PEUGEOT Vivacity Instruction manual

Sales division
Technical network leadership
WORKSHOP MANUAL
-
Workshop manual
Technica l network leaders hip
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS.
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS.
TABLE OF CONTENTS.....................................................................................................................................1
PRODUCTS DANGER SYMBOLS USED.........................................................................................................3
CHARACTERISTICS.........................................................................................................................................5
Engine........................................................................................................................................................5
Capacities..................................................................................................................................................5
Chassis......................................................................................................................................................5
Dimensions and weight..............................................................................................................................6
Tyres ..........................................................................................................................................................6
Brakes........................................................................................................................................................6
SERVICE SCHEDULE AND COMMISSIONING...............................................................................................7
To be checked at each service...................................................................................................................7
Service operations.....................................................................................................................................7
Battery preparation (Except battery without maintenance)* ......................................................................8
Installing the battery vent hose..................................................................................................................8
New machine preparation..........................................................................................................................8
SPECIAL IMPORTANT POINTS.......................................................................................................................9
Oil and fuel.................................................................................................................................................9
Starting up after overhauling the engine....................................................................................................9
TIGHTENING TORQUES ................................................................................................................................10
Engine part ..............................................................................................................................................10
Body panels.............................................................................................................................................10
Cycle part.................................................................................................................................................11
Standard ..................................................................................................................................................11
SPECIAL TOOLS ............................................................................................................................................12
LOCATION OF COMPONENTS......................................................................................................................14

TABLE OF CONTENTS.
2Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS ...............................................................................................................................................15
Location of body components..................................................................................................................15
Body component sequence of disassembly.............................................................................................16
Removal of the rear storage compartment ..............................................................................................17
Removal of the rear cover assembly and mudflap...................................................................................17
Removal of the front storage compartment..............................................................................................19
Removal of the rear shield panel .............................................................................................................19
Removal of the front shield panel.............................................................................................................20
Removal of the footboard.........................................................................................................................21
Removal of the instrument cluster ...........................................................................................................22
SERVICE OPERATIONS.................................................................................................................................23
Removal of the spark plug .......................................................................................................................23
Replacing the air filter..............................................................................................................................23
Front brake pads......................................................................................................................................24
Replacing the brake pads........................................................................................................................24
Checking the brake fluid level ..................................................................................................................25
Rear brake linings....................................................................................................................................26
Transmission............................................................................................................................................29
Checking the drive belt ............................................................................................................................31
Checking the clutch linings.......................................................................................................................31
Replacing the clutch lining assembly.......................................................................................................32
Removal of the fuel filter ..........................................................................................................................33
MISCELLANEOUS OPERATIONS .................................................................................................................34
Removal of the fork..................................................................................................................................34
Replacing the bearings of the steering system........................................................................................34
Steering system tightening method..........................................................................................................36
Removal of the fuel pump........................................................................................................................38
Removal of the fuel gauge.......................................................................................................................38
Removal of the fuel tank ..........................................................................................................................38
Removal of the carburettor.......................................................................................................................40
Removal of the float, needle valve and jets....................................................................................................... 41
Removal of the engine speed adjuster screw and mixture control screw. ........................................................ 42
Reassembly .............................................................................................................................................43
Removal of the power unit .......................................................................................................................45

PRODUCTS DANGER SYMBOLS USED
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
PRODUCTS DANGER SYMBOLS USED
Protection of individuals and of the environment.
Möbius band Recyclable.
Means that the product or the package
can be recycled. However, this does not
guarantee that the product will be
recycled.
Irritant The product can irritate the skin, eyes and repiratory
organs.
Avoid contact with the skin and clothes.
Wear gloves, safety glasses and
appropriate clothes such as a cotton
overall. Do not breath fumes. If in contact,
wash thoroughly with water.
Flammable The product is flammable.
Keep it away from any flame or heat
source (barbecue, radiator, heating
device, etc.). Do not leave the product in
the sun.
Corrosive The product can damage living
tissues or other surfaces.
Avoid contact with the skin and clothes.
Wear gloves, safety glasses and
appropriate clothes such as a cotton
overall. Do not breath fumes.
Explosive The product can explode under certain circumstances (flame,
heat, impact, friction). Avoid impacts, friction, sparks and heat.
Hazardous to
the environment
The product affects fauna and
flora. Do not dump it in
garbage cans, sinks or nature.
The ideal solution is to bring this product
to your nearest household waste recycling
centre.
Toxic The product can seriously affect health if it is inhaled,
ingested or in contact with skin.
Avoid direct contact with the body even by
inhalation. If you feel unwell, seek medical
advice immediately.
Do not throw
away into a
garbage can
One of the product's
component is toxic and can be
hazardous to environment. Ex.
Used batteries.
This symbol informs the consumer that the
used product shall not be thrown away into
a garbage can, but shall be brought back
to the merchant or dropped at a specific
collection point.
Compulsory
gloves Operation that can be dangerous for people.
People's safety can be seriously affected if
the recommendations are not fully
respected.

PRODUCTS DANGER SYMBOLS USED
4Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
People's safety Operation that can be
dangerous for people.
People's safety can be seriously affected if
the recommendations are not fully
respected.
Important Operation that can be
hazardous to the vehicle.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Good operating
condition of the
vehicle
The operation must be carried
out in strict compliance with the
documents.
Serious damage to the vehicle and in
certain cases a cancellation of the
warranty can be involved if the
recommendations are not fully respected.
Note Operation that can be difficult. Indicate a note which gives key
information to make the procedure easier.
Lubricate Lubricate the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Grease Grease the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Glue Glue the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
New part Use a new part. Indicate the specific procedures that shall be followed in order not to damage the
vehicle.
GLUE
N

CHARACTERISTICS
5
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Engine
Capacities
Chassis
Marking B1E400MB
Type 2-stroke single-cylinder
Horizontal cylinder
Cooling By a circulation of forced air by means of a turbine on the flywheel
magneto
Bore x stroke 39.9 x 39.8 mm
Cubic capacity 49.9 cc
Max. power output 3 kW at 7000 rpm
Max. torque rating 4 Nm at 5800 rpm
Compression 6 bars 700 rpm
Fuel supply Carburettor. PZØ12
Lubrication Separate lubrication by an electric pump driven by the Oil Pump Control
Ignition Unit
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Catalytic
Starter motor By kick starter or electric starter
Spark plug NGK BPR7HS
Electrode gap: 0.6 mm
Magneto flywheel 90 W
Relay box oil 0.12 l SAE 80W90.
Minimum grade: API GL4
Fork oil 0.85 l per tube (Esso Univis 46 or Agip HLift 46)
Fuel tank 8.5 l
Oil tank 1.3 l
Chassis Steel tube
Front suspension Hydraulic telescopic fork. Ø32 mm
Travel: 75 mm
Rear suspension Combined spring and hydraulically-damped shock absorber
Travel: 65 mm

CHARACTERISTICS
6Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Dimensions and weight
Tyres
Brakes
Overall length 1923 mm
Width at handlebar 670 mm
Height. (without rear-view
mirrors) 1170 mm
Wheelbase 1337 mm
Saddle height 786 mm
Unladen weight 95 kg
Front wheel rim 12 inch aluminium alloy
Front tyre 120/70 - 12
Front tyre pressure 1.8 bars
Rear wheel rim 12 inch aluminium alloy
Rear tyre 120/70 - 12
Rear tyre pressure 2 bars
Front brake Single disc type, hydraulic control
Disc diameter and
thickness 200 mm - 3.5 mm
Rear brake cable-controlled, single cam drum type
Brake drum diameter 110 mm
Brake lining thickness 4mm
Chassis markings Engine marking
(1) number and manufacturer's plate Engine number. (2)
*VGAV1AAAA0JXXXXXX*
1
B1E400MB
XXXXXXXX
2

SERVICE SCHEDULE AND COMMISSIONING
7
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing applies to vehicles used under rugged operating 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 Every 10000 kms Every 20000 kms
Heavy duty servicing 500 kms Every
2500 kms Every 5000 kms Every 10000 kms
To be checked at each service
Throttle cable play V V V V
Steering column play V V V V
Operation of electrical equipment V V V V
Condition of front and rear brake hydraulic
controls* VVVV
Brake fluid level* V V V V
Front brake pad wear V V V V
Rear brake lining wear V V V V
Condition of petrol pipes V V V V
Condition of oil pipes V V V V
Tyre condition, pressure and wear V V V V
Condition of the front suspension. Condition
of the rear suspension. CCCC
Battery electrolyte level. Battery charge C C C C
Tightness of nuts and bolts V V V V
Headlight height adjustment V V V V
Overall functioning. Road test V V V V
Service operations
Spark plug R R R
Air filter V R R
Drive pulley bearings and guides C R R
Transmission belt V R R
Kick starter mechanism G G
Setting the carburettor V V V
Petrol filter R
Fork oil R
Brake fluid Once every 2 years
Time required for maintenance
Code 9100 9300 9400 9600
Time required for maintenance 0.5 1.3 1.4 2
V: Check, clean, adjust. C: Inspect and change if necessary.
R: Change. * Depending on equipment.
G: Check, clean, lubricate.

SERVICE SCHEDULE AND COMMISSIONING
8Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Battery preparation (Except battery without maintenance)*
Remove the battery.
Remove the 6 filler caps and the vent plug.
Fill all the battery cells with electrolyte to the upper level shown on the battery "UPPER LEVEL".
Electrolyte: (35% sulfuric acid = 1.28 g/cm3). 0.5 litre can P/N 739733.
Leave the battery to stand for around half an hour.
Top up if necessary.
Charge the battery for at least 2 hours with a current of 0.4 A.
Refit the battery and connect the vapour vent pipe.
Connect the red wire lug to the battery's + terminal, and the green wire lug to the battery's - terminal.
Then, the battery level should be topped up if necessary, after fully charging, using distilled wateronly.
* Depending on equipment.
Installing the battery vent hose.
- After being disconnected from the battery,
the vent hose must be routed through the
2 holders located in the rear splash guard.
- Cut the vet hose 1 cm after the second
holder.(1)
New machine preparation
Check the tightness of the carburettor float chamber drain screw.
Check the wheel nuts are tight.
Check nuts and bolts are tight.
Check brake adjustment and efficiency.
Check the tyre pressures cold.
Check operation of the lights, flashers, horn, and brake light.
Check the different warning lights work.
Carry out a road test.
1

SPECIAL IMPORTANT POINTS
9
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
Oil and fuel
This engine is designed to run on 95 or 98 unleaded fuel only.
Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc.
The air pipe between the air pump and the exhaust is specific owing to its heat resistance
properties.
Should it be changed, replace it with a genuine pipe
The clips are specific, they must always be changed each time they are removed and replaced
with new genuine parts clips.
Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or
sparks.
Before carrying out any work, leave the engine to cool for at least 2 hours.
Starting up after overhauling the engine
The oil pump must be drained in accordance with the recommended procedures.
The light comes on when the ignition is turned on to check it is operational and comes off as soon as
the engine starts if there is no incident.
When starting the engine hot or cold do not accelerate.

TIGHTENING TORQUES
10 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TIGHTENING TORQUES
Engine part
Body panels
Drive pulley 40 Nm
Driven pulley 45 Nm
Clutch plate and shoes 40 Nm
Transmission cover 10 Nm
Relay box cover 10 Nm
Stator 10 Nm
Engine speed sensor 5 Nm
Rotor 40 Nm
Turbine 7Nm
Starter motor 10 Nm
Spark plug 20 Nm
Cylinder head 12 Nm
Inlet manifold 10 Nm
Crankcase 10 Nm
Front mudguard 8 to 10 Nm
Handlebar cover 2 to 4 Nm
Front shield panel 2 to 4 Nm
Rear shield 2 to 4 Nm
Bottom panel 2 to 4 Nm
Floor panel 6 to 8 Nm
Saddle storage compartment 8 to 10 Nm
Rear panels 6 to 8 Nm
Grab handle 20 to 25 Nm
Rear mudguard 2 to 4 Nm

TIGHTENING TORQUES
11
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Cycle part
Standard
Front wheel spindle 65 Nm
Rear wheel spindle nut 100 Nm
Linkrod to engine pivot 60 Nm
Linkrod to frame pivot 60 Nm
Shock absorber top mount 45 Nm
Shock absorber bottom mount 22 Nm
Exhaust to cylinder mounting nut 15 Nm
Exhaust to casing mounting bolt 20 Nm
Upper cone (in 2 operations) 40/23 Nm
Upper cone locknut Hand tightened
Steering locknut 70 Nm
Front brake caliper 25 Nm
Front brake disc 22 Nm
Handle bar 25 Nm
Nut and bolt 5 mm diameter 5 Nm
Nut and bolt 6 mm diameter 10 Nm
Nut and bolt 8 mm diameter 22 Nm
Nut and bolt 10 mm diameter 35 Nm
Nut and bolt 12 mm diameter 55 Nm

SPECIAL TOOLS
12 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
Tool N° Designation Used
with Tool N° Designation Used with
64706 Casing extractorand
opening tool
754006
750069 750539 Tie-wrap pliers
64710 Shouldered centering
tool 64706 750808 Thrust
washer 64706
64765 Engine
mount 755982 752000 Piston circlip
pliers
68007 Protective end-piece
small model 755985 752127 Clutch
compression
tool 756725
69098 Protective end-piece
large model 64706 752237 Adjustable
pin wrench
69104 Pin nut 750069 753726 Steeinghead
cup push tool
750069 Pin Ø10
pitch 125 69104 754006
Modified
casing
opening
plate
67706

SPECIAL TOOLS
13
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
(*) New or modified tool.
Tool N° Designation Used
with Tool N° Designation Used
with
755585 Bearing
extractor tool 756668 Crank
assembly lip
seal tool
755982 Engine mount
adapter 64765 756725 38 mm pipe
wrench 752127
755983 Casing
opening tool 68007 757860 Steering tool
755985 Flywheel
puller 68007 757990 Steeinghead cup push tool
755996 Hose clamp

LOCATION OF COMPONENTS
14 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
LOCATION OF COMPONENTS
1. Oil pump control unit
2. Battery
3. Ignition sensor
4. Oil level indicator
5. Oil pump
6. HT coil
7. Low oil level warning light
8. Regulator
9. Starter motor relay
10.Fuel gauge
11.Horn
12.Outside temperature sensor
13.Speed sensor
5
11
1
2
9
8
6
7
3
4
14
10
12
13
-
UPPERLEVEL
LOWERLEVEL
NC
NC

BODY PANELS
15
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
Location of body components
Description.
1. Handlebar front fairing
2. Handlebar rear fairing
3. Tool compartiment cover
4. Front storage compartment
5. Rear shield
6. Front mudguard
7. Front wheel
8. Front shield panel
9. Saddle and storage compartment
10.Central panel
11.Footboard
12.Grab handle
13.Rear panels
14.Bottom panel
NC
12
1
2
14
7
13
3
4
8
9
6
5
11
10

BODY PANELS
16 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Body component sequence of disassembly
1. Handlebar front fairing
2. Handlebar rear fairing
3. Tool compartiment cover
4. Front storage compartment
5. Rear shield
6. Front mudguard
7. Front wheel
8. Front shield panel
9. Saddle and storage compartment
10.Central panel
11.Footboard
12.Grab handle
13.Rear panels
14.Bottom panel
*This item may be removed on its own.
5*
10
14*
13
12*
9*
8
7*
2
1*
6*
11
3*
4

BODY PANELS
17
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Removal of the rear storage
compartment
Procedure 1.
- Lift the saddle.
- Remove the storage compartment.
(8 screw).
- Disconnect the accessory plug.
Removal of the rear cover assembly and
mudflap
Procedure 2.
- Remove the rear storage compartment.
See: Procedure 1. page 17.
- Remove the grab handle. (3 screw). (1)
- Remove the central cover panel.(5 screw).
1

BODY PANELS
18 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Remove the rear cover assembly.(5 screw)
(3)
-Disconnect the taillights.
- Remove the splash guard. (6 screw)
- Separate the 3 fairings. (4)
3
3
4
4