PEUGEOT XS1P52QMI-4 Page 8 Workshop Manual Download | Manualshive

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SPECIAL IMPORTANT POINTS

6

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

SPECIAL IMPORTANT POINTS

Oil and fuel

This engine is designed 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 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.

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Summary of Contents for XS1P52QMI-4

Page 1: ...Sales division Technical network leadership WORKSHOP MANUAL 125 151 CC 4 STROKE ENGINE 2 VALVES SYM...

Page 2: ......

Page 3: ...n cover 11 Removal of the drive pulley 11 Removal of the driven pulley 12 Changing the drive pulley bearings 12 Checking the drive belt 12 Removal of the clutch lining assembly 13 Refitting the clutch...

Page 4: ...he cylinder head 29 Removal of the camshaft and or rockers 32 Removal of the valves or valve stem seals 33 Removal of the cylinder piston 35 Checking the cylinder 36 Checking the piston 36 Checking th...

Page 5: ...ppropriate 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 Hazardo...

Page 6: ...e 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...

Page 7: ...8 2 mm Cubic capacity 124 6 cc 150 6 cc Max power output 6 5 kW at 7500 rpm 7 7 kW at 7500 rpm Max torque rating 9 Nm at 6000 rpm 10 6 Nm at 6000 rpm Compression 11 8 bars at 380 rpm 7 bars Minimum Lu...

Page 8: ...ed 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 mus...

Page 9: ...ead cover 10 Nm Camshaft gear 12 Nm Valve clearance covers 10 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Cylinder casings 12 Nm RH casing cov...

Page 10: ...ith 64765 Engine mount 802349 756668 Lip seal push tool 750016 Flywheel pul ler 757990 Lip seal push tool 752237 Adjustable pin wrench 758008 Clutch com pression tool 752361 801682 752361 39 mm pipe w...

Page 11: ...st P N 500140 Set of shims 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...

Page 12: ...Put 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 yo...

Page 13: ...on cover Remove the transmission cover 8 screws 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 Remo...

Page 14: ...drum and the clutch and drive pulley assembly Tightening torque 45 Nm Changing the drive pulley bearings Remove the holder 1 and its 3 plastic guides 2 Remove the moving flange 4 6 bearings 3 The bea...

Page 15: ...espect 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 clutc...

Page 16: ...rease the governor seat 3 pins 6 high temperature grease and assemble the parts in reverse order to removal Compress the clutch and driven pulley assembly using tool 758008 equipped with the protectio...

Page 17: ...Removal of the starter system Remove the plate 7 screws 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...

Page 18: ...Hook the 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 cir...

Page 19: ...relay box 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 screws Tightening torque 22 Nm Remove the paper gask...

Page 20: ...and 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 g...

Page 21: ...of Peugeot Motocycles CARBURETTOR Removal of the carburettor Disconnect the vacuum hose Loosen the collar Remove the carburettor Removal of the choke Remove the choke cap Locate the position of the c...

Page 22: ...screws Remove the spring Remove the needle valve and membrane assembly Remove the needle stop 2 and its spring 3 by pulling it out Remove the needle and its washer 4 The height oif the needle is fact...

Page 23: ...consent of Peugeot Motocycles Remove the float 6 pin 5 Remove the float and the needle valve Remove the idle jet 7 Remove the main jet 8 Remove the needle well 9 Check the condition of the needle valv...

Page 24: ...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 Remo...

Page 25: ...ondition Clean the carburettor body with Biosane cleanser ref 754748 or use an ultrasonic cleaning tank Blow into every jet and duct of the carburettor body with compressed air Do not use any metal to...

Page 26: ...o remove the magneto flywheel Remove the carburettor Remove the inlet coupling 2 nuts Tightening torque 10 Nm Remove the plastic spacer The paper gasket must be changed each time it is removed Remove...

Page 27: ...e pin wrench P N 752237 Remove the nut and the washer Tightening torque 45 Nm Tighten flywheel extractor P N 750016 on the rotor Lock the flywheel extractor and turn the thrust bolt until the rotor is...

Page 28: ...mm C Screw Length 100 mm Remove the RH cover Tightening torque 12 Nm Remove the paper gasket 1 and the 2 locating pins 2 Remove the starter ring 3 Remove the starter dog 4 Using pin spanner ref 752237...

Page 29: ...Checking the overrunning clutch Rotate the overrunning clutch by hand It must rotate in direction A It must be block in direction B If it doesn t replace the overrunning clutch Replacing the lip seal...

Page 30: ...L FREEWHEEL 28 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Remove the circlip 1 Remove the oil pump gear 2 Remove the pin Remove the oil pum...

Page 31: ...e paper gasket must be changed each time it is removed Removal of the cylinder head Remove the pneumatic valve 1 Remove the volute 2 6 screws Remove the cylinder cover Right side 3 4 screws Disconnect...

Page 32: ...itten consent of Peugeot Motocycles Removal of the chain tensioner plug 4 Remove the O ring Using a screwdriver slacken the chain tensioner 5 Removal of the chain tensioner Remove the camshaft gear 6...

Page 33: ...without the written consent of Peugeot Motocycles Remove the 2 bolts 7 Gradually loosen in a crosswise order the 4 nuts which secure the cylinder head 8 Remove the 4 nuts Remove the plate 9 Remove the...

Page 34: ...tten consent of Peugeot Motocycles Removal of the camshaft and or rockers Remove the cylinder head Remove the stopper plate 1 Tightening torque 10 Nm Remove the pins from the rockers using a 5 mm scre...

Page 35: ...Compress the spring of one of the valves using the valve lifter P N 754035 Remove the 2 half cones 1 Uncompress the spring and remove the tool Remove The upper cup 2 The spring 3 The valve 4 The valv...

Page 36: ...o the cup forcefully with the tool when decompressing the spring When re installing the rocker pins position the indentation of the axles towards the outside of the cylinder head to fit the cylinder s...

Page 37: ...t the written consent of 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...

Page 38: ...iston The piston should show no traces of scoring or seizure The rings must be free in their grooves Measure the piston diameter at 9 mm from the piston skirt 125 cc 151 cc Piston diameter 52 385 to 5...

Page 39: ...cial direction Fit the 2 piston rings 2 on each side of the spring offsetting the gap of each ring no special direction Install the compression ring 3 by placing the 2R mark upwards Install the top co...

Page 40: ...ing gap Install the cylinder base gasket and the 2 guiding pillars on the crankcase When refitting the cylinder we recommend locking the piston using the fork part number 756575 in order to facilitate...

Page 41: ...ng torque 20 Nm Fit and tighten the 2 fixing bolts 6 Tightening torque 12 Nm Setting the timing Turn the magnetic wheel to line up the T mark with the the crankcase boss A Fit the timing chain on the...

Page 42: ...Tightening torque 8 Nm Checking the timing Rotate the engine twice 2 revolutions in the engine s operating direction Turn the magnetic wheel to line up the T mark with the the crankcase boss A Make s...

Page 43: ...measure the clearance of each valve Clearances 0 12 0 02 mm at the intake 0 12 0 02 mm at the exhaust If the clearance is not correct adjust by means of the cam follower screw Checking the valve clear...

Page 44: ...rrunning clutch Remove the cylinder and the piston Remove the starter motor 2 screws Tightening torque 10 Nm Remove the 2 screws that secure the RH half casing Remove the RH casing Remove the 2 centri...

Page 45: ...end side play The maximum side play on the conrod end must not exceed 0 55 mm The out of round values measured on the ends of the crank should not exceed 0 1 mm and must be measured 80 mm from the tra...

Page 46: ...he conrod and crankshaft assembly Position the LH casing horizontally Fit the timing chain 2 through the timing well Fit the conrod and crankshaft assembly into the LH crankcase Fit the 2 guiding bush...

Page 47: ...KCASE 45 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Fit and tighten the 2 clamping bolts Tightening torque 12 Nm Trim the casing gasket in...

Page 48: ...P N MA0020GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC APV 06 2010 non contractual pictures...

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