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Peugeot 50 Vertical 2T Engine Manual PDF
Peugeot 50 Vertical 2T Engine Manual PDF
GB
Motor FB-0-1-2-4
CONTENTS
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 RECOMMENDATIONS
- Removing the carburettor and choke, ................. 7 Designation Page
- Removing the intake valve and connecting part, . 7 - Spark plug ............................................................. 2
- Removing the complete primary drive assy, ........ 7 - Fuel ...................................................................... 4
- Removing the kick starter system, ....................... 8 - Separate lubrication .............................................. 4
- Removing the relay unit, ...................................... 8 - Relay unit ............................................................. 4
- 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
Trekker - Squab 1
TECHNICAL DATAS
Number XXXXXXXX
Type
FB2
Identification
plate
FB2 ENGINE
Forced-air cooled 2 stroke engine :
Identification : VGAS1A . . . . . . . . . . .
- Bore and stroke : ................................................ 40 x 39.1
- Cylinder capacity : ............................................. 49.13cm3
- Front tyre : ...................................................... 120/90 x 10
- Compression ratio : ................................................... 6.6:1
- Rear tyre : ...................................................... 130/90 x 10
- Maximum power (ISO) : .......................................... 3.1 kw
Pressure :
Distribution :
- Front : .................................................................... 1,3 bar
- Exhaust port : ........................................................... 160c°
- Rear : .................................................................... 1,6 bar
- Scavenging port : ....................................................... 110°
- Air intake : ..................................... by reed valve induction
- Ignition : ....................... CDI (capacitive-discharge ignition) Capacities
- Spark advance : ....................................... 13° before TDC
- Spark plug ................................................... Resistive 5KÙ - Fuel tank : .............................................................. 6 litres
..................................................................... NGK - BR7HS - Oil tank : .............................................................. 1.3 litres
.................................................................. EYQUEM R 850 - Transmission case : ............................................ 0.12 litre
................................................................. BOSCH WR4AC - Under-seat storage compartment : ............................. 3 kg
- spark plug gap : ..................................................... 0.6mm
Carburettor : .......................................... GURTNER PA350
- Idling speed : .................................... 1800 rpm ± 1 00 rpm Dimensions
- Initial position of the pilot air adjusting screw :
- Anticlockwise rotation : ..................................... 1/2 to 13/4
- Needle with 3 levels : .................................. clips at the top - Overall length : .................................................... 1760mm
- Main jet : ........................................................................ 74 - Overail width : ........................................................ 670mm
Flywheel magneto : Excluding rear view mirror :
- Number of poles : ............................................................ 6 Overall height : ...................................................... 1110mm
- Power : .......................................................... 2500t = 55w Excluding rear view mirror :
........................................................................ 5000t = 85w Wheelbase : .......................................................... 1250mm
Starter.motor : .................................................... MITSUBA
................................................................ 2000w SM10 129
................................................................. 1500w SM10254 Weight
Oil pump : .............................................................. MIKUNI
flow 24cm3 ± 1.7cm3 / hour at 3800 rpm, wide open
- Complete vehicle dry weight : .................................... 82kg
throttle. 1CM3 = 0.031 cubic inch
- Vehicie weight with tanks full : ................................... 88kg
Transmission
Markings 49cc
- Clutch : .................................... centrifugai, automatic type
- Primary réduction gear : ........................ by a ribbed V-beit
- Left hand casing (under the starter motor)
- Life of belt : ...................................................... 1 0 000 km
- Cylinder head (front right)
- Reducer equipped with 2 gearsets.
- Cylinder (exhaust flange left hand side)
- Intake pipe (on the front «49»)
2 Trekker - Squab
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.
* reforced maintenance
Trekker - Squab 3
INSTRUCTIONS FOR MAKING OPERATIONAL
2. Fuel - 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
Capacity : .............................................................. 6 litres and on a level surface.
- Conventional 4-star petrol. Esso Oil SAE 80 W 90
- Lead free petrol 98 octanes. REF : .................................................................... 753009
capacity 0. 1 2 litre
A = 1.2m.daN.
3. Separate lubrication:
4 Trekker - Squab
TIGHTENING TORQUES AND SPECIAL TOOLS
Standard
Trekker - Squab 5
REMOVAL
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 nut (right-hand thread).
Remove : - Fit the crankshaft end protector
- The lower anchor bolt of the shock 68007 onto the end of the crankshaft.
absorber and the front anchor pin of
the engine.
750806
68007
6 Trekker - Squab
REMOVAL
Removal of the
- Unclip the oil inlet pipe to the carburettor / choke
carburettor. assembly
- Unscrew the 2 hex head socket
- Remove the cover with both locating
screws.
- Take off the 2 fastening screws from dowls.
- Remove the oil pump and the control
the carburettor and remover the
flange.
carburettor / choke
- Remove the 2 square fastening nuts
assembly, as well as the isothermal
Q from their housings.
spacer.
- Remove the flexible washer lodged
between the pump and the shaft
bearing of the oil pump.
Trekker - Squab 7
REMOVAL
Make careful note of where this tool - Removal of the drive shaft (or input
comes level with the starter ring gear Removal of the kick shaft) from the transmission cover is
plate of the starter motor in order to starter system done using a mallet.
make sure, when refitting, that the - Remove the thrust washer from the
pressure plate fits correcte into the - Actuate the kick starter spindle with counter shaft (14.3x26xO.5).
grooves of the crankshaft. your thumb and remove the drive
- Loosen the fastening nut (right-hand ratchet and its washer.
thread) of the gear plate of the drive
pulley.
- Remove the nut, washer and plate.
- Remove the belt.
- Remove the drive pulley assembly
(variable speed drive) and the washer
on the engine housing side (12,35 X
19,75 X 1). - Drain the transmission case
completely before removing the final
shaft (or output shaft) in order to avoid
contamining brake linings.
- Remove the kickstarter lever. Using
- Pull out the final shaft (output shaft).
snipe-nosed pliers (ref. 69117), take
off the circlips, the washer, then
remove the kick starter toothed
section, the pull-back spring and the
bushing.
Rdl 12,35x19,75x1
Dismantling the
- Block the clutch drum with the fly-
transmission case
wheel pinch bolt no.68570 or the ad- After draining the transmission case:
justable pin type face wrench 752237. - Remove the 5 screws securing the
cover.
752237
Removing the cylinder
head
- Unscrew in a crosswise order the 4
screws securing the cylinder head and
cylinder block assembly.
- Remove the cylinder head and
gasket.
- Loosen the screw, remove the drum
and the clutch driven pulley assembly. - Remove the cover with the drive
shaft (or input shaft), the gasket and
both locating dowls.
8 Trekker - Squab
REMOVAL
- Turn the inner thrust bolt of tool - Secure the plate to the crankcage by
Removing the cylinder 750807 until the crankcase halves tightening the 4 screws.
and piston split Hold the connecting rod so that it - Withdraw the crankshaft by turning
does not knock against the crankcase the inner thrust bolt of tool 64706.
- Remove the cylinder and cylinder-to- halves.
crankcase gasket. - Remove the RH half casing.
- Pack the crankcase mouth with
clean cloth or paper.
Trekker - Squab 9
REFITTING
Refitting the engine Closing the crankcase halves Refitting the piston
Assembly of the crankshaft into the - Position both locating dowls in the - Check the cylinder and piston parts
left hand crankcase: LH crankcase: are a matched pair.
- Fit the crankshaft into the bearing. - Put the crankcase gasket in place
- Screw the ex tended nut 750069 (no oil, no grease).
onto the end of the crankshaft.
64706
752168
750069
- Position the RH crankcase and fit it
on being careful not to damage the oil - Fit the needie bearing race into the
seal where it meets the cotter key. conrod small end after having oiled it
-Screw the extended nut 750069 onto (2-stroke engine oil).
the end of the crankshaft.
- Fit tool 64706 with the plate 752168 - Position the washer 750808 (50 x 29
onto the extended nut and centre the x 3mm).
assembly onto the crankcase using 4 -Position the tool 64706.
screws.
- Position the centring tool 64710.
750808
69104
64710
10 Trekker - Squab
REFITTING
Trekker - Squab 11
REFITTING / FITTING
- Hold the assembly using tool 752127 - After cleaning, check the rollers in
Instailing the kick starter (LH in a vice and loosen the special nut particular. Their diameter should not
cover) with the wrench 752361 (39) or a 34 show any flat spots.
mm wrench depending on the clutch.
- Fit the spindle bushing and the nylon - Remove in the followin’g order : 3. Refitting
spacer (mark 1). . the clutch shoe assembly - Reverse opérations to dismantling
. the spring having lubricated the 6 rollers, the
1
. the spring guiding sleeve ramp, and the movable
. take out the three guide pins of the clutch plate bore with high
variable speed drive, température grease 752093.
. separate the movable driven face
from the fixed driven face. NOTE :
On the first generation FB engines
(Zenith, Buxy, Speedake), the rollers
- Position the return spring, fit the of the drive pulley were assembled
longest hook onto the pin on the cover. without grease.
- Instail the spindle into the bushing
after lubrication. 2. Refitting
- Fit the second hook of the spring - Check the oil seals of the movable
C. Refit the primary
onto the toothed section. driven face. transmission.
- Wind the spring slightly so as to - Assemble the fixed and movable
position the kick starter spindle onto driven faces. Fitting a variator
the central rib of the cover. - Refit the 3 guide pins and lubricate Warning: do not delete any piling up
- Install the washer and circlips onto the ramp of the variable speed drive. element or reduce the dimensions.
the axis of the toothed section. - Position the sleeve having checked This would lead to a tightening of the
- Position the drive ratchet: that both «0» rings are in good nut on the grooves of the crankshaft
place the washer over the boss of the condition. assembly and not on the fixes driven
ratchet shaft housing - Position the spring and the clutch face and hence would destroy the
load the kick starter by about 1/8 of a assembly. crankshaft assembly.
turn in order to position the ratchet - Using the tool 752127, compress the
(after lubricating the spring and check that the nut is
shaft), tightened to 5m.daN.
position the ratchet stop in its housing.
(Mark 2).
B. Drive pulley - variator
assembly :
2
1. Dismantling
- Remove the thrust spacer L = 38mm
and the 3 bolts that secure the
- Place the washer 12.35 x 19.75 X 1
housing and the stop (no 7 wrench).
on the crankshaft assembly.
- Position the variable speed drive
while keeping the movable driven
face, the 6 rollers and the variation
ramp with the thrust spacer under
pressure.
PRIMARY - Fit the drive belt.
TRANSMISSION - Position the start ring gear plate
while checking that it is properly fitted
on the grooves of the crankshaft as-
sembly, position the nut and tighten by
A. Clutch and driven puiley - Remove the housing using a
hand.
assembly : screwdriver.
- Check that the ring is flush with the
- Remove the stop, the ramp plate, the
tool 752370.
3 plastic spacers and the 6 rollers, the
1. Dismantling: - Tighten the nut to 4m.da.N.
«0»ring (81/1.5).
752361
2. Inspection
752127
12 Trekker - Squab
FITTI NG
NOTE
- The rollers must be checked every
50OOkm.
- The belt must be changed every
100OOkm.
No good
Trekker - Squab 13
FITTING
PARTIE
CYCLECYCLE
PART
Activate the brake lever several times Warning :
DISK BRAKE with the cover refitted. - The brake fluid attracts humidity.
Loosen the bleed screw again. Air ln certain conditions humidity may
Filling the circuit : bubbles should escape through the impair braking efficiency. You must
At the receiver (brake calliper), flexible hose. always use brake fluid from a recently
remove the cap of the bleed screw. When there are no more air bubbles, opened container (tightness cap). The
Connect a flexible hose to this screw, tighten the bleed screw with the brake liquid recovered in the bleed container
the other end put into an empty lever constantly on. must not be reused. Do not open the
container (fuel hose for example). Repeat the operation until no bubbles container when there is a high degree
Loosen this bleed screw. appear in the liquid. of hi-imidity in the atmosphère (rain,
Remove the cover and seal, with the Note: At the end of the opération, top fog .... ).
tank positioned horizontally, f rom the up the level. - Brake fluid is corrosive. Avoid
emitter (master cylinder). Fill the tank - It is sometimes necessary to tap the spillage on painted parts.
with brake fluid. Activate the brake elements of the brake system lightly in - Do not spill fluid onto the pads or the
handle gently until the liquid comes order for the air to escape. disks.
through to the bleeding container. - Certain callipers need to be - Use brake fluid which complies with
Tighten the bleed screw. dismounted in order to place the bleed the DOT 3 or DOT 4 standards.
Fill the emitter tank to the top. screw in the high position. (Lockeed D55 for exam
14 Trekker - Squab
ELECTRIC EQUIPMENT
3 2
IGNITION
a 1
off 5
Operating principle :
4 on
The ignition coil charges a condenser b
6
in the CDI unit. Passage of the rotor
1
pad in front of the sensor authorises 15
the discharging of the condenser in
12V 4Ah
the primary winding of the high voltage
coil via a thyristor, in order to generate 3
through transformation in the
secondary, a voltage in the region of
20 000 volts at the spark plug.
4
Troubleshooting :
- Check the connections, especially
the earth connection of the starter
motor.
- Check by successively replacing with
5 5kΩ
new components: the spark plug,
radio interference suppressor, high 26
voltage coil, CDI unit. 6 5kΩ
- Check the key switch.
Example of a breakdown: the engine
only runs with the rear brake applied.
Cause: earth wire of the starter 1 - Flywheel
motor is damaged. a - ignition
The CDI unit, ref. 709205 is used on b - sensor
2 - Ignition switch
all 50cc powered two-wheelers as well 3 - (CDI) ignition unit
as on the SV 80cc. 4 - High voltage coil
Warning : 5 - Interference suppresser 5 KW
A second CDI unit, ref. 705272 6 - Spark plug resistance 5 KW
15 - Battery
(marked CI 08) is reserved for SV 125 26 - Starter motor
SC-SX models.
ALTERNATING CURRENT 9
13
POWERED CIRCUITS 8 6,7Ω 5w
A B
3 x 1,2w 1,2w 15w
LIGHTING AND STARTER 10
5,9Ω 30w
MOTOR 11
a
Operating principle:
Three coils connected in series in the
flywheel magneto generate an
alternating current stabilised by the
regulator to give a maximum voltage
of 12V ± 0.5V.
LIGHTING
1
a
Trekker - Squab
7
1 - Flywheel
c - alternative current
7 - Regulator
a - AC regulator
8 - Choke
9 - Resistance 6,7 W 5W
10 - Lighting control
11 - Resistance 5,9 W 30w
13 - Headlamp
A - Instrument panel lighting
B - Headlamp telltale
14 - Rear and stop light
15 - Battery
26 - Starter motor
27 - Current limiter
14
5/21w
27 0,75Ω 4w
15
15
12V 4Ah
26
ELECTRIC EQUIPMENT
Note :
CHOKE 1
The rear bulb is composed of 2
filaments, one 5W filament supplied
3
with alternating current for the taillight, 1. Operating principle
one 21 W filament supplied with direct Cold starting: the choke is 2
4
current for the stop light. automatically in opération: the
carburettor’s mixture enrichment 5
1/ Solving lighting faults circuit is open. 6
- Check the bulbs; power, voltage, As soon as the vehicle is switched on,
7
compliance with European standards the heat résistance which is supplied
(El). by the flywheel magneto causes the 8
- Check the connections (especially continuons wax to expand in its
those of the regulator). capsule. The diaphragm pushes the 14 9
- Check the voltage master and intermediate pistons which
using a multimeter (MX40) set to the cause the air duct to the throttle valve 10
13
AC voltmeter position. to close gradually and to progressively
11
check at the terminale of a bulb block fuel flow with the needle. When
(brown wire), that voltage does not the engine is warm, with the ducts
12
exceed 12 volts ± 0.5V when blocked, the enriching circuit is not
accelerating the engine. If the voltage operational.
is over 13V, check the regulator
connection (especially the green earth 2. Checking 1 - Yellow wire
- Average résistance value of the 2 - Green-black wire
wire). If necessary, change the 3 - Heating resistance (PTC)
regulator (it is not possible to check choke alone - 5 ohms. 4 - Wax
the regulator when static). Note : 5 - Membrane
The résistance value varies depending 6 - Intermediate fluid
on résistance température: the colder 7 - Push piston
2/ Checking 8 - Return piston
Check the continuité capacities of the the température, the lower the 9 - Return spring
three coils of the flywheel. Engine résistance value and vice versa. 10 - Air throttle valve
stopped. 11 - Needle
12 - Needle well
Lighting and starter: yellow wire and 13 - Needle spring
earth wire = 0.4 ohm. 14 - “O” ring seal
0,7 Ω 750 Ω
d
a
1 - Flywheel
a - ignition b
b - sensor
c - alternative current
d - battery charge current
c
1 110 Ω
0,4 Ω
16 Trekker - Squab
ELECTRIC EQUIPMENT
1 - Flywheel
c : alternative current
d : battery charge current DIRECT CURRENT POWERED CIRCUITS
2 - Ignition switch
7 - Regulator, rectifier
b : regulator, rectifier (DC) CHARGING BATTERY - STARTER MOTOR - FUEL GAUGE -
14 - Rear and stop light
15 - Battery OIL GAUGE - TURNSIGNAL LIGHTS - HORN
16 - 5A Fuse
17 - Horn Operating principle:
18 - Horn button
19 - Indicator control In the flywheel, the three coils used for the alternating current circuits are
21 - Indicator bulbs associated with two other coils to produce a regulated current increased to
D - Indicator telltale 14.5V ± 0.5V maximum by the current increasing regulator. (This time, its is the
22 - Fuel gauge
second stage of the regulator which is used),
E - Fuel gauge receiver
23 - Stop contact switch
24 - Starter motor relay
25 - Starter motor control
26 - Starter motor
27 - Current limiter
28 - Low oil level contact switch
C - Low oil level telltale
14 27 0,75Ω 4w
7 5/21w
b
5A
15
16 12V 4Ah
d 3 2
1
off 5
4 on
6 24
1 23
c
19
18 28 20 25
26
D E
1,2w 22
17 C 10Ω
1,2w
21
4x 10w
100Ω
10/07/97
FUEL GAUGE
INDICATORS
Operating principle
Resistance from the fuel meter to the Operating principle 5A
tank varies depending on the level of A direct current supplies the blinker 15
fuel from 10 to 100 ohms. On the ins- control unit located under the front 16 12V 4Ah
trument panel, the needle will vary ac- cover. This current is sent to the left- 3 2
cording to this resistance from min. to 1
hand grip handle to be distributed by off 5
max. When the needle reaches the the switch to the left-hand or right-
on
reserve supply level, this indicates a hand bulbs of the turnsignal lights. 4
remaining riding range of about 25km. The telltale on the instrument panel is 6
18 Trekker - Squab
ELECTRIC EQUIPMENT
Operating principle :
The starter motor requires two circuits.
1. Control circuît :
This consists of the following elements
connected in series: 14 27 0,75Ω 4w
Battery, fuse, key switch, stop 5/21w
switches, starter motor relay, start
switch (START). 5A
With the ignition key in the ON 15
position, one or both stop switches 2 16
12V 4Ah
closed, the start switch closed, the 3
current supplied by the battery runs 1
through the coils of the relay and off 5
closes by magnetic force, the power
on
circuit contact. 4
6 24
2. Power circuit :
This consists of the battery and starter 23
motor.
Activated by the relay, this circuit
consists of big wires aimed at
supporting high intensity. This circuit
is not protected by the 1OA fuse.
Troubleshooting :
Checks in the event of non starting.
Battery in good condition.
If the relay «clicks», check the battery 25
connections, the starter motor
connector, earthing of the starter 26
motor, the starter motor itself.
If the relay does not «click», look at
the taillight:
. if the taillight comes on, check the
relay
. if the taillight does not come on,
check: the battery, fuse, key switch,
stop lights, connectons.
Relay is good and working order
Relay at of order
Trekker - Squab 19
9
13
20
6,7Ω 5w
8
A B
3 x 1,2w 1,2w 15w
5,9Ω 30w
10
11
a 14 27 0,75Ω 4w
7 5/21w
b
5A
15
16 12V 4Ah
d 3 2
a 1
off 5
c 4 on
b 6 24
1
23
19
Trekker - Squab
4 25
18 28 20
26
D E
1,2w 22
Squab 50 without dipped headlights
5 5kΩ 17 C 10Ω
1,2w
6 5kΩ 21
4x 10w
100Ω
9
6,7Ω 5w
13
35/35w B A
1,2w 3 x 1,2w
5,9Ω 30w
L H
12
11
5w 33
a 14 27 0,75Ω 4w
7 5/21w
b
5A
15
16
12V 4Ah
3 2
a 1
off 5
4 on
b 6 24
23
Trekker - Squab
19
dipped headlights
4 18 28 25
20
26
D E
1,2w 22
17 C 10Ω
1,2w
Trekker 50 all types and Squab 50 with main beam +
21
21
KEY TO ELECTRIC CIRCUITS
1 Flywheel
a ignition
b sensor
c alternative current
d battery charge current
2 Ignition switch
3 CDI ignition unit
4 High voltage coil
5 Interference suppresser 5 KW
6 Spark plug 5 KW
7 Regulator, rectifier
a regulator (AC)
b regulator, rectifier (DC)
8 Choke
9 Resistance 6,7 W - 5 W
10 Lighting control
11 Resistance 5,9 W - 30 W 22
12 Headlamp control
13 Headlamp bulb
14 Rear and stop light bulb
15 Battery
16 Fuse
17 Horn
18 Horn button
19 Turn signal relay
20 Indicator control
21 Indicator bulbs
22 Fuel gauge
23 Stop light contact switches
24 Starter motor relay
25 Starter motor control
26 Starter motor
27 Current limiter
28 Low oil level contact switch
33 Number* plate lighting
22 Trekker - Squab
Note
Trekker - Squab 23
INTRODUCTION
This workshop manual concerns the FB engine which is fitted on several 50cm3
vehicles on the air-cooled version:
The electric part of this manual only concerns the TREKKER and SQUAB vehicle
ranges.
GREASE
Trekker - Squab
Dans un souci constant d'amélioration Peugeot Motocycles se réserve le droit de modifier, supprimer ou ajouter toute référence citée
DC/PS/SH Imp. en U.E 10/07/98
recommends
N° 11.753784.00