PEUGEOT Speedfight 2 User manual

Contents
LIVINGWITH YOUR SCOOTER
Introduction
The Peuaeot Storv Paae
0.4
Acknowledgements Page 0.7
About this manual Page 0.7
Identificationnumbers Pane 0.8
Buyingspare parts Page 0.9
Modeldevelopment Page 0.9
Safetyfirst! Page 0.11
Daily(pre-ride checks)
Engineoil levelcheck Page 0.12
Coolant levelcheck(liquid-cooledengines) Page 0.12
Brakefluid levelcheck Page 0.13
Fuel check Paae 0.13
Suspensionand steering checks Page 0.13
Tyre checks Page 0.14
Legaland safety checks Pane 0.14
MAINTENANCE
Routine maintenanceand servicing
Modelspecificationsand serviceschedules Page 1.2
Routinemaintenanceand servicing procedures Page 1.26

Contents
REPAIRSAND OVERHAUL
Engine, transmissionand associated systems
Air-cooled two-strokeengines Page 2A.1
Liauid-cooledtwo-strokeenaines Paae 28.1
Transmission Page 2C.1
Coolingsystem (liquid-cooledengines) Page 3.1
Fuelandexhaust systems Page 4.1
Ignitionsvstems Pane 5.1
Chassiscomponents
Frame and suspension Page 6.1
Bodywork Page 7.1
Brakes, wheelsandtvres Pane 8.1
Electricalsystem Page 9.1
Wiring diagrams Page 9.20
REFERENCE
Conversionfactors Page REF4
Fault Finding Page REF02
Index Page REF~Q

0.4 Introduction
The Peugeot Story
D
eugeot celebrated its 100th automotive
anniversarvin1998 but its histowstretches
1 back a furiher 88 years and en&mpasses
an incrediblydiverserangeof products.
Now part of the massive PSA industrial
conglomerate that includes Citrogn and
Peugeot, the Peugeot dynasty has classically
humblebeginnings.
Brothers, Jean-Pierre and Jean-Frederic
Peugeot decided to manufacture cold rolled
steel in the family mill on the Doubsriver in
eastern France. A far cry from the high-profile
World Rally Championship, Le Mans and
FormulaOne with which Peugeot has latterly
become known. Fine steel strips and springs
were sold to the nearby Swiss clock-making
industryand by 1818the brothershadmoved
into producing steel for tools, mainly saw
blades. By 1824, 70 workers toiled in the
factory at Herimoncourt and in 1850 the
famous Peugeottrademark, therampant Lion,
was being used to mark their top grade of
steel. The king of beasts was formerly
registeredas atrademark in 1858.
In a manner which reflectedthe innovative
industrial production of Victorian Britain,
Peugeotfurther diversified into coffee mills
made of wood or metal, some for grocers'
shops and cafes, others for the home. There
followed pepper mills, washing machines,
furniture, wireless sets, sewing machines,
crinolines, umbrellas, irons and even
shotguns. Much later, the first modernfood
processor,the Peugimix, was the talisman in
a whole rangeof kitchenappliances.
The First MotorVehicles
The first bicycles were made in 1882 at
Beaulieu-Mandeure after Armand Peugeot
was inspired by this new form of locomotion
during his stay inEnglandas a student.
In 1889, Peugeottook a leap of faith with
itsfirst 'car', actually a tricycle powered by a
steam engine. From this inauspicious start
The lOOcc Speedfight 2
they designed a four-wheeler the following
year which used a Panhard-produced
Daimler 565 cc V-twin engine. Cooled by
water circulatingintheframetubes, itweighed
500 kg and produced 1hp at 1000 rpm. Top
speedwas littlemorethanstationary.
The type 3 car of 1891 introduced mass
productiontechniques for the day
- 64 were
made in four years. Six years on, the type 15
was the first car powered by an all-Peugeot
engine.
The first Peugeot motor-bicycle appeared
in 1902, a 1.5 bhp single cylinder engine in a
cycleframe, and the company found itself in
the heady position, repeated elsewhere
acrossEurope, as newcomersto bothcar and
motorcycle
manufacturing.
The first Peugeot motor-
bicycleappeared in 1902
5 hp machinewas producedintandem
with the Bebe car designed by Ettore
A ugatti. In 1905, a 12 hp racing
motorcycleemergedtoset two world records
including the level kilometreat 76.612 mph.
Peugeot'salso featured in the first
lT races
onthe Isleof Man in 1907.
After the First World War Peugeot won
various Grands Prix races with a 500 cc
machine and in 1925 rider Pean set a new
worldspeedrecordat 103.15mphona750cc
machine.
By 1929Peugeot embarked on itsfirst truly
mass-produced car, the 201, and Peugeot
motorcycles were selected for use by the
French army, Gendarmerie and the national
postal service. A new Peugeot bicycle was
also coming off the assembly line every 45
seconds.
The motorcycle range expandedto include
175,250,350 and 500 cc machines but after
theSecondWorldWar productionfocussed on
smaller machineswith the first scooters being
made in 1955. Racing hadtaken a back seat
but Peugeot won the 175
cc class at the 1952
Bol d'Or leadingto the launch of the 175 cc
GrandSport roadmodel.

Introduction 0.5
B
y 1970their rangehadgrownto include
23 models, mainly cycle-motors. It was
not until 1982that the first recognisably
modern scooters were made with the SC/SX
range and these were the first machines in
Europe to use plastic bodywork. The
formation of Peugeot Motocycles in 1987
acted as the catalyst for the new era of
modernscooter production.
Scooter Production
Scooter and cycle-motor production at
Peugeot is centred on two contrasting
manufacturing plants close to the small town
of Sochaux famous as the heartland of the
Peugeot dynasty and the faded glory of a
oncefamousfootballteam.
L
ess than an hour's drive from Basle
airport on the Franco-Swiss border,
Beaulieu-Mandeure is home to the
Peugeot Motocycles assembly plant. Here,
tubes are bent into frames, electrical wire is
made into looms, silencers are fabricated,
bodyworkand chassisare paintedand largely
home-produced components are assembled
by the workforce of over 1000 people.
Approximately 60% of the machines
produced are for export, with the remainder
consumed bythe home market.
Back along the autoroute towards Basle,
Peugeot'smodernengine plantat Dannemarie
produce the company's four-stroke engines
fitted to the Elystar and Elyseo 125 and 150
luxury scooters, using technology from
Peugeot's car engine division.At Dannemarie,
where the legend 'Honda Engineering' adorns
many a high tech machinetool, they produce
seven different types of engine, but in a The
Wcc Speedfight 2 X-Race
The
Wcc Speedfight 2 X-Team The
50cc Trekker Road

0.6 Introduction
bewildering 190 different specifications.This
compact facility has the capacity to produce
2000 engines per day and has its own
pressureand gravitydie-castingplants.
Manyenginecomponents are sourcedfrom
Mahle, Mikuniand Dell'Ortoand partssuch as
pistons, clutches, cylinders and crankshafts
are machinedon site. The factory has its own
nickel and zinc coating facility and heat-
treating plant.
w
hilePeugeot's success in Britain has
been meteoric it's not without
parallel as Peugeot seeks an ever
larger share of the massive European scooter
market.The Italian50 cc scooter sector alone
accounts for 570,000 machines a year;
together with Spain, Germany, France and
Hollandthetotal tops a million.
Peugeot leads markets in France, Finland,
Belgium, Holland and Denmark and is
aggressively pursuing the German and Italian
markets where it established subsidiaries in
1997. Despite stiff competition from Piaggio,
Aprilia and Malaguti, Peugeot see the Italian
marketas the keyto itsgreatestexpansion.
Speedfight,Trekker and
Vivacity
The mainstay of Peugeot's twist-and-go
scooter range are the Speedfight 50 and
100 cc models. Unveiled in the
UK in late
1996 as a 50 cc, and then joined by a 100cc
modelthefollowingsummer, the Speedfight's
success was responsible for Peugeot
becoming the most popular scooter marque
inthe UK market.
The 50cc Trekker Off Road
-
The 50cc Trekker Streetboard
The 50ccVivacity