PEUGEOT MOTOR ENGINE Workshop Manual Download Page 1 | Manualshive

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WORKSHOP

MANUAL

MOTOR

ENGINE

SALES DIVISION
NETWORK TECHNICAL INFORMATION

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Summary of Contents for MOTOR ENGINE

Page 1: ...WORKSHOP MANUAL MOTOR ENGINE SALES DIVISION NETWORK TECHNICAL INFORMATION...

Page 2: ...and seal in the RH casing 19 To fit the crank assembly in the LH casing 20 Assembling the casings 21 To assemble the engine bottom end and engine mount 22 To fit the valve and inlet manifold 23 To fi...

Page 3: ...o 8 5 1 Ignition CDI Spark plug KVAS 850 NGK BR7HS depending on plug cap Carburettor Gurtner or Dell Orto Inlet Valves Transmission Automatic clutch with or without speed governor Magneto flywheel Peu...

Page 4: ...l 69098 Butterfly nut 69104 Bearing and crank assembly seal guide 69108 Bearing and crank assembly seal remover 69109 Assembly guide 69110 Assembly plate tool 69111 Assembly guide 69112 Assembly guide...

Page 5: ...ven partial forbidden without the written consent of Peugeot Motocycles IDENTIFICATION Differences between the 3 types of assembly Type 1 without governor and kickstart Type 2 with governor and withou...

Page 6: ...ter P N 65255 using a nut and bolt 1 diameter 8 x 110 mm Protect both ends of the engine mount with 2 washers 2 Fit the engine with its adapter to the stand P N 64765 with the stand held in a vice To...

Page 7: ...ht plate 1 with the adjustable pin wrench P N 755586 Remove the nut 2 from the end of the crank assembly Remove the governor assembly 1 To remove the clutch pulley assembly Remove the panels 1 Remove...

Page 8: ...nslation even partial forbidden without the written consent of Peugeot Motocycles Remove the governor cover 8 Remove the LH footrest 9 Slacken the engine tension spring 1 Remove the belt 11 Remove the...

Page 9: ...end of the crank assembly Fit protective tool P N 68007 to the crank assembly Fully tighten the flywheel extractor tool P N 69254 on the rotor Lock the rotor with the adjustable pin wrench P N 755586...

Page 10: ...l forbidden without the written consent of Peugeot Motocycles Type 2 4 pole assembly Remove the 2 bolts 3 from the coil assembly Remove the coil assembly 5 To remove the coil assembly plate Remove the...

Page 11: ...cylinder head bolts and lockwashers in the order shown Remove the cylinder head and its gasket Remove the cylinder and its gasket Remove one of the clips 1 with pliers P N 752000 Remove the gudgeon p...

Page 12: ...ve the engine mount 2 and the belt guard bracket 3 Special tooling required Protective cap P N 69098 Casing extraction and opening tool P N 64706 Casing opening closing plate P N 750369 Casing opening...

Page 13: ...Special tooling required Protective cap P N 69098 Casing extraction and opening tool P N 64706 Casing opening closing plate P N Casing opening closing bush P N 69137 Have to hand 2 bolts and nuts 6 x...

Page 14: ...and opening tool P N 64706 Shell for 40 mm bearing P N 64728 Shell for 47 mm bearing P N 64729 Fit protective cap P N 69098 to the crank assembly on the side the bearing is to be removed from Fit tool...

Page 15: ...ing the casing half the work must proceed quite quickly Heat the casing half to 80 to 90 C Fit the casing half on the guide P N 69108 with the mating surface upwards Fit the seal guide P N 69110 the k...

Page 16: ...REASSEMBLY Page 18 Reproduction or translation even partial forbidden without the written consent of Peugeot Motocycles...

Page 17: ...g half to 80 to 90 C Fit guide P N 69112 16 mm into base P N 69111 Fit the casing half with mating surface upwards on tool P N 69111 Fit the seal guide P N 69113 the knurled side facing upwards into t...

Page 18: ...r seal P N 69143 Casing opening closing plate P N 750369 Fit the magneto flywheel this will act as a support Fit dowel P N 69143 to the crank assembly to prevent damage to the seal Fit the crank assem...

Page 19: ...0104 Shouldered centring tool P N 64710 64710 Pin 10 pitch 100 P N 64754 64711 Casing opening closing bush P N 69137 Casing opening closing plate P N 750369 Fit the drum this will act as a support Fit...

Page 20: ...ngs come into contact Note During assembly check the casing gasket is correctly positioned To assemble the engine bottom end and engine mount Remove the 3 previously fitted centring bolts Locate the e...

Page 21: ...support Fit in the following order the gasket to the casing 1 the valve 2 the manifold gasket 3 the inlet manifold Fit the 4 fixing bolts to the inlet manifold To fit the piston Check the cylinder pi...

Page 22: ...hich has been previously cleaned of all impurities Ensure that the piston ring gaps are opposite the piston positioning spigots Fit the cylinder 6 and lower it while compressing the rings Check that t...

Page 23: ...engine Check the condition of the cylinder head mating surface Fit a new cylinder head gasket 7 to the cylinder the widest metal ring pointing upwards Fit a new O ring 8 round the outer edge of the c...

Page 24: ...governor without kickstart Drive pulley composition Fitting method Fitting the non governor drive pulley type 1 Adjust the clutch before assembly see chapter on adjusting the clutch Fit to the crank...

Page 25: ...n the slots A in the plate 7 Fit the countersunk washer 10 to the plate with the countersink on the casing side Fit the spacer 11 Lock the assembly with tool P N 69142 Fit the spring washer 12 over th...

Page 26: ...thout kickstart Drive pulley composition Fitting method Fitting the with governor drive pulley type 2 Adjust the clutch before assembly see chapter on adjusting the clutch Fit to the crank assembly in...

Page 27: ...A in the plate 7 Fit the countersunk washer 10 to the plate with the countersink on the casing side Fit the spacer 11 Lock the assembly with tool P N 69142 69142 Drive pulley with governor Re assembl...

Page 28: ...kickstart Drive pulley composition Fitting method To fit the governor type 3 Fit in the following order the plain washer 1 the fixed flange 2 the washer 4 the spacer 5 the rotating flange 3 and the n...

Page 29: ...l Coil assembly support Fit the half moon key 9 into its housing in the crank assembly straight section Fit the stator plate 7 and its 2 bolts Type 1 6 pole assembly Fit the coil assembly 5 and its tw...

Page 30: ...dden without the written consent of Peugeot Motocycles Fit the rotor 1 ensuring its is correctly positioned over the key Tighten the nut 2 with the chamfered side facing inwards Immobiliser le rotor a...

Page 31: ...duction or translation even partial forbidden without the written consent of Peugeot Motocycles MISCELLANEOUS OPERATIONS Drive pulley assembly Composition of the drive pulley without governor Composit...

Page 32: ...ge 7 the balls 8 4 or 6 depending on type the drum 9 the washer 10 the spacer 53527 for use on the engine with governor to replace the existing spacer the nut 15 and tighten the assembly to the recomm...

Page 33: ...A on the pivot and hook it on the pivot pin B the spring loop openings should be facing the inside of the jaw Hook the other end of the spring to the second peg C on the jaw Fit the cup 1C To assemble...

Page 34: ...l Locate the bobweight mounting plate 1D in the tool 4 pegs Fold down the nut locking tab 1J Remove the 32 mm nut 1K Remove the fixed 1A and rotating 1G flanges if necessary unclip the moving flange 1...

Page 35: ...k washer 3 Nut 4 Circlip 5 Stiffener plate 6 Spring washers 7 Clutch shoes 8 Springs 9 Clutch output shaft and cover 10 To change clutch shoes Disassembly Remove the 3 circlips 5 Remove the stiffener...

Page 36: ...les Disassembly Remove the clutch shoes Tighten the support in a vice Position the pulley 1 on the support lining up the sprocket teeth 2 with the support teeth 3 Fold down the nut locking tab 4 Remov...

Page 37: ...the ignition coil requires removal of the coil s located either side In the rest position ensure the coil is fixed with no play on the coil assembly and that the tin solders are good quality Apply a b...

Page 38: ...l tooling required Decompressor removal fitting tool P N 68048 Remove the cylinder head Cut off the end of the pin 1 compress the spring 2 remove the pin 1 and the lever 3 Remove the valve 4 from the...

Page 39: ...consent of Peugeot Motocycles When re assembling NB coat the decompressor casing threads 5 with gasket compound Fit the decompressor casing 5 and tighten it to the recommended torque Fit the spring 2...

Page 40: ...risation crite de Peugeot Motocycles RECOMMENDED REF 755903 With a constant concern for improvement Peugeot Motocycles reserves the right to delete modify or add any quoted reference DC PS ATR printed...

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