PEUGEOT Django 125 Workshop Manual Download Page 65 | Manualshive

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STEERING/FORK

64

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

The fork and its components

A. Fork tube cap.
B. O-ring.
C. Spring.
D. Calibrated hydraulic tube.
E. Expansion stop spring.
F. Fork tube.
G. End of compression cone.
H. Dust cover.
I.

Retaining clip.

J. Tightness seal.
K. Hollow shaft.
L. Tightness seal.
M. Stanchion assembly screw.

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.

A

H

B

C

D

E

F

G

I

J

K

L

M

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Summary of Contents for Django 125

Page 1: ...Q uality department After Sales WORKSHOP MANUAL ...

Page 2: ...battery 11 New machine preparation 11 Electricity 11 SPECIAL IMPORTANT POINTS 12 TIGHTENING TORQUES 13 Engine part 13 Body panels 13 Cycle part 14 Standard 14 SPECIAL TOOLS 15 STANDARD TOOLS 16 LOCATION OF COMPONENTS 17 BODY PANELS 18 Location of body components 18 Description 18 Body component sequence of disassembly 19 Removal of the passenger s saddle 20 Removal of the storage compartment 20 Re...

Page 3: ...om the engine 31 Draining the relay box 32 Replacing the air filter with transmission maintenance 33 Reassembly 33 Replacing the air filter without transmission maintenance 33 Reassembly 34 Removal of the spark plug 34 Idle setting 35 Removal of the primary transmission cover 36 Removal of the starter system 36 Fitting the starter system 38 Removal of the transmission air filter 38 Removal of the ...

Page 4: ... 60 STEERING FORK 61 Changing the front fork seals 61 The fork and its components 64 Reassembly 65 Removal of the fork 67 Replacing the bearings of the steering system 69 Steering headset cups 69 Steering cone 70 Installing the fork 70 FUEL SYSTEM 72 Removal of the fuel gauge 72 Fuel gauge check 72 Removal of the fuel pump 72 ELECTRICITY 74 Ignition principle schematic Carburetor heater Battery ch...

Page 5: ...d cotton overalls 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 recycling centre Toxic The product can...

Page 6: ...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 7: ... kW at 8000 rpm Max torque rating 8 9 Nm at 7000 rpm 11 Nm at 6000 rpm Compression Compression ratio 10 6 0 2 1 Compression ratio 10 4 0 2 1 Compression ratio 11 4 bars at 700 rpm 7 bars Minimum Lubrication Trochoid pump driven by a chain from the crankshaft Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust Catalytic Spark plug NGK CR7HSA Electrode gap 0 7 0 8...

Page 8: ...ar suspension Combined spring and hydraulically damped shock absorber Travel 88 mm Overall length 1925 mm Width at handlebar 710 mm Height without rear view mirrors 1190 mm Wheelbase 1350 mm Ground clearance 110 mm Saddle height 770 mm Unladen weight 129 kg Front wheel rims 3 x12 inch aluminium alloy Front tyre 120 70 12 Front tyre pressure 1 8 bars Rear wheel rim 3 x12 inch aluminium alloy Rear t...

Page 9: ...ni thickness 3 mm Front caliper Floating calliper equipped with 2 pistons Floating calliper equipped with 3 pistons Rear brake Single disc type hydraulic control Disc diameter and thickness 196 mm 4 mm Mini thickness 3 5 mm 190 mm 4 mm Mini thickness 3 5 mm Rear caliper Fixed calliper with 2 pistons Floating caliper equipped with one piston Chassis markings 1 VIN number 2 Manufacturer s plate Engi...

Page 10: ...l V V V V V V Brake pad wear C C C C C C Condition of petrol pipes C C C C C C Tyre condition pressure and wear C C C C C C Condition of thefront suspension Condition of the rear suspension V V V V V V Battery charge V V V V V V Engine oil level Every 1000 km Headlight height adjustment V V V V V V Tightness of nuts and bolts V V V V V V Overall operation Road test V V V V V V Service operations S...

Page 11: ...ave the battery to stand for around half an hour Fit the strip of caps 1 over the battery s filler holes Battery charge Once it is filled with electrolyte a new battery is charged up to approximately 80 The battery must be charged before being used for the first time If it is not charged in this way a loss of 20 of its maximum nominal capacity and 30 of its life expectance will be permanent You mu...

Page 12: ...side 2 plastic screws New machine preparation See the new vehicle preparation sheet 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 Electricity All components of the electrical system are powered ...

Page 13: ...8 unleaded fuel only 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 least 2 hours ...

Page 14: ...Inlet manifold 2 M6 1 0 8 to 12 Nm Cylinder casings 2 M6 1 0 8 to 12 Nm RH casing cover 10 M6 1 0 7 to 11 Nm Freewheel 1 M22 90 to 100 Nm Oil pump 2 M6 1 0 8 to 12 Nm Anti splash plate 2 M6 1 0 8 to 12 Nm Transmission cover 8 M6 1 0 8 to 12 Nm Relay box cover 7 M8 1 25 26 to 30 Nm Relay box drain plug 1 M8 1 25 10 to 15 Nm Relay box filler cap 1 M8 1 25 10 to 15 Nm Starter motor 2 M6 1 0 7 to 11 N...

Page 15: ...o cylinder head mounting nut 20 to 25 Nm Exhaust to casing mounting bolt 20 to 25 Nm Steering nut1 in 2 operations 38 to 42 Nm 15 to 19 Nm Steering nut2 Hand tightened Steering locknut 70 to 85 Nm Front brake caliper 27 to 32 Nm Brake pad pins 12 to 18 Nm Front brake disc 27 to 32 Nm Rear brake caliper 27 to 32 Nm Rear brake disc 27 to 32 Nm Brake unions 27 to 35 Nm Handle bar 35 to 45 Nm Fork tub...

Page 16: ...ot Scooters SPECIAL TOOLS New or modified tool Tool N Designation Used with Tool N Designation Used with 752237 Adjustable pin wrench 757860 Steering tool 752361 39 mm pipe casing seal drift 758008 Clutch compression tool 801682 759788 Steeing head cup push tool 801682 Spacer adaptor 758008 755996 Hose clamp ...

Page 17: ...om 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 Multimeter Automatic resetting type torque wrench 40 to 200 Nm Type Facom S 208A200 Fork seal insertion kit Type Marolotest 601055 Wrenches with interchangeable end fittings for valve clearance adjustment Type Marolotest 500140 OFF VDC VAC ...

Page 18: ... Starter motor relay 2 Starter resistor 3 Regulator 4 CDI unit 5 Temperature control unit 6 HT coil 7 Outside temperature sensor 8 Speed sensor 9 12 volt plug 10 Ignition sensor 11 Instrument panel 12 Fuses 13 Battery 14 Choke 15 Carburetor heater 16 Kickstand contact switch 17 Fuel gauge 18 Horn FB X X X X 6 4 3 7 9 2 10 5 1 8 16 14 17 12 13 15 11 18 ...

Page 19: ...ld panel 2 Front mudguard 3 Mudguard 4 Front wheel 5 Bottom panel 6 Floor panel 7 Central panel 8 Lower side fairing 9 Upper side fairing 10 Rear central fairing 11 Grab handle 12 Battery holder 13 Passenger backseat 14 Saddle storage compartment 15 Rider saddle 16 Rear shield 17 Counter panel 18 Headlight fairing 19 Sheath guide FB 4 3 7 9 2 10 1 8 13 17 16 11 5 12 14 18 6 15 19 ...

Page 20: ...dguard 4 Front wheel 5 Bottom panel 6 Floor panel 7 Central panel 8 Lower side fairing 9 Upper side fairing 10 Rear central fairing 11 Grab handle 12 Battery holder 13 Passenger backseat 14 Saddle storage compartment 15 Rider saddle 16 Rear shield 17 Handlebar rear fairing 18 Handlebar front fairing 19 Sheath guide This item may be removed on its own 8 14 11 12 2 3 15 9 7 13 10 1 18 17 19 16 6 4 5...

Page 21: ...eat 1 A screws Removal of the storage compartment Procedure 2 Remove the passenger seat See Procedure 1 page 20 Remove the storage compartment 4 washer head screws B Removal of the battery holder Procedure 3 Remove the storage compartment See Procedure 2 page 20 Remove the battery cover 2 plastic screws Disconnect and remove the battery Remove the fuse holders Remove the battery bracket 1 washer h...

Page 22: ... B Removal of the central cover panel Procedure 5 Remove the central cover panel 2 plastic screws C Disconnect the license plate light Removal of a lower RH or LH side fairing Procedure 6 Remove the central fairing under the saddle See Procedure 4 page 21 Remove the central cover panel See Procedure 5 page 21 Remove the chrome trim 1 plastic screws A Push the front of the trim away slightly and th...

Page 23: ...en consent of Peugeot Scooters Open the foot rest 1 Remove the lower side fairing 4 plastic screws B 1 washer head screw C 2 washer head screws D Removal of the grab handles Procedure 7 Remove the battery bracket See Procedure 3 page 20 Remove the grab handles 4 Ø8 mm screw B B B B C D D ...

Page 24: ...g assembly Procedure 8 Remove the lower side fairing See Procedure 6 page 21 Remove the grab handles See Procedure 7 page 22 Remove the upper side fairing assembly 12 washer head screws E Removal of the front shield panel Procedure 9 Unclip the front of the trim then slide it towards the front of the vehicle Remove the 2 chrome trims E E E E E E E E ...

Page 25: ...or translation even partial is forbidden without the written consent of Peugeot Scooters Remove the front shield panel 4 plastic screws Disconnect The indicators The outside temperature probe The side light depending on the model ...

Page 26: ...emoval of the head light fairing Procedure 10 Remove the front shield panel See Procedure 9 page 23 Remove the sheath guide 2 plastic screws Lever off the 2 master cylinder covers through the rearview mirror holes Carefully unclip the upper part and remove the head light fairing 4 plastic screws Disconnect the lighting ...

Page 27: ...trument panel The control clusters The brake light switches Remove the speedometer fairing 4 plastic screws Removal of the footboard Procedure 12 Remove the upper side fairings See Procedure 6 page 21 Remove the storage compartment See Procedure 2 page 20 Remove the bracket and the driver s saddle 1 2 washer head screws 2 Ø8 mm screw Remove the central fairing bracket under the saddle 2 2 Ø5 mm sc...

Page 28: ...9 page 23 Remove the footboard See Procedure 12 page 26 Open the tank filler cap door Remove the tank filler cap Disconnect the accessory plug Remove the rear shield panel 4 plastic screws A 2 washer head screws B Removal of the door locking system Procedure 14 Remove the rear shield panel See Procedure 13 page 27 Remove the RH or LH door locking pin 1 and its cable by turning it through a 1 4 tur...

Page 29: ...See Procedure 13 page 27 Remove the rear shield panel plate 1 5 plastic screws Remove the RH or LH door 2 pins 2 When refitting the doors position the pin indexing in the orifices A Removal of the RH or LH under body panel Procedure 16 Remove the rear shield panel See Procedure 13 page 27 Remove the RH or LH under body panel 5 plastic screws A 1 washer head screw B A A 2 2 1 B A A A A ...

Page 30: ... partial is forbidden without the written consent of Peugeot Scooters Removal of the front mudguard Procedure 17 Suspend or immobilize the machine securely Remove the front wheel Tightening torque 65 Nm Remove the front mudguard 4 washer head screws ...

Page 31: ...t the written consent of Peugeot Scooters Removal of the dirt shield Procedure 18 Remove the RH and LH under body panel See Procedure 16 page 28 Remove the front mudguard See Procedure 17 page 29 Remove the lower mudguards 4 plastic screws A Remove the upper mudguards A A A A ...

Page 32: ... Wear gloves in order not to get burnt Place the vehicle on its central stand on flat ground Remove the engine s oil filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Tightening torque 40 Nm Replace the copper seal every time you change oil Remove the strainer cap 3 and clean the strainer Tightening torque 15 Nm Every time oil is changed the filter 4 mu...

Page 33: ...nto 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 Check the level with the machine parked on its centre stand on level ground Draining the relay box The engine must be drained when it is warm to allow the oil to run easier Wear gloves in order not to get burnt Place the vehicle on its central stand on flat ground Remove th...

Page 34: ... 21 Remove the air filter cover 9 bolts and its seal Remove the inlet silencer drain plug to let humidity and oil drip out 1 Remove the air filter 2 Clean inside the air filter box Clean the oil vapour return filter 3 Reassembly Fit a new air filter Fit the gasket Install the air filter cover Replacing the air filter without transmission maintenance Remove the storage compartment See Procedure 2 p...

Page 35: ...ntrol when bringing out the air unit Disconnect the relay box air vent hose 1 Disconnect the oil vapour return pipe 2 Remove the air filter cover 9 bolts and its seal Remove the inlet silencer drain plug to let humidity and oil drip out 3 Remove the air filter 4 Clean inside the air filter box Clean the oil vapour return filter 5 Reassembly Fit a new air filter Fit the gasket Install the air filte...

Page 36: ...ommended spark plug NGK CR7 HSA Electrode gap 0 7 to 0 8 mm Essential precautions When re installing srew in the spark plug a few turns by hand Idle setting Open the saddle Remove the access door 1 screw Engine at operating temperature Check the operating clearance in the throttle Start the engine Screw or unscrew the engine speed adjuster screw 1 to alter the idle speed Idle setting 1800 100 rpm ...

Page 37: ...of the primary transmission cover Remove the upper RH fairing See Procedure 6 page 21 Remove the 2 air filter box fixing bolts A Remove the transmission cover 8 Ø6 mm screw Tightening torque 10 Nm Remove the paper gasket When re installing use a new gasket Removal of the starter system Remove the kickstart pedal 1 Ø 8 mm screws A A ...

Page 38: ...emove the plate 7 Ø5 mm screws Remove the paper gasket Actuate the kick starter gear sector 1 by hand and remove the kick starter drive piece 2 and washer Remove the lock ring 3 using circlip pliers Remove the washer Remove the elastic washer Remove the starter gear sector 1 and the washer 4 from the drive train cover 4 2 1 3 ...

Page 39: ...er gear sector Wind the spring so as to position the kick starter sector on the stop C of the cover Turn over the cover fit the washer and the circlip on the the gear sector spindle Wind approximately 1 8th of a turn the gear sector so as to place the kick starter drive piece 2 Position the pin 6 on the kick starter drive piece in the cover housing D Fit the paper gasket When re installing use a n...

Page 40: ...cover Hold the fixed flange with tool P N 752237 Remove the nut and the washer Remove the fixed flange Pull the belt aside 1 Remove the drive pulley 2 with the guide hub 3 Removal of the driven pulley Lock the clutch drum 1 with the pin wrench P N 752237 Remove the nut and the washer Remove the clutch drum the clutch drive pulley and driven pulley assembly and belt Make a note of the direction of ...

Page 41: ...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 Checking the drive belt Measure the width of the belt A Minimum width 18 5 mm Make sure the belt is not cracked 4 3 2 1 1 A A ...

Page 42: ... high temperature grease Checking the thickness of the clutch linings 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 Removal of the clutch lining assembly Compress the clutch and driven pulley assembly using tool 758008 equipped with the protection spacer ...

Page 43: ...ve 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 Compress the clutch drive pulley and driven pulley assembly with the tool P N 758008 Tighten ...

Page 44: ...pulley and driven pulley to the input shaft fit the belt into the pulley bottom by opening the flanges by hand Respect the direction of rotation of 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 clutch cover Fit washer Lock the clutch drum 1 with the pin wrench P N 752237 Fit...

Page 45: ...nstalling the valve clearance Remove the saddle storage compartment See Range 2 page 20 Remove the central fairing under the saddle See Procedure 4 page 21 Remove the passenger seat See Procedure 1 page 20 Remove the battery cover Disconnect and remove the battery Suspend the rear of the machine Remove the hatch giving access to the shock absorber upper screw 1 Lift the rear of the machine Remove ...

Page 46: ...pe 2 Remove the pneumatic valve 3 2 nuts Ø6 mm Remove the rocker cover 4 Ø6 mm 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 Using the set of feeler gauges measure the clearance of each valve Clearances 0 12 0 02 mm at the intake 0 12 0 02 mm at the exhaust 3 2 ...

Page 47: ...the contrary if the fealer gauge goes reset the clearances Tighten the nock nut Tightening torque 10 Nm Changing the fuel filter Remove the protective shoe 3 screw Using tool part number 755996 clamp the fuel supply hose between the tank and the fuel pump Disconnect the 2 fuel pipes 1 Remove the fuel filter When re installing respect the direction of installation of the filter shown by the arrow w...

Page 48: ...dden without the written consent of Peugeot Scooters Integral braking Brake pad wear Front 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 If it shows signs of wear change the shaft A 1 5mm ...

Page 49: ...ads must be changed A Mini thickness 1 5 mm Replacing the brake pads Front brake Remove the brake pad pin cap 1 Loosen the brake pad pin first Tightening torque 10 Nm Remove the calliper 2 screw Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts When changing the brake pads it is essential to replace the brake pad attachment system spindle pin clips A...

Page 50: ...l to replace the brake pad attachment system spindle pin clips Remove the wheel trim Remove the 5 screws fastening the rear wheel Tightening torque 30 Nm Remove the brake caliper 2 screw Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts Squeeze the caliper holder in orderto remove the first brake pad 1 Remove the second brake pad 2 Remove the brake p...

Page 51: ...plashed by brake fluid Position the handlebars so that the master cylinder will be horizontal Remove the cover and the diaphragm from the master cylinder 2 screw Using the syringe empty the LH master cylinder Fill the syringe with brake fluid Connect the syringe to the bleed screw of the rear calliper Open the bleed screw by 1 to 2 turns Inject the brake fluid slowly into the circuit until the lev...

Page 52: ... brake lever in an even way and without undue haste while topping up with brake fluid in the master cylinder Don t lean over the master cylinder when bleeding the circuit in order not to get splashed by brake fluid Stop the operation when no more bubbles are expelled from the modulator bleeder screw Close the bleeder screw Connect the reservoir containing brake fluid to the front brake calliper bl...

Page 53: ... the circuit in order not to get splashed by brake fluid Stop the operation when no more bubbles are expelled from the calliper bleeder screw Close the bleeder screw Bleeding the emergency system Remove the master cylinder cover See Procedure 10 page 25 Protect plastic parts that can be splashed by brake fluid Remove the cover and the diaphragm from the master cylinder 2 screw Using the syringe em...

Page 54: ...Fill the syringe with brake fluid Connect the syringe to the bleed screw of the rear calliper Open the bleed screw by 1 to 2 turns Inject the brake fluid slowly into the circuit until the level inside the reservoir of the master cylinder is halfway up Close the bleeder screw Add brake fluid until it reaches the maximum level ...

Page 55: ...en without the written consent of Peugeot Scooters Conventional braking Brake pad wear Front 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 If it shows signs of wear change the shaft A 1 5mm ...

Page 56: ...brake pad pins beforehand Tightening torque 10 Nm Remove the calliper 2 screw Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts When changing the brake pads it is essential to replace the brake pad attachment system spindle pin clips Remove the 2 spindles from the brake pads 2 Remove the brake pads 3 When refitting the brake pads push the pistons all...

Page 57: ...stening the rear wheel Tightening torque 30 Nm Loosen the brake pad pin first 1 Remove the brake caliper 2 screw Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts Remove the brake pad pin 2 Remove the tension spring 3 Remove the brake pads 4 When refitting the brake pads push the pistons all the way into their housing After refitting actuate the brak...

Page 58: ... the cover and the diaphragm from the master cylinder 2 screw Using the syringe empty the LH master cylinder Position the handlebars so that the master cylinder will be horizontal Fill the syringe with brake fluid Connect the syringe to the bleed screw of the rear calliper Open the bleed screw by 1 to 2 turns Inject the brake fluid slowly into the circuit untilthe level inside the reservoir of the...

Page 59: ...nd the diaphragm from the master cylinder 2 screw Using the syringe empty the LH master cylinder Position the handlebars so that the master cylinder will be horizontal Fill the syringe with brake fluid Connect the syringe to the bleed screw of the rear calliper Open the bleed screw by 1 to 2 turns Inject the brake fluid slowly into the circuit untilthe level inside the reservoir of the master cyli...

Page 60: ... 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 master cylinder cover See Procedure 10 page 25 Remove the cover and the diaphragm from the master cylinder 2 screw Add brake fluid until it reaches the maximum level LOW MIN ...

Page 61: ...fork Remove the fork tubes See chapter Changing the front fork seals page 61 Remove the fork tube cap A Remove the spring C Turn thefork tube upside down to drain the oil into a recipient Pour 0 092 l SAE10Whydraulic oil into the fork tube Refit the other items in the reverse order to disassembly Repeat the operation with the other stanchion C ...

Page 62: ...ut disconnecting it 2 Ø 8 mm screw When refitting the brake caliper spread standard thread lock on the bolts Unscrew and remove the 2 upper screws 1 from the fork Tee Before loosen the fork tube caps A Unscrew the 2 lower screws 2 from the fork Tee Remove the fork stanchions Remove the fork tube cap A Check the condition of the O rings B Remove the spring C Drain the front fork See chapter Drainin...

Page 63: ...allet to dislodge the screws If the screw is hard to remove temporarily refit the spring and the plug Get someone to help you and compress the fork unit to block the calibrated hydraulic tube Remove the calibrated hydraulic tube D Remove the expansion stop spring E Separate the fork s tube F from the cover K Gently work the tube free from the hollow shaft whose lip seal washer and guide ring shoul...

Page 64: ...3 Reproduction or translation even partial is forbidden without the written consent of Peugeot Scooters Remove the compression stop cone G Remove the dust cover H Remove the retaining clip I Remove the seal J G J H I ...

Page 65: ...ring F Fork tube G End of compression cone H Dust cover I Retaining clip J Tightness seal K Hollow shaft L Tightness seal M Stanchion assembly screw 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 cl...

Page 66: ...stall the calibrated hydraulic tube D Install the compression stop cone G on the calibrated hydraulic tube Fit the fork sleeve K to the slightly oiled fork tube F Install the stanchion assembly screw and its seal LM Tightening torque 25 Nm Using the marolotest lip seal insertion kit tool push the seal J under the groove in the retaining ring D E G F K LM K GLUE GLUE J ...

Page 67: ...ew lightly greased dust cover H Pour 0 092 l SAE10W hydraulic oil into the fork tube Install the spring C Fit the fork tube cap A Tightening torque 28 Nm Fit the fork tubes into the fork triple clamps Fit and tighten the upper screws on the fork tee 1 Tightening torque 28 Nm Tighten the lower screws on the fork tee 2 Tightening torque 28 Nm H I A C 2 A 1 ...

Page 68: ...e fork stanchion Fit the wheel spindle and tighten Tightening torque 65 Nm When re installing use a new nut Fit the brake calliper 2 Ø 8 mm screws Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts Removal of the fork Remove the front mudguard See Procedure 17 page 29 Remove the brake caliper without disconnecting it Tightening torque 30 Nm When refit...

Page 69: ...ugeot Scooters Unclip the hydraulic controlsand the speedometer control Remove the speedometer fairing Voir Procedure 11 page 26 Remove the handlebars from the fork tube 1 screws and 1 nut 1 Tightening torque 40 Nm When re installing use a new nut Using tool P N 757860 remove the steering locknut 1 757860 ...

Page 70: ...ut 5 The flat washer 6 The dust cover 7 The upper cone 8 Remove the caged ball bearings 9 Remove the fork 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 Install new steering head cups using tool P N 759788 2 3 4 5 7 9 6 8 759788 ...

Page 71: ...ers Steering cone Tap out the steering cone using a drift placed behind the flat washer Install the following new parts The flat washer 1 The fork cone 2 Installing the fork Grease the cup bearing races Install new ball cage bearings 7 respect the right way of installation Fit the fork into the steering column 2 1 7 ...

Page 72: ...18 Nm Install the rubber washer 4 Do not tighten the steering nut beyond the recommended value to avoid damanging the steering bearings 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 it Tightening torque 75 Nm Check that there is no play in t...

Page 73: ...tten consent of Peugeot Scooters FUEL SYSTEM Removal of the fuel gauge Remove the footboard See Procedure 12 page 26 Remove the fuel gauge 4 Ø5 mm screw Fuel gauge check A Full fuel tank 10 Ω 20 B Empty fuel tank 95 Ω 20 Removal of the fuel pump Remove the protective shoe 3 screw Ω A B ...

Page 74: ...dden without the written consent of Peugeot Scooters Using tool part number 755996 clamp the fuel supply hose between the tank and the fuel pump Disconnect the fuel pump 1 The vacuum pressure hose 2 The fuel inlet pipe 3 The carburetor fuel supply hose 1 2 3 755996 ...

Page 75: ... 1 Ignition switch 2 Kickstand contact switch 3 Resistor warming carburator 4 Voltage regulator 5 Temperature control unit 6 Ignition unit 7 HT coil 8 Starter resistor 9 Automatic starter 10 Magneto flywheel 11 Battery 12 7 5 A fuse 7 5A F1 OFF ON 2 1 4 3 X X RG VE RG RG VE VE VE BA VE JN NR VE VE NR JN JN NR VE RG NR NR NR NR VE NR JN NR JN BA JN BA JN BA JN BA JN JN RG 8 10 6 11 12 1 9 7 2 3 5 4...

Page 76: ...d take the measurements on the harness side Between the green wire and the ground 0 Ω Between the green black wire and the ground Ignition sensor 195 Ω 20 Between the yellow black wire and the earth High voltage primary coil 0 5 Ω 20 Between the black wire and the ground ignition on 12V Battery voltage If the values are correct replace the ignition module If the values are incorrect check The harn...

Page 77: ... 20 Between the black wire and the ground ignition on 12V Battery voltage Between the yellow wire and the ground engine running 13 5V Regulated alternating current If the values are correct replace the temperature control unit If the values are incorrect check The harness The ignition switch The carburettor heating resistor 9 5 Ω 20 Checking the starter circuit Checking the starter resistance Disc...

Page 78: ...p light and the side light Remove the side light or the rear light 1 Connect the side light in series with a battery and an ammeter Normal consumption 0 25 0 35 A 2 Connect the stop light in series with a battery and an ammeter Normal consumption 0 25 0 35 A 3 Connect the red light in series with a battery and an ammeter Normal consumption 0 60 0 70 mA If the consumption is outside this range chan...

Page 79: ...move the power propulsion unit For removal of the cylinder head cylinder and piston see the workshop manual MA0020 MA0050 Remove the storage compartment See Procedure 2 page 20 Disconnect The carburettor heater 1 The choke 2 The magneto 3 The starter motor 4 The engine ground 5 The suppressor 6 Disconnect The throttle control 7 The fuel hose 8 The vacuum pressure hose 9 4 5 6 1 2 3 7 8 9 ...

Page 80: ...ters Remove the wheel trim Remove the wheel 5 screw Tightening torque 30 Nm Remove the brake calliper 2 screw Tightening torque 30 Nm When refitting the brake caliper spread standard thread lock on the bolts Unclip the hydraulic control Temporarily reinstall the wheel Remove the protective shoe 3 screw GLUE GLUE ...

Page 81: ...ure 1 page 20 Remove the battery cover Disconnect and remove the battery Suspend the rear of the machine Remove the hatch giving access to the shock absorber upper screw 1 Remove the shock absorber upper fixing bolt Tightening torque 48 Nm Remove the 2 connecting rod chassis fastening screws 2 Tightening torque 60 Nm Use new nuts when refitting 1 2 2 ...

Page 82: ...POWER UNIT 81 Reproduction or translation even partial is forbidden without the written consent of Peugeot Scooters Remove the power propulsion unit from the frame Remove the covers from the power unit ...

Page 83: ... N MA0051GB In our permanent concern to make improvements PEUGEOT Scooters reserves the right to suppress modify or add any reference mentioned DQ APV Printed in E U July 16 2014 non contractual pictures ...

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