Peugeot Motorcycles JetForce 50 cc 2002 Instruction manual

SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL

CONTENTS
Page : 2
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CONTENTS
CONTENTS.......................................................................................................................................... 2
CHARACTERISTICS.........................................................................................................................5
Engine............................................................................................................................................................. 5
Capacities ....................................................................................................................................................... 5
Chassis markings............................................................................................................................................ 5
Engine markings............................................................................................................................................. 5
Frame.............................................................................................................................................................. 6
Dimensions and weight.................................................................................................................................. 6
Tyres............................................................................................................................................................... 6
SERVICE SCHEDULE AND COMMISSIONING .........................................................................7
Check.............................................................................................................................................................. 7
Change............................................................................................................................................................ 7
Check and lubricate........................................................................................................................................ 7
Reading the ECU fault codes ......................................................................................................................... 7
Test machine................................................................................................................................................... 7
SPECIAL IMPORTANT POINTS ....................................................................................................8
Oil and fuel..................................................................................................................................................... 8
Starting up after overhauling the engine ........................................................................................................ 8
Electricity ....................................................................................................................................................... 8
Special features............................................................................................................................................... 8
TIGHTENING TORQUES.................................................................................................................9
Body panels.................................................................................................................................................... 9
Frame.............................................................................................................................................................. 9
Standard.......................................................................................................................................................... 9
SPECIAL TOOLS ............................................................................................................................. 10
INSTRUMENT CLUSTER...............................................................................................................11
Instrument cluster description...................................................................................................................... 11
Description of the multi-function display .................................................................................................... 12
MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS................................................12
Changing from the total distance display to the daily display ..................................................................... 12
Changing the distance unit........................................................................................................................... 13
Setting the clock........................................................................................................................................... 13
Maintenance function................................................................................................................................... 14
Fuel gauge self-diagnostic............................................................................................................................ 14
CONTROL CABLE AND HARNESS ROUTINGS.......................................................................15
ABS/PBS panel ............................................................................................................................................ 15
Conventional braking panel.......................................................................................................................... 15
Right-hand side 50 cc................................................................................................................................... 16
Left-hand side 125 cc................................................................................................................................... 17
Rear right...................................................................................................................................................... 18
Rear centre.................................................................................................................................................... 18
LOCATION OF COMPONENTS....................................................................................................19
50 cc ............................................................................................................................................................. 19
125 cc ........................................................................................................................................................... 20
BODY.................................................................................................................................................. 21
Location of body components (50 and 125 cc)............................................................................................ 21
Body component sequence of disassembly (50 and 125 cc)........................................................................ 21
Removal of front lower legshields (50 and 125 cc) Procedure 1............................................................... 22
Removal of the headlight and sidelight assemblies (50 and 125 cc)............................................................ 22
Method for fitting the lower legshield bracket (50 and 125 cc)................................................................... 22

CONTENTS
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Removal of the storage compartment (50 and 125 cc) Procedure 2........................................................... 23
Removal of the shield)(50 and 125 cc) Procedure 3................................................................................... 23
Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4 ....................................... 25
Removal of the rear light / storage compartment trim (50 and 125 cc) ...................................................... 25
FRAME...............................................................................................................................................26
Removal of the rear frame (50 cc)................................................................................................................ 26
Removal of the frame (50 cc)....................................................................................................................... 27
MISCELLANEOUS OPERATIONS...............................................................................................29
Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc)......................... 29
To remove the oil filter (50 cc) .................................................................................................................... 29
To remove the header tank (50 and 125 cc)................................................................................................. 29
Removal of the radiator / radiator bracket (50 and 125 cc).......................................................................... 30
Removal of the fuel gauge (50 cc) ............................................................................................................... 31
Removal of the strainer (50 cc).................................................................................................................... 32
Removal of the fuel tank filler ring (50 and 125 cc).................................................................................... 33
Removal of the fuel tank (50 cc).................................................................................................................. 33
Removal of the central shock absorber / from the swingarm (50 and 125 cc)............................................. 34
Removal of the radiator deflector (50 cc) .................................................................................................... 35
Removal of the braking limiter (50 cc)........................................................................................................ 35
Removal of the saddle strut (50 and 125 cc)................................................................................................ 35
WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc) ....................36
Removal of the inlet coupling and valves.................................................................................................... 36
To remove the cylinder head Procedure 5.................................................................................................. 37
Removal of the cylinder / piston .................................................................................................................. 37
Removal of the temperature sensor.............................................................................................................. 38
Removal of the air compressor..................................................................................................................... 38
SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE................. 39
Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc) ........................................................ 39
Procedure for bleeding the fuel circuit Procedure 7 (50 and 125 cc)......................................................... 39
Removal of the injection manifold (50 cc)................................................................................................... 40
Removal of the air injector (50 cc)............................................................................................................... 40
Removal of the thermostat (50 cc)............................................................................................................... 41
Removal of the ECU (50 and 125 cc) .......................................................................................................... 42
Removal of the throttle unit (50 cc) ............................................................................................................. 42
Removal of the oil pump (50 cc).................................................................................................................. 43
Removal of the fuel gauge (50 cc) ............................................................................................................... 43
ELECTRICITY.................................................................................................................................. 44
Removal of the instrument cluster (50 and 125 cc)...................................................................................... 44
Removal of the voltage regulator and saddle actuator (50 and 125 cc)....................................................... 44
Removal of the battery cover, battery, fuses (50 and 125 cc)...................................................................... 44
Removal of the starter motor and/or lighting relay (50 and 125 cc) and/or the fuel pump and/or
ABS/PBS system relay (125 cc)................................................................................................................... 45
Removal of the high tension coil (50 and 125 cc)........................................................................................ 45
Removal of the horn, immobiliser module (50 and 125 cc)......................................................................... 45
Removal of the transponder antenna (50 and 125 cc).................................................................................. 46
Removal of the starter motor (50 cc)............................................................................................................ 46
ENGINE REMOVAL........................................................................................................................47
Removal of the 50 cc engine........................................................................................................................ 47
125 cc SPECIFIC MISCELLANEOUS WORK............................................................................. 48
Removal of the idle valve............................................................................................................................. 48
Removal of the thermostat ........................................................................................................................... 48

CONTENTS
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Removal of the engine temperature sensor .................................................................................................. 48
Removal of the fuel injector......................................................................................................................... 49
Removal of the oil pressure switch .............................................................................................................. 49
Removal of the throttle unit.......................................................................................................................... 49
Removal of the fuel pump / of the fuel gauge.............................................................................................. 51
Removal of the starter motor........................................................................................................................ 52
Removal of the rear brake pads or caliper.................................................................................................... 53
Removal of the suspension arm.................................................................................................................... 53
Removal of the engine mounting twin linkrod............................................................................................. 54
Method of fitting the engine mounting twin linkrod.................................................................................... 55
Removal of the motor-driven fan heat switch.............................................................................................. 56
Removal of the motor-driven fan................................................................................................................. 56
125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL..................................................57
Removal of the power unit Procedure 8 ..................................................................................................... 57
Removal of the engine Procedure 9............................................................................................................ 58
Removal of the rocker cover, setting the rockers, removal of the camshaft, removal of the rockers.......... 58
Removal of the cylinder head, removal of the cylinder and/or piston, removal of the cylinder head or
base gasket, removal of the timing chain, setting the timing....................................................................... 58
Removal of the connecting rod and/or LH bearing and/or changing the casings ........................................ 58

CHARACTERISTICS
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CHARACTERISTICS
Engine
50 cc 125 cc
Type Single cylinder 2-stroke direct
injection Single cylinder 4-stroke indirect injection
Cooling Liquid
Bore x stroke 39.9 x 39.8 mm 57 x 48.9 mm
Cubic capacity 49.9 cc 124.8 cc
Max. power
output 3.6 kW at 7500 rpm 9.2 kW at 8750 rpm
Max. torque at 6500 rpm 7250 rpm
Fuel system Direct electronic injection
(TSDI) Indirect electronic injection (EFI)
Lubrication Electric oil pump Trochoidal pump
Transmission 2 variable pulleys and Vee belt
Clutch Centrifugal automatic
Spark plug NGK CPR8E NGK CR7EB
Exhaust Catalytic Non-catalytic
Capacities
Fuel tank 8 litres 95 or 98 lead-free
Oil tank 1.2 litres semi-synthetic (API TC)
Engine oil 1.25 litres SAE 10W40
Relay box oil 0.12 litres SAE 80W90 Life lubricated
Coolant* 1.3 l 1.6 l
Fork 125 ccby tube Esso Univis 46
or Agip H Lift 46 190 ccby tube Esso Univis 46 or Agip H Lift 46
* Peugeot coolant part number 754614
Chassis markings
1 – VIN number and manufacturer’s plate
Engine markings
2 – Engine number

CHARACTERISTICS
Frame
50 cc 125 cc
Frame Direct Perimetric Frame
Front suspension Ø 32 mm telescopic fork Ø 36 mm telescopic fork
Travel 85 mm 95 mm
Rear suspension Central shock absorber
Travel 95 mm 90 mm
Dimensions and weight
Overall length 1914 mm 1918 mm
Width at
handlebar 740 mm
Height with rear
view mirror 1260 mm 1279 mm
Wheelbase 1314 mm 1369 mm
Ground clearance 137 mm 112 mm
Saddle height: 820 mm 845 mm
Unladen weight 115 kg 149 kg
Tyres
Front wheel 13-inch alloy
Front tyre 130/60 - 13
Front tyre
pressure 2 bar 2 bar
Rear wheel 13-inch alloy
Rear tyre 130/60 - 13 140/60 - 13
Rear tyre pressure 2.2 bar 2.2 bar
Page : 6
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SERVICE SCHEDULE AND COMMISSIONING
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SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing is for vehicles used under “harsh” conditions: door-to-door deliveries, intensive
urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.
Service operations 500 kms
or 1 months Every 5000 kms or 12 months Every 10000 kms
Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms
Check
Throttle cable play X X X
Steering column play X X X
Operation of electrical equipment X X X
Condition of front and rear brake hydraulic
controls X X X
Condition of fuel pipes X X X
Condition of oil pipes X X X
Tyre pressures X
Tyre condition, pressure and wear X X
Brake fluid level X X X
Battery electrolyte level * X X X
Coolant level X X X
Engine oil level X
Tightness of nuts and bolts X X X
Change
Spark plug X X
Inlet silencer/air filter**
Front brake pads# X
Rear brake pads *# X
Drive pulley bearings and guides # X X
Transmission belt X
Engine oil (+ clean strainer) X
Engine oil filter X
Brake fluid and coolant**
Check and lubricate
Driven pulley: moving flange and needle
bush X
Drive pulley: moving flange and rollers* X
Reading the ECU fault codes
Injection and ABS/PBS system* X X X
Test machine
On road X X X
* depending on equipment
# if necessary
** every 20000 km for the 50 cc (10000 if harsh use servicing) and every 40000 for the 125 cc (20000
km if harsh use servicing)

SPECIAL IMPORTANT POINTS
Page : 8
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SPECIAL IMPORTANT POINTS
Oil and fuel
This engine is designed to run on 95 or 98 unleaded fuel only
Never run the machine with a petrol/oil mixture.
The oil used for the separate lubrication system is « Esso 2T Spécial » or « Esso 2T Spécial anti-
fumée » recommended by the manufacturer
Starting up after overhauling the engine
The oil circuit bleed system (50 cc) must be checked with the diagnostic tool, the fuel pump bleeds itself
automatically when the ignition is turned on
Starting should not be with a 2-stroke mixture, as the fuel pump and injectors are not designed to
operate with oil.
When starting the engine hot or cold do not accelerate
Check the coolant level in the header tank
After road-testing the machine, check there are no fault codes left in the ECUs (read with diagnostic
tool)
Electricity
All components of the electrical system are powered with 12 volts DC.
The battery must not be disconnected while the engine is running and the voltage must be at least 8.5
volts for the ECU to function and enable engine starting
To avoid any risk of forgetting to turn off the ignition after opening the saddle, the ignition key
should be removed after each job
Special features
After changing the injection ECU or the throttle, the initialisation procedure must be carried out with the
diagnostic tool
The ECU has a diagnostic function which via the instrument cluster Led or the diagnostic tool, enables
reading of the faults in the memory
The fuel inlet and injection manifold return pipes must only be replaced by genuine service parts.
The fuel pressure of 8 bars requires special pipes.
The fuel pipes must be changed if they show signs of wear, cracks, etc.
The clips are specific, they must always be changed each time they are removed and replaced with
new genuine parts clips
Note:
Before carrying out any work, leave the engine to cool for a minimum of 2 hours.
Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks.
Work in a clear and well-ventilated area.

TIGHTENING TORQUES
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TIGHTENING TORQUES
Body panels
Front mudguard 0.8 to 1.2 mdaN
Handlebar cover 0.2 to 0.4 m.daN
Front legshields 0.2 to 0.4 m.daN
Rear shield 0.2 to 0.4 m.daN
Bottom panel 0.2 to 0.4 m.daN
Footboard 0.4 to 0.6 m.daN
Saddle storage compartment 0.4 to 0.6 m.daN
Rear panels 0.2 to 0.4 m.daN
Grab handle 2 to 2.5 m.daN
Rear mudguard 0.2 to 0.4 m.daN
Frame
Front wheel spindle 6 to 7 m.daN
Rear wheel bolt 8.5 to 9.5 m.daN
Rear wheel spindle nut 10 to 12 m.daN
Linkrod to engine pivot 4.3 to 5 m.daN
Linkrod to swingarm 4.3 to 5 m.daN
Engine-upper linkrod pivot 4.3 to 5 m.daN
Shock absorber top mount 2.4 to 2.6 m.daN
Shock absorber bottom mount 2.4 to 2.6 m.daN
Front and rear frame mounting nut 2 to 2.5 m.daN
Exhaust to cylinder mounting nut 1.5 to 1.8 m.daN
Exhaust to cylinder head mounting nut (125 cc) 1.5 to 1.8 m daN
Exhaust to casing mounting bolt 2 to 2.5 m.daN
Upper cone (in 2 operations) 3.8/2.3 mdaN
Upper cone locknut Tighten manually
Steering locknut 7 to 8 m.daN
Front brake caliper 2.5 to 3.5 m.daN
Rear brake caliper 2 to 2.5 m.daN
Front disc brake 0.9 to 1 m.daN
Rear disc brake 0.9 to 1 m.daN
Handlebar 2.5 to 3.5 mdaN
Standard
Nut and bolt 5 mm diameter 0.5 m.daN
Nut and bolt 6 mm diameter 1 m.daN
Nut and bolt 8 mm diameter 2.2 m.daN
Nut and bolt 10 mm diameter 3.5 m.daN
Nut and bolt 12 mm diameter 5.5 m.daN

SPECIAL TOOLS
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SPECIAL TOOLS
. Tool N° Description Used with
68994 Torque wrench 8
Nm to 54 Nm extension
752235
adapter
752236
750539 Tie-wrap pliers
752235 1/2 extension 69802 or
753977
752236 1/2-3/8 adapter 69802 or
753978
753977 Torque wrench
30 Nm to 150
Nm
extension
752235
adapter
752237
754086 Steering tool
755806 Cartridge France 755878
755807 Cartridge Export 755878
755878 Diagnostic tool
(game boy
colour)
755806
755807
755990 Diagnostic tool
update software
755996 hose clamp
756017 petrol injection
power supply
harness
756715 Tank gauge spanner
756449 ABS/PBS interface
cable for diagnostic
tool
755878
755806
755807
756575 Piston locking fork
756716 Tank ring spanner
756607 Fork seal fitting tool
125 cc
756608 Fork seal fitting tool
50 cc

INSTRUMENT CLUSTER
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INSTRUMENT CLUSTER
Instrument cluster description
1. Multi-function display
2. Rev counter
3. Speedometer
4. Engine temperature gauge
5. Control button
6. Injection system diagnostic warning light
7. Transponder immobiliser dissuasion light
8. ABS/PBS system diagnostic warning light (125 cc)
9. Headlight warning light
10. Low oil level (50 cc) or oil pressure (125 cc) warning light
11. Direction indicator warning light
12. Battery charge warning light
When the ignition is turned on, the different functioning tests are carried out automatically for 5
seconds:
- Display of all of the multi-function display items (1) and the speed (3)
- Lighting of all the warning lights (except ABS/PBS depending on version)
- Test of rev counter stepper motors (2) and engine temperature (4) giving one sweep of the needles and
zero reset where necessary

INSTRUMENT CLUSTER
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Description of the multi-function display
13. Tripmeter (total or daily)
14. Tripmeter display
15. Type of unit used by the tripmeter
16. Clock
17. Maintenance indicator (spanner symbol)
18. Fuel gauge
MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS
Setting and function change operations can only be carried out if the machine is stationary (engine
not running) This is for safety reasons.
Changing from the total distance display to the daily display
The tripmeter (13) has two functions:
- Total distance (15) displays and memorises the total distance covered by the machine
- The tripmeter (14) displays and memorises the distance covered over a given period
With the ignition on, changeover from the main to the daily distance and inversely is by briefly pressing
the control button (5)
With the ignition on, reset of the daily tripmeter is by pressing the control button for more than 3
seconds

INSTRUMENT CLUSTER
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Changing the distance unit
Changing the distance unit (km or miles) is as follows:
- Ignition off, hold down the control button (5) and turn on the ignition, the distance unit flashes
- Select the unit by briefly pressing the control button, the distance unit changes from “km” to “miles”
or inversely.
-Turn off ignition to confirm
Setting the clock
The time can only be set in the tripmeter total distance position
- Ignition on, press the button (5) until the time flashes
- Set the time by successive pushes on the control button
- To change the tenths of a minute, press the button until the minute tenths flash
- Change the minute tenths by pressing as required on the button
- Proceed in the same way to set the minutes
- Press the button for more than 3 seconds to validate the clock setting

INSTRUMENT CLUSTER
Maintenance function
Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service
After servicing the machine, erase the spanner symbol as follows:
- Ignition off, hold down the button (5) and turn on the ignition, the spanner symbol flashes
- Release the control button
- Press the button again for at least 5 seconds, the spanner symbol goes off
Fuel gauge self-diagnostic
If the fuel system is cut off from the fuel gauge, when the ignition is turned on, the display segments
light one after the other
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CONTROL CABLE AND HARNESS ROUTINGS
CONTROL CABLE AND HARNESS ROUTINGS
ABS/PBS panel
1. Main harness
2. Throttle control
3. Transponder antenna
4. Speed sensor
5. Brake light switch
6. ABS/PBS brake module reservoir feed pipe
7. Rear brake pipe
8. Right master cylinder to module brake pipe
9. Module brake pipe to front caliper
10. Left master cylinder to module brake pipe
Conventional braking panel
1. Main harness
2. Throttle control
3. Transponder antenna
4. Speed sensor
5. Brake light switch
6. Front brake pipe
7. Rear brake pipe
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CONTROL CABLE AND HARNESS ROUTINGS
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Right-hand side 50 cc
1. Main harness
2. Throttle cable (50 cc)
3. Transponder antenna
4. Speed sensor
5. Front brake pipe
6. Rear brake pipe
7. Fuel feed pipe

CONTROL CABLE AND HARNESS ROUTINGS
Page : 17
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Left-hand side 125 cc
1. Main harness
2. Throttle cable (125 cc)
3. Rear brake pipe
4. Fuel supply pipe
5. Air pressure slave pipe
6. Fuel overflow pipe

CONTROL CABLE AND HARNESS ROUTINGS
Rear right
1. Main harness
Rear centre
1. Main harness
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LOCATION OF COMPONENTS
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LOCATION OF COMPONENTS
50 cc
1. Injection ECU
2. Throttle unit
3. Engine position and speed sensor
4. Temperature sensor
5. Battery
6. Fuel injector
7. Air injector
8. Ignition coil
9. Immobiliser module
10. Fuel pump
11. Oil pump
12. Diagnostic light
13. Diagnostic plug
14. Air compressor
15. Fuses
16. Voltage regulator
17. Horn
18. Saddle lock
19. Starter / lighting relay

LOCATION OF COMPONENTS
125 cc
1. Injection ECU
2. Throttle unit
3. Engine position and speed sensor
4. Temperature sensor
5. Air pressure and air temperature sensor
6. Battery
7. Fuel injector
8. Idle control valve
9. Ignition coil
10. Immobiliser module
11. Fuel pump
12. Diagnostic light
13. Diagnostic plug
14. Fuel pump relay, ABS/PBS, lighting, 25A
fuse
15. Heat switch
16. Motor-driven fan
17. Starter relay, 15 A fuse
18. Voltage regulator
19. Horn
20. Saddle lock
21. ABS/PBS module
22. Vehicle speed sensor and ABS/PBS
Page : 20
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