PEUGEOT Ludix 4T Workshop Manual Download | Manualshive

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ELECTRICITY

41

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

Checking the starter resistance

- Resistance: 12

Ω

±10%

Checking the high tension coil

Condition

Measurement

Standard values

Disconnect the high voltage

coil.

Disconnect the suppressor.

Between terminals

A and B

R=0.2

Ω

±20%

Between terminals

B and C

R=3 k

Ω

±20%

Ω

Ω

Ω

A

C

C

B

A

B

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Summary of Contents for Ludix 4T

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

Page 2: ......

Page 3: ...t each service 7 Service operations 8 Time required for maintenance 8 Battery preparation Except battery without maintenance 9 New machine preparation 9 SPECIAL IMPORTANT POINTS 10 Fuel 10 TIGHTENING TORQUES 11 Engine part 11 Body panels 12 Cycle part 12 Standard 12 SPECIAL TOOLS 13 STANDARD TOOLS 14 LOCATION OF COMPONENTS 15 BODY PANELS 16 Removal of the front shield panel 16 Removal of the rear ...

Page 4: ...l 29 Rear brake linings 30 MISCELLANEOUS OPERATIONS 33 Removal of the fork 33 Replacing the bearings of the steering system 33 Steering system tightening method 35 Wheel bearing replacement 36 ELECTRICITY 37 Ignition principle schematic Carburetor heater 37 Checking the ignition system 38 Checking the carburettor heating circuit 39 Regulator Starter motor relay Ignition unit Starter resistor HT co...

Page 5: ...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 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: ...pm 7 bars Minimum Fuel supply Carburettor KEIHIN NCV Lubrication Pressurised wet sump lubrication Trochoid pump driven by a chain from the crankshaft 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 CR6HSA Electrode gap 0 6 0 7 mm Magneto flywheel 80 W Standards Euro 2 Relay box 0 1 l ...

Page 8: ...aluminium alloy Front tyre 80 80 14 Front tyre pressure 2 5 bars Rear wheel rim 14 inch aluminium alloy Rear tyre 170 70 14 Rear tyre pressure 2 8 bars Front brake Single disc type hydraulic control Fixed calliper with 2 pistons Disc diameter and thickness 190 mm 3 mm Rear brake Single cam drum type controlled by cable Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine ...

Page 9: ...service Steering column play V V V V V V Wheel bearing play C C C C C C Throttle cable play V V V V V V Operation of electrical equipment V V V V Condition of the front brake hydraulic control V V V V V V Brake fluid level V V V V V V Front brake pad wear C C C C C C Rear brake lining 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 State of front...

Page 10: ... bearings and guides V C V C Transmission belt R R R R Driven pulley caged needle bearing G G G G Kick starter mechanism G G Valve clearances V V V V V Setting the carburettor V V Joints Central stand Brake levers G G G G Petrol filter R Engine oil clean strainer R R R R R R Relay box oil R R R R R Petrol pipe Once every 5 years Brake fluid Once every 2 years Time required for maintenance Code 910...

Page 11: ...ary 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 water only Depending on equipment New machine preparation Check the tightness of the car...

Page 12: ...el 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 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 fo...

Page 13: ...m Camshaft gear 20 Nm Valve clearance covers 15 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Crankcase 12 Nm RH casing cover 12 Nm Freewheel 90 Nm Oil pump 10 Nm Transmission cover 10 Nm Relay box cover 22 Nm Relay box drain plug 10 Nm Relay box filler cap 10 Nm Starter motor 10 Nm Rotor 50 Nm Turbine 10 Nm Stator 10 Nm Engine speed sensor 1...

Page 14: ...inkrod to engine pivot 50 Nm Linkrod to frame pivot 50 Nm Shock absorber top mount 45 Nm Shock absorber bottom mount 22 Nm Exhaust to cylinder head 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 30 Nm Front brake disc 22 Nm Handle bar 40 Nm Fuel tank 22 Nm Luggage carrier 25 N...

Page 15: ...of Peugeot Motocycles SPECIAL TOOLS Tool N Designation Used with Tool N Designation Used with 752127 Clutch compression tool 756607 Steeing head cup push tool 752237 Adjustable pin wrench 757860 Steering tool 752361 39 mm pipe wrench 759788 Steeing head cup push tool 755996 766062 Spark plug spanner ...

Page 16: ...Type Marolotest P N 500140 Set of shims Slide calipers Multimeter Automatic resetting type torque wrench 5 to 25 Nm Type Facom R 306A25 Automatic resetting type torque wrench 40 to 200 Nm Type Facom S 208A200 Automatic resetting type torque wrench 10 to 50 Nm Type Facom J 208A50 Inertia extraction tool and sockets with internal grip OFF OFF VDC DC VAC AC Ω 20 m 20 m 200 m 200 m DC DC 10A 10A VΩ CO...

Page 17: ...nsent of Peugeot Motocycles LOCATION OF COMPONENTS 1 CDI unit 2 Battery 3 Magneto flywheel 4 Fuse 5 HT coil 6 Regulator 7 Starter motor relay 8 Switch Reserve 9 Horn 10 Starter resistor 11 Resistor warming carburator 12 Temperature control unit U PP ER LE V EL LO W ER LE V EL 5 11 1 2 9 8 6 7 3 4 12 10 ...

Page 18: ... Unclip the control cable from the front mudguard Remove the front shield panel 4 screws A Disconnact the headlight Disconnect the instrument cluster Removal of the rear shield panel Procedure 2 Remove the front shield panel See Procedure 1 page 16 Remove the utility hanger 1 Remove the 3 screws B that secure the rear shield panel Unclip the rear shield panel from the footboard C Remove the rear s...

Page 19: ...Procedure 3 Remove the rear shield panel See Procedure 2 page 16 Remove the shock absorber trim 2 Remove the side fairings 2 screws each D Remove the 2 clips E in order to avoid scratching the frame Remove the footboard 2 screws F Removal of the under body panel Remove the footboard See Procedure 3 page 17 Unclip the under body panel 2 D D F E ...

Page 20: ...hicle in order to unlock the front chassis fastener G Removal of the fuel tank Procedure 4 Remove the saddle 1 screw A Tightening torque 22 Nm Remove the luggage carrier 4 screws B Tightening torque 25 Nm Remove the plastic cover 1 Lift the fuel tank 1 nuts C Disconnect the fuel gauge D Disconnect the vacuum hose E Disconnect the fuel supply hose F G 1 A B C D F E ...

Page 21: ...on or translation even partial is forbidden without the written consent of Peugeot Motocycles Removal of handlebar fairing Procedure 5 Remove the handlebar front cover 4 screw A Remove the rear handlebar fairing 3 screw B A A B ...

Page 22: ...ngine s oil filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Replace the copper seal every time you change oil Remove the strainer cap 3 and clean the strainer 4 Every time oil is changed the filter 4 must be cleaned and the O ring changed 5 Put back the drainage cap and strainer cap fitted with a new seal Tightening torques Filler cap 20 Nm Screen 15 ...

Page 23: ... level with the machine parked on its centre stand on level ground Draining the relay box The gearbox must be drained when the engine is warm so that the oil will run easier Wear gloves in order not to get burnt Place the vehicle on its central stand on flat ground Remove the relay box filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Insert the drain p...

Page 24: ... air filter Remove the air filter cover 7 bolts and its seal Remove the air filter Clean inside the air filter box Reassembly Fit a new air filter Fit the gasket Install the air filter cover Check the condition of the seals and make sure they are properly positioned Remove the inlet silencer drain plug to let humidity and oil drip out A A ...

Page 25: ...trodes and correct it if necessary Electrode gap 0 6 to 0 7 mm Essential precautions When re installing srew in the spark plug a few turns by hand Tighten the spark plug Tightening torque 12 Nm Transmission Remove the transmission cover 10 screw Tightening torque 10 Nm Remove the paper gasket and the two 2 centering pins Hold the fixed flange with tool P N 752237 Remove the fixed flange nut and wa...

Page 26: ... with the guide hud Lock the clutch drum with the pin wrench P N 752237 Remove the clutch drum and the clutch and drive pulley assembly Tightening torque 55 Nm Checking the drive pulley Remove the holder 3 and its 4 plastic guides Remove the moving flange 5 6 bearings 4 The bearings must be changed if they show major signs of wear The guides shall be replaced if they show signs of wear 3 1 2 75223...

Page 27: ...he moving flange bore lightly high temperature grease Checking the drive belt Measure the width of the belt A Minimum width 17 2 mm Make sure the belt is not cracked Checking the clutch linings Using the depth calliper measure the thickness of the clutch linings Mini thickness 2 mm Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear A ...

Page 28: ...tch lining assembly Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 clamped in the jaws of a vice Remove nut 1 using spanner P N 752361 Tightening torque 55 Nm Slacken tool P N 752127 Remove the clutch lining assembly 2 When re installing the driven pulley lubricate the needle bearing 3 752361 1 752127 3 2 ...

Page 29: ...by hand in the operating direction in order to bring the rocker pads on the back of the cams A Using the set of feeler gauges measure the clearance of each valve Clearances Intake 0 05 mm 0 02 mm Exhaust 0 10 mm 0 02 mm If the clearance is not correct adjust by means of the cam follower screw Use a wrench to adjust the valve clearance Type Marolotest P N 500140 Checking the valve clearance At the ...

Page 30: ...ne Screw or unscrew the engine speed adjuster screw 1 to alter the idle speed The rear wheel should not turn Idle setting 2000 to 2200 rpm Removal of the fuel filter Remove the fuel tank See Procedure 3 page 18 Remove the fuel filter 1 Respect the direction of mounting of the filter shown by an arrow indicating the direction of flow of the fuel Brake inspection If one of the 2 brake pads is worn d...

Page 31: ...way into its housing Always use a new clip when refitting 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 A Maximum level B Minimum level Remove the cover and the diaphr...

Page 32: ... the cam tierod A compared to the mark B on the engine housing If the cam tierod mark is lined up with or passes the wear mark on the engine housing the brake lining must be replaced Disassembly Disconnect the air hose from the exhaust 1 Remove the 2 screws from the exhaust Tightening torque 20 Nm Remove the 2 screws that secure the muffler Tightening torque 15 Nm Remove the exhaust assembly Use a...

Page 33: ...rrel 3 and the brake control cable 4 Remove the brake arm 5 the brake cam 6 and the spring 7 Reassembly Lubricate the brake cam spindle and fit it into the casing Fit the brake arm 5 by aligning it with the brake cam axis 6 Tightening torque 8 Nm Slightly lubricate the brake cam and pin Install the brake linings 3 Install the spring 7 Install the brake control cable the barrel and the adjusting nu...

Page 34: ... translation even partial is forbidden without the written consent of Peugeot Motocycles Measure the free travel of the rear brake control lever Ajust the lever free travel using the adjusting nut B Brake control free travel 10 to 20 mm B ...

Page 35: ... securely Remove the front brake caliper from the fork tube 2 screws Tightening torque 30 Nm Remove the front mudguard 3 screws Remove the front wheel Tightening torque 65 Nm When re installing use a new gasket Remove the handlebars from the fork tube 1 screw and 1 nut 1 Tightening torque 40 Nm When re installing use a new gasket Using tool P N 757860 remove the steering locknut Remove The brake w...

Page 36: ...oduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Using a drift remove the steering head cups Using a drift remove the steering headset cone Reassembly Fit a new steering head cone 2 2 ...

Page 37: ...ring tube Using push tool P N 759788 fit a lower cup into the steering tube Grease the cup bearing races Install new ball cage bearings 3 Fit the fork into the steering column Install new ball cage bearings 4 Steering system tightening method Install the adjustable cone and tighten it 5 Tightening torque 40 Nm Loosen and then retighten the adjustable cone Tightening torque 23 Nm 756607 3 4 5 ...

Page 38: ...ne Use the tool ref 757860 to tighten the steering locknut 9 Tightening torque 70 Nm Refit the other items in the reverse order to disassembly Wheel bearing replacement Remove the wheel Use an inertia extractor to remove the bearings Remove the spacer Reassembly Use a drift driver to fit the first bearing Fit the spacer Insert the wheel spindle to guide the spacer with the bearings Use a drift dri...

Page 39: ...ple schematic Carburetor heater 1 Ignition switch 2 Battery 3 CDI unit 4 Spark plug socket 5 Spark plug 6 HT coil 7 Resistor warming carburator 8 Temperature control unit 9 Choke 10 Magneto flywheel 11 Regulator 7 5A OFF ON R U PP ER LE VE L LO W ER LE VE L 1 2 3 10 9 11 8 7 6 4 5 JN BE JN BA JN NR VE NR JN BE VE RG RG NR VE VE VE VE VE JN JN NR ...

Page 40: ...e If the values are correct replace the ignition module If the values are incorrect check The harness The ignition switch The ignition sensor The high voltage coil Component Connector Wire colours Standard values Ground A Green To the ground R 0Ω Ignition sensor A Yellow blue To the ground R 115 Ω 20 Battery positive power B Black To the ground Ignition on U 12V Ignition off U 0V HT coil Primary S...

Page 41: ...re control unit and take the measurements on the harness side 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 Regulator The magneto Component Connector Wire colours Standard values Ground A Green To the ground R 0Ω Resistor warming carburator A Yellow white To the ground R 8 5 Ω 20 Bat...

Page 42: ... and remove the electrical components The ignition unit starter relay and lighting resistance are attached to a removable holder The regulator and high tension coil are attached to the chassis Checking the starter motor relay Condition Operation Measurement Standard values Disconnect and remove the starter motor relay Between terminals A R 3 6 Ω 10 Between terminals B R Ω Apply a voltage of 12 V t...

Page 43: ...ent of Peugeot Motocycles Checking the starter resistance Resistance 12 Ω 10 Checking the high tension coil Condition Measurement Standard values Disconnect the high voltage coil Disconnect the suppressor Between terminals A and B R 0 2 Ω 20 Between terminals B and C R 3 kΩ 20 Ω Ω Ω A C C B A B ...

Page 44: ...t of Peugeot Motocycles Vacuum operated cock Remove the fuel tank See Procedure 3 page 18 Remove the vacuum operated cock Checking the fuel reserve contact A Full fuel tank Ω B Empty fuel tank 0 Ω When refitting position the vacuum operated cock as shown Check the condition of the O ring Ω A B 1 ...

Page 45: ...the fuel tank See Procedure 3 page 18 Disconnect The throttle control 1 The fuel inlet pipe 2 Disconnect the carburettor heater 3 Remove the intake silencer 1 collar and 2 screws Disconnect the electric choke Loosen the collar Remove the carburettor Removal of the choke Remove the choke cap Remove the screw and the holder plate Locate the position of the choke 1 and then remove it 2 1 3 1 ...

Page 46: ...choke holder and its gasket 2 screws Check the condition of the O ring Removal of the throttle valve Remove the chamber cap 2 screws Remove the spring Remove the needle valve and membrane assembly Check that the membrane is in good condition Remove the needle stop 1 Remove the spring 2 Remove the needle 3 The height oif the needle is factory set and cannot be modified 1 2 3 ...

Page 47: ...es Removal of the float needle valve and jets Remove the float chamber and its O ring 4 screws Check the condition of the float chamber O ring Loosen the float pin clamping screw 2 Remove the float 3 its pin 4 and the needle valve 5 Remove the idle jet 6 Remove the main jet 7 Remove the needle well 8 1 2 3 4 5 6 7 8 ...

Page 48: ...w Turn clockwise the mixture control screw 1 while counting the number of turns until it is screwed home When re fitting this operation allows you to put it back to its initial adjustment position Removal of the pick up pump Remove the 2 screws from the sheathing holder plate Remove the bushing 1 and the protective rubber 2 Check the condition of the bushing and the rubber protection Remove the pi...

Page 49: ...e the jet Remove the spring Remove the ball Removal of the deceleration enrichment device Remove the cover 2 screws Remove the spring Remove the membrane Remove the O ring Check that the membrane is in good condition Check the condition of the O ring Removal of the carburetor heater Remove the carburator warming resistor 1 Remove the heater earthing connection 2 2 1 ...

Page 50: ...tank Blow into every jet and duct of the carburettor body with compressed air Do not use any metal tool which can damage the ducts of these items Re install all the other components and if necessary when starting the engine readjust according to the values indicated on the technical data card When refitting the carburettor adjust the throttle tensioner to obtain a clearance on the handlebar of A 4...

Page 51: ...Motocycles The carburettor and its components 1 Choke 2 Piston 3 Sump 4 Float 5 Idle jet 6 Main jet 7 Needle well 8 Needle valve 9 Mixture screw 10 Pick up pump 10a and 10b 11 Idle screw 12 Pick up pump suction valve 13 Deceleration enrichment device 14 Carburetor heater 1 2 3 4 5 8 9 10b 11 12 13 14 6 7 10a ...

Page 52: ...it For removal of the cylinder head cylinder and piston see the workshop manual 50 cc engine 2 valves SYM Disconnect the battery Remove the side fairings See Procedure 3 page 17 Disconnect The magneto 1 The starter motor 2 The choke 3 The carburettor heater 4 The suppressor Disconnect The throttle control 5 The fuel inlet pipe 6 The vacuum pressure hose 7 Pulsair The vacuum pressure hose 8 Petrol ...

Page 53: ...lve hose 9 The rear brake control cable 10 Remove the linkrod to engine connecting pin 11 Tightening torque 50 Nm When re installing use a new nut Remove the shock absorber upper mount 12 Tightening torque 45 Nm Lift the rear of the machine Remove the power propulsion unit from the frame Remove the covers from the power unit 9 10 11 N 12 ...

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Page 56: ...N MA0027GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC APV Printed in the E U 11 2010 non contractual pictures ...

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