PEUGEOT TSDI Workshop Manual
PEUGEOT TSDI Workshop Manual

PEUGEOT TSDI Workshop Manual

50 cc injection engine
Table of Contents

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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
50 cc INJECTION
ENGINE

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Table of Contents
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Summary of Contents for PEUGEOT TSDI

  • Page 1 SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL 50 cc INJECTION ENGINE...
  • Page 2: Table Of Contents

    To remove/refit the drive pulley rollers ....................... 28 To remove the clutch lining assembly......................29 To refit the clutch lining assembly ....................... 29 To remove the fuel tank..........................30 Page: 2 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 3 To remove the HT coil ..........................40 Setting the spark plug electrode gap......................40 To remove the oil pump ..........................41 Parameter reading ..........................42 Page: 3 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 4: Characteristics

    Throttle unit Bing 235 011 Temperature Synerject sensor Oil pump Mikuni ESOP-03 Spark plug NGK CPR8E Magneto Mitsuba 180W flywheel Starter motor Mitsuba 150 W Page: 4 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 5: Special Important Points

    Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a clear and well-ventilated area. Page: 5 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 6: Tightening Torques

    1 m.daN Turbine 1 m.daN Drive pulley 4 m.daN Driven pulley 4.5 m.daN Spark plug 1 m.dan Compressor 0.65 m.daN Injection rail 0.65 m.daN Page: 6 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 7: Special Tools

    64754 753977 Torque wrench 30 extension 69117 Exterior circlip Nm to 54Nm 752235 pliers adapter 752237 750069 Stud Ø10 pitch 69104 754086 Steering tool Page: 7 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 8 (Color Gameboy) 756056 Tank ring spanner 755982 Engine support 64765 adapter 756057 Crank assembly lip seal tool 755983 Casing opening 64706 tool Page: 8 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 9: Introduction

    - Remove the shock absorber lower mount and the engine linkrod fixing bolt - Remove the power unit - Remove the rear wheel - Remove the stand with its bracket Page: 9 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 10: Putting The Engine On The Stand

    - Remove the 4 bolts (8) from the cooling volute and the cylinder cover - Remove the 2 parts (9) the cooling volute and the cylinder cover Page: 10 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 11: To Remove The Magneto Flywheel

    - Tighten flywheel extractor P/N 755985 on the rotor - Lock the flywheel extractor and turn the thrust bolt until the rotor is released Page: 11 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 12: To Remove The Stator And Sensor Assembly

    - Lock the fixed flange (2) with tool P/N 755874 - Remove the fixed flange nut (1) - Remove the fixed flange - Remove the starter dog (3) Page: 12 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 13: To Remove The Driven Pulley

    Note: use a container to catch the transfer box oil when the cover is removed - Remove the cover (2) six fixing bolts (1) - Remove the cover with the primary shaft Page: 13 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 14: To Remove The Secondary Transmission

    - Remove the cylinder head and its gasket - Remove the cylinder and the bottom seal Note: do not remove the air injector if this is not necessary Page: 14 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 15: To Remove The Air Injector

    - Remove the circlips (1) with pliers P/N 752000 - Remove the gudgeon pin - Remove the piston (2) - Remove the needle bearing race from the connecting rod end Page: 15 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 16: To Remove The Inlet Manifold And Valve

    - Check that the valve assembly blades and support are in perfect condition Note: the position of the limiter must be 3 mm from the valve support Page: 16 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 17: Opening The Casings

    - Tighten the tool centre screw until the casings separate - Remove the RH casing - Remove the paper gasket (3) and the 2 locating dowels (4) Page: 17 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 18: To Remove The Crankshaft

    (the plate opening facing the cylinder side) - Tighten the tool centre screw holding the crank with one hand on the other side until it is fully extracted Page: 18 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 19: Checking The Crank

    1/10 mm and must be measured: - 25 mm from the transmission side end - 40 mm from the magneto flywheel end Page: 19 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 20: Refitting Specific Components

    - the seal on the drive pulley side 3 mm from the outer edge of the casing - the seal on the magneto flywheel side 6 mm from the outer edge of the casing Page: 20 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 21: Assembling The Casings

    - Fit the two locating dowels (2) and a new paper gasket (3) with no oil or grease to the LH casing Page: 21 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 22 - Check the crank turns freely in the casings - Cut the casing seal flush at (A) - Grease the crank and bearings with 2-stroke oil Page: 22 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 23: To Fit The Piston

    Imperative: the circlips must be renewed each time they are removed The circlip gaps must face upwards or downwards, but under no circumstances to the side (2) Page: 23 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 24: To Fit The Cylinder

    Important: if one or more bolts are changed, genuine original parts must be used Their design guarantees a constant tightening torque whatever the cylinder/piston assembly temperature Page: 24 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 25: To Fit The Magneto Flywheel

    To remove the cooling system - Fit the cooling turbine and its 3 bolts - Fit the volute and cylinder cover (1) with the 4 bolts (2) Page: 25 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 26: To Fit The Injection Manifold And Compressor

    Any modifications may cause the nut to tighten against the crank splines instead of the fixed flange and damage the crank splines Page: 26 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 27: Miscellaneous Operations

    - Set the quadrant at around 1/8 turn in order to be able to fit the kick start drive gear - Fit the kick start drive gear pin (6) in the cover housing (D) Page: 27 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 28: To Remove/Refit The Drive Pulley Rollers

    To re-assemble, proceed in reverse order to disassembly after lightly greasing the rollers and rotating flange inside (high temperature grease) Note: Do not over-grease to avoid splashing the belt Page: 28 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 29: To Remove The Clutch Lining Assembly

    - Fit and tighten the nut to the recommended torque - Fit the cover with its locating pin - Fit the cover 8 fixing bolts Page: 29 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 30: To Remove The Fuel Tank

    Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a well ventilate area Page: 30 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 31: Procedure Used To Lower The Pressure In The Fuel System Instruction 1

    Page: 31 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 32: Fuel Circuit Bleeding Procedure Instruction 2

    (the O-ring must be renewed each time it is removed) Re-assembly: Proceed in reverse order to disassembly and bleed the fuel system (see instruction 2) Page: 32 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 33: To Remove The Air Injector

    Re-assembly: Re-assemble in the reverse order to dismantling Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page: 33 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 34: To Remove The Air Compressor

    Re-assembly: Re-assemble in the reverse order to dismantling Note: The compressor O-ring must be renewed each time it is removed and refitted lightly greased Page: 34 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 35: To Remove The Throttle Unit

    - Disconnect the accelerator cable (2) - Cut the plastic tie (8) holding the throttle unit to the air filter box - Remove the throttle unit (6) Page: 35 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 36 (refer to the documentation "Using the Diagnostic Tool for the Injection Engine) Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page: 36 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 37: To Remove The Fuel Pump

    (if changed, these clips must not be replaced by screw-type clips) Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page: 37 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 38: To Remove The Strainer

    - Tighten the fuel gauge with the ring spanner P/N 756056 in order to line up the arrow with the centring mark on the tank Page: 38 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 39: To Remove The Ecu

    Re-assembly: Re-assemble in the reverse order to dismantling Check: Connect the diagnostic tool and check there are no fault codes, erase them if necessary Page: 39 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 40: To Remove The Ht Coil

    If one of these values cannot be obtained, the plug must be changed Page: 40 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 41: To Remove The Oil Pump

    (see documentation Use of the Diagnostic Tool for the Injection Engine) Check: Connect the diagnostic tool and check there are no fault codes, erase them if necessary Page: 41 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 42: Parameter Reading

    Temperature sensor 3 to 4.20 volts 4.10 to 5 volts Petrol pump Oil pump Immobiliser Unlock Unlock ECU locking Unlock Unlock Photocopy and send to Peugeot Motocycles in case of problem requiring help from our network training department Page: 42...
  • Page 43 RECOMMENDS REF: 756012 With a constant concern for improvement Peugeot Motocycles reserves the right to delete, modify, or add any quoted reference DC/PS/ATR printed in E.U. 02/2002 (photos non-contractual) Page: 43 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

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