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PEUGEOT XS1P37QMA-2, Workshop Manual

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PEUGEOT XS1P37QMA-2 Workshop Manual Download Page 36

CYLINDER HEAD/CYLINDER/PISTON

34

Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles

„

Removal of the cylinder / piston

- Remove the cylinder head. 
- Remove the chain guide pad (1). 

- Remove the cylinder. 
- Remove the base gasket (2) and the 

2 centring pillars (3). 

- Remove one of the circlips (4) with pliers. 
- Remove the gudgeon pin. 
- Remove the piston. 

1

2

3

2

4

Summary of Contents for XS1P37QMA-2

Page 1: ...Direction commerciale Animation technique r seau WORKSHOP MANUAL 50 CC ENGINE 4 STROKE 2 VALVES SYM...

Page 2: ...Workshop manual Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles...

Page 3: ...he engine on the stand 10 Changing the engine oil 10 PRIMARY TRANSMISSION 11 Removal of the primary transmission cover 11 Removal of the drive pulley 11 Removal of the driven pulley 12 Changing the dr...

Page 4: ...MAGNETO FLYWHEEL FREEWHEEL 25 To remove the magneto flywheel 25 Removal of the overrunning clutch 26 Checking the overrunning clutch 27 CYLINDER HEAD CYLINDER PISTON 29 Removal of the cylinder head 2...

Page 5: ...priate clothes 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...

Page 6: ...o 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 in...

Page 7: ...of forced air by means of a turbine on the flywheel magneto Bore x stroke 37 x 46 mm Cubic capacity 49 5 cc Max power output 2 8 kW at 8000 rpm Max torque rating 3 5 Nm at 6500 rpm Lubrication Trocho...

Page 8: ...to run on 95 or 98 unleaded fuel only Never run the machine with a petrol oil mixture Fuel pipes must absolutely be changed if there are any signs of wear cracks etc The clips are specific they must a...

Page 9: ...Nm 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 Cylinder casings 12 Nm RH casing cover 12 Nm Free...

Page 10: ...Tool N Designation Used with 064765 Engine mount 755982 754035 Valve lifter 068007 Protective end piece small model 750806 755585 Bearing extractor tool 750806 Flywheel puller 68007 755982 Engine moun...

Page 11: ...Standard tools 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 torq...

Page 12: ...the assembly on stand P N 064765 clamped in the jaws of a vice Changing the engine oil To drain the engine remove the cap and let the oil drip Tightening torque 20 Nm Replace the seal each time you c...

Page 13: ...the transmission cover 10 screw Remove the paper gasket and the two 2 centering pins Tightening torque 10 Nm Removal of the drive pulley Hold the fixed flange with tool P N 752237 Remove the nut 1 and...

Page 14: ...ch drum and the clutch and drive pulley assembly Tightening torque 55 Nm Changing the drive pulley bearings Remove the ramp 1 and its 3 guides 2 Remove the moving flange 4 6 bearings 3 The bearings mu...

Page 15: ...respect the way the rollers are installed Grease the moving flange bore lightly high temperature grease Removal of the clutch lining assembly Using the depth calliper measure the thickness of the clu...

Page 16: ...of the rotating flange 8 are in good condition grease the governor seat 3 pins 6 high temperature grease and assemble the parts in reverse order to removal Compress the clutch drive pulley and driven...

Page 17: ...eot Motocycles Removal of the starter system Remove the plate 6 screw 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 c...

Page 18: ...e second buckle B of the spring onto the starter 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...

Page 19: ...Tightening torque 10 Nm Use a drip pan to catch the transfer box oil when the cover is removed Remove the secondary transmission cover 7 screw Tightening torque 22 Nm Remove the paper gasket 1 and the...

Page 20: ...d 90 C Use an inertia type extractor tool to remove the bearings While the casing is expanded fit the new bearing fully home in its housing Using fitting tool P N 757990 fit a new lightly greased gask...

Page 21: ...ETTOR Removal of the carburettor 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 re...

Page 22: ...e chamber cap 1 Remove the chamber cap Remove the spring Remove the needle valve and membrane assembly Remove the needle stop 2 Remove the spring 3 Remove the needle 4 The height oif the needle is fac...

Page 23: ...Motocycles 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 Check the condition of the nee...

Page 24: ...il 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...

Page 25: ...condition of the O ring Removal of the carburetor heater Remove the carburator warming resistor 1 Remove the heater earthing connection 2 Clean the carburettor body with Biosane cleanser ref 754748 o...

Page 26: ...interdite sans autorisation crite de Peugeot Motocycles Removal of the intake pipe Remove the inlet coupling 2 nuts Tightening torque 10 Nm Remove the plastic spacer Check the condition of the O ring...

Page 27: ...eugeot Motocycles MAGNETO FLYWHEEL FREEWHEEL To remove the magneto flywheel Remove the volute 4 screw Remove the cylinder housing 3 screw on the right side Remove the turbine 4 screw Tightening torque...

Page 28: ...P N 750806 on the rotor Lock the flywheel extractor and turn the thrust bolt until the rotor is released Remove the stator and sensor assembly 3 2 screws each Tightening torque 10 Nm Removal of the ov...

Page 29: ...752237 immobilise the overrunning clutch 5 Using tool P N 800673 remove the notched nut and the washer of the overruning clutch Tightening torque 90 Nm The notched nut of the overrunning clutch has a...

Page 30: ...AGNETO FLYWHEEL FREEWHEEL 28 Reproduction ou traduction m me partielle interdite sans autorisation crite de Peugeot Motocycles Using fitting tool P N 756668 fit a new lightly greased gasket 1 756668 1...

Page 31: ...oval of the cylinder head Remove the cylinder housing 1 screw Left side Removal of the camshaft gear cover 1 2 screw Tightening torque 10 Nm Turn the crankshaft in the direction of operation to line u...

Page 32: ...by pressing the ratchet tooth A Immobilize the camshaft gear 4 using the adjustable pin wrench P N 752237 Remove the camshaft gear Tie a wire to the timing chain in order to prevent it from falling in...

Page 33: ...moval of the metal gasket 7 and the 2 centring pillars 8 Removal of the camshaft and or rockers Remove the cylinder head Remove the stopper plate 1 Remove the valve clearance adjustment covers 2 Apply...

Page 34: ...kers Remove the springs 5 Remove the camshaft 6 Removal of the valves or valve stem seals Compress the spring of one of the valves using the valve lifter P N 754035 Remove the 2 half cones 1 Uncompres...

Page 35: ...linder head When re installing lubricate the 2 half cones 1 so as to hold them in the groove of the valve s stem Do not place the 2 half cones into the cup forcefully with the tool when decompressing...

Page 36: ...utorisation crite de Peugeot Motocycles Removal of the cylinder piston Remove the cylinder head Remove the chain guide pad 1 Remove the cylinder Remove the base gasket 2 and the 2 centring pillars 3 R...

Page 37: ...imit 36 900 mm Checking the piston rings Carefully remove the piston rings Place a ring in the bore parallel to it and measure the gap using a feeler gauge Piston ring gap Top compression ring gap 0 0...

Page 38: ...so that the mark IN is on the inlet side Fit the gudgeon pin and circlips The circlip gaps 1 must face upwards or downwards but under no circumstances to the side Use new rings Fitting the cylinder Po...

Page 39: ...e piston by compressing the piston rings by hand Lubricate the cylinder Fit the chain and the chain guide tensioner into the timing chain tunnel Fit the chain pad 1 Fit the 2 guiding pillars 2 and the...

Page 40: ...front of the crankcase boss C Fit the gear in the chain on one of the sides Using a tool with a small diameter finish fitting the chain around the gear Install the camshaft gear Make sure the mark A o...

Page 41: ...hment screws 3 Tightening torque 10 Nm Install the spring 4 Fit the chain tensioner gasket 5 Install the tensioner cap 6 Tightening torque 8 Nm Check the timing Install the timing gear cover Tightenin...

Page 42: ...lve clearance adjustment covers Apply the correct tightening torque to the valve clearance adjustment covers Tightening torque 15 Nm Using the set of feeler gauges measure the clearance of each valve...

Page 43: ...ary drive Remove the overrunning clutch Remove the cylinder and the piston Remove the starter motor 2 screw Tightening torque 10 Nm Remove the drive gear from the oil pump 1 Remove the circlip 2 Remov...

Page 44: ...od assembly Remove the timing chain and notice its direction of rotation Checking the crankshaft and conrod assembly Using a set of shims check the big end side play The maximum side play on the conro...

Page 45: ...fitting tool P N 757990 fit a new lightly greased gasket 1 Position the LH casing horizontally Fit the timing chain 2 through the timing well Fit the conrod and crankshaft assembly into the LH crankca...

Page 46: ...RANKCASE 44 Reproduction ou traduction m me partielle interdite sans autorisation crite de Peugeot Motocycles Fit and tighten the 2 clamping bolts Tightening torque 12 Nm Trim the casing gasket in A A...

Page 47: ......

Page 48: ...N MA0010GB Peugeot Motocycles is constantly improving its vehicles It therefore reserves the right to remove modify or add any reference mentioned in this manual DC APV 05 2009 non contractual picture...

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