PEUGEOT Django 125 Workshop Manual
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PEUGEOT Django 125 Workshop Manual

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Q uality department
After-Sales
WORKSHOP MANUAL
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Summary of Contents for PEUGEOT Django 125

  • Page 1 Q uality department After-Sales WORKSHOP MANUAL...

  • Page 2: Table Of Contents

    Remove the central fairing under the saddle ................... 21 Removal of the central cover panel......................21 Removal of a lower RH or LH side fairing ....................21 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 3 Checking the valve clearance ........................46 Changing the fuel filter ..........................46 Integral braking ............................47 Brake pad wear ............................47 Front brake ................................47 Rear brake................................. 48 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 4 Checking the indicators..........................77 Checking the red light, the stop light and the side light ................77 POWER UNIT ..............................78 Removal of the power unit ........................78 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 5: Products Danger Symbols Used

    Example: Used batteries. collection point. People's safety can be seriously affected if Compulsory Operation that can be the recommendations are not fully gloves dangerous for people. respected. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 6 Indicate the specific procedures that shall New part Use a new part. be followed in order not to damage the vehicle. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 7: Characteristics

    0.18 L SAE 80W90 (0.17 L at oïl change) Relay box Minimum grade: API GL4 8.5 L Fuel tank Unleaded 95 or 98 Fork oil 0.092 L per tube SAE 10W. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 8: Chassis

    Front tyre 120/70 - 12 Front tyre pressure 1.8 bars Rear wheel rim 3"x12 inch aluminium alloy Rear tyre 120/70 - 12 Rear tyre pressure 2 bars Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 9: Brakes

    Floating caliper equipped with one Rear caliper Fixed calliper with 2 pistons piston Chassis markings 1. VIN number 2. Manufacturer's plate Engine marking 3. Engine number Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 10: Service Schedule And Commissioning

    After 20000 km, resume the service schedule again from 5000 km. a.Perform these maintenance operations if the vehicle is used in severe conditions: areas that are damp, dusty, or have high températures, urban use only, etc Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 11: Battery Preparation

    - Leave the battery to stand for around half an hour. Never remove the battery's strip of caps, and never add water or electrolyte into the battery. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 12: Installing The Battery

    The battery must not be disconnected while the engine is running and the voltage must be at least 8.5 volts for the ECU to function and enable engine starting. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 13: Special Important Points

    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 at least 2 hours. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 14: Tightening Torques

    Floor panel 8 to 10 Nm Saddle storage compartment 8 to 10 Nm Rear body panels 1 to 2 Nm Grab handle 20 to 25 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 15: Cycle Part

    10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm Nut and bolt 12 mm diameter 55 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 16: Special Tools

    752361 casing seal 758008 compression 801682 drift tool Steeing head Spacer 759788 801682 758008 cup push tool adaptor 755996 Hose clamp (*) New or modified tool Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 17: Standard Tools

    40 to 200 Nm VΩ Type: Facom S.208A200 Wrenches with interchangeable end Fork seal insertion kit fittings for valve Type: Marolotest 601055 clearance adjustment Type: Marolotest 500140 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 18: Location Of Components

    5. Temperature control unit 15.Carburetor heater 6. HT coil 16.Kickstand contact switch 7. Outside temperature sensor 17.Fuel gauge 8. Speed sensor 18.Horn 9. 12-volt plug 10. Ignition sensor Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 19: Body Panels

    6. Floor panel 16.Rear shield 7. Central panel 17.Counter panel 8. Lower side fairing 18.Headlight fairing 9. Upper side fairing 19.Sheath guide 10. Rear central fairing Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 20: Body Component Sequence Of Disassembly

    8. Lower side fairing 18.Handlebar front fairing 9. Upper side fairing 19.Sheath guide 10.Rear central fairing * * This item may be removed on its own. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 21: Removal Of The Passenger's Saddle

    • 2 plastic screws. - Disconnect and remove the battery. - Remove the fuse holders. - Remove the battery bracket. • 1 washer head screw (C). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 22: Remove The Central Fairing Under The Saddle

    - Remove the chrome trim. - 1 plastic screws (A). - Push the front of the trim away slightly and then slide it towards the front of the vehicle. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 23: Removal Of The Grab Handles

    Removal of the grab handles Procedure 7. - Remove the battery bracket. See: Procedure 3. page 20. - Remove the grab handles. • 4 Ø8 mm screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 24: Removal Of The Upper Side Fairing Assembly

    Removal of the front shield panel Procedure 9. - Unclip the front of the trim, then slide it towards the front of the vehicle. - Remove the 2 chrome trims. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 25 - Remove the front shield panel. • 4 plastic screws. - Disconnect: • The indicators. • The outside temperature probe. • The side light (depending on the model). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 26: Removal Of The Head Light Fairing

    - Lever off the 2 master cylinder covers through the rearview mirror holes. - Carefully unclip the upper part and remove the head light fairing. • 4 plastic screws. - Disconnect the lighting. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 27: Removal Of The Speedometer Fairing

    • 2 Ø8 mm screw - Remove the central fairing bracket under the saddle (2). • 2 Ø5 mm screw - Remove the 3 footboard mats (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 28: Removal Of The Rear Shield Panel

    - Remove the double-acting control plate (2). • 3 plastic screws. - Push back the locking ratchet (A) and extract the barrel from the rear shield panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 29: Removal Of A Rh Or Lh Door

    - Remove the rear shield panel. See: Procedure 13. page 27. - Remove the RH or LH under body panel. • 5 plastic screws (A). • 1 washer head screw (B). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 30: Removal Of The Front Mudguard

    - Suspend or immobilize the machine securely. - Remove the front wheel. Tightening torque :65 Nm. - Remove the front mudguard. • 4 washer head screws. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 31: Removal Of The Dirt Shield

    Procedure 16. page 28. - Remove the front mudguard. See: Procedure 17.page 29. - Remove the lower mudguards. • 4 plastic screws (A). - Remove the upper mudguards. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 32: Service Operations

    - Remove the strainer cap (3) and clean the strainer. Tightening torque:15 Nm. Every time oil is changed, the filter (4) must cleaned O-ring changed (5). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 33: Draining The Relay Box

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. • 0.18 L at oïl change. - Fit the filler cap. Tightening torque: 10 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 34: Replacing The Air Filter With Transmission Maintenance

    Replacing the air filter without transmission maintenance - Remove the storage compartment. See: Procedure 2. page 20. - Remove the 2 screws that secure the air filter. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 35: Reassembly

    - Install the air filter cover. Removal of the spark plug - The engine must be cold. - Open the saddle. - Remove the access door. • 1 screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 36: Idle Setting

    - Check the operating clearance in the throttle. - Start the engine. - Screw or unscrew the engine speed adjuster screw (1) to alter the idle speed. ±100 Idle setting: 1800 rpm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 37: Removal Of The Primary Transmission Cover

    - Remove the paper gasket. When re-installing, use a new gasket. Removal of the starter system - Remove the kickstart pedal. • 1 Ø 8 mm screws. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 38 - Remove the lock ring (3), using circlip pliers. - Remove the washer. - Remove the elastic washer. - Remove the starter gear sector (1) and the washer (4) from the drive train cover. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 39: Fitting The Starter System

    Removal of the transmission air filter - Remove the transmission air filter (1). • 1 collar. - Clean or change the filtering elment if necessary (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 40: Removal Of The Drive Pulley

    - 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. 752237 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 41: Changing The Drive Pulley Bearings

    (A). Checking the drive belt - Measure the width of the belt (A). Minimum width: 18.5 mm. - Make sure the belt is not cracked. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 42: Checking The Thickness Of The Clutch Linings

    758008 equipped with the protection spacer P/N 801682. - Remove nut (1) using spanner P/N 752361. 752361. - Slacken tool P/N 758008. 801682 758008 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 43: Refitting The Clutch Lining Assembly

    - Compress the clutch drive pulley and driven 752361 pulley assembly with the tool P/N 758008. - Tighten the nut (1). Tightening torque: 58 Nm. 801682 758008 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 44: Installing The Primary Drive

    - Fit washer. - Lock the clutch drum (1) with the pin wrench P/N 752237. - Fit and tighten the nut. Tightening torque: 58 Nm. 752237 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 45: Installing The Valve Clearance

    • 2 washer head screws Ø6 mm. • 2 Ø8 mm screw. - Remove the central fairing bracket under the saddle (2). • 2 Ø6 mm screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 46 - Using the set of feeler gauges, measure the clearance of each valve. Clearances: • 0.12±0.02 mm at the intake. • 0.12±0.02 mm at the exhaust. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 47: Checking The Valve Clearance

    - Remove the fuel filter. 755996 When re-installing, respect the direction of installation of the filter shown by the arrow which indicates in which direction the fuel flows. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 48: Integral Braking

    (A), the 2 brake pads must be changed. A. Mini. thickness: 1.5 mm. - If it shows signs of wear, change the shaft. A = 1.5mm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 49: Rear Brake

    When refitting the brake caliper, spread standard thread lock on the bolts. When changing the brake pads, it is essential to replace the brake pad attachment system (spindle, pin, clips, ...) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 50: Rear Brake

    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 the brake disc. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 51: Bleeding The Integral Circuit

    - Close the bleeder screw. Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 52 The reservoir must be kept higher than the brake calliper to easily check that the air bubbles are being expelled. - Open the bleed screw by 1 to 2 turns. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 53: Bleeding The Emergency System

    • 2 screw. - Using the syringe, empty the LH master cylinder. - Position the handlebars so that the master cylinder will be horizontal. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 54 - Close the bleeder screw. Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 55: Conventional Braking

    (A), the 2 brake pads must be changed. A. Mini. thickness: 1.5 mm. - If it shows signs of wear, change the shaft. A = 1.5mm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 56: Rear Brake

    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 the brake disc. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 57: Rear Brake

    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 the brake disc. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 58: Draining The Rear Brake Circuit

    - Inject the brake fluid slowly into the circuit until the level inside the reservoir of the master cylinder is halfway up. - Close the bleeder screw. Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 59: Draining The Front Brake Circuit

    - Inject the brake fluid slowly into the circuit until the level inside the reservoir of the master cylinder is halfway up. - Close the bleeder screw. Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 60: Checking The Brake Fluid Level

    Procedure 10. page 25. - Remove the cover and the diaphragm from the master cylinder (2 screw). Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 61: Draining The Front Fork

    - Pour 0.092 l SAE10W hydraulic oil into the fork tube. - Refit the other items in the reverse order to disassembly. - Repeat the operation with the other stanchion. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 62: Steering/Fork

    Check the condition of the O-rings (B). - Remove the spring (C). - Drain the front fork. See chapter : Draining the front fork, page 60. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 63 Gently work the tube free from the hollow shaft whose lip seal, washer and guide ring should still be in place. Operation that can be difficult. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 64 STEERING/FORK - Remove the compression stop cone (G). - Remove the dust cover (H). - Remove the retaining clip (I). - Remove the seal (J). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 65: The Fork And Its Components

    • Or use an ultrasonic cleaning tank. - Check the condition of the fork tube, there shall be no corrosion or impact marks, and the tube shall be perfectly straight and clean. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 66: Reassembly

    (LM). Tightening torque: 25 Nm. - Using the marolotest lip seal insertion kit tool, push the seal (J) under the groove in the retaining ring. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 67 - Fit and tighten the upper screws on the fork tee (1). Tightening torque: 28 Nm. - Tighten the lower screws on the fork tee (2). Tightening torque: 28 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 68: Removal Of The Fork

    - Remove the front mudguard. See: Procedure 17. page 29. - Remove the brake caliper without disconnecting Tightening torque: 30 Nm. When refitting the brake caliper, spread standard thread lock on the bolts. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 69 (1 screws and 1 nut) (1). Tightening torque: 40 Nm. When re-installing, use a new nut. - Using tool P/N 757860 remove the steering locknut. 757860 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 70: Replacing The Bearings Of The Steering System

    - Using a drift, remove the steering head cups. - Install new steering head cups using tool P/N 759788. 759788 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 71: Steering Cone

    - Grease the cup bearing races. - Install new ball cage bearings (7) (respect the right way of installation). - Fit the fork into the steering column. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 72 - Turn the fork from left to right to check that there are no tight spots. - Refit the other items in the reverse order to disassembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 73: Fuel System

    A. Full fuel tank: 10 Ω ±20% B. Empty fuel tank: 95 Ω ±20% Removal of the fuel pump - Remove the protective shoe. • 3 screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 74 - Disconnect the fuel pump: 1. The vacuum pressure hose. 755996 2. The fuel inlet pipe. 3. The carburetor fuel supply hose. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 75: Electricity

    8. Starter resistor. 3. Resistor warming carburator. 9. Automatic starter. 4. Voltage regulator. 10.Magneto flywheel. 5. Temperature control unit. 11.Battery. 6. Ignition unit. 12.7.5 A fuse Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 76: Regulator/Temperature Control Unit/Starter Motor Relay/Cdi Unit/Starter Resistor

    • Secondary: 3.7 KΩ ±20% • Spark plug socket: 5 KΩ . Low voltage coil: - The ignition sensor: Between the green/black wire and the ground: 195 Ω ±20% Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 77: Checking The Carburettor Heating Circuit

    5 Ω ±20% Ω Checking the electric starter - Removal of the electric choke. - Connect the starter to a battery. The starter piston should retract. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 78: Checking The Indicators

    - If the consumption of the side light or the rear light is correct: Check: • The main harness. • The stop light contactors. • The magneto. • The regulator. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...

  • Page 79: Power Unit

    • The engine ground (5). • The suppressor (6). - Disconnect: • The throttle control (7). • The fuel hose (8). • The vacuum pressure hose (9). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 80 When refitting the brake caliper, spread standard thread lock on the bolts. - Unclip the hydraulic control. - Temporarily reinstall the wheel. - Remove the protective shoe. • 3 screw. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 81 - Remove the shock absorber upper fixing bolt. Tightening torque: 48 Nm. • Remove the 2 connecting-rod/chassis fastening screws (2). Tightening torque: 60 Nm. Use new nuts when refitting. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 82 POWER UNIT - Remove the power propulsion unit from the frame. - Remove the covers from the power unit. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters...
  • Page 83 P/N. MA0051GB In our permanent concern to make improvements PEUGEOT Scooters reserves the right to suppress, modify, or add any reference mentioned. DQ/APV Printed in E.U. July 16, 2014. (non contractual pictures)

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