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Peugeot JetForce manual

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Table of contents for the manual

  • Page 1

    TECHNICAL TRAINING SALES DIVISI ON PRESENTATION OF THE MACHINE réf :.JET.0 10.02/2003.GB[...]

  • Page 2

    [...]

  • Page 3

    CONTENTS TRAINING MANUAL: JET FO RCE: Page : 3/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cles CHARACTERISTICS ................................................................................................................................ 5 Engine ....................................[...]

  • Page 4

    CONTENTS TRAINING MANUAL: JET FO RCE: Page : 4/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Hazard warning lights without ignition on (125 cc) ................................................................................. 30 Functioning principle of the ABS/PBS system (125 cc) [...]

  • Page 5

    CHARACTERISTICS TRAINING MANUAL: JET FO RCE: Page : 5/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es CHARACTERISTICS Engine 50 cm 3 125 cm 3 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[...]

  • Page 6

    50 CC ENGINES TRAINING MANUAL: JET FO RCE: Page : 6/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 50 CC ENGINES 50 cc 2-stroke TSDI liquid cooled engine 45 km/h version Sport version Unlimited version (registered)[...]

  • Page 7

    50 CC ENGINES TRAINING MANUAL: JET FO RCE: Page : 7/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Description HL1 engine marking Separate lubrication 1.2 l tank capacity Cooling 1.2 l capacity[...]

  • Page 8

    CATALYTIC EXHAUST TRAINING MANUAL: JET FO RCE: Page : 8/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es CATALYTIC EXHAUST Composition of the catalytic exhaust system: The catalytic exhaust system is disti nguished by the fitting of a « catal y ser cone » just after the exhaust inle[...]

  • Page 9

    INJECTION SYSTEMS / TSDI IGNITION TRAINING MANUAL: JET FO RCE: Page : 9/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es INJECTION SYSTE MS / TSDI IGNITION Introduction Of the throttle angle / engine speed type, the SYNERJEC T sy stem was developed for the following applications: Mono[...]

  • Page 10

    SYSTEM COMPONENTS TRAINING MANUAL: JET FO RCE: Page : 10/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es SYSTEM COMPONENTS Functioning principle 1. Crank assembly 2. Compressor 3. Throttle unit 4. Spark plug 5. Lubrication system 6. Feed rail a / petrol injector b / air injector c/ p[...]

  • Page 11

    PRESENTATION OF THE 2-STROKE INJECTION SYSTEM TRAINING MANUAL: JET FO RCE: Page : 11/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es PRESENTATION OF THE 2 S TROKE INJECTION SYSTEM Fuel system 1. Fuel tank 2. Fuel pump 3. Pressure regulator Ignition system: 4. Coil and suppressor 5. R[...]

  • Page 12

    DIAGNOSTIC TRAINING MANUAL: JET FO RCE: Page : 12/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es DIAGNOSTIC Warning A LED comes on on the instrument cluster to warn the rider of a fault on the injection and ignition system ELECTRICS Fault processing principle Three priority levels 1[...]

  • Page 13

    125 CC ENGINES TRAINING MANUAL: JET FO RCE: Page : 13/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 125 CC ENGINES 125 cc 4-stroke EFI liquid cooled engine Naturally aspirated version Turbo version (compressor)[...]

  • Page 14

    125 CC ENGINES TRAINING MANUAL: JET FO RCE: Page : 14/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Description FD5 engine markings Lubrication 1.25 l capacity Cooling 1.5 l capacity Cooling system functioning principle 1. Battery 2. Ignition switch 3. Fan 4. Heat switch[...]

  • Page 15

    125 CC ENGINES TRAINING MANUAL: JET FO RCE: Page : 15/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es INTRODUCTION Of the throttle angle / engine speed type, the EFI system was developed for the following applicatio ns: Monopoint sequential injection Static timing The system basic pr[...]

  • Page 16

    INJECTION SYSTEM / EFI IGNITION TRAINING MANUAL: JET FO RCE: Page : 16/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es INJECTION SYSTE M / EF I IGNITION Reminder of operation 1. ECU 2. Battery Fuel system 3. Fuel tank 4. Fuel pump 5. Pressure regulator Ignition system: 6. HT coil 7. [...]

  • Page 17

    FRAME TRAINING MANUAL: JET FO RCE: Page : 17/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es FRAME Frame Steel wrap-round frame (DIRECT PERIMETRIC FRAME - DPF)[...]

  • Page 18

    50 CC FRAME TRAINING MANUAL: JET FO RCE: Page : 18/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Suspension 50 cm 3 Front suspension: Ø 32 mm hydraulic telescopic fork Travel 85 mm Rear suspension Central hydraulic shock absorber Travel 95 mm Tyres Front wheel 13-inch alloy Front [...]

  • Page 19

    125 CC FRAME TRAINING MANUAL: JET FO RCE: Page : 19/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Suspension 125 cm 3 Front suspension Ø 36 mm hydraulic telescopic fork Travel 95 mm Rear suspension Central hydraulic shock absorber Travel 90 mm Tyres Front wheel 13-inch alloy Front[...]

  • Page 20

    BRAKES TRAINING MANUAL: JET FO RCE: Page : 20/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es BRAKES Reminder of functioning of the different braking systems Conventional hydraulic system SBC integral hydraulic braking sys tem SBC2 integral hydraulic braking sys tem[...]

  • Page 21

    BRAKES TRAINING MANUAL: JET FO RCE: Page : 21/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es ABS/PBS hydraulic braking system 1. Braking control unit 2. Right-hand brake master cylinder (emergenc y br ake) 3. Front brake caliper 4. Left-hand brake master cylinder (integral brake) 5.[...]

  • Page 22

    ABS/PBS SYSTEM SYNOPT I C S TRAINING MANUAL: JET FO RCE: Page : 22/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es ABS/PBS SYSTEM SYNOPTICS RH brake lever contactor Hydraulic pump RH brake lever contactor Brake light Front wheel speed sensor Regulation solenoid valve Battery voltage [...]

  • Page 23

    BODY PANELS TRAINI NG MANUAL: JET FORCE Page : 23/43 Reproduction or translation, ev en partial, is forbid den without the w rit ten co nsent of Peugeo t Motocycles BODY PANELS[...]

  • Page 24

    BODY PANELS TRAINI NG MANUAL: JET FORCE Page : 24/43 Reproduction or translation, ev en partial, is forbid den without the w rit ten co nsent of Peugeo t Motocycles HANDL BAR FRONT FAI R ING (2) FRONT L OWER LEGSHI ELDS (4) LEGSHI ELD REAR PA NEL (11) MUDGUA RD AND FORK GUA RD (12) FOOTBOA RDS (5) TUNN ELS (6) FUEL TANK FAIRING (10) RIDER SA DDLE ([...]

  • Page 25

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 25/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es ELECTRICITY Functioning principle of the 50 cc starter and lighting circuits 1. Battery 2. Ignition switch 3. Starter button 4. Lighting control 5. Rear light 6. Instrument cluster 7. Br[...]

  • Page 26

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 26/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 50 cc ignition on or engine running The lighting relay (11) is powered when the ignition is on via terminals 1 and 3 Over terminal 2 of the relay, the control coil is earthed through the[...]

  • Page 27

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 27/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 50 cc starting function Press starter button (3): Pressing the starter button (3) earths the starter rela y winding (12) which then powers: - The starter motor - Terminal 2 of the lighti[...]

  • Page 28

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 28/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Direction indicator functioning principle (125 cc) Direction indicator function 1. Battery 2. Ignition switch 3. Instrument cluster 4. Direction indicator switch 5. Hazard warning lights[...]

  • Page 29

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 29/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Hazard warning lights with ignition on (125 cc)[...]

  • Page 30

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 30/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Hazard warning lights without ignition on (125 cc)[...]

  • Page 31

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 31/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Functioning principle of the ABS/PBS system (125 cc) 1. Battery 2. Ignition switch 3. Module main relay 4. Starter motor relay 5. RH brake contactor 6. LH brake contactor 7. Instrument c[...]

  • Page 32

    ELECTRICITY TRAINING MANUAL: JET FO RCE Page : 32/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es ABS/PBS ELYSTAR 125cc[...]

  • Page 33

    TRANSPONDER IMMOBILISER TRAINING MANUAL: JET FO RCE Page : 33/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es TRANSPONDER IMMOBILISER Precautions: Check that the diagnostic plug jumper is fitted. The jumper provides the link between the immobiliser module and the injection/ignition E[...]

  • Page 34

    TRANSPONDER IMMOBILISER TRAINING MANUAL: JET FO RCE Page : 34/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Synoptics Assembly correct Cut between the immobiliser module and the ECU Cut between the antenna and the immobiliser unit or no transponder in they key Wrong key or immobili[...]

  • Page 35

    TRANSPONDER IMMOBILISER TRAINING MANUAL: JET FO RCE Page : 35/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Blank ECU (starting possible with red key) Immobiliser module and ECU blank Programmed immobiliser module and key from another machine Blank ECU, with 16 memorised switch on [...]

  • Page 36

    INSTRUMENT CLUSTER TRAINING MANUAL: JET FO RCE Page : 36/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 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[...]

  • Page 37

    INSTRUMENT CLUSTER TRAINING MANUAL: JET FO RCE Page : 37/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Description of the multi-function display 13. Odom ètre (totaliseur ou journalier) 14. Indication de l 'affichage de l'odomètre journalier 15. Indication de l 'un[...]

  • Page 38

    INSTRUMENT CLUSTER TRAINING MANUAL: JET FO RCE Page : 38/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Tripmeter Total/Daily display - Turn on the ignition -Press and release the button to select the function required Daily Km reset -Hold down the button for >5s Time setting The[...]

  • Page 39

    INSTRUMENT CLUSTER TRAINING MANUAL: JET FO RCE Page : 39/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es Maintenance reset Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service After servicing the machine, erase the symbol as follows: - [...]

  • Page 40

    LOCATION OF COMPONENTS TRAINING MANUAL: JET FO RCE Page : 40/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 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. Ignitio[...]

  • Page 41

    LOCATION OF COMPONENTS TRAINING MANUAL: JET FO RCE Page : 41/43 Reproduction or tra nslation, eve n partial, is forbidden without the written co nsent of Peugeot Motocy cl es 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. Id[...]

  • Page 42

    SPECIAL TOOLING TRAINING MANUAL : Page : 42/43 SPECIAL TOOLING . Tool N° Description Used with 756717 Engine mount adapter 125 cc 750539 Tie-wrap plier s 755996 Pipe clamp 755986 air injector setting tool 50 cc 755989 air injector drift 50 cc replaces 756076 Tank gauge spanner 756716 replaces 755056 Tank ring spanner . Tool N° Description Used wi[...]

  • Page 43

    SPECIAL TOOLING TRAINING MANUAL : Page : 43/43 . Tool N° Description Used with 756607 Fork seal fitting tool 125 cc 756608 Fork seal fitting tool 50 cc 756668 Crank assembl y lip seal tool 50 cc[...]