Sign in today to find solutions:

Forgot your password?

Don't have an account? Sign up

 
Sales division
Technical network leadership
WORKSHOP MANUAL

Summary of Contents

  • 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: Table Of Contents

    Removal of the central cover panel......................15 Removal of the lower side fairings......................16 Removal of the side fairings........................16 Removal of the footboard.........................16 Removal of the taillignt..........................17 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 4: Table Of Contents

    Removal of the calliper..........................30 Removal of the brake pads........................30 Removal of the fork..........................31 Replacing the bearings of the steering system..................31 Steering system tightening method......................32 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 5: Characteristics, Engine, Capacities

    Euro 2. Capacities. Fuel tank. 6.3 l. Engine oil. 0.8 l. Relay box. 0.12 l. Fork. 87cc by tube Esso Univis 46 or Agip H Lift 46. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 6: Chassis, Dimensions And Weight, Tyres

    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 pressure. 1.75 bars. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 7: Brakes

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

  • Page 8: Service Schedule And Commissioning, Check, Change, Check And Lubricate, Test Machine

    * Depending on equipment R : Change # Change if necessary G : Check and lubricate ## Or once every 5 years Battery preparation (Except battery without maintenance)*. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Checks Before Handing Over To The Customer

    Check the tyre pressures cold. Check operation of the lights, flashers, horn, and brake light. Check the different warning lights work. Carry out a road test. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Special Important Points, Oil And Fuel, Starting Up After Overhauling The Engine

    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 not accelerate. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 11: Tightening Torques, Engine Part, Body Panels

    1 m.daN Floor panel. 1 m.daN Saddle storage compartment. 1 m.daN Rear panels. 0.2 à 0.4 m.daN Grab handle. 2.5 m.daN Rear mudguard. 0.8 à 1 m.daN Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 12: Cycle Part, Standard

    0.9 m.daN Nut and bolt 8 mm diameter. 1.2 m.daN Nut and bolt 10 mm diameter. 2.6 m.daN Nut and bolt 12 mm diameter. 3.9 m.daN Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 13: Instrument Panel, Analog Functions (hands)

    Fuel gauge. When a flasher bulb has failed the repeater light and the other flasher light flash more quickly to alert the rider of a failure. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 14: Electricity, Fuses And Energy Distribution, Location Of Components

    2. Ignition sensor. 7. Starter motor relay. 3. Ignition unit. 8. Horn. 4. Oil level indicator. 9. 10 A fuse. 5. HT coil. 10. Kickstand switch. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Body Panels, Location Of Body Components

    5. Mudflap. 13. Handlebar rear fairing. 6. Side panels. 14. Rear shield. 7. Lower side fairings. 15. Floor panel. 8. Bottom panel. 16. Battery access door. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Body Component Sequence Of Disassembly

    BODY PANELS Body component sequence of disassembly. *This item may be removed on its own. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Removal Of The Storage Compartment, Removal Of The Grab Handle

    - Removal of the storage compartment (see procedure 1). - Remove the footboard mat (1). - Remove the 4 fixing bolts (2). - Remove the central cover panel (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Removal Of The Lower Side Fairings, Removal Of The Side Fairings, Removal Of The Footboard

    - Remove the side fairings (see procedure 5). - Remove the footboard mat. - Remove the 4 fixing bolts. - Remove the battery access door (1). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Removal Of The Taillignt, Removal Of The Splash Guard

    - Removal of the side fairings (see procedure 5). - Disconnect the taillight. - Remove the 2 nuts (1). - Remove the 2 bolts (2). - Remove the taillight. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Removal Of The Front Top Cover Panel

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

  • Page 21: Removal Of The Front Mudguard, Removal Of The Front Shield Panel

    - Removal of the front top cover panel (see procedure 7). - Removal of the front mudguard (see procedure 8). - Remove the 6 fixing bolts. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Removal Of The Rear Shield Panel, Removal Of The Under Body Panel

    - Open the front shield panel. - Remove the 3 nuts and the screw of the underbody panel. - Remove the bottom panel (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 23: Removal Of A Headlight Bulb, Removal Of A Taillight Bulb

    - Remove the 2 screws that secure the taillight lens (2). - Disconnect the bulb. - Remove the taillight lens ans turnsignal light lenses. - Remove the bulb. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Removal Of A Turnsignal Light

    - Open the front shield panel. - Remove the 3 screws that secure the front turnsignal light. - Remove the front turnsignal light. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Removal Of The Air Filter Foam, Removal Of The Transmission Filter

    - Change if necessary. Removal of the fuel filter. - Removal of the storage compartment (see procedure 1). - Removal of the fuel filter (1). - Change if necessary. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 26: Removal Of The Pulsair Filter, Removal Of The Pulsair Reed Valve

    - Loosen the collars (1). - Disconnect the fuel supply hose (2). - Pull the throttle control cable (3) out of the carburettor. - Disconnect the electric choke (4). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Installing The Valve Clearance, Removal Of The Exhaust System

    - Remove the 2 fixing bolts (2). - Remove the exhaust. - Removal of the gasket. Tightening torque: Screw 1: 1.5 m.daN. Screw 2: 2.3 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Removal Of The Cylinder Head, Removal Of The Cylinder / Piston

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

  • Page 29: Removal Of The Engine, Removal Of The Battery, Removal Of The Starter Motor Relay

    Removal of the ignition module (CDI). Removal of the fuse. - Remove the footboard mat. - Remove the 4 fixing bolts. - Remove the battery access door. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Removal Of The Regulator, Removal Of The Choke Resistor, Removal Of The Horn

    - Remove the lower LH side fairing (see procedure 4). - Disconnect the kickstand contact switch. - Remove the 2 fixing bolts (1). - Remove the lickstand cinstact switch. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Removal Of The Fuel Gauge, Removal Of The Tank, Removal Of The Front Wheel

    (1). - Remove the wheel spindle nut. - Remove the wheel. - Remove the spacer. - Remove the speedometer driver (2). Tightening torque: 5.3 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Removal Of The Rear Wheel, Removal Of The Calliper, Removal Of The Brake Pads

    - Pivot the calliper relative to the yoke. - Remove the calliper yoke. Note: If the caliper is to be changed, the hydraulic control must be slackened off before removal. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Removal Of The Fork, Replacing The Bearings Of The Steering System

    - Remove the handlebars from the fork tube. - Remove the steering locknut (1) (1). - Remove: The lock washer (2). the adjustable cone (3). - Remove the fork. - Remove the balls. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 34: Steering System Tightening Method

    - Loosen and then retighten the adjustable cone. - Fit the lock washer (4). - Install the steering head locknut and tighten it (5). Tightening torque: 3 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 38

    P/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).

Comments to this Manuals

Symbols: 0

Latest comments:

  • a snels Jun 18, 2013 05:21:
    Thanks voor donwload this document
×

Select the desired size and copy embed code

Copy your embed code and put on your site: