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TABLE OF CONTENTS

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

TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................ 1

CHARACTERISTICS............................................................................................................ 3

Capacities............................................................................................................................ 3

SPECIAL IMPORTANT POINTS.......................................................................................... 4

Oil and fuel .......................................................................................................................... 4

TIGHTENING TORQUE........................................................................................................ 5

SPECIAL TOOLS ................................................................................................................. 6

DISASSEMBLY .................................................................................................................... 9

Putting the engine on the stand........................................................................................... 9

Removal of the primary transmission cover......................................................................... 9

Removal of the drive pulley................................................................................................ 10

Removal of the driven pulley.............................................................................................. 10

Removal of the rocker cover. ............................................................................................. 11

Removal of the chain tensioner. ........................................................................................ 11

Removal of the RH cover / ignition coil and sensor. .......................................................... 12

Removal of the rotor. ......................................................................................................... 13

Removal of the cylinder head. ........................................................................................... 14

Removal of the temperature sensor. ................................................................................. 16

Removal of the thermostat. ............................................................................................... 16

Removal of the camshaft and/or rockers. .......................................................................... 16

Removal of the valves or valve stem seals. ....................................................................... 17

Removal of the cylinder. .................................................................................................... 19

Removal of the piston........................................................................................................ 19

Removal of the oil pump. ................................................................................................... 20

Removal of the RH crankcase half. ................................................................................... 22

Removal of the oil discharge valve. ................................................................................... 23

Removal of the water pump............................................................................................... 23

Removal of the crankshaft. ................................................................................................ 24

Содержание 150 CC

Страница 1: ...WORKSHOP MANUAL TECHNICAL NETWORK LEADERSHIP WORKSHOP MANUAL 125 CC 150 CC 4 STROKE ENGINE...

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

Страница 3: ...ve pulley 10 Removal of the driven pulley 10 Removal of the rocker cover 11 Removal of the chain tensioner 11 Removal of the RH cover ignition coil and sensor 12 Removal of the rotor 13 Removal of the...

Страница 4: ...pump inside the RH crankcase 28 Assembly of the engine casings 30 Installing the piston rings on the piston 32 Fitting the piston 32 Fitting the cylinder 33 Fitting the cylinder head 33 Setting the t...

Страница 5: ...Max power output 9 kW at 8750 rpm 10 kW at 8450 rpm 9 kW at 8750 rpm 10 kW at 8450 rpm Max torque rating 7250 rpm 6500 rpm 7250 rpm 6500 rpm Lubrication Trochoidal pump Transmission By 2 variable pul...

Страница 6: ...or 98 unleaded fuel only Never run the machine with a petrol oil mixture The fuel pipes must be changed if they show signs of wear cracks etc The clips are specific they must always be changed each t...

Страница 7: ...der head 1 8 2 3 m daN Cylinder casings 1 m daN Transmission cover 1 m daN RH casing cover 1 m daN Automatic tensioner 1 m daN Oil control valve 4 m daN Temperature sensor 1 m daN Starter motor 1 m da...

Страница 8: ...model 64706 64710 Shouldered centering tool 64706 69104 Pin nut 750 64711 64712 64754 64712 Pin 12 pitch 125 69104 750539 Tie wrap pliers 64765 Engine mount Engine mount adapter 752000 Piston circlip...

Страница 9: ...752235 extensi on 752236 adapte r 754034 Camshaft locking pin 754003 Flywheel puller 69098 754035 Valve lifter 754005 Clutch compression tool 754046 754040 46 mm pipe wrench 754005 754006 Casing openi...

Страница 10: ...8 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles 757988 Water pump bearing drift 757989 Water pump bearing drift 757990 Crankcase seal install...

Страница 11: ...D4 P N 756717 for engines FD5 Put the assembly on stand P N 64765 clamped in the jaws of a vice Empty the oil from the engine Note Every time oil is changed the filter must be cleaned and the copper s...

Страница 12: ...the nut 1 and washer 2 from the fixed flange Remove the fixed flange Tightening torque 7 m daN Remove the belt 3 Remove the drive pulley 4 with the guide hub 5 Removal of the driven pulley Immobilize...

Страница 13: ...rocker cover Remove the paper gasket Tightening torque 1 m daN Note The O ring must be changed every time it is removed Every time the rocker cover is removed and re installed make sure the plug 1 is...

Страница 14: ...Remove the chain tensioner and slacken it by pressing the ratchet tooth A Remove the paper gasket Tightening torque 1 m daN Removal of the RH cover ignition coil and sensor Remove the 8 bolts that se...

Страница 15: ...over and the crankshaft stem shall lubricate the conrod big end The tighteness of the oil lubrication system between the cover and the RH stem of the crankshaft is provided by a seal The seal is place...

Страница 16: ...eel extractor and turn the thrust bolt until the rotor is released Remove the rotor Tightening torque 7 m daN Note When re installing make sure the key 1 is properly positioned on the crankshaft stem...

Страница 17: ...haft gear bolt Remove the camshaft gear Hang the timing chain Remove the chain guide pad 2 which is fitted inside the cylinder head on the exhaust side Loosen the 2 washer screws 3 Gradually loosen in...

Страница 18: ...olts and the thermostat valve 1 Remove the thermostat 2 Tightening torque 1 m daN Note The drain bolt is located on the cover Tighteness of the bolt is provided by a fiber seal Removal of the camshaft...

Страница 19: ...s 3 Remove the inlet 4 and exhaust 5 rockers When re installing the lubrication holes A of the shafts shall be directed towards the stopper plate Removal of the valves or valve stem seals Compress the...

Страница 20: ...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 decom pressing the spring In case you remove the seal of a valve stem 6 re...

Страница 21: ...cycles Removal of the cylinder Remove the front bolt 1 of the cylinder located beside the oil pressure swich Remove the cylinder Remove the base gasket 2 and the 2 centring pillars 3 Removal of the pi...

Страница 22: ...emoval of the oil pump Remove the 2 screws which secure the 1st anti splash plate 1 Remove the plate Remove the 2 circlips 2 from the plastic gears 3 which drive the water pump and oil pump Remove the...

Страница 23: ...forbidden without the written consent of Peugeot Motocycles Remove the 3 screws which secure the oil pump 6 Remove the oil pump Tightening torque 1 m daN Note Before re assembling lubricate the oil p...

Страница 24: ...s direction of rotation Remove the 2 bolts that secure the starter motor 3 Remove the starter motor Tightening torque 1 m daN Note Check the condition of the starter motor O ring Remove the 8 bolts On...

Страница 25: ...crew the turbine 1 from the drive shaft 2 while immobilizing it using a 2 mm diameter drift in A Remove the circlip 3 located on the bearing side Drive out the bearing 4 on the timing side by pushing...

Страница 26: ...torque 1 m daN Fit the protective cap P N 69098 to the crank Fit to casing with tool P N 64706 fitted with plate P N 754006 Fix the assembly to the casing using 4 bolts 2 Tighten the tool centre scre...

Страница 27: ...rankshaft and conrod assembly Using a set of shims check the big end side play The maximum side play on the conrod end must not exceed 7 10 mm The out of round values measured on the ends of the crank...

Страница 28: ...he cover with the primary shaft 2 Tightening torque 1 m daN Note The primary shaft can be drifted out of the cover using a mallet Removal of the secondary transmission Remove the 2 centring pillars an...

Страница 29: ...ISASSEMBLY 27 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Remove the intermediate shaft and its second friction washer 6 located behind it 6...

Страница 30: ...earing is positioned into the casing by means of a press Fit the seal into the casing using the installation buffer P N 757990 Installing the water pump inside the RH crankcase Fit the caged needle be...

Страница 31: ...written consent of Peugeot Motocycles Install the bearing 3 on the drive shaft 4 by pushing it by the inner cage using bearing drift P N 757988 Fit the drive shaft and bearing assembly by the outer ca...

Страница 32: ...e joint Assembly of the engine casings Insert the crank assembly into the LH casing bearing Tighten pin P N 64712 at the end of the crank assembly Fit tool P N 64706 fitted with plate P N 754006 to th...

Страница 33: ...e LH casing assembly Note No tools are necessary for assem bling the casings which shall be car ried out without effort Fit and tighten the 8 fixing bolts Tightening torque 1 m daN Check the crank ass...

Страница 34: ...n rings 2 on each side of the spring by offsetting the gap of each ring no special direction Install the compression ring 3 by placing the TOP mark upwards Install the top compression ring 4 by placin...

Страница 35: ...oil control ring gap Note Lubricate the cylinder Fit the timing belt through the cylinder timing well Compress the piston rings and fit them manually one after the other into the cylinder barrel Fit...

Страница 36: ...ly Pre tighten the 4 nuts in a crosswise order to 18 Nm and the 2 washer screws to 8 Nm 2nd step Torque the 4 nuts in a crosswise order to 23 Nm and the 2 washer screws to 10 Nm Collar nut B This oper...

Страница 37: ...tensioner Fit the locking pin P N 754033 in the crankcase gauge hole Rotate the crankshaft until the pin enters the crankshaft gauging hole Install the camshaft gear 1 on the camshaft Immobilize the c...

Страница 38: ...the chain tensioner and the 2 attachment screws Install the spring and its screw Tightening torque 1 m daN Immobilize the camshaft gear using the adjustable pin wrench P N 752237 The lower strand of t...

Страница 39: ...so as to bring the rocker pads over the cam lobes Loosen the lock nut of the rocker adjustment screw By means of feeler gauges adjust the clearance of every valve by acting on the rocker set screw Cle...

Страница 40: ...of Peugeot Motocycles Refitting the rocker cover Important Make sure you fit the plug 1 over the cylinder head gauging hole Install a new paper gasket Install the rocker cover and its 5 scews Tighten...

Страница 41: ...cover 1 Remove the cover and the O ring 2 check the condition of the O ring and change it if necessary Remove the oil filter 3 Note The oil filter has no installing direc tion Tightening torque 1 m da...

Страница 42: ...ut Tightening torque 7 m daN It is forbidden to use a power driver this may upset the crank position Precautions when refitting the drive pulley Drive pulley components shall neither be suppressed nor...

Страница 43: ...flange bore lightly high temperature grease Removal of the clutch lining assembly Remove the transmission cover 8 fixing bolts Removal of the primary transmission cover Lock the clutch drum with the...

Страница 44: ...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 pulley assembly with the...

Страница 45: ...Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles...

Страница 46: ...Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles...

Страница 47: ...Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles...

Страница 48: ...the written consent of Peugeot Motocycles RECOMMENDS P N 757904 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned D...

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