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

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Страница 3: ...sis 6 Dimensions and weight 7 Tyres 7 Brakes 8 SERVICE SCHEDULE AND COMMISSIONING 9 To be checked at each service 9 Service operations 10 Time required for maintenance 10 Battery preparation Except battery without maintenance 11 New machine preparation 11 SPECIAL IMPORTANT POINTS 12 Oil and fuel 12 TIGHTENING TORQUES 13 Engine part 13 Body panels 13 Cycle part 14 Standard 14 SPECIAL TOOLS 15 STAND...

Страница 4: ... 23 Removal of the rear shield panel 23 Removal of the front lower shield pannel 24 Removal of the footboard 25 SERVICE OPERATIONS 26 Changing the engine oil 26 Draining the relay box 27 Removal of the spark plug 28 Replacing the air filter 28 Transmission 29 Installing the valve clearance 34 Idle setting 35 Removal of the fuel filter 36 Brake inspection 36 Replacing the brake pads 36 Checking the...

Страница 5: ...the fuel gauge 55 Removal of the high tension coil 55 FUEL SYSTEM 56 Removal of the fuel tank 56 Removal of the carburettor 56 The carburettor and its components 62 POWER UNIT 63 Removal of the power unit 63 Removal of the cylinder head 64 Removal of the camshaft and or rockers 66 Removal of the valves or valve stem seals 67 Fitting the cylinder head 68 Method for tightening the cylinder head 68 S...

Страница 6: ...and appropriate 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 Hazardous to the environment The product affects fauna and flora Do not dump it in dustbins sinks or in the environment The ideal solution is to bring this product to your nearest household waste recycl...

Страница 7: ...age 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 information to make the procedure easier Lubricate Lubricate the parts to be assembled Indicate the specific procedures that shall be followed in order not to damage the vehicle Grease Grease the p...

Страница 8: ...rication Pressurised wet sump lubrication Trochoid pump driven by a chain from the crankshaft Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust Catalytic Starter motor By kick starter or electric starter Spark plug NGK CR7HSA Electrode gap 0 6 to 0 7 mm Magneto flywheel 90 W Fuel supply Carburettor Deni DPD 18J Standards Euro 2 Crankcase 0 8 l SAE 5W40 Minimum...

Страница 9: ...weight Tyres Overall length 1849 mm Width at handlebar 667 mm Height without rear view mirrors 1156 mm Wheelbase 1256 mm Saddle height 760 mm Unladen weight 95 kg Front wheel rim 12 inch aluminium alloy Front tyre 110 70 12 Front tyre pressure 1 6 bars Rear wheel rim 12 inch aluminium alloy Rear tyre 110 70 12 Rear tyre pressure 1 8 bars ...

Страница 10: ...sc type hydraulic control Disc diameter and thickness 170 mm 4 mm Front caliper Floating caliper equipped with one piston Rear brake cable controlled single cam drum type Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking Manufacturer s plate 1 Engine number 2 Chassis no 3 1 XXXXXX X XXXXXXXX 2 xxxxxxxxxxxxxxxxx 3 ...

Страница 11: ...ring column play V V V V V V Wheel bearing play C C C C C C Throttle cable play V V V V V V Operation of electrical equipment V V V V Condition of the front brake hydraulic control V V V V V V Brake fluid level V V V V V V Front brake pad wear C C C C C C Rear brake lining wear C C C C C C Joints Central stand Brake levers Rear brake cam G G G G Condition of petrol pipes C C C C C C Tyre condition...

Страница 12: ...ain N N Drive pulley bearings and guides V C V C Transmission belt R R Kick starter mechanism G G Valve clearances V V V V V Setting the carburettor V V Joints Central stand Brake levers Rear brake cam G G G G Petrol filter R Engine oil clean strainer R R R R R R Relay box oil R R R R R Fork oil R Petrol pipe Once every 5 years Brake fluid Once every 2 years Time required for maintenance Code 9100...

Страница 13: ...sary Charge the battery for at least 2 hours with a current of 0 4 A Refit the battery and connect the vapour vent pipe Connect the red wire lug to the battery s terminal and the green wire lug to the battery s terminal Then the battery level should be topped up if necessary after fully charging using distilled water only Depending on equipment New machine preparation Check the tightness of the ca...

Страница 14: ...d fuel only Fuel pipes must absolutely be changed if there are any signs of wear cracks etc The air pipe between the air pump and the exhaust is specific owing to its heat resistance properties Should it be changed replace it with a genuine pipe Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Before carrying out any work leave the engine to coo...

Страница 15: ...8 Nm Crankcase 10 Nm RH casing cover 10 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Starter motor 10 Nm Rotor 50 Nm Stator 8 Nm Engine speed sensor 6 Nm Transmission cover 10 Nm Turbine 10 Nm Drive pulley 50 Nm Driven pulley 50 Nm Clutch plate and shoes 50 Nm Inlet manifold 10 Nm Front mudguard 8 to 10 Nm Handlebar cover 2 to 4 Nm Front shield panel 2 to 4 Nm Rear shield 2 to 4 Nm B...

Страница 16: ...25 Nm Exhaust to cylinder head mounting nut 15 18 Nm Exhaust to casing mounting bolt 20 25 Nm Upper cone in 2 operations 38 42 Nm 15 19 Nm Upper cone locknut Hand tightened Steering locknut 70 80 Nm Handle bar 35 45 Nm Front brake caliper 27 32 Nm Front brake disc 27 32 Nm Fastening screw for brake linkrod on cam 8 11 Nm Fastening screw for fork stanchion on tee 30 40 Nm Nut and bolt 5 mm diameter...

Страница 17: ...gnation Used with 64765 Engine mount 755982 754035 Valve lifter 758595 68007 Protective end piece small model 750806 755982 Engine mount adapter 64765 750806 Flywheel puller 68007 755996 Hose clamp 752127 Clutch compression tool 756725 756668 Lip seal push tool 752237 Adjustable pin wrench 756725 38 mm pipe wrench 752127 753726 Steeing head cup push tool 757860 Steering tool ...

Страница 18: ...pring lifter adapter 754035 759467 Fixed flange locking tool STANDARD TOOLS Wrenches with interchangeable end fittings for valve clearance adjustment Type Marolotest P N 500140 Multimeter Set of shims Automatic resetting type torque wrench 5 to 25 Nm Type Facom R 306A25 Automatic resetting type torque wrench 10 to 50 Nm Type Facom J 208A50 Automatic resetting type torque wrench 40 to 200 Nm Type F...

Страница 19: ...es LOCATION OF COMPONENTS 1 Fuel gauge 2 CDI unit 3 Regulator 4 Starter motor relay 5 Fuse 6 Flasher unit 7 Starter resistor 8 Horn 9 Battery 10 HT coil 11 Ignition sensor 12 Carburetor heater 13 Carburettor heater thermo switch 14 Drive sensor N C U PP ER LE V EL LO W ER LE V EL 1 4 5 9 7 8 11 2 3 10 6 XX XX XXX XXXX 13 12 14 ...

Страница 20: ...mponents Description 1 Handlebar front fairing 2 Handlebar rear fairing 3 Legshield top panel 4 Rear shield 5 Front lower legshields 6 Front mudguard 7 Front wheel 8 Mudguard 9 Bottom panel 10 Central bottom panel 11 Floor panel 12 Mudflap 13 Saddle and storage compartment 14 Rear body panels 15 Central panels N C 5 9 7 8 11 3 6 1 2 4 10 12 14 13 15 ...

Страница 21: ...ar front fairing 2 Handlebar rear fairing 3 Legshield top panel 4 Rear shield 5 Front lower legshields 6 Front mudguard 7 Front wheel 8 Mudguard 9 Bottom panel 10 Central bottom panel 11 Floor panel 12 Mudflap 13 Saddle and storage compartment 14 Grab handle 15 Rear body panels 16 Central panels This item may be removed on its own 9 14 12 15 13 8 7 2 1 6 11 4 5 3 10 ...

Страница 22: ...ompartment Procedure 1 Lift the saddle Remove the tank filler cap Remove the storage compartment 6 screw Removal of the rear cover assembly and mudflap Procedure 2 Remove the rear storage compartment See Procedure 1 page 20 Remove the splash guard 6 screw Remove the grab handle 3 screw Remove the rear cover assembly 4 screw Disconnect the taillight ...

Страница 23: ...he taillight 4 screw Remove the fastening screw on the fairings Separate the 2 fairings Removal of the RH or LH central cover panel Procedure 3 Remove the rear cover assembly See Procedure 2 page 20 Remove the battery access door 1 screw Remove the complete footrest assembly 1 screw Remove the 5 screws from the central fairing ...

Страница 24: ...ster Procedure 4 Remove the handlebar front cover 4 screw Disconnect the instrument cluster Unscrew the speedometer cable Remove the handlebar rear cover and instrument cluster assembly 4 screw Remove the instrument cluster 4 screw Removal of the RH or LH under body panel Procedure 5 Remove the 2 screws from the bottom panel Remove the bottom panel ...

Страница 25: ...rews that secure the front shield panel Remove the 4 screws that secure the front shield panel Remove the front upper shield panel Disconnect the headlight and the indicator lights Removal of the rear shield panel Procedure 7 Remove the handlebar front and rear covers See Procedure 4 page 22 Remove the front upper shield panel See Procedure 6 page 23 Remove the ingnition switch trim ...

Страница 26: ...ure the rear shield panel Pull upwards the lower part of the shield panel in order to separate it from the footboard Removal of the front lower shield pannel Procedure 8 Remove the rear shield panel See Procedure 7 page 23 Remove the RH and LH under body panel See Procedure 5 page 22 Remove the 4 fastening screws from the mudguard A Remove the 2 screws that secure the front shield panel B A A A A ...

Страница 27: ...cycles Removal of the footboard Procedure 9 Remove the rear shield panel See Procedure 7 page 23 Remove the right and left central fairings Procedure 3 page 21 Remove the RH and LH under body panel Procedure 5 page 22 Remove the battery Remove the starter relay Remove the fuse holder Remove the footboard 4 screw ...

Страница 28: ...flat ground Remove the engine s oil filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Remove the strainer cap 3 and clean the strainer Insert the drain plug fitted with a new seal Tightening torque 20 Nm Re install the filter cap fitted with a new seal Tightening torque 30 Nm Pour the required quantity of oil corresponding to the manufacturer s standard...

Страница 29: ...out exceeding the latter Add oil if necessary Draining the relay box The gearbox must be drained when the engine is warm so that the oil will run easier Put on protective gloves Place the vehicle on its central stand on flat ground Remove the relay box filler cap 1 Remove the drainage cap and its seal 2 and allow the oil to drip into a recipient Insert the drain plug fitted with a new seal Tighten...

Страница 30: ... Remove the rear storage compartment See Procedure 1 page 20 Disconnect the suppressor 1 Remove the spark plug access hatch A Remove the spark plug Essential precautions When re installing srew in the spark plug a few turns by hand Tighten the spark plug Tightening torque 18 Nm Replacing the air filter Remove the 6 screws from the air filter cover 1 A ...

Страница 31: ... box Fit a new air filter Remove the inlet silencer drain plug to let humidity and oil drip out A Transmission Removal of the primary transmission cover Lift the air filter box to reach the transmission cover 1 screw B Remove the transmission sensor 2 screw Remove the transmission cover 9 screw Tightening torque 10 Nm Remove the paper gasket and the two 2 centering pins A B ...

Страница 32: ...9467 Remove the fixed flange nut and washer Tightening torque 50 Nm Remove the starter hub 1 and the turbine 2 Remove the fixed flange Remove the belt Remove the drive pulley 3 together with the guide hud Removal of the driven pulley Lock the clutch drum with the pin wrench P N 752237 Remove the clutch drum and the clutch and drive pulley assembly Tightening torque 50 Nm 759467 1 2 3 752237 ...

Страница 33: ...The bearings must be changed if they show major signs of wear The guides shall be replaced if they show signs of wear Reassembly Proceed in reverse order to disassembly and do not grease the bearings When refitting respect the way the rollers are installed Grease the moving flange bore lightly high temperature grease Checking the drive belt Measure the width of the belt A Minimum width 16 3 mm Mak...

Страница 34: ... Replacing the clutch lining assembly Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 clamped in the jaws of a vice Remove nut 1 using spanner P N 756725 Slacken tool P N 752127 Remove the clutch linings 2 the upper centring sleeve 3 the spring 4 and the lower centring sleeve 5 Remove the 3 pins 6 from the variable speed drive seat Separate the fixed 7 and rota...

Страница 35: ... grease and assemble the parts in reverse order to removal Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 clamped in the jaws of a vice Tighten the nut 1 Tightening torque 50 Nm Before fitting the clutch drive pulley and driven pulley to the input shaft fit the belt into the pulley bottom by opening the flanges by hand Fit the clutch drive pulley and driven pu...

Страница 36: ...Disconnect the pipe from the pulsair reed valve 2 Remove the 2 screws that secure the pulsair pipe 3 Tightening torque 10 Nm Remove the cylinder head cover and its O ring 4 screw Tightening torque 10 Nm The O ring must be changed every time it is removed Remove the turbine on the the flywheel magneto side 4 screw Rotate the engine by hand in the operating direction in order to align the A mark on ...

Страница 37: ...arolotest P N 500140 Checking the valve clearance At the intake a 0 15 mm feeler gauge shouldn t go At the exhaust a 0 15 mm feeler gauge shouldn t go On the contrary if the fealer gauge goes reset the clearances Idle setting Remove the rear storage compartment See Procedure 1 page 20 The engine must be at its operating temperature Switch off the engine Park the vehicle on its stand Check the oper...

Страница 38: ...ure 2 page 20 Empty the reservoir Disconnect the fuel supply hose 1 Disconnect the vacuum hose 2 Loosen the collar 3 Remove the vacuum operated cock 4 Brake inspection If one of the 2 brake pads is worn down to the minimum dimensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Replacing the brake pads Remove the calliper 2 screw Tightening torque 27 32 Nm 1 2 3 4 A 1 5mm ...

Страница 39: ... After refitting actuate the brake levers several times to bring the brake pads against the brake disc Checking the brake fluid level Position the handlebars so that the master cylinder will be horizontal Check the brake fluid level and if necessary top up in the master cylinder A Maximum brake fluid level B Minimum brake fluid level Remove the handlebar front cover 6 screw See Procedure 4 page 22...

Страница 40: ... on the cam tierod A compared to the mark B on the engine housing If the cam tierod mark is lined up with or passes the wear mark on the engine housing the brake lining must be replaced Disassembly Remove the 2 screws that secure the muffler Tightening torque 15 18 Nm Use a new exhaust gasket Remove the 2 screws fastening the mudguard Remove the 2 screws from the exhaust Tightening torque 20 25 Nm...

Страница 41: ...10 130 Nm When re installing use a new nut Remove the rear wheel Remove the brake linings 4 Remove the adjusting nut the barrel 5 and the brake control cable 6 Remove the brake arm 7 the brake cam 8 and the spring 9 Reassembly Lubricate the brake cam spindle and fit it into the casing Fit the brake arm onto the cam and align the punched marks A Tightening torque 8 11 Nm 1 5 7 6 4 9 8 A ...

Страница 42: ...e brake cam and pin Install the brake linings 4 Install the spring 9 Install the brake control cable the barrel and the adjusting nut 5 Refit the other items in the reverse order to disassembly Measure the free travel of the rear brake control lever Ajust the lever free travel using the adjusting nut B Brake control free travel 10 to 20 mm 5 4 9 B ...

Страница 43: ...ork nut 1 in the hold in the mudguard Before loosen the fork tube caps 1 Repeat this operation by turning the handlebars to the left Suspend or immobilize the machine securely Remove the caliper 2 fixing bolts Remove the front wheel Removal of the front mudguard 4 screw Unscrew and remove the 2 upper screws 2 from the fork Tee Unscrew the 2 lower screws 3 from the fork Tee Remove the fork stanchio...

Страница 44: ...e fork tube upside down to drain the oil into a recipient Pour new oil into the fork tube Type SAE10W Quantity 0 035 l Install the spring 4 Fit and screw the cap home 1 Tightening torque 18 20 Nm Insert the fork stanchions into the fork tee Fit and tighten the 4 clamping bolts Tightening torque 30 40 Nm Fit the front shield panel 1 4 ...

Страница 45: ... the front mudguard Fit the speedometer drive gear assembly to the wheel drive pins Fit the wheel matching the speedometer drive gear assembly to the pin A on the fork stanchion Fit the wheel spindle and tighten Tightening torque 50 60 Nm When re installing use a new nut Refit the other items in the reverse order to disassembly A ...

Страница 46: ... a new nut Tightening torque 35 45 Nm Suspend or immobilize the machine securely Remove the front brake caliper from the fork tube Tightening torque 27 32 Nm Remove the front wheel When re installing use a new nut Tightening torque 50 60 Nm Remove the front mudguard Remove the brake control cable grommet and the speed sensor located under the fork triple clamp 2 2 screw Using tool P N 757860 remov...

Страница 47: ... forbidden without the written consent of Peugeot Motocycles Using a drift remove the steering head cups Using a chisel pry the steering head cup off by pressing the tool behind the dust cover Reassembly Install the following new parts The dust cover 1 The fork cone 2 2 1 ...

Страница 48: ...he steering tube Using push tool P N 757990 fit a lower cup into the steering tube Grease the cup bearing races Install new ball cage bearings 3 Fit the fork into the steering column Grease the cup bearing races Install new ball cage bearings 4 Install the upper cone 5 Install the dust cover 6 Fit and tighten the nut 7 Tightening torque 38 42 Nm Loosen and re tighten the nut Tightening torque 15 1...

Страница 49: ...he written consent of Peugeot Motocycles Install the rubber washer 4 Fit and finger tighten the nut 5 so that its notches are aligned with those of the nut Fit the lock washer 6 in the notches of the 2 nuts Install the steering head locknut and tighten it 7 Tightening torque 70 80 Nm 4 5 6 7 ...

Страница 50: ...seal 8 Fork tube 9 End of compression cone 10 Hollow shaft 11 Stanchion assembly screw Disassembly Suspend or immobilize the machine securely Remove the front brake caliper from the fork tube 2 screw Remove the front wheel Remove the front mudguard 4 screw Remove the front upper shield panel See Procedure 6 page 23 Before loosen the fork tube caps 1 Unscrew and remove the 2 upper screws A from the...

Страница 51: ...n consent of Peugeot Motocycles Remove the fork tube cap 1 Remove the spring 2 Turn the fork tube upside down to drain the oil into a recipient Remove the stanchion assembly screw 11 and its seal If necessary use a mallet to dislodge the screws Separate the fork s tube 8 from the cover 10 1 2 11 10 8 ...

Страница 52: ...t the written consent of Peugeot Motocycles The compression stop cone may remain inside the shaft Remove the compression stop cone 9 Remove the calibrated hydraulic tube 3 Remove the expansion stop spring 4 Remove the dust cover 5 Remove the retaining clip 6 Remove the seal 7 8 3 4 9 6 7 5 ...

Страница 53: ...corrosion or impact marks and the tube shall be perfectly straight and clean Reassembly Fit a new lightly greased lip seal using push tool P N 757893 7 Install the retaining ring Install the dust cover Install the expansion stop spring 4 Install the calibrated hydraulic tube 3 Install the compression stop cone 9 on the calibrated hydraulic tube Fit the fork sleeve 10 to the slightly oiled fork tub...

Страница 54: ...35 l SAE10W hydraulic oil into the fork tube Fit the spring 2 with the close coils upwards Fit and screw the cap home 1 Tightening torque 18 20 Nm Fit the fork tubes into the fork triple clamps Fit and tighten the 4 clamping bolts Tightening torque 30 40 Nm Re install all the fork equipment Refit the fairings in reverse order to removal 1 2 ...

Страница 55: ...it 4 Spark plug socket 5 Spark plug 6 HT coil 7 Starter resistor 8 Automatic starter 9 Magneto flywheel 10 Voltage regulator 11 Carburetor heater 12 Carburettor heater thermo switch 13 Drive sensor 7 5A OFF ON R U PP ER LE VE L LO W ER LE VE L X X X X X X X X X X X JN BE JN NR VE NR JN BE VE RG RG NR VE VE VE JN JN JN BA RG NR RG NR VE BA NR BA NR BE NR VE JN JN VE 1 2 3 6 4 5 7 8 9 10 13 12 11 ...

Страница 56: ...rect check The harness The ignition switch The high voltage coil The magneto The transmission sensor Component Connector Wire colours Standard values Ground A Green_Ground R 0 Ignition switch Ignition on Ignition off A A Black_Green Black_Green V 12 Volt Battery voltage V 0 Volt Engine cut off B White black_Green Ignition on f Ignition off Drive sensor C Blue_Green R 145 20 Ignition sensor A Yello...

Страница 57: ...the fuel gauge 4 screw when dismantling notice in which direction it is so that you will replace it in its initial position when reassembling Remove the rubber gasket When re installing use a new gasket Check A Full fuel tank 8 20 B Empty fuel tank 95 20 Removal of the high tension coil Remove the rear storage compartment See Procedure 1 page 20 Disconnect the suppressor 1 Disconnect and remove th...

Страница 58: ... Procedure 2 page 20 Disconnect the fuel supply hose Disconnect the vacuum hose Disconnect the fuel gauge 1 Remove the 3 screws on the rear support Remove the fuel tank 3 screw Removal of the carburettor Remove the rear storage compartment See Procedure 1 page 20 Disconnect The throttle control 1 The fuel supply hose 2 Disconnect The choke 3 The carburettor heater 2 Connectors 4 1 2 1 3 4 ...

Страница 59: ...of Peugeot Motocycles Remove the carburettor 2 collars 5 6 Disassembly Removal of the choke Remove the choke cap Remove the screw 1 and the holder plate 2 Locate the position of the choke 3 and then remove it Remove the choke holder and its gasket 2 screw Check the condition of the O ring 6 5 1 3 2 ...

Страница 60: ... Remove the heater earthing connection 5 Removal of the throttle valve Remove the 2 screws that secure the chamber cap Remove the chamber cap 6 Remove the spring Remove the needle valve and membrane assembly Check that the membrane is in good condition Remove the needle stop 7 Remove the spring 8 Remove the needle 9 The height oif the needle is factory set and cannot be modified 4 5 6 7 8 9 ...

Страница 61: ...al of the float needle valve and jets Remove the 3 screws that secure the float chamber 10 Remove the float chamber and its O ring Check the condition of the float chamber O ring Remove the float 11 its pin 12 and the needle valve 13 Remove the idle jet 14 Remove the main jet 15 Remove the needle well 16 10 12 11 13 16 15 14 ...

Страница 62: ... of the engine speed adjuster screw and mixture control screw Remove the 2 screws from the sheathing holder plate Turn clockwise the mixture control screw 15 while counting the number of turns until it is screwed home Do not turn the screw home forcefully Remove the mixture screw and its spring 17 When re fitting this operation allows you to put it back to its initial adjustment position A 17 ...

Страница 63: ... the membrane 20 Check that the membrane is in good condition 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 tool which can damage the ducts of these items Re install all the other components and if necessary when starting the engine readjust according to th...

Страница 64: ... support 2 Choke 3 Carburettor chamber cap 4 Needle 5 Spring 6 Needle stop 7 Sump 8 Float 9 Float pin 10 Needle valve 11 Idle jet 12 Main jet 13 Needle well 14 Mixture screw 15 Choke cover 16 Spring 17 Diaphragm 18 Idle screw 19 Piston 20 Float chamber gasket 21 Carburetor heater 22 Heater earth connection 1 3 4 5 6 10 9 8 7 2 19 18 17 16 15 14 13 12 11 20 21 22 ...

Страница 65: ...isconnect the battery Remove the rear cover assembly See Procedure 2 page 20 Remove the RH and LH under body panel See Procedure 5 page 22 Disconnect The magneto 3 Connectors 1 The choke 2 The carburettor heater 3 The suppressor 4 Starter power supply wires A The power wire 5 B Starter earth wire The transmission sensor 6 Disconnect The throttle control 7 The fuel inlet pipe 8 The vacuum pressure ...

Страница 66: ...1 Tightening torque 43 50 Nm Lift the rear of the machine Remove the power propulsion unit from the frame Removal of the cylinder head Remove the inlet pipe and the carburettor Tightening torque 10 Nm Remove the exhaust Remove the cooling volutes 7 screw Remove the spark plug Removal of the chain tensioner Remove the screw the O ring and the tensioner spring 1 Tightening torque 8 Nm Remove the 2 m...

Страница 67: ...rom the pulsair reed valve 4 Remove the 2 screws that secure the pulsair pipe 5 Tightening torque 10 Nm Remove the cylinder head cover and its O ring 4 screw Tightening torque 10 Nm The O ring must be changed every time it is removed Rotate the engine manually in the direction of operation in order to bring the rocker pads over the cam lobes B Remove the rubber plug 6 3 4 5 B 6 ...

Страница 68: ...ire to the timing chain in order to prevent it from falling into the crankcase Loosen the 2 washers screws 8 Gradually loosen in a crosswise order the 4 nuts which secure the cylinder head 9 Remove the cylinder head Removal of the camshaft and or rockers Remove the pins from the rockers using a 5 mm screw Remove the inlet 1 and exhaust 2 rockers Remove the stopper plate 3 Tightening torque 15 Nm R...

Страница 69: ...r P N 758595 Remove The upper cup 2 The spring 3 The lower washer 4 The valve 5 Remove the 2nd valve in the same way When re installing fit the valve springs the closest coils against the cylinder head When removing a valve always change the valve stem seal Using tool P N 758596 fit a new valve stem seal When re installing lubricate the 2 half cones 1 so as to hold them in the groove of the valve ...

Страница 70: ... lithium soap grease Seals and valve stems must be lubricated Fitting the cylinder head Fit the 2 guiding pillars and the metal gasket 6 on the cylinder Fit the timing chain through the cylinder head timing well Install the cylinder head You must set the timing every time you remove the cylinder head when servicing Method for tightening the cylinder head Fit the 4 washers Tighten the 4 nuts 1 and ...

Страница 71: ...boss A Fit the timing chain on the camshaft gear Install the camshaft gear Make sure the mark B of the camshaft gear is aligned with the mark C of the cylinder head If necessary dislodge the gear from the camshaft without removing it and move the chain around the gear on the required side Fit the 2 screws Immobilise the magnetic wheel using a wrench and tighten the camshaft pinion Tightening torqu...

Страница 72: ...ensioner gasket 5 Check the condition of the O ring and change it if necessary Install the tensioner cap 4 Tightening torque 8 Nm Checking the timing Rotate the engine twice 2 revolutions in the engine s operating direction Rotate the flywheel magneto 1 to bring the T mark in front of the crankcase boss A Make sure the mark B of the camshaft gear is aligned with the mark C of the cylinder head If ...

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Страница 76: ... MA0016GB 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 07 2010 non contractual pictures ...

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