramp plate, the3 plastic spacers and the 6 rollers, the«0»ring (81/1.5).

2. Inspection

- After cleaning, check the rollers inparticular. Their diameter should notshow any flat spots.

3. Refitting- Reverse opérations to dismantlinghaving lubricated the 6 rollers, theramp, and the movableclutch plate bore with hightempérature grease 752093.

NOTE :On the first generation FB engines(Zenith, Buxy, Speedake), the rollersof the drive pulley were assembledwithout grease.

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FITTI NG

13

Good

1

No good

21

Fitting the reed valve andintake pipe

- Check:the condition of the petals and theseats.- lnstall in the following order on thecrankcase:

- Fasten all the parts using 4 screws(L = 28mm), and tighten to 1 m.dan.

Fitting of the «clutch drivepulley» assembly and the belt

- Introduce the belt to the bottom ofthe groove of the driven puiley bypulling apart the drive faces using bothhands.- Position the belt on the drive pulley.- Fit the «clutch / drive pulley»assembly onto the primary shaft of thetransmission.- Position the clutch casing and tightenthe nut to 4.5m.daN while holding it inplace with theadjustable pin type face wrench752237 (or the flywheel holder).

NOTE- The rollers must be checked every50OOkm.- The belt must be changed every100OOkm.

Fitting the transmissioncase

- Position the washer 8.5 x 16 x 0.8,the kick starter gear assembly.Grease its bearings.- Position both dowel pins and thetransmission case using 1 1 screws.Tighten to 1 m.dan.

Fitting the starter motor

- Install the starter motor with its «0»ring.- The lower screw also ensuresearthing of the battery to the engine(green wire).- The upper screw also ensuresfixation of the cable harness clamp.- Tighten to 1 m.dan.

Fitting the carburettor

- Position both carburettor holdingscrews (L = 28 and 50mm) onto theintake pipe.- Position the isothermic spacer withthe seai on the intake pipe side. Thisspacer is aimed at avoiding heat fromthe engine being transferred to thecarburettor. A foolproof system on theedge of the spacer guarantees that itis positioned correctly (arrow pointingtowards the front).

a gasketa reed valvea gasket

seefoolproof

device

- Fit the carburettor and tighten to 0.8m.danScrew 1: air screwInitial adjustment: screw until it seatswithout forcing, then loosen by 11/2 to13/4 of a turn.Screw 2: throttle stop screw (idlespeed: 1800 rpm ± 100 rpm).Needle : clips at the top.

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Bleed screw

FITTING

14

Mark

PARTIE CYCLE

Fitting the cooling systern

- Position and fasten the fan onto therotor (4 screws L = 1 8). Tighten to 1m.dan.- Position and fasten the cylinder caseand cooling cover (4 screws M = 25).Make sure that it is fastened correctlyaround the sensor.- Tighten to a torque of 1 m.dan.

Fitting of the oil pump

- Position both square nuts (Q) in theirhousings.- Place the flexible washer on the seat.- Position the pump fitted with its«0»ring, position the sheath stopfastening hook and fasten the clusterwith two n».4 hex head socket screws.- tighten to 0.8m.daN.

Adjustment of the oil purnp

1) Check the free play in the throttlegrip (2 to 5mm) and adjust ifnecessary using the adjusting screw.2) Open the throttle fully.-Check that the alignment mark on thepump control lever is opposite themark on the pump body.

- Adjust if necessary by turning thepump cable abjusting nuts.

Checking the lubricationcircuit

- Supply the carburettor from aseparate tank containing 2-stroke fuelmixture.

Fitting the flywheel

- Position the stator / sensor assemblyon the crankcase.- Fasten with 4 screws (2 screws L =16, 2 screws L = 20). Tighten to 1m.dan.

- Make sure that the woodruff key isindeed on the crankshaft.

- Disconnect the oil input hose on thepump and check the oil flow. Checkalso : . that there is oil in the tank, . that the hose is not trapped, . that the oil filter is not blocked, . that the tank filler hole is notblocked (atmospheric pressure hole).- Reconnect the hose onto the pumpbody.- Open the pump bleeding screw untilail the air bubbles have escaped andthen close again.- Turn the engine on.Disconnect the oil input hose on thecarburettor. Check that the oil dripsout. Dripping frequency depends onthe engine’s speed- Reconnect the hose onto thecarburettor. OIL PUMP FLOW: 24cm3 ± 1.7cm3 hour at 3800 rpm.Wide open throttle.

- Position the rotor.- Keep the rotor in place using the ad-justable pin type face wrench 752237.- Tighten the nut at 4m.daN.

DISK BRAKE

Filling the circuit :At the receiver (brake calliper),remove the cap of the bleed screw.Connect a flexible hose to this screw,the other end put into an emptycontainer (fuel hose for example).Loosen this bleed screw.Remove the cover and seal, with thetank positioned horizontally, f rom theemitter (master cylinder). Fill the tankwith brake fluid. Activate the brakehandle gently until the liquid comesthrough to the bleeding container.Tighten the bleed screw.Fill the emitter tank to the top.

Activate the brake lever several timeswith the cover refitted.Loosen the bleed screw again. Airbubbles should escape through theflexible hose.When there are no more air bubbles,tighten the bleed screw with the brakelever constantly on.Repeat the operation until no bubblesappear in the liquid.Note: At the end of the opération, topup the level.- It is sometimes necessary to tap theelements of the brake system lightly inorder for the air to escape.- Certain callipers need to bedismounted in order to place the bleedscrew in the high position.

Warning :- The brake fluid attracts humidity.ln certain conditions humidity mayimpair braking efficiency. You mustalways use brake fluid from a recentlyopened container (tightness cap). Theliquid recovered in the bleed containermust not be reused. Do not open thecontainer when there is a high degreeof hi-imidity in the atmosphère (rain,fog .... ).- Brake fluid is corrosive. Avoidspillage on painted parts.- Do not spill fluid onto the pads or thedisks.- Use brake fluid which complies withthe DOT 3 or DOT 4 standards.(Lockeed D55 for exam

CYCLE PART

Trekker - Squab

ELECTRIC EQUIPMENT

15

a

b

5kΩ

5kΩ

3

4

5

6

1

26

5

on

off

6

3

1

4

2

12V 4Ah

15

c

a

aa1

10

8

7

6,7Ω 5w

9

5,9Ω 30w

11

26

B1,2w

5/21w

12V 4Ah

A

0,75Ω 4w

13

3 x 1,2w 15w

15

14 27

1 - Flywheela - ignitionb - sensor

2 - Ignition switch3 - (CDI) ignition unit4 - High voltage coil5 - Interference suppresser 5 KW6 - Spark plug resistance 5 KW

15 - Battery26 - Starter motor

1 - Flywheelc - alternative current

7 - Regulatora - AC regulator

8 - Choke9 - Resistance 6,7 W 5W

10 - Lighting control11 - Resistance 5,9 W 30w13 - Headlamp

A - Instrument panel lightingB - Headlamp telltale

14 - Rear and stop light15 - Battery26 - Starter motor27 - Current limiter

IGNITION

Operating principle :The ignition coil charges a condenserin the CDI unit. Passage of the rotorpad in front of the sensor authorisesthe discharging of the condenser inthe primary winding of the high voltagecoil via a thyristor, in order to generatethrough transformation in thesecondary, a voltage in the region of20 000 volts at the spark plug.

Troubleshooting :- Check the connections, especiallythe earth connection of the startermotor.- Check by successively replacing withnew components: the spark plug,radio interference suppressor, highvoltage coil, CDI unit.- Check the key switch.Example of a breakdown: the engineonly runs with the rear brake applied.Cause: earth wire of the startermotor is damaged.The CDI unit, ref. 709205 is used onall 50cc powered two-wheelers as wellas on the SV 80cc.Warning :A second CDI unit, ref. 705272(marked CI 08) is reserved for SV 125SC-SX models.

ALTERNATING CURRENTPOWERED CIRCUITS

LIGHTING AND STARTERMOTOR

Operating principle:Three coils connected in series in theflywheel magneto generate analternating current stabilised by theregulator to give a maximum voltageof 12V ± 0.5V.

LIGHTING

When in the < lights off > position(Day*), current is directed from theswitch towards a résistance of 5.9 Ù30W where it is consumed (pink wire).When in the “ lights on ” position(night), current is supplied to the bulbs(brown wire); headlight, taillight, instru-ment panel light, headlight telltale.

Trekker - Squab16

ELECTRIC EQUIPMENT

a

d

b

c1 110 Ω

750 Ω

0,4 Ω

0,7 Ω

Value flywheel control

1 - Flywheela - ignitionb - sensorc - alternative currentd - battery charge current

1 - Yellow wire2 - Green-black wire3 - Heating resistance (PTC)4 - Wax5 - Membrane6 - Intermediate fluid7 - Push piston8 - Return piston9 - Return spring

10 - Air throttle valve11 - Needle12 - Needle well13 - Needle spring14 - “O” ring seal

2

3

4

5

7

8

9

10

11

12

14

6

13

1Note :The rear bulb is composed of 2filaments, one 5W filament suppliedwith alternating current for the taillight,one 21 W filament supplied with directcurrent for the stop light.

1/ Solving lighting faults- Check the bulbs; power, voltage,compliance with European standards(El).- Check the connections (especiallythose of the regulator).- Check the voltageusing a multimeter (MX40) set to theAC voltmeter position.check at the terminale of a bulb(brown wire), that voltage does notexceed 12 volts ± 0.5V whenaccelerating the engine. If the voltageis over 13V, check the regulatorconnection (especially the green earthwire). If necessary, change theregulator (it is not possible to checkthe regulator when static).

2/ CheckingCheck the continuité capacities of thethree coils of the flywheel. Enginestopped.Lighting and starter: yellow wire andearth wire = 0.4 ohm.

CHOKE

1. Operating principleCold starting: the choke isautomatically in opération: thecarburettor’s mixture enrichmentcircuit is open.As soon as the vehicle is switched on,the heat résistance which is suppliedby the flywheel magneto causes thecontinuons wax to expand in itscapsule. The diaphragm pushes themaster and intermediate pistons whichcause the air duct to the throttle valveto close gradually and to progressivelyblock fuel flow with the needle. Whenthe engine is warm, with the ductsblocked, the enriching circuit is notoperational.

2. Checking- Average résistance value of thechoke alone - 5 ohms.Note :The résistance value varies dependingon résistance température: the colderthe température, the lower therésistance value and vice versa.

Trekker - Squab

C

5/21w

12V 4Ah

4x 10w

D1,2w

1,2w

E

5

on

off

5A

0,75Ω 4w

6

3

1

4

10/07/97

25

26

15

24

14 27

16

23

22

20

19

21

17

18 28

10Ω

100Ω

2

b7

d

c

1

17

1 - Flywheelc : alternative currentd : battery charge current

2 - Ignition switch7 - Regulator, rectifier

b : regulator, rectifier (DC)14 - Rear and stop light15 - Battery16 - 5A Fuse17 - Horn18 - Horn button19 - Indicator control21 - Indicator bulbs

D - Indicator telltale22 - Fuel gauge

E - Fuel gauge receiver23 - Stop contact switch24 - Starter motor relay25 - Starter motor control26 - Starter motor27 - Current limiter28 - Low oil level contact switch

C - Low oil level telltale

ELECTRIC EQUIPMENT

DIRECT CURRENT POWERED CIRCUITS

CHARGING BATTERY - STARTER MOTOR - FUEL GAUGE -OIL GAUGE - TURNSIGNAL LIGHTS - HORN

Operating principle:In the flywheel, the three coils used for the alternating current circuits areassociated with two other coils to produce a regulated current increased to14.5V ± 0.5V maximum by the current increasing regulator. (This time, its is thesecond stage of the regulator which is used),

BATTERY CHARGING

This circuit consists of the followingelements connected in series: flywheelmagneto - regulator - fuse- battery.The voltage depends on the engine’sspeed.While this voltage is lower than batteryvoltage, it is the battery which suppliesthe various circuits. As soon as thisvoltage is higher than battery voltage,it is the flywheel which supplies thevarious circuits and recharges the

battery.Putting the battery into service: seemaintenance page N° 3.

Checking the chargeUse a multimeter (MX40) set to theDC voltmeter position (=) connectedto the terminale of the battery. Checkthat the voltage varies depending onthe speed of rotation of the engine upto a maximum of 14.5V ± 0.5V.If the voltage at the battery terminaleexceeds 15V, the regulator is notconnected to earth or is faulty. Ifthere is no variation in voltage at thebattery terminale, check the fuse,

connections, especiahy those of theflywheel or regulator harnesses (looseconnections inversion of wires in theconnecter for example).

Checking a dischargeEngine off.Disconnect the red wire from thebattery.Use a multimeter (MX40) set in theAmpmeter (1OA) position, connect theblack wire (COM) to the + terminal ofthe battery and the red wire (1OA) tothe disconnected red wire of thebattery.

Trekker - Squab

4x 10w

D1,2w

5A

5

on

off

6

3

1

4

12V 4Ah

21

20

19

162

15

2 - Ignition switch15 - Battery16 - 5A Fuse19 - Turn signal relay20 - Indicator control21 - Indicator bulbs

D - Indicator telltale

18

ELECTRIC EQUIPMENT1. Key switch to OFFNo display should appear on themultimeter. If a value is displayed (forexample 0.5mA), either the regulator(connection wires) or the key switch isfaulty.

2. Key switch to ONA slight discharge can be explained bysending a volt supply to the fuel gaugeand to the oil low levelwarning light (0.9mA to 1OOmAmaximum).A significant dischar@e indicates amore or less earthed circuit.Disconnect the various circuits untilthe discharge disappears and locateeither the defective unit or wire(starter, motor, stop light, fuel gauge,oil, indicator, horn, key switch orinstrument panel circuits).

Checking the capacities of theflywheel magneto.Battery charge (current = )White wire = 0.7 ohm and earth.

Operating principleA direct current supplies the blinkercontrol unit located under the frontcover. This current is sent to the left-hand grip handle to be distributed bythe switch to the left-hand or right-hand bulbs of the turnsignal lights.The telltale on the instrument panel iscommon to both sides. Its earthreturn line is via the bulbs on the sidenot used.

Checks :If the central unit starts functioningerratically, either an indicator bulb isnot working or the main connecter (9-way) is not properly connected.If the central unit makes a cracklingsound, either there is a short circuitbetween an orange or blue wire andearth or the battery is discharged.If the central unit does not work,before changing it, check:- Battery voltage (it must be over 10volts).the 4 bulbs of the indicators and thetelltale bulb.- that the central unit is supplied with12 volts (if not, check the fuse, the keyswitch, the connections, the blackwire).

HORN

Operating principleSupplied with a continuons current, ahorn and a switch are fitted in series.

Check :- If the horn does not work, check thecircuit (fuse, key switch, left-hand griphandie switch), in order to get 12 voltsat the horn terminals.- Check that the horn is planned foruse with continuons current (presenceof an adjustment screw, here hiddenby a plug). Horn test

FUEL GAUGE

Operating principleResistance from the fuel meter to thetank varies depending on the level offuel from 10 to 100 ohms. On the ins-trument panel, the needle will vary ac-cording to this resistance from min. tomax. When the needle reaches thereserve supply level, this indicates aremaining riding range of about 25km.

Checks :ignition to ONIf the fuel meter is permanently atmaximum level:- Disconnect the gauge if the minimumlevel appears, check the gauge.- If the maximum level is still shown,disconnect the 5-way connector on theinstrument panel. Check, using a mul-timeter (MX40), set in the ohm posi-tion, that the yellow / white wire is notearthed. If this wire is earthed, checkthe harness. If this wire is not ear-thed, change the instrument panel.If the gauge indicator is permanentlyat minimum level:- Check that the tank gauge isconnected properly- Check the capacities of this gauge (5to 100 Ù)- Check the 5-way connector on theinstrument panel: black wire to wayno.1, yellow/white wire to way N° 4.- Check that the black wire receives a12 volt continuons supply.- Check that the yellow/white wire iscontinuons up to the gauge. If not,

OIL GAUGE

Operating principleSupplied with a continuons current.The float acts like a switch; when it isin a low position, it closes the circuitwhich causes the warning light on theinstrument panel to come on.Checking :If the bulb on the instrument panelremains permanently on, check thefloat.If the bulb remains permanently on,check the 4-way connector on theinstrument panel (terminal 4,the blue / white wire must not receivea 12 volt supply while the float is inhigh position).

check way N°1 on the 9-way mainconnector.

INDICATORS

Trekker - Squab 19

ELECTRIC EQUIPMENT

5/21w

12V 4Ah

5A

0,75Ω 4w

5

on

off

6

3

1

4

15

2714

24

162

23

26

25

2 - Ignition switch14 - Rear and stop light15 - Battery16 - 5A Fuse23 - Stop contact switch24 - Starter motor relay25 - Starter motor control26 - Starter motor27 - Current limiter

STARTER MOTOR CIRCUITS

Operating principle :The starter motor requires two circuits.

1. Control circuît :This consists of the following elementsconnected in series:Battery, fuse, key switch, stopswitches, starter motor relay, startswitch (START).With the ignition key in the ONposition, one or both stop switchesclosed, the start switch closed, thecurrent supplied by the battery runsthrough the coils of the relay andcloses by magnetic force, the powercircuit contact.

2. Power circuit :This consists of the battery and startermotor.Activated by the relay, this circuitconsists of big wires aimed atsupporting high intensity. This circuitis not protected by the 1OA fuse.

Troubleshooting :Checks in the event of non starting.Battery in good condition.If the relay «clicks», check the batteryconnections, the starter motorconnector, earthing of the startermotor, the starter motor itself.If the relay does not «click», look atthe taillight: . if the taillight comes on, check therelay . if the taillight does not come on,check: the battery, fuse, key switch,stop lights, connectons.Relay is good and working orderRelay at of order

Checking the starter motor :Connect the starter motor directly tothe terminale of a 12 volt battery.

Checking the relay :Connect a battery to the terminale ofthe control circuit (small yellow / greenand purple wires). If the relay isworking correctly, it will «click» and willmake contact with the two otherterminals.

Trekker - Squab

a

d

b

c

b

B1,

2w

C

5/21

w

12V

4A

h

4x 1

0wD1,

2w

1,2w

E

A

5

on

off

a

5A

5kΩ

5kΩ

5,9Ω

30w

6,7Ω

5w

0,75

Ω 4

w

13

63

1 4

3 x

1,2

w15

w

25

2615

24

1427

16 23

22

2019

21

171828

3

4

5 6

1108

119

7

10Ω

100Ω

2

Squab 50 without dipped headlights

20

Trekker - Squab

a

b

b

C

5/21

w

12V

4A

h

D1,

2w

1,2w

E22

2524

5

on

off

a

5A

5,9Ω

30w

6,7Ω

5w

0,75

Ω 4

w

35/3

5w

13

335w

63

1 4

B1,

2w

12H

L

A3

x 1

,2w

4

3

7

9 11

2818 17

19 20

21

10Ω

26

23

15

27

16

14

2

21

Trekker 50 all types and Squab 50 with main beam +dipped headlights

Trekker - Squab22

* According to the model

22

A Instrument panel lightingB Headlamp telltaleC Low oil level telltaleD Indicator telltaleE Fuel gauge receiver

1 Flywheela ignitionb sensorc alternative currentd battery charge current

2 Ignition switch3 CDI ignition unit4 High voltage coil5 Interference suppresser 5 KW6 Spark plug 5 KW7 Regulator, rectifier

a regulator (AC)b regulator, rectifier (DC)

8 Choke9 Resistance 6,7 W - 5 W10 Lighting control11 Resistance 5,9 W - 30 W12 Headlamp control13 Headlamp bulb14 Rear and stop light bulb15 Battery16 Fuse17 Horn18 Horn button19 Turn signal relay20 Indicator control21 Indicator bulbs22 Fuel gauge23 Stop light contact switches24 Starter motor relay25 Starter motor control26 Starter motor27 Current limiter28 Low oil level contact switch33 Number* plate lighting

KEY TO ELECTRIC CIRCUITS

Trekker - Squab

Note

2

23

Trekker - Squab

PEUGEOT MOTOCYCLES RECOMMENDS

2 STROKE OIL

- ESSO 2T SPECIAL ................. 1 LITRE........ Ref. : 753752

- ESSO 2T SYNTHETIC ............ 1 LITRE........ Ref. : 753759

TRANSMISSION CASE OIL

- GEAR OIL GX-SAE 8OW-90... 2 LITRES ..... Ref. : 753009

HIGH TEMPERATURE GREASE

- SKF LGHT 3/0.4 ............................................ Ref. : 752093

GREASE

- MULTI-PURPOSE .......................................... Grease 4746

TIME SAVINGS = MONEY SAVINGS

This workshop manual concerns the FB engine which is fitted on several 50cm3vehicles on the air-cooled version:

- FB0 ............................................ ZENITH

- FB1 ............................................ BUXY - SPEEDAKE

- FB2 ............................................ SQUAB - TREKKER

- FB4 ............................................ SPEEDFIGHT - TREKKER ROAD

The electric part of this manual only concerns the TREKKER and SQUAB vehicleranges.

INTRODUCTION

N° 11.753784.00

recommends

Dans un souci constant d'am

élioration Peugeot M

otocycles se réserve le droit de modifier, supprim

er ou ajouter toute référence citée D

C/P

S/S

H Im

p. en U.E

10/07/98