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POWER UNIT

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

POWER UNIT

Removal of the power unit

Note: To remove the cylinder head, remove the power propulsion unit.

For removal of the cylinder head, cylinder and piston, see the workshop manual:

• 50 cc engine. 2 valves. SYM.
• 125/151 cc engine. 2 valves. SYM.

- Remove the rear cover assembly. See: Range 2. page 20
- Disconnect and remove the battery.

50 cc

125/151 cc

- Disconnect:

• The magneto (A).
• The choke (A).
• The starter motor (A).
• The suppressor.

- Disconnect:

• The magneto (A).
• The choke (A).
• The power supply wire from the starter to the

relay (B).

• The suppressor.

- Disconnect:
- The engine ground (1).

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

Страница 2: ......

Страница 3: ...thout maintenance 11 New machine preparation 11 SPECIAL IMPORTANT POINTS 12 TIGHTENING TORQUES 13 Engine part 13 Body panels 13 Cycle part 14 Standard 14 SPECIAL TOOLS 15 Standard tools 16 LOCATION OF COMPONENTS 17 BODY PANELS 18 Location of body components 18 Body component sequence of disassembly 19 Removal of the storage compartment 20 Removal of the rear cover assembly 20 Removal of the front ...

Страница 4: ... 29 Checking the thickness of the clutch linings 30 Removal of the clutch lining assembly 30 Refitting the clutch lining assembly 31 Installing the valve clearance 32 Checking the valve clearance 33 Brake pad wear 34 Replacing the brake pads 34 Checking the brake fluid level 36 Rear brake linings 50 cc 36 Removal of the fuel filter 38 Draining the front fork 39 STEERING FORK 41 Changing the front ...

Страница 5: ...c Starting off 50 cc 48 Checking the ignition system 49 Ignition principle schematic Starting off 125 151 cc 50 Checking the ignition system 51 Removal of the regulator Starter resistor 52 Removal of the starter motor relay 52 FUEL SYSTEM 54 Removal of the carburettor 54 Vacuum operated cock 54 Removal of the fuel gauge 52 POWER UNIT 55 Removal of the power unit 55 ...

Страница 6: ...and appropriate 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 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 recycli...

Страница 7: ...cle 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 parts to be asse...

Страница 8: ... 3 1 Nm at 6500 rpm 9 Nm at 6000 rpm 10 6 Nm at 6000 rpm Compression 9 5 bars at 550 rpm 7 bars Minimum 11 8 bars at 380 rpm 7 bars Minimum Lubrication Trochoid pump driven by a chain from the crankshaft Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Exhaust Catalytic Spark plug NGK CR6HSA Electrode gap 0 7 0 8 mm NGK CR7HSA Electrode gap 0 7 0 8 mm Magneto flywhee...

Страница 9: ...r suspension Combined spring and hydraulically damped shock absorber Travel 80 mm Combined spring and hydraulically damped shock absorber Travel 75 mm Overall length 2000 mm Width at handlebar 690 mm Height without rear view mirrors 1125 mm Wheelbase 1330 mm Unladen weight 97 kg 106 kg Front wheel rim 16 inch aluminium alloy Front tyre 90 80 16 Front tyre pressure 1 75 bars Rear wheel rim 16 inch ...

Страница 10: ...mm Mini thickness 3 5 mm Front caliper Floating calliper equipped with 2 pistons Rear brake cable controlled single cam drum type Single disc type hydraulic control Drum diameter 130 mm Disc diameter and thickness 226 mm 4 mm Mini thickness 3 5 mm Rear caliper Fixed calliper with 2 pistons Chassis markings Engine marking 1 The VIN number and the manufacturer s plate are under the seat 2 Engine num...

Страница 11: ... C C C C Throttle cable play V V V V V V Operation of electrical equipment V V V V V V Condition of front and rear brake hydraulic controls b b Depending on model V V V V V V Brake fluid level b V V V V V V Brake pad wear C C C C C C Rear brake lining wear b C C C C C C Condition of petrol pipes C C C C C C Tyre condition pressure and wear C C C C C C State of front suspension State of rear suspen...

Страница 12: ...ne oil clean strainer R R R R R R Relay box oil R R R R R Fork oil R Petrol pipe R Once every 5 years Brake fluid R Once every 2 years V Check clean adjust R Change G Check clean lubricate C Inspect and change if necessary N Clean After 20000 km resume the service schedule again from 5000 km Code 9000 9100 9150 9300 9400 9500 9600 Normal servicing in km 0 500 2000 5000 10000 15000 20000 Extensive ...

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: ...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 cool for a...

Страница 15: ...r 10 Nm Automatic tensioner plug 8 Nm Chains guide 10 Nm Inlet manifold 10 Nm Cylinder casings 12 Nm RH casing cover 12 Nm Freewheel 90 Nm Oil pump 10 Nm Transmission cover 10 Nm Relay box cover 22 Nm Relay box drain plug 10 Nm Starter motor 10 Nm Rotor 45 Nm Turbine 10 Nm Stator 10 Nm Engine speed sensor 10 Nm Drive pulley 55 Nm Driven pulley 55 Nm Clutch plate and shoes 55 Nm Front mudguard 8 to...

Страница 16: ...Shock absorber top mount 40 Nm Shock absorber bottom mount 28 Nm Exhaust to cylinder head mounting nut 15 Nm Exhaust to casing mounting bolt 30 Nm Adjustment cone Hand tightened Steering locknut 20 Nm Front brake caliper 30 Nm Front brake disc 40 Nm Rear brake caliper 30 Nm Rear brake disc 40 Nm Handle bar 45 Nm Nut and bolt 5 mm diameter 5 Nm Nut and bolt 6 mm diameter 10 Nm Nut and bolt 8 mm dia...

Страница 17: ...ol N Designation Used with Tool N Designation Used w ith 752127 Clutch compression tool 50 cc 756057 Fork seal push tool 752237 Adjustable pin wrench 758008 Clutch compression tool 125 151 cc 801682 752361 39 mm pipe wrench 759788 Steeing head cup push tool 755039 Steeing head cup push tool 801682 Spacer adaptor 758008 755996 Hose clamp ...

Страница 18: ...end fittings for valve clearance adjustment Type Marolotest P N 500140 Set of shims Slide calipers Multimeter Automatic resetting type torque wrench 5 to 25 Nm Type Facom R 306A25 Automatic resetting type torque wrench 40 to 200 Nm Type Facom S 208A200 Automatic resetting type torque wrench 10 to 50 Nm Type Facom J 208A50 OFF VDC VAC Ω 20 m 200 m DC 10A VΩ COM mA Ω ...

Страница 19: ...of Peugeot Motocycles LOCATION OF COMPONENTS 1 Instrument panel 2 CDI unit 3 Battery 4 Fuses 5 HT coil 6 Magneto flywheel 7 Starter motor relay 8 Regulator 9 Starter resistor 10 Fuel gauge 11 Opening the saddle 12 Horn 13 Flasher unit UP PE R LE VE L LO W ER LE VE L 12 8 1 10 11 3 4 2 7 5 9 13 6 ODO TRIP TIME ...

Страница 20: ...Rearview mirrors 2 Handlebar front fairing 3 Handlebar rear fairing 4 Front wheel 5 Fork tube 6 Front mudguard 7 Legshield top panel 8 Front lower legshields 9 Mudguard 10 Bottom panel 11 Central bottom panel 12 Rear shield 13 Floor panel 14 Battery access door 15 Rear panels Mudflap 16 Saddle and storage compartment 17 Grab handle 17 2 1 11 13 15 7 9 8 16 6 5 4 12 3 10 14 ...

Страница 21: ...bar front fairing 3 Handlebar rear fairing 4 Front wheel 5 Fork tube 6 Front mudguard 7 Legshield top panel 8 Front lower legshields 9 Mudguard 10 Bottom panel 11 Central bottom panel 12 Rear shield 13 Floor panel 14 Battery access door 15 Rear panels Mudflap 16 Saddle and storage compartment 17 Grab handle This item may be removed on its own 2 3 15 11 7 8 13 14 6 5 4 1 9 12 17 10 16 ...

Страница 22: ...orage compartment Range 1 Lift the saddle Remove the storage compartment 1 plastic screw A 4 screw Ø6 mm B Disconnect the cutout switch Removal of the rear cover assembly Range 2 Remove the storage compartment See Range 1 page 20 Remove the grab handle 3 screw Ø8 mm A Remove the battery access door 5 plastic screws B B B A A A A B B B B ...

Страница 23: ...mbly 3 screw Ø6 mm C 6 plastic screws D Disconnect the taillight Removal of the front top shield panel Range 3 Remove the front upper shield panel 4 plastic screws A Removal of the front lower shield pannel Range 4 Remove the front upper shield panel See Range 3 page 21 Remove the RH and LH under body panel 4 screw Ø6 mm A C D D C D A A A A A A ...

Страница 24: ...emove the front lower shield panel 4 plastic screws C 1 Screw Ø6 mm D Disconnect the direction indicators Removal of the rear shield panel Range 5 Remove the front lower shield panel See Range 4 page 21 Remove the ingnition switch trim Remove the utility hanger 1 Remove the rear shield panel 2 plastic screws A D C C B I G N I T I O N P U S H O F F ON LOCK A 1 ...

Страница 25: ...ard 4 washer head screws Ø6 mm A Removal of handlebar fairing Range 7 Remove the rearview mirrors Remove the handlebar front cover 4 plastic screws A 1 Screw Ø6 mm Under the headlight B Disconnect the lighting Remove the front upper shield panel See Range 3 page 21 Disconnect the speedometer cable 1 Disconnect The main harness 2 The brake light switches 3 The horn 2 The flasher unit 2 Remove the h...

Страница 26: ...Wear gloves in order not to get burnt Place the vehicle on its central stand on flat ground Remove the engine s oil filler cap Remove the drainage cap and its seal 1 and allow the oil to drip into a recipient Tightening torque 20 Nm Replace the copper seal every time you change oil Remove the strainer cap 2 and clean the strainer 3 Tightening torque 15 Nm Every time oil is changed the filter 3 mus...

Страница 27: ... Remove the filler cap gauge and check the oil level A Oil level low B Oil level high Add oil if necessary Check the level with the machine parked on its centre stand on level ground Draining the relay box The gearbox must be drained when the engine is warm so that the oil will run easier Wear gloves in order not to get burnt Place the vehicle on its central stand on flat ground Remove the relay b...

Страница 28: ...placing the air filter Remove the air filter cover 9 bolts and its seal Remove the air filter 1 3 screw Clean inside the air filter box Clean the oil vapour return filter 2 Reassembly Fit a new air filter Fit the gasket Install the air filter cover Remove the oil vapour return drain plug to let humidity and oil drip out 3 1 2 3 ...

Страница 29: ...n the spark plug a few turns by hand Idle setting The engine must be at its operating temperature Switch off the engine Check the operating clearance in the throttle Remove the rubber plug Start the engine Screw or unscrew the engine speed adjuster screw 1 to alter the idle speed Idle speed 50 cc 2000 to 2200 rpm 125 151 cc 1700 to 1900 rpm Transmission Lift the air filter box to reach the transmi...

Страница 30: ...ixed flange Tightening torque 55 Nm Pull the belt aside 1 Remove the plastic spacer 50 cc Remove the drive pulley 2 together with the guide hud 3 Removal of the driven pulley Lock the clutch drum 1 with the pin wrench P N 752237 Remove the nut and the washer Remove the clutch drum the clutch drive pulley and driven pulley assembly and belt Make a note of the direction of rotation of the belt Tight...

Страница 31: ...ust be changed if they show major signs of wear The guides shall be replaced if they show signs of wear Checking the drive belt Measure the width of the belt A Minimum width 50 cc 17 2 mm 125 151 cc 17 5 mm Make sure the belt is not cracked 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 fl...

Страница 32: ...inings Mini thickness 2 mm Removal of the clutch lining assembly 50 cc 125 151 cc Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 Remove nut 1 using spanner P N 752361 Slacken tool P N 752127 Compress the clutch and driven pulley assembly using tool 758008 equipped with the protection spacer P N 801682 Remove nut 1 using spanner P N 752361 Slacken tool P N 7580...

Страница 33: ...ngs 10 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 50 cc 125 151 cc Compress the clutch drive pulley and driven pulley assembly with the tool P N 752127 Compress the clutch and driven pulley assembly using tool 758008 equipped with the protection spacer P N 801682 Tighten the nut 1 Tight...

Страница 34: ...earance adjustment covers 1 Tightening torque 15 N When re installing use a new gasket Disconnect the oil vapour return hose to the rocker cover Remove the pneumatic valve 2 Remove the rocker cover 4 screws and 2 nuts Tightening torque 10 Nm When re installing use a new gasket Remove the turbine on the the flywheel magneto side 4 screw Turn the magnetic wheel to line up the T mark with the the cra...

Страница 35: ... 02 mm at the exhaust If the clearance is not correct adjust by means of the cam follower screw Use a wrench to adjust the valve clearance Type Marolotest P N 500140 Checking the valve clearance At the intake a 0 10 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 At the intake a 0 15 mm feeler gauge shoul...

Страница 36: ...down to the minimum dimensions A the 2 brake pads must be changed A Mini thickness 1 5 mm Rear brake Remove the plastic cover 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 Front brake Loosen the brake pad pin first 1 Remove the calliper 2 screw Tightening torque 30 Nm A 1 5mm A 1 5mm 1 ...

Страница 37: ...l the way into their housing After refitting actuate the brake levers several times to bring the brake pads against the brake disc Rear brake 125 151 cc Remove the plastic cover 1 Remove the brake pad stop pin 2 Remove the brake pads When refitting the brake pads push the pistons all the way into their housing After refitting actuate the brake levers several times to bring the brake pads against t...

Страница 38: ...phragm from the master cylinder 2 screw Add brake fluid until it reaches the maximum level Rear brake linings 50 cc Actuate the brake control lever and check the position of the wear mark 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 Disconnect the ...

Страница 39: ...g use a new nut Remove the brake linings 3 Remove the adjusting nut the barrel 4 and the brake control cable 5 Remove the brake arm 6 the brake cam 7 and the spring Reassembly Lubricate the brake cam spindle and fit it into the casing Fit the brake arm 6 by aligning it with the brake cam axis 7 Tightening torque 6 Nm Slightly lubricate the brake cam and pin Install the brake linings Install the sp...

Страница 40: ...ake control free travel 10 to 20 mm Refit the other items in the reverse order to disassembly Removal of the fuel filter Remove the storage compartment See Range 1 page 20 Clamp the end of the fuel inlet pipe using a clip ref 755996 Disconnect the fuel supply hose Remove the fuel filter 1 When re installing respect the direction of installation of the filter shown by the arrow which indicates in w...

Страница 41: ...move the fork tubes See chapter Changing the front fork seals page 41 Immobilise the tube in a vice fitted with protection Push the fork tube cap B to remove the retaining spring clip 2 Remove the fork tube cap 1 Remove the spring 3 Turn the fork tube upside down to drain the oil into a recipient Pour 0 1 l SAE10W hydraulic oil into the fork tube 1 2 3 ...

Страница 42: ...TIONS 40 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Install the spring 3 Install the cap Push the fork tube cap to install the retaining spring clip 1 2 3 ...

Страница 43: ...rom the fork tube 2 screw Remove the wheel spindle A Remove the front wheel Unscrew and remove the 2 upper screws B from the fork Tee Unscrew the 2 lower screws C from the fork Tee Remove the fork tubes Drain the front fork See chapter Draining the front fork page 39 Remove the tightening screw from the internal tube and its seal 4 If necessary use a mallet to dislodge the screws Separate the fork...

Страница 44: ...sion stop spring 8 Remove from the fork sleeve The dust cover 9 The retaining clip 10 The seal 11 The fork and its components 1 Retaining spring clip 2 Fork tube cap 3 Spring 4 Screw and copper seal 5 Hollow shaft 6 End of compression cone 7 Calibrated hydraulic tube 8 Expansion spring 9 Dust cover 10 Circlip 11 Tightness seal 12 Fork upper tube 13 Fork triple clamp 7 8 6 11 10 9 2 3 7 8 12 13 6 4...

Страница 45: ...impact marks and the tube shall be perfectly straight and clean Reassembly Fit the plain washer Fit a new lightly greased lip seal using push tool P N 756057 11 Install the retaining ring Install the dust cover Install the expansion stop spring 8 Install the calibrated hydraulic tube 7 Install the compression stop cone 6 on the calibrated hydraulic tube Fit the fork sleeve 5 to the slightly oiled ...

Страница 46: ... 3 Install the cap Install the retaining spring clip Fit the fork tubes into the fork triple clamps Fit and tighten the 4 fixing bolts B Tightening torque 28 Nm Fit 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 When re installing use a...

Страница 47: ...immobilize the machine securely Remove the front brake caliper from the fork tube Tightening torque 30 Nm Remove the front wheel Tightening torque 60 Nm When re installing use a new nut Remove the handlebars from the fork tube 1 screw and 1 nut 1 Tightening torque 45 Nm When re installing use a new nut Remove the steering locknut 1 2 Remove the adjustment cone 3 Remove the fork Remove the balls 1 ...

Страница 48: ...lso be changed Using a drift remove the steering head cups Using push tool P N 755039 fit a new upper cup into the steering tube Using push tool P N 759788 fit a lower cup into the steering tube Fork cone Unscrew and remove the 2 upper screws 4 from the fork Tee Unscrew the 2 lower screws 5 from the fork Tee Remove the fork tubes Remove the front mudguard 3 screw Using a drift remove the steering ...

Страница 49: ...stall the adjustment cone Steering system tightening method Screw the adjustment cone until it comes into contact with the balls Tighten the adjustment cone by 2 8 to 3 8 of a turn Do not tighten the adjustment cone beyond the recommended value to avoid damaging the steering bearings Install and tighten the locknut without altering the adjustment Tightening torque 20 Nm Check that there is no play...

Страница 50: ...neto flywheel b Ignition sensor 4 Ignition switch 5 HT coil 6 Resistive spark plug and suppressor 7 Emergency stop switch 8 Circuit breaker Storage compartment 9 Starter motor switch 10 Starter motor relay 11 Stop light switch 12 Stop tail bulb OFF ON R OFF ON 9 7 4 8 1 5 6 2 3 b 10 11 12 UP PE R LE VE L LO W ER LE VE L VE VE VE JN BA VE VE VE NR JN BE JN BE JN BE JN NR RG JN RG NR 15A 10A RG JN V...

Страница 51: ... colours Standard values Ground A Green To the ground R 0 High voltage primary coil A Yellow black To the ground R 0 2 20 Ignition sensor Circuit breaker ON position A Yellow blue To the ground R 115 20 Battery positive power Ignition switch ON position Emergency stop switch ON position B Red black To the ground U 12V Battery voltage Battery positive power Ignition switch OFF position Emergency st...

Страница 52: ... unit 2 Magneto flywheel a Ignition b Ignition sensor 3 Ignition switch 4 HT coil 5 Resistive spark plug and suppressor 6 Emergency stop switch 7 Circuit breaker Storage compartment 8 Starter motor switch 9 Starter motor relay 10 Stop light switch 11 Stop tail bulb OFF ON R OFF ON 8 6 3 7 4 5 1 2 b a 9 10 11 AC VE VE VE VE JN BA VE VE RG NR BA NR JN BE JN BE RG NR JN NR RG JN ...

Страница 53: ... A Yellow black To the ground R 0 2 20 Ignition sensor Circuit breaker ON position A Yellow blue To the ground R 145 20 Low voltage coil B Red black To the ground R 600 20 Ignition switch Ignition switch OFF position Emergency stop switch ON position B White black To the ground R 0 Ignition switch ON position Emergency stop switch ON position B R f Emergency stop switch Emergency stop switch OFF p...

Страница 54: ...tery Remove Regulator 1 The starter resistor 2 Removal of the starter motor relay Remove the rear cover assembly See Range 2 page 20 Disconnect the battery Disconnect and remove the starter motor relay 1 Removal of the fuel gauge Remove the storage compartment See Range 1 page 20 Disconnect the fuel gauge Unscrew the fuel gauge locking plate 1 Remove the fuel gauge Remove the rubber gasket When re...

Страница 55: ...ELECTRICITY 53 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Check A Full fuel tank 8 20 B Empty fuel tank 95 20 Ω A B ...

Страница 56: ...ge compartment See Range 1 page 20 Disconnect The throttle control 1 The fuel inlet pipe 2 Disconnect the electric choke Loosen the collars Remove the carburettor Reassembly Fit the carburettor by making sure its pin is correctly positioned A in the recess B provided in the intake pipe Vacuum operated cock Drain the fuel tank Disconnect the vacuum hose taking note of its location 1 Disconnect the ...

Страница 57: ...the cylinder head cylinder and piston see the workshop manual 50 cc engine 2 valves SYM 125 151 cc engine 2 valves SYM Remove the rear cover assembly See Range 2 page 20 Disconnect and remove the battery 50 cc 125 151 cc Disconnect The magneto A The choke A The starter motor A The suppressor Disconnect The magneto A The choke A The power supply wire from the starter to the relay B The suppressor D...

Страница 58: ...Peugeot Motocycles 50 cc 125 151 cc Remove the air inlet 1 screw Disconnect The throttle control 2 The fuel inlet pipe 3 The vacuum pressure hose 4 Disconnect the pipe from the pulsair reed valve 5 Remove the exhaust assembly 3 screws and 2 nuts Remove the exhaust assembly 4 screws and 2 nuts 2 4 3 5 ...

Страница 59: ... cc 125 151 cc Disconnect the rear brake control cable 6 Disconnect the transmisson cooling air intake 6 Remove the 2 air filter box fixing bolts 7 Remove the rear brake caliper 2 screw Tightening torque 30 Nm Suspend the rear of the machine Remove the shock absorber lower mounts 8 Tightening torque 28 Nm 6 14 6 7 8 14 8 ...

Страница 60: ...he transmisson cooling air intake 9 Remove the linkrod to engine connecting pin 10 Tightening torque 60 Nm Remove the linkrod to engine connecting pin 9 Tightening torque 60 Nm When re installing use a new nut Lift the rear of the machine Remove the power propulsion unit from the frame Remove the covers from the power unit 10 9 9 ...

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Страница 64: ... Peugeot Motocycles is constantly improving its vehicles It therefore reserves the right to remove modify or add any reference mentioned in this manual DC PS APV Printed in the E U 04 2010 non contractual pictures ...

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