PEUGEOT V-CLIC - Workshop Manual Download | Manualshive

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Sales division
Technical network leadership

WORKSHOP MANUAL

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Summary of Contents for V-CLIC -

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

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

Page 3: ... over to the customer 7 SPECIAL IMPORTANT POINTS 8 Oil and fuel 8 Starting up after overhauling the engine 8 TIGHTENING TORQUES 9 Engine part 9 Body panels 9 Cycle part 10 Standard 10 INSTRUMENT PANEL 11 Analog functions hands 11 ELECTRICITY 12 Fuses and energy distribution 12 Location of components 12 BODY PANELS 13 Location of body components 13 Body component sequence of disassembly 14 Removal ...

Page 4: ...of the spark plug 24 Removal of the carburettor 24 Installing the valve clearance 25 Removal of the exhaust system 25 Removal of the cylinder head 26 Removal of the cylinder piston 26 MISCELLANEOUS OPERATIONS 27 Removal of the engine 27 Removal of the battery 27 Removal of the starter motor relay 27 Removal of the ignition module CDI 27 Removal of the fuse 27 Removal of the regulator 28 Removal of...

Page 5: ...verhead camshaft Cooling Air Bore x stroke 39 0 x 41 4 mm Cubic capacity 49 58 cm3 Max power output 2 0 kW à 7000 tr min Max torque rating 6000 tr min Fuel supply Carburettor Lubrication Trochoidal pump Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Spark plug NGK CR 7HSA Exhaust Catalytic Standards Euro 2 Fuel tank 6 3 l Engine oil 0 8 l Relay box 0 12 l Fork 87cc...

Page 6: ...m Rear suspension Combined spring and hydraulically damped shock absorber Travel 85 mm Overall length 1660 mm Width at handlebar 700 mm Height without rear view mirrors 1070 mm Wheelbase 1200 mm Ground clearance 115 mm Unladen weight 79 kg Front wheel rim 10 inch aluminium alloy Front tyre 3 50 10 Front tyre pressure 1 25 bars Rear wheel rim 10 inch aluminium alloy Rear tyre 3 50 10 Rear tyre pres...

Page 7: ...en consent of Peugeot Motocycles Brakes Front disc diameter and thickness 155 mm 4 mm Front brake caliper 1 piston of 30 2 mm Brake drum diameter 110 mm Chassis markings Engine marking 1 VIN Rear shield 2 Engine number Manufacturer s plate Right side xxxxxxx xxxxxxx xxx 1 XXXXXX XXXXXXXX 2 ...

Page 8: ... the front brake hydraulic control C C C C C Condition of petrol pipes C C C C C Condition of oil pipes C C C C C Tyre pressures C C C C C Tyre condition pressure and wear C C C C C Condition of the front suspension C C C C C Condition of the rear suspension C C C C C Brake fluid level C C C C C Battery electrolyte level C C C C C Tightness of nuts and bolts C C C C C Change Spark plug R R R Inlet...

Page 9: ... Top up if necessary Charge the battery for at least 6 hours with a current of 0 5A Refit the battery and connect the vapour vent pipe Connect the terminal with the red wire to the battery and the terminal with the black and white wire to the battery Then the battery level should be topped up if necessary after fully charging using distilled water only Checks before handing over to the customer Ch...

Page 10: ... unleaded fuel only Fuel pipes must absolutely be changed if there are any signs of wear cracks etc Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Work in a clear and well ventilated area Before carrying out any work leave the engine to cool for at least 2 hours Starting up after overhauling the engine When starting the engine hot or cold do n...

Page 11: ...tic tensioner 0 8 1 m daN Starter motor 1 m daN Rotor 5 m daN Stator 0 8 m daN Engine speed sensor 0 6 m daN Drive pulley 5 m daN Driven pulley 5 m daN Spark plug 1 8 m daN Inlet manifold 1 m daN Front mudguard 0 8 à 1 2 m daN Handlebar cover 0 2 à 0 4 m daN Front shield panels 0 2 à 0 4 m daN Rear shield 0 2 à 0 4 m daN Bottom panel 1 m daN Floor panel 1 m daN Saddle storage compartment 1 m daN R...

Page 12: ...ock absorber top mount 2 9 m daN Shock absorber bottom mount 2 9 m daN Exhaust to cylinder head mounting nut 1 8 m daN Exhaust to casing mounting bolt 2 3 m daN Upper cone Hand tightened Steering locknut 3 m daN Front brake caliper 2 6 m daN Front brake disc 2 3 m daN Handle bar 4 9 m daN Nut and bolt 5 mm diameter 0 4 m daN Nut and bolt 6 mm diameter 0 9 m daN Nut and bolt 8 mm diameter 1 2 m daN...

Page 13: ...led by the vehicle Fuel gauge Functions of the instrument panel Speedometer Odometer Fuel gauge Instrument panel indicator lamps Intermitent signal High beam 1 Speedometer 2 Odometer 3 Fuel gauge 4 Intermitent signal 5 High beam When a flasher bulb has failed the repeater light and the other flasher light flash more quickly to alert the rider of a failure 10 10 20 20 30 30 40 40 50 50 60 60 70 70 ...

Page 14: ...nergy distribution When the main fuse 10A is blown all the the electric functions of the vehicle are disabled Replace the burnt out fuse with a new one Location of components 1 Battery 2 Ignition sensor 3 Ignition unit 4 Oil level indicator 5 HT coil 6 Regulator 7 Starter motor relay 8 Horn 9 10 A fuse 10 Kickstand switch 8 4 7 1 5 2 3 9 6 10 ...

Page 15: ...mponents 1 Central panel 2 Saddle Storage compartment 3 Grab handle 4 Rear cover 5 Mudflap 6 Side panels 7 Lower side fairings 8 Bottom panel 9 Front mudguard 10 Front shield panels 11 Front top cover panel 12 Handlebar front fairing 13 Handlebar rear fairing 14 Rear shield 15 Floor panel 16 Battery access door 11 8 12 14 15 7 6 5 3 2 1 9 10 13 16 4 ...

Page 16: ... Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Body component sequence of disassembly This item may be removed on its own 2 3 4 11 9 13 12 10 14 8 15 5 6 7 1 ...

Page 17: ...4 nuts and the 4 washers 2 Remove the screw 3 Remove the storage compartment Removal of the grab handle Procedure 2 Remove the plastic cover 1 Remove the 3 bolts 2 that secure the grab handle Remove the grab handle 3 Tightening torque 2 5 m daN Removal of the central cover panel Procedure 3 Removal of the storage compartment see procedure 1 Remove the footboard mat 1 Remove the 4 fixing bolts 2 Re...

Page 18: ...re 3 Removal of the lower side fairings see procedure 4 Remove the fixing screw 1 located on each side of the vehicle Remove the fixing screw 2 located on each side of the vehicle Remove the tank filler cap 3 Disconnect from the lock the cable that controls the opening of the saddle Remove the side panels by sliding them backwards in order to release them Removal of the footboard Procedure 6 Remov...

Page 19: ...to the rear part of the leg shield panel 5 Remove the footboard 6 Removal of the taillignt Removal of the splash guard Removal of the storage compartment see procedure 1 Removal of the grab handle see procedure 2 Removal of the central cover panel see procedure 3 Removal of the lower side fairings see procedure 4 Removal of the side fairings see procedure 5 Disconnect the taillight Remove the 2 nu...

Page 20: ...consent of Peugeot Motocycles Remove the splash guard by releasing it from the pins 3 and bracket 4 Removal of the front top cover panel Procedure 7 Remove the 4 fixing bolts 1 Unclip the front cover panel from on top of the front leg shield panel Remove the front top cover panel 2 3 4 1 2 ...

Page 21: ...e fixing screw 1 located on each side of the vehicle Remove the front part of the mudguard 2 by unclipping it from the holder 3 Remove the 2 fixing bolts 4 Remove the rear part of the mudguard and its holder Removal of the front shield panel Procedure 9 Removal of the lower side fairings see procedure 4 Removal of the front top cover panel see procedure 7 Removal of the front mudguard see procedur...

Page 22: ...ove the 3 fixing screws 1 located on each side of the vehicle Remove the fixing screw 2 located on each side of the vehicle Remove the 2 fixing bolts 3 Remove the screw of the utility hanger 4 Remove the utility hanger Remove the rear shield panel Removal of the under body panel Procedure 11 Removal of the lower side fairings see procedure 4 Removal of the front top cover panel see procedure 7 Rem...

Page 23: ...move the 2 fixing bolts 2 Remove the handlebar front cover Remove the lamp lens 3 Disconnect the bulb Remove the bulb Removal of a taillight bulb Remove the 2 screws that secure the rear panel Remove the rear body cover 1 Remove the 2 screws that secure the taillight lens 2 Disconnect the bulb Remove the taillight lens ans turnsignal light lenses Remove the bulb 2 1 2 3 1 3 2 1 ...

Page 24: ...moval of the lower side fairings see procedure 4 Removal of the front top cover panel see procedure 7 Remove the 3 fixing screws 1 located on each side of the vehicle Remove the fixing screw 2 located on each side of the vehicle Open the front shield panel Remove the 3 screws that secure the front turnsignal light Remove the front turnsignal light 1 2 ...

Page 25: ...r filter foam Remove the 6 screws from the ait filter cover 1 Remove the air filter cover 1 move the air filter foam Change if necessary Removal of the transmission filter Loosen the collar 1 Remove the transmission filter sleeve 2 Remove the transmission air filter 3 Change if necessary Removal of the fuel filter Removal of the storage compartment see procedure 1 Removal of the fuel filter 1 Chan...

Page 26: ...f the pulsair reed valve 2 Refer to the workshop manual 2 valve 50cc 4 stroke engine P N 759517 Removal of the spark plug Removal of the storage compartment see procedure 1 Removal of the central cover panel see procedure 3 Disconnect the suppressor 1 Remove the spark plug Removal of the carburettor Removal of the storage compartment see procedure 1 Loosen the collars 1 Disconnect the fuel supply ...

Page 27: ...the 4 fixing bolts 1 Remove the 2 fixing bolts 2 Disconnect the oil vapour return pipe Tightening torque 1 m daN Remove the rocker cover Remove the timing mark plug 1 Installing the valve clearance Refer to the workshop manual 2 valve 50cc 4 stroke engine P N 759517 Removal of the exhaust system Remove the 2 nuts 1 Remove the 2 fixing bolts 2 Remove the exhaust Removal of the gasket Tightening tor...

Page 28: ...ompartment see procedure 1 Removal of the central cover panel see procedure 3 Removal of the exhaust system For the following steps Removal of the intake pipe Removal of the cooling volutes Removal of the rocker cover Removal of the chain tensioner Removal of the cylinder head Removal of the cylinder Removal of the piston Refer to the workshop manual 2 valve 50cc 4 stroke engine P N 759517 ...

Page 29: ...m hose Disconnect the oil vapour return pipe Remove the 2 screws that secure the air filter Remove the air filter Disconnect The suppressor The magneto The starter motor Suspend or immobilize the machine securely Remove the shock absorber lower mount Remove the nut that secures the engine Remove the bolt that secures the engine Remove the engine Removal of the battery Removal of the starter motor ...

Page 30: ...cedure 7 Removal of the high tension coil Removal of the storage compartment see procedure 1 Removal of the central cover panel see procedure 3 Remove the lower RH side fairing see procedure 4 Disconnect the high voltage coil 1 Disconnect the suppressor Remove the fastening screw 2 Remove the high tension coil Removal of the kickstand contact switch Remove the lower LH side fairing see procedure 4...

Page 31: ...edure 4 Removal of the side fairings see procedure 5 Disconnect the fuel gauge 1 Remove the 4 fixing bolts 2 Remove the fuel gauge Remove the flat gasket Remove the 2 fixing bolts 2 Remove the 2 nuts 3 Remove the holder and saddle lock assembly 4 Loosen the 2 nuts 5 Remove the 2 fixing bolts 6 Remove the grab handle holder Remove the tank Removal of the front wheel Unscrew the speedometer cable fr...

Page 32: ...ve the wheel Tightening torque 12 m daN Removal of the calliper Removal of the brake pads Loosen the screw 1 that secures the calliper to the yoke Remove the 2 screws that secure the brake calliper but do not disconnect it 2 Tightening torque 2 6 m daN Remove the screw 1 Pivot the calliper relative to the yoke Remove the calliper yoke Note If the caliper is to be changed the hydraulic control must...

Page 33: ... times to bring the brake pads against the brake disc Removal of the fork Replacing the bearings of the steering system Removal of the front wheel see page 29 Removal of the front mudguard see procedure 8 Removal of the calliper see page 30 Removal of the front top cover panel see procedure 7 Remove the 3 fixing bolts 1 Remove the fastening screw 2 Remove the handlebar front and rear covers Remove...

Page 34: ...ing new parts The fork cone 1 The steering headset cups 2 Steering system tightening method Grease the cup bearing races Fit 26 balls 1 for the upper cup and 29 balls 2 for the lower cup Diameter 4 mm Fit the fork into the steering column Install the adjustable cone and tighten it 3 Loosen and then retighten the adjustable cone Fit the lock washer 4 Install the steering head locknut and tighten it...

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Page 38: ...N 759522 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned DC PS APV Printed in the E U 03 2007 non contractual pictures ...

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