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1.34
Routine maintenance and servicing procedures
28.2 Unscrew the plug to check the oil
level
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24 Variator pulley
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and drive belt
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check
and rolle
Variator pulley and rollers
1 Referring to Chapter 2C, remove the drive
belt cover.
2 A Peugeot service tool or home made
alternative is required to remove the variator
(see Chapter 2C). Dismantle the variator and
renew any parts that are worn; if applicable,
lubricate the rollers, ramp plate and housing
with high temperature grease (Peugeot
recommend Esso SKF LGHT 3/0.4) before
reassembly. Note: The variator housing O-ring
and variator centre nut must be replaced with
a new one on reassembly.
Drive belt
3 lnspect the drive belt when checking the
variator pulley and rollers. No specifications
are available regarding belt wear limits but
signs of premature belt wear should be
investigated. Refer to Chapter 2C, Section 5
for more details.
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25 Drive
renew-.
1 The drive belt must be renewed at the
specified service interval (see Chapter 2C).
28.4 Top-up with the specified oil only
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26 Clutch pulley and bearing
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check and lubrication
1 Referring to Chapter 2C, remove the drive
belt cover. The outer half of the clutch pulley
should slide outwards on the clutch hub,
against the pressure of the clutch centre
spring.
2 Grasp the pulley assembly and check for
play in the pulley hub bearings. A Peugeot
service tool or home made alternative is
required to dismantle the clutch and pulley
assembly (see Chapter 2C). Renew any parts
that are worn and lubricate the pulley needle
bearing and the pulley guide pins with high
temperature grease (Peugeot recommend
Esso SKF LGHT 3/0.4) before reassembly.
Note: The clutch centre nut must be replaced
with a new one on reassembly.
gear
lle bush
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27 Kickstart
and spind
check
1 Referring to Chapter 2C, remove the driver
belt cover. The kickstart lever should move
smoothly and retum to the rest position under
the tension of the retum spring.
2 lnspect the component parts for damage
and wear and renew any parts as necessary
(see Chapter 2C). Lubricate the kickstart
spindle with high temperature grease
(Peugeot recommend Esso SKF LGHT 3/0.4)
before reassembly.
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28 Relay box oil level
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Note 1: Early models were fitted with a relay
box drain plug. For those models Peugeot
recommend changing the oil every 10,000 km.
For all models without a drain plug, i t is
sufficient to check the oil level at 10,000 km as
described below.
Note 2: From mid-2002 the oil level plug was
deleted from the casing
-
it is not necessary to
change the oil during the life of the scooter,
except in the event of relay box overhaul. The
level can however be checked if desired when
the drive belt cover is removed for inspection
of the belt and rollers (see Section 24); with
the cover removed the relay box oil level plug
is accessible.
1 Support the machine in an upright position
on its stand on level ground. Raise the front
wheel, if necessary, so that the rear wheel is
touching the ground.
2 Clean the area around the oil level plug on
the back of the casing, then unscrew the plug
(see illustration).
3 The oil level should come up to the plug
threads so that it is just visible on the threads.
4 If the oil is below the level of the plug
threads, add the specified grade and type of
oil to bring it up to the correct level (see
illustration). Do not overfill. Note that
Peugeot specify 120 ml of 80W-90 scooter
gear oil and specifically advise against the use
of a hypoid oil.
5 If the oil level is very low, or oil is leaking
from the relay box case, refer to Chapter 2C
and inspect the condition of the case seals
and gaskets and replace them with new ones
if necessary.
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29 Rear drum brake cam
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check and lubrication
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1 Remove the rear wheel and brake shoes,
then remove the brake arm and pull the brake
cam out of the casing (see Chapter 8).
2 Clean the shaft and cam and inspect the
bearing surfaces for wear; replace the cam
with a new one if necessary.
3 Apply some copper grease to the bearing
surfaces of the cam and the shaft before
reassembly.
Caution: Do not apply too much grease
otherwise them is a risk o f it contaminating
the brake dnrm and shoe linings.
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30 Wheels and
general check
Wheels
1 Cast wheels are virtually maintenance free,
but they should be kept clean and checked
periodically for cracks and other damage.
Also check the wheel runout and alignment
(see Chapter 8). Never attempt to repair
damaged cast wheels; they must be replaced
with new ones.
2 Wheel bearings will wear over a period of
time and result in handling problems. Support
the machine on its centre stand and check for
any play in the bearings by pushing and
pulling the wheel against the hub. Also rotate
the wheel and check that it turns smoothly.
3 If any play is detected in the hub, or if the
wheel does not rotate smoothly (and this is
not due to brake or transmission drag), the
wheel bearings must be inspected for wear or
damage (see Chapter 8).
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4 Check the tyre condition and tread depth
thoroughly
-
see Daily @re-ride) checks.
Check the valve rubber for signs of damage or
deterioration and have it replaced if
necessary. Also, make sure the valve stem
cap is in place and tight.
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