50cc 4-stroke engine 2 valves - Scootergrisen
50cc 4-stroke engine 2 valves - Scootergrisen
50cc 4-stroke engine 2 valves - Scootergrisen
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-<br />
Sales division<br />
Technical network leadership<br />
TECHNICAL TRAINING<br />
P/N MOT50SYM.001.03/2009.GB<br />
50CC 4-STROKE ENGINE<br />
2 VALVES
Sales division<br />
Technical network leadership<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS<br />
TABLE OF CONTENTS<br />
TABLE OF CONTENTS..................................................................................................................................... 1<br />
CHARACTERISTICS......................................................................................................................................... 2<br />
HOW A 4 STROKE ENGINE WORKS .............................................................................................................. 3<br />
ENGINE ............................................................................................................................................................. 4<br />
Crankcase..................................................................................................................................................5<br />
Cylinder head.............................................................................................................................................6<br />
Cylinder/piston ...........................................................................................................................................7<br />
Distribution .................................................................................................................................................8<br />
Transmission ..............................................................................................................................................9<br />
Relay box .................................................................................................................................................10<br />
Starter system..........................................................................................................................................11<br />
Starter motor............................................................................................................................................12<br />
Lubrication system...................................................................................................................................13<br />
Cooling system ........................................................................................................................................14<br />
Carburettor...............................................................................................................................................15<br />
Ignition system .........................................................................................................................................16<br />
Ignition system .........................................................................................................................................16<br />
Exhaust ....................................................................................................................................................18<br />
SPECIAL TOOLS ............................................................................................................................................ 19<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
1
CHARACTERISTICS<br />
CHARACTERISTICS<br />
2<br />
Capacities<br />
50 cc<br />
Make P152QMI-A<br />
Type<br />
4-<strong>stroke</strong> single-cylinder.<br />
2 <strong>valves</strong> per cylinder with chain driven overhead camshaft<br />
Cooling By a circulation of forced air by means of a turbine on the flywheel magneto<br />
Bore x <strong>stroke</strong> 37 x 46 mm<br />
Cubic capacity 49.5 cm3<br />
Max. power output 2.8 kW at 8000 rpm<br />
Max. torque rating 3.5 Nm at 6500 rpm<br />
Lubrication Trochoid pump driven by a gear set from the crankshaft<br />
Transmission By 2 variable pulleys and V-type belt<br />
Clutch Centrifugal automatic<br />
Exhaust Catalytic<br />
Spark plug NGK CR 7HSA<br />
Magneto flywheel 70 W<br />
Fuel supply Carburettor Keihin NVC18(c/d)<br />
Standards Euro3<br />
Crankcase 0.7 l<br />
Relay box 0.1 l<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
HOW A 4 STROKE ENGINE WORKS<br />
1<br />
4 <strong>stroke</strong> cycle<br />
1st<br />
revolutio<br />
2nd<br />
revolutio<br />
4<br />
2<br />
3<br />
HOW A 4 STROKE ENGINE WORKS<br />
1. TDC: Top dead centre<br />
2. BDC: Bottom dead centre<br />
3. V : Volume between the TDC and the BDC<br />
4. v : Volume on top of the piston when it is at its TDC<br />
(V+v)/v : Compression ratio. It is the ratio of the initial<br />
volume (V+v) to the final volume (v).<br />
1st <strong>stroke</strong>, Intake<br />
When the piston goes down, it creates a vacuum pressure<br />
(TDC-BDC) which suctions the air and petrol mixture into<br />
the cylinder through the intake valve.<br />
The intake valve is open.<br />
2nd <strong>stroke</strong>, Compression<br />
The piston goes up and compresses the air and petrol<br />
mixture (BDC-TDC) until it fills only the compression<br />
chamber.<br />
The intake valve is closed.<br />
The exhaust valve is closed.<br />
3rd <strong>stroke</strong>, Explosion (expansion)<br />
The spark plug lights up the compressed air and petrol<br />
mixture. The heat expands the gases which violently<br />
pushes the piston downwards (TDC-BDC).<br />
The intake valve is closed.<br />
The exhaust valve is closed.<br />
4th <strong>stroke</strong>, Exhaust<br />
When the piston goes up, it expels the burnt gases through<br />
the exhaust valve.<br />
The <strong>engine</strong> is ready again to perform a new cycle.<br />
The exhaust valve is open.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
3
ENGINE<br />
ENGINE<br />
4<br />
4 <strong>stroke</strong>, <strong>50cc</strong> <strong>engine</strong> with pulsed air cooled horizontal cylinder.<br />
2 <strong>valves</strong> per cylinder with chain driven overhead camshaft.<br />
1. Engine number<br />
2. Filler cap<br />
1<br />
4<br />
3. Oil level indicator (Oil level inspection with<br />
the cap/gauge. Gauge cap unscrewed)<br />
4. Screen<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
2<br />
3<br />
Max<br />
Min
Crankcase<br />
Cast aluminium alloy <strong>engine</strong> crankcase.<br />
Aluminium alloy transmission cover fitted with the starter system.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
ENGINE<br />
PEUGEOT<br />
5
ENGINE<br />
6<br />
Cylinder head<br />
4<br />
5<br />
1<br />
2<br />
1. Light alloy cylinder head<br />
2. Valve. (Valve clearances: 0.05 mm at the intake. 0.10 mm at the exhaust)<br />
3. Camshaft<br />
4. Rockers<br />
5. Rocker shafts<br />
6. Cylinder head gasket<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
6<br />
3<br />
4<br />
5
Cylinder/piston<br />
ATG<br />
A<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
ENGINE<br />
Piston:<br />
In light allow and featuring a dome<br />
head design, and equipped with<br />
three piston rings:<br />
- Top compression ring.<br />
- Middle compression ring.<br />
- Bottom oil control ring.<br />
Cylinder:<br />
- Aluminium with Nicazil<br />
treatment and paper cylinder<br />
base gasket.<br />
Conrod and crankshaft assembly:<br />
- Installed on two bearings.<br />
7
ENGINE<br />
8<br />
Distribution<br />
Single overhead camshaft driven by a noiseless chain from the crankshaft.<br />
Automatic chain tensioner.<br />
T: TDC<br />
F: Ignition timing<br />
Note: Timing mark on the camshaft gear (A).<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
A
Transmission<br />
Fixed flange of the pulley equipped with cooling fins to cool the belt.<br />
Driven/centrifugal 3 block lined clutch pulley mounted on the end of the relay box input shaft.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
ENGINE<br />
9
ENGINE<br />
10<br />
Relay box<br />
By shaft and pinions. Double set of pinions.<br />
1st gear teeth set: Helical.<br />
2nd gear teeth set: Helical.<br />
Note: Low helix angle teeth.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Starter system<br />
Composition:<br />
- Kick lever boss<br />
- Kick starter gear sector shaft<br />
- Return spring<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
ENGINE<br />
11
ENGINE<br />
12<br />
Starter motor<br />
2<br />
1<br />
3<br />
1. Starter motor<br />
2. Idler gear<br />
3. Freewheel<br />
Actuated by the starter motor The <strong>engine</strong> is running<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Lubrication system<br />
1. Screen<br />
2. Oil pump<br />
3. Bearing lubrication<br />
4. Jet<br />
Pressurised wet sump lubrication.<br />
Trochoid pump driven by a gear set from the crankshaft.<br />
0.7 l capacity.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
3<br />
1<br />
4<br />
2<br />
ENGINE<br />
13
ENGINE<br />
14<br />
Cooling system<br />
By a circulation of forced air by means of a turbine on the flywheel magneto.<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Carburettor<br />
10<br />
11<br />
2<br />
5<br />
9<br />
1<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
6<br />
3<br />
4<br />
7<br />
8<br />
ENGINE<br />
1. Diaphragm<br />
2. Pick-up pump<br />
3. Idle screw<br />
4. Throttle valve control<br />
5. Deceleration enrichment device<br />
6. Choke<br />
7. Fuel inlet<br />
8. Chamber drain circuit (water or<br />
impurities)<br />
9. Chamber drain screw<br />
10. Mixture screw<br />
11. Resistor warming carburator<br />
15
ENGINE<br />
16<br />
Ignition system<br />
Capacitor discharge ignition (CDI):<br />
1. Magneto flywheel<br />
2. CDI unit<br />
3. HT coil<br />
1<br />
10<br />
VE<br />
VE<br />
OFF<br />
ON<br />
1. Ignition switch<br />
2. Battery<br />
3. CDI unit<br />
4. Spark plug socket<br />
5. Spark plug<br />
6. HT coil<br />
1 23 4 5<br />
7.5A<br />
F1<br />
9<br />
NR<br />
JN-BE<br />
VE<br />
2<br />
-<br />
UPPER LEVEL<br />
LOWER LEVEL<br />
JN<br />
VE<br />
4. Spark plug socket<br />
5. Spark plug<br />
7. Carburetor heater<br />
8. Temperature control unit<br />
9. Automatic starter<br />
10. Magneto flywheel<br />
11. Revolution counter (SPEEDFIGHT 3)<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
VE<br />
JN-BA<br />
VE<br />
JN-NR<br />
VE-NR VE-NR 7<br />
8<br />
3<br />
VE<br />
VE<br />
2<br />
1<br />
VE<br />
2<br />
1<br />
6<br />
11<br />
0 1 2 3 4 5 6 7 8 9 10 1112<br />
TRIP<br />
km mi<br />
km/h mph<br />
X 1000rpm<br />
R<br />
4<br />
5
Starting circuit<br />
Schematic diagram of the starting circuit.<br />
1 2<br />
OFF<br />
ON<br />
NR<br />
1. Ignition switch<br />
2. Battery<br />
3. Starter motor switch<br />
4. Starter motor relay<br />
RG<br />
7.5A<br />
F1<br />
6<br />
3<br />
5. Starter motor<br />
6. Stop light switch<br />
7. Brake light<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
-<br />
RG<br />
ENGINE<br />
The starter motor is powered by the battery which must be charged enough in order to activate it. The<br />
starter motor is the most power consuming component of the vehicle. The fact of using a starter motor<br />
often on a vehicle which is not frequently ridden will discharge the battery completely.<br />
To start, you have to actuate the brake switches (6) at the same time as the stater switch (3) in order<br />
to power the starter motor relay (4).<br />
UPPER LEVEL<br />
LOWER LEVEL<br />
NR JN-VE<br />
VE RG<br />
VE<br />
VI<br />
VE 7<br />
VE<br />
VI<br />
JN-VE<br />
RG<br />
VE<br />
3<br />
2<br />
1<br />
5<br />
5<br />
4<br />
17
ENGINE<br />
18<br />
Exhaust<br />
1. Exhaust pipe<br />
2. Catalyser cone<br />
3. Catalytic block<br />
4. Heat insulation<br />
5. Pulsair reed valve<br />
2<br />
4<br />
3<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
5<br />
1
SPECIAL TOOLS<br />
Tool N° Designation Used<br />
with<br />
64765<br />
68007<br />
750806<br />
752127<br />
752237<br />
752361<br />
Engine<br />
mount<br />
Protective<br />
end-piece<br />
small model<br />
Flywheel<br />
puller<br />
Clutch<br />
compression<br />
tool<br />
Adjustable<br />
pin wrench<br />
39 mm pipe<br />
wrench<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles<br />
SPECIAL TOOLS<br />
Tool N° Designation Used<br />
with<br />
755982 754035 Valve lifter<br />
750806 755585<br />
68007 755982<br />
Bearing<br />
extractor tool<br />
Engine<br />
mount<br />
Engine<br />
mount<br />
adapter<br />
752361 756668 Seal piston<br />
68007 757990 Seal piston<br />
752127 800673<br />
Freewheel<br />
nut tool<br />
64765<br />
19
SPECIAL TOOLS<br />
20<br />
766062<br />
(*) New or modified tool<br />
Spark plug<br />
spanner<br />
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
P/N MOT50SYM.001.03/2009.GB<br />
Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add<br />
any reference mentioned in this manual.<br />
DC/APV 07/2009 (non contractual pictures)
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