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Peugeot Motorcycles Citystar 125i, Workshop Manual

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Peugeot Motorcycles Citystar 125i Workshop Manual Download Page 29

BODY PANELS

27

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

- Remove the header tank (2 screw) (Right side). 
- Remove the ingnition switch trim (1). 
- Remove the utility hanger (2) (2 screw). 
- Disconnect the accessory plug (3). 

- Remove the rear shield panel. 

• 1 washer head screws Ø5 mm (F). 
• 2 washer head screws Ø6 mm (G). 

„

Removal of the footboard

Procedure 7. 

- Remove the under-saddle panels. See: 

Procedure 2. page 23. 

- Remove the rear shield panel. See: 

Procedure 2. page 23.

- Remove the RH and LH under body panel. 

• 3 plastic screws (A). 
• 2 screw Ø6 mm (B). 

- Remove the footboard. 

G

F

2

G

1

3

B

A

Summary of Contents for Citystar 125i

Page 1: ...Sales division Technical network leadership WORKSHOP MANUAL ...

Page 2: ......

Page 3: ...he battery 11 New machine preparation 12 SPECIAL IMPORTANT POINTS 13 TIGHTENING TORQUES 14 Engine part 14 Body panels 15 Cycle part 15 Standard 15 SPECIAL TOOLS 16 Standard tools 18 LOCATION OF COMPONENTS 19 4 STROKE INDIRECT INJECTION SYSTEM FUNCTIONAL DIAGRAM 20 BODY PANELS 21 Location of body components 21 Body component sequence of disassembly 22 Removal of the storage compartment 23 Removal o...

Page 4: ...primary drive 35 125 cc 35 200 cc 36 Removal of the overrunning clutch 36 Checking the overrunning clutch 37 Changing the drive pulley bearings 38 200 cc 39 Checking the drive belt 39 Removal of the clutch lining assembly 39 Refitting the clutch lining assembly 40 Fitting the overrunning clutch 41 Installing the primary drive 43 125 cc 44 200 cc 44 Fitting the primary transmission cover 45 125 cc ...

Page 5: ...eals 52 The fork and its components 55 Removal of the fork 59 Replacing the bearings of the steering system 60 Steering headset cups 60 Steering cone 61 Installing the fork 62 FUEL SYSTEM 63 Procedure for reducing the fuel circuit pressure 63 Checking fuel pressure 63 Measuring the petrol flow 64 Removal of the fuel pump 65 POWER UNIT 66 Removal of the power unit 66 ...

Page 6: ...and appropriate clothing 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 dustbins sinks or in the environment The ideal solution is to bring this product to your nearest household waste recycl...

Page 7: ...ge 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 pa...

Page 8: ...at 8500 rpm Max torque rating 10 8 Nm at 8700 rpm 17 Nm at 6700 rpm Compression 12 5 bars at 580 rpm 7 bars Minimum Lubrication Trochoid pump driven by a gear set from the crankshaft Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust Catalytic Spark plug NGK CR8EB Electrode gap 0 7 0 8 mm Magneto flywheel 360 W Fuel supply Indirect electronic injection Standard...

Page 9: ...elescopic front fork Travel 95 mm Rear suspension Combined spring and hydraulically damped shock absorber Travel 96 mm Overall length 1985 mm Width at handlebar 750 mm Height without rear view mirrors 1300 mm Wheelbase 1430 mm Unladen weight 150 kg Front wheel rim 13 inch aluminium alloy Front tyre 120 70 13 Front tyre pressure 1 8 bars Rear wheel rim 13 inch aluminium alloy Rear tyre 130 60 13 Re...

Page 10: ...kness 240 mm 4 mm Mini thickness 3 5 mm Front caliper Floating calliper equipped with 2 pistons Rear brake Single disc type hydraulic control Disc diameter and thickness 210 mm 4 mm Mini thickness 3 5 mm Rear caliper Fixed calliper with 2 pistons Chassis markings Engine marking 1 The VIN number and the manufacturer s plate are under the seat 2 Engine number VGAV1AAAA0JXXXXXX PEUGEOTMOTOCYCLES 1 xx...

Page 11: ...ttle cable play V V V V V Operation of electrical equipment V V V V V Condition of front and rear brake hydraulic controls V V V V V Brake fluid level V V V V V Brake pad wear C C C C C Condition of petrol pipes C C C C C Tyre condition pressure and wear C C C C C Condition of the front suspension Condition of the rear suspension V V V V V Battery electrolyte level Battery charge V V V V V Coolant...

Page 12: ...ant R Once every 5 years Servicing for 125 cc models Engine oil clean strainer Every 10000 kms Oil filter Every 10000 kms Servicing for 200 cc models Engine oil clean strainer Every 5000 kms Oil filter Every 10000 kms V Check clean adjust R Change G Check clean lubricate C Inspect and change if necessary N Clean After 40000 km resume the service schedule again from 10000 km Normal servicing in km ...

Page 13: ...he battery for at least 2 hours with a current of 1 2 A Then the battery level should be topped up if necessary after fully charging using distilled water only Depending on equipment Installing the battery Connect the battery breather hose to the battery Insert the end of the hose into the opening in the battery compartment Place the hose in the battery compartment guide channel Fit the battery in...

Page 14: ...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 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 functi...

Page 15: ...etrol or on 95 E10 lead free petrol Fuel pipes must absolutely be changed if there are any 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 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 l...

Page 16: ...10 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Cylinder 10 Nm Oil pressure switch 10 Nm Thermostat valve 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Injection rail 10 Nm Cylinder casings 10 Nm Flywheel magneto cover 10 Nm Oil pump 10 Nm Relief valve 40 Nm Anti splash plate 10 Nm Transmission cover 10 Nm Transmission air filter cover 10 Nm Relay box cover 10 Nm Starter motor 10 N...

Page 17: ...bolt 80 Nm Linkrod to engine pivot 70 Nm Linkrod to frame pivot 70 Nm Shock absorber top mount 45 Nm Shock absorber bottom mount 22 Nm Exhaust to cylinder head mounting nut 22 Nm Exhaust clamp 10 Nm Exhaust to casing mounting bolt 22 Nm Adjustment cone in 2 operations 40 22 Nm the adjustable cone locknut Hand tightened Steering locknut 75 Nm Front brake caliper 30 Nm Brake pad pins 15 Nm Front bra...

Page 18: ...Adjustable pin wrench 757877 Pressure gauge 754040 46 mm pipe wrench 758008 758008 Clutch compression tool 754040 801412 755585 Bearing extractor tool 759492 Driven pulley pin spanner 756017 Fuel injector power supply harness 759788 Steeinghead cup push tool 756607 Steeinghead cup push tool 759982 Control point 32 way 757860 Steering tool 766062 Spark plug spanner 0 6 8 10 2 4 bar BM 2005 by xxote...

Page 19: ...s forbidden without the written consent of Peugeot Motocycles New or modified tool Tool N Designation Used with Tool N Designation Used with 801760 Fork extraction tool 802638 Extraction tool 801412 Spacer adaptor 758008 802809 TEP2010 OK SDO 1 0 by xxotest 50V ...

Page 20: ...Slide calipers Multimeter Heat gun Automatic resetting type torque wrench 5 to 25 Nm Type Facom R 306A25 Intertia type extractor tool for bearings from 6 to 18 mm Type Facom U 49PJ3 Automatic resetting type torque wrench 10 to 50 Nm Type Facom J 208A50 Automatic resetting type torque wrench 40 to 200 Nm Type Facom S 208A200 Fork seal insertion kit Type Marolotest 601055 OFF OFF VDC DC VAC AC Ω 20 ...

Page 21: ... 6 Fuel pump 7 Engine speed and position sensor 8 Petrol injector 9 Engine temperature sensor 10 Lambda sensor 11 HT coil 12 Kickstand contact switch 13 Transponder antenna 14 Immobiliser module 15 Regulator 16 Oil pressure switch 17 Starter motor relay 18 Speed sensor 19 Horn 20 Cooling fan 21 Diagnostic plug UP PE R LE VE L LO W ER LE VE L 12V 25A 12V 25A OK TEP 2005 by xxotest 6 15 4 13 3 22 16...

Page 22: ...ature sensor 10 Petrol injector 11 HT coil 12 Engine speed and position sensor 13 Electronics dashboard 14 Immobiliser module 15 Transponder antenna 16 Kickstand contact switch UP PE R LE VE L LO W ER LE VE L 12V 25A 1 2 1 3 2 1 1 2 6 OFF ON 3 B1 A3 A2 A1 A3 A2 A1 B1 1D 2D 1H 4H 2C 1G 3H 8 2 3 6 4 19 6 7 4B 2G 4F 4G 4D 3F 2B 2H 1B R 30A F1 VE VE VE VE VE 10A F2 RG RG OR BE NR BA NR GR RG MR BA GR ...

Page 23: ... 3 Plastic cover 4 Headlight fairing 5 Wind protector 6 Cooling duct 7 Counter panel 8 Front lower legshields 9 Mudguard 10 Front mudguard 11 Cover 12 Lower handlebar cover 13 Upper handlebar cover 14 Rear shield 15 Floor panel 16 Footrest 17 Under saddle panel 18 Bottom panel 19 Saddle and storage compartment 20 Grab handle 21 Rear body panels 22 Mudflap 17 18 19 20 21 22 2 1 11 13 15 7 9 8 16 6 ...

Page 24: ...ght fairing 5 Wind protector 6 Cooling duct 7 Counter panel 8 Front lower legshields 9 Mudguard 10 Front mudguard 11 Cover 12 Lower handlebar cover 13 Upper handlebar cover 14 Rear shield 15 Floor panel 16 Footrest 17 Under saddle panel 18 Bottom panel 19 Saddle and storage compartment 20 Grab handle 21 Rear body panels 22 Mudflap This item may be removed on its own 15 6 12 9 18 3 5 8 4 14 22 19 2...

Page 25: ...ody cover Procedure 2 Remove the storage compartment See Procedure 1 page 23 Remove the grab handle 4 screw Ø8 mm A Remove the rear body cover 4 plastic screws B 2 washer head screws Ø5 mm C 2 washer head screws Ø5 mm D Disconnect the taillight Removal of under saddle panels Procedure 3 Remove the rubbers from the footrests 1 2 screws each Open the tank filler cap door Remove the under saddle pane...

Page 26: ...er panel 1 1 plastic screws A Remove the plastic cover 2 1 washer head screw Ø5 mm B Remove the radiator grille 4 plastic screws C On each side remove 3 plastic screws D Unclip the tabs on the front shield panels 3 4 Remove the headlight panels Reassembly Fit the headlight panels by sliding them upwards Fit the retention tabs 3 over the cooling system duct C C A B 1 2 D D D 4 3 3 3 ...

Page 27: ...ht panels See Procedure 2 page 23 Remove the front lower shield panels 3 plastic screws A 11 washer head screws Ø5 mm B Disconnect the direction indicators When refitting attach the temperature sensor with a screw from a lower shield panel 1 Removal of the rear shield panel Procedure 6 Remove the front lower shield panels See Procedure 2 page 23 Remove the screen 4 screw A A B A 1 C C ...

Page 28: ...g 6 plastic screws Remove the instrument cluster fairing 4 plastic screws D 2 washer head screws Ø5 mm E Disconnect the instrument cluster Procedure Press the locking system X to actuate the positioning lever Y of the instrument cluster s connector Push the lever all the up Z in order to remove the connector from the instrument cluster E D D E D X Y Z ...

Page 29: ... the utility hanger 2 2 screw Disconnect the accessory plug 3 Remove the rear shield panel 1 washer head screws Ø5 mm F 2 washer head screws Ø6 mm G Removal of the footboard Procedure 7 Remove the under saddle panels See Procedure 2 page 23 Remove the rear shield panel See Procedure 2 page 23 Remove the RH and LH under body panel 3 plastic screws A 2 screw Ø6 mm B Remove the footboard G F 2 G 1 3 ...

Page 30: ...es in order not to get burnt Place the vehicle on its central stand on flat ground Remove the engine s oil filler cap Remove the cap and the filter to drain oil from the engine 1 Replace the copper seal every time you change oil Remove the fairing under the saddle Left side See Procedure 2 page 23 Remove the filter cover 2 screw Remove the oil filter Check the condition of the O ring and change it...

Page 31: ...nufacturer s standards into the filler hole 0 92 I at oil change 0 95 I at oil filter change Fit the filler cap Start the engine and let it run for a short while Remove the engine s oil filler cap gauge Wipe dry the filler cap gauge and fit it back but do not screw it into the filler hole Remove the filler cap gauge and check the oil level A Oil level low B Oil level high Add oil if necessary Chec...

Page 32: ...Peugeot Motocycles Replacing the air filter Remove the air filter cover 8 bolts and its seal Remove the air filter 1 3 screw Clean inside the air filter box Remove the inlet silencer drain plug to let humidity and oil drip out 2 Reassembly Fit a new air filter Fit the gasket Install the air filter cover 1 2 ...

Page 33: ... to 0 8 mm Essential precautions When re installing srew in the spark plug a few turns by hand Draining the cooling circuit The cooling system is drained when the engine is cold Remove the storage compartment See Procedure 1 page 23 Remove the headlight panels Right side See Procedure 2 page 23 Remove the radiator plug Remove the drainage cap 1 and its seal and allow the oil to drip into a recipie...

Page 34: ...ed in the engine Close the bleeder screw Check and top up the coolant level in the radiator Start the engine and accelerate in order to warm it up Allow the engine to cool down Stop the engine once it reaches its operating temperature Check and top up the coolant level in the radiator Check the coolant level in the header tank The level of coolant should be between the minimum A and maximum B mark...

Page 35: ...lter Remove the air filter cover 3 screw Tightening torque 10 Nm Remove the air filter 1 Clean or replace the air filter if it is dirty Removal of the primary transmission cover 125 cc Remove the plastic cover Lock the clutch drum with the pin wrench P N 759492 Remove the nut Tightening torque 70 Nm Remove the transmission cover 8 screw 1 759492 ...

Page 36: ... A Remove the transmission cover 8 screw Tightening torque 10 Nm Checking the transmission cover bearing 125 200 cc Check the condition of the bearing seals 1 Using your finger turn the internal bearing ring it should turn freely and silently Check that the bearing is tightly fitted to the casing Replacement Place the cover on its gasket seat surface heat it 80 to 90 C until the bearing 1 falls ou...

Page 37: ...otocycles Removal of the primary drive Hold the fixed flange with tool P N 752237 Remove the nut Remove the fixed flange Tightening torque 125 cc 70 Nm 200 cc 110 Nm Pull the belt aside Remove the drive pulley 1 with the guide hub 2 125 cc Remove the clutch and driven pulley assembly together with the belt 752237 1 2 ...

Page 38: ...h P N 752237 Tightening torque 70 Nm Remove the clutch and driven pulley assembly together with the belt Removal of the overrunning clutch Remove the kick starter stopper 1 1 screw Tightening torque 10 Nm Remove the starter dog 2 Using the réf 802638 extraction tool remove the overrunning clutch Position the tool s hooks towards the perimeter A 752237 1 2 802638 A A ...

Page 39: ...in direction B If it doesn t replace the overrunning clutch Separate the overrunning clutch from the ring gear Check the condition of the caged needle bearing and replace if necessary 1 Using your finger turn the internal bearing ring it should turn freely and silently 2 Using a brush clean the overrunning clutch Using your hand actuate the 3 rollers to check the condition of release springs 3 Che...

Page 40: ...s 3 plastic guides 2 Remove the moving flange 4 6 bearings 3 The bearings must be changed if they show major signs of wear The guides shall be replaced if they show signs of wear Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear A Reassembly Fit the drive rollers variator pulley cam and its guide without using grease 4 3 2 1 2 A ...

Page 41: ... are installed Checking the drive belt Measure the width of the belt A Minimum width 125 cc 20 5 mm 200 cc 23 mm Make sure the belt is not cracked Removal of the clutch lining assembly Using the depth calliper measure the thickness of the clutch linings Mini thickness 2 mm The balance of the clutch jaw assembly is factory set and therefore the assembly cannot be dismantled A ...

Page 42: ...ve the 3 pins 6 from the variable speed drive seat Separate the fixed 7 and rotating 8 flanges Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear Refitting the clutch lining assembly Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear A After checking the 2 lip seals 9 and the 2 O rings...

Page 43: ...he clutch and driven pulley assembly using tool 758008 equipped with the protection spacer P N 801412 Tighten the nut 1 Tightening torque 60 Nm Fitting the overrunning clutch Fit the starter ring Fit the spacer 1 Fit and engage the overrunning clutch on the ring gear of the starter by turning it counterclockwise 754040 801412 1 758008 1 ...

Page 44: ...ven partial is forbidden without the written consent of Peugeot Motocycles Lightly grease the caged needle bearing of the kick starter 2 Fit the starter motor dog Fit the kick starter stopper 3 2 screw Tightening torque 10 Nm Use lithium soap grease 2 3 ...

Page 45: ...f the belt which is shown by an arrow Lightly grease the drawn cup needle roller bearing of the driven pulley Fit the clutch drive pulley and driven pulley assembly Fit the drive pulley with its guide hub onto the connecting rod 1 Fit the belt 2 to the guide hub Fit the fixed flange 3 to the crank assembly ensuring that it is properly positioned on the crank assembly splines and checking that it i...

Page 46: ...l is forbidden without the written consent of Peugeot Motocycles 125 cc Fit the clutch cover 4 Fit the spacer 5 Chamfer facing you 200 cc Fit the clutch cover Hold the cover with the pin wrench P N 752237 Fit and tighten the nut Tightening torque 70 Nm 5 4 752237 ...

Page 47: ...ission cover 125 cc Install the transmission cover 8 screw Tightening torque 10 Nm Lock the clutch drum with the pin wrench P N 759492 Fit and tighten the nut Tightening torque 70 Nm Fit the plastic cover 200 cc Install the transmission cover 8 screw Tightening torque 10 Nm Fit the intake silencer fastening screw A Fit the under saddle panels 759492 A ...

Page 48: ...panels See Procedure 2 page 23 Remove the transmission air filter cover Disconnect the oil vapour return hose to the rocker cover Remove the rocker cover 5 screw Tightening torque 10 Nm Rotate the engine by hand in the operating direction in order to bring the rocker bearings on the back of the cams A Using the set of feeler gauges measure the clearance of each valve Clearances 0 10 0 02 mm at the...

Page 49: ...0 Checking the valve clearance At the intake a 0 15 mm feeler gauge shouldn t go At the exhaust a 0 25 mm feeler gauge shouldn t go On the contrary if the fealer gauge goes reset the clearances Changing the fuel filter The fuel filter is incorporated into the pump Remove the footboard See Procedure 7 page 27 Carry out the procedure for lowering the pressure in the fuel system See Procedure 8 page ...

Page 50: ...e of the 2 brake pads is worn down to the minimum dimensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Rear brake If one of the 2 brake pads is worn down to the minimum dimensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Replacing the brake pads Front brake Remove the calliper 2 screw Tightening torque 30 Nm A 1 5mm A 1 5mm ...

Page 51: ...que 18 Nm Remove the brake pads 1 When refitting the brake pads push the pistons all the way into their housing After refitting actuate the brake levers several times to bring the brake pads against the brake disc Rear brake Remove the exhaust muffler trim 3 screw Remove the exhaust 1 collar and 3 screws Remove the suspension arm 5 screws and 1 nut Remove the wheel 3 screw 1 ...

Page 52: ...ll the way into their housing After refitting actuate the brake levers several times to bring the brake pads against the brake disc Checking the brake fluid level Position the handlebars so that the master cylinder will be horizontal Check the brake fluid level and if necessary top up in the master cylinder Remove the cover and the diaphragm from the master cylinder 2 screw Add brake fluid until i...

Page 53: ...t fork Remove the fork tubes See chapter Changing the front fork seals page 52 Remove the spring 1 Turn the fork tube upside down to drain the oil into a recipient Pour 0 18 l SAE10W hydraulic oil into the fork tube Refit the other items in the reverse order to disassembly See chapter Changing the front fork seals page 52 Install the spring 1 ...

Page 54: ...ghtening torque 10 Nm Loosen the wheel spindle clamping screw 1 Remove the wheel spindle 2 Remove the front wheel Remove the fork guard 2 screw Unscrew the 2 upper screws 3 on the fork tee Remove the fork tube cap 4 Unscrew the 2 lower screws 5 from the fork Tee Remove the fork tubes Drain the front fork See chapter Draining the front fork page 51 Secure the stanchion in a vice fitted with protect...

Page 55: ... the calibrated hydraulic tube 7 Remove the expansion stop spring 8 Remove the dust cover 9 Remove the retaining clip 10 Extraction of the tube assembly seals and rings Screw the pin A of tool ref 801760 onto the fork tube 11 in place of the cap Pull on the fork tube 11 as far out of the hollow shaft as possible 8 7 5 10 9 11 A ...

Page 56: ...tool ref 801760 on the hollow shaft Install the split washer C ref 801760 under the washer Secure the pin A and screw the nut D on the pin as far as the separation of the shaft 12 and fork tube Remove the tool ref 801760 Remove the compression stop cone 13 Remove the seal 14 Remove the washer 15 Remove the guiding rings 16 B C A 12 13 10 10 14 15 16 ...

Page 57: ...n spring 13 Calibrated hydraulic tube 14 Fork triple clamp Pre assembly checks Clean all the parts with a degreasing agent Biosane type ref 754748 Or use an ultrasonic cleaning tank Check the condition of the fork tube there shall be no corrosion or impact marks and the tube shall be perfectly straight and clean Reassembly Install a new guiding ring 1 Install the expansion stop spring 2 Install th...

Page 58: ...be 6 Install the stanchion assembly screw and its seal 7 Tightening torque 25 Nm Install a new guiding ring 8 Fit washer 9 Using the marolotest lip seal installation kit tool partially push the guiding balk ring Install the new lightly lubricated seal 10 Using the marolotest lip seal insertion kit tool push the seal 10 under the groove in the retaining ring 6 5 7 5 9 8 10 ...

Page 59: ...ew lightly greased dust cover 12 Pour 0 18 l SAE10W hydraulic oil into the fork tube Install the spring 3 Fit the fork tubes into the fork triple clamps Tighten the lower screws on the fork tee 13 Tightening torque 28 Nm Install and screw up the cap 14 Tightening torque 28 Nm Tighten the upper screws on the fork tee 15 Tightening torque 28 Nm 12 11 15 14 13 ...

Page 60: ...eter drive gear assembly to the wheel drive pins Fit the wheel matching the speedometer drive gear assembly to the pin A on the fork stanchion Fit the wheel spindle and tighten Tightening torque 60 Nm When re installing use a new nut Tighten the spindle clamping screw 16 Tightening torque 10 Nm Refit the other items in the reverse order to disassembly A 16 N ...

Page 61: ...he front mudguard 4 screw Remove the front brake caliper from the fork tube 2 screw Tightening torque 30 Nm Remove the front wheel Tightening torque 60 Nm When re installing use a new nut Remove the fork guard 2 screw Remove the handlebar upper fairing 6 plastic screws Remove the handlebars from the fork tube 1 screw and 1 nut 1 Tightening torque 45 Nm When re installing use a new nut N 1 N ...

Page 62: ...teering locknut Remove The brake washer 2 The nut 3 The rubber washer 4 The adjustable cone 5 Remove the fork Remove the caged ball bearings Replacing the bearings of the steering system Steering headset cups If the steering head cups are changed the cones and ball bearings must also be changed Using a drift remove the steering head cups 757860 2 3 4 5 N ...

Page 63: ... the written consent of Peugeot Motocycles Using push tool P N 756607 fit a new upper cup into the steering tube Using push tool P N 759788 fit a lower cup into the steering tube Steering cone Using a drift remove the steering headset cone Fit a new steering head cone 6 759788 6 ...

Page 64: ... and then retighten the adjustable cone Tightening torque 20 Nm Do not tighten the adjustment cone beyond the recommended value to avoid damaging the steering bearings Install the rubber washer 4 Fit and finger tighten the nut 3 so that its notches are aligned with those of the nut Fit the lock washer 2 in the notches of the locknut and adjustable cone Install the steering head locknut and tighten...

Page 65: ...nd the battery Place the injector above a pan Actuate the contact switch of the tool 3 times for 5 seconds while respecting a released time of 5 seconds between each action in order to drop the pressure inside the supply hose of the fuel manifold The pressurised jet of fuel may be dangerous for the skin do not expose the hands to the jet of fuel when opening the injector Checking fuel pressure Mod...

Page 66: ...nition on 3 times to bleed the fuel system With the engine stopped check the fuel pressure which must be 2 5 bars when switching on the fuel pump Measuring the petrol flow Carry out the procedure for lowering the pressure in the fuel system See Procedure 8 page 63 Disconnect the fuel injector pipe and place it in a graduated recipient Turn on the ignition to run the fuel pump and measure the outpu...

Page 67: ...tocycles Removal of the fuel pump Remove the footboard See Procedure 7 page 27 Carry out the procedure for lowering the pressure in the fuel system See Procedure 8 page 63 Disconnect the fuel pump output hose 1 Disconnect the fuel pump 2 Remove the fuel pump 3 5 nuts Check the condition of the rubber seal 1 2 3 ...

Page 68: ...er head cylinder and piston see the workshop manual Engine 125 200cc 4 valves Remove the under saddle panels See Procedure 2 page 23 Disconnect the battery Drain the cooling circuit See chapter page 31 Carry out the procedure for lowering the pressure in the fuel system See Procedure 8 page 63 Disconnect Regulator 1 The engine speed sensor 2 The lambda sensor 3 The starter motor 4 The engine groun...

Page 69: ...rbidden without the written consent of Peugeot Motocycles The oil pressure 7 The throttle box 8 The fuel injector 9 The suppressor 10 Disconnect The fuel inlet pipe 11 The throttle control 12 Disconnect the water pump and cylinder head hoses 13 7 9 8 10 11 12 13 ...

Page 70: ...rbidden without the written consent of Peugeot Motocycles Remove the exhaust 1 collar and 3 screws Remove the suspension arm 5 screws and 1 nut Remove the wheel 3 screw Remove the rear brake caliper 2 screw Tightening torque 30 Nm Temporarily reinstall the wheel ...

Page 71: ...t Motocycles Suspend the rear of the machine Remove the shock absorber lower mount 14 Tightening torque 22 Nm Remove the linkrod to engine connecting pin 15 Tightening torque 70 Nm When re installing use a new nut Remove the power propulsion unit from the frame Remove the covers from the power unit 14 15 N ...

Page 72: ...P N MA0024GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC PS APV 12 7 11 non contractual pictures ...

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