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2 B . 2
Liquid-cooled two-stroke engine
Torque settings
Alternator rotor nut
.........................................
Crankcasebolts
...........................................
Cylinder head bolts
.........................................
Drive belt cover bolts
.......................................
Enginecoverbolts
.........................................
Engine mountings
Crankcase-to-front bracket bolt
.............................
................................
Front bracket-to-frame bolt
Engine/transmission case-to-rear shock bolt
...................
.........................................
Inlet manifold bolts
Oil pump mounting bolts
....................................
.................................
Starter motor mounting bolts
General informal
The engine unit is a single cylinder two-
stroke with liquid cooling. The water pump is
driven by the alternator rotor, which is on the
right-hand end of the crankshaft. The
crankshaft assembly is pressed, incorporating
the connecting rod, with the big-end running
on the crankpin on a needle roller bearing.
The piston also runs on a needle roller bearing
fitted in the small-end of the connecting rod.
The crankshaft runs in caged ball main
bearings. The crankcase divides vertically.
*
e
, + - .
2 Operatic
engine i
Dns possi
in the
fra~
ible with
'
ne
the
All components and assemblies, with the
exception of the crankshaWconnecting rod
and its bearings, can be worked on without
having to remove the engine/transmission unit
from the frame. If however, a number of areas
require attention at the same time, removal of
the engine is recommended, as it is easy to
do so.
3 Operations requiring engine
removal
To access the crankshaft and connecting
rod and its bearings, the engine must be
removed from the Game and the crankcase
halves must be separated.
4 Major el
general
I
ngine rep
note
1 It is not always easy to determine when or if
an engine should be completely overhauled,
as a number of factors must be considered.
2 High mileage is not necessarily an
indication that an overhaul is needed, while
low mileage, on the other hand, does not
preclude the need for an overhaul. Frequency
of servicing is probably the single most
important consideration. An engine that has
regular and frequent maintenance will most
likely give many miles of reliable service.
Conversely, a neglected engine, or one which
has not been run in properly, may require an
overhaul very early in its life.
3 If the engine is making obvious knocking or
rumbling noises, the connecting rod and/or
main bearings are probably at fault.
4 Loss of power, rough running, excessive
noise and high fuel consumption rates may
also point to the need for an overhaul,
especially if they are all present at the same
time. If a complete tune-up does not remedy
the situation, major mechanical work is the
only solution.
5 An engine overhaul generally involves
restoring
the
internal
parts
to
the
specifications of a new engine. This may
require fitting new piston rings and crankcase
seals, or, after a high mileage, renewing the
crankshaft and connecting rod assembly. The
end result should be a like-new engine that
will give as many trouble-free miles as the
original.
6 Before beginning the engine overhaul, read
through the related procedures to familiarise
yourself with the scope and requirements of
the job. Overhauling an engine is not all that
difficult, but it is time consuming. Check on
the availability of parts and make sure that
any necessary special tools and materials are
obtained in advance.
7 Most work can be done with typical
workshop hand tools, although Peugeot
produce a number of service tools for specific
5.4 Disconnect the temperature sender
wiring connector
purposes such as separating the crankcase
halves. Precision measuring tools are required
for inspecting parts to determine if they must
be renewed. Alternatively, a Peugeot dealer
will handle the inspection of parts and offer
advice
concerning
reconditioning
and
replacement. As a general rule, time is the
primary cost of an overhaul so it does not pay
to install worn or substandard parts.
8 As a final note, to ensure maximum life and
minimum trouble from a rebuilt engine,
everything must be assembled with care in a
spotlessly clean environment.
5 Engine
removi
Caution: The engine i s not heavy, however
engine m o v a l and installation should b e
carried out with the aid o f a n assistant;
personal injury o r damage could occur if
the engine falls o r is dropped.
Removal
1 Support the machine securely in an upright
position. Work can be made easier by raising
the machine to a convenient working height
on an hydraulic ramp or a suitable platform.
Make sure it is secure and will not topple over.
2 Remove the body panels as necessary
according to model (see Chapter 7).
3 If the engine is dirty, particularly around its
mountings, wash it thoroughly before starting
any major dismantling work. This will make
work much easier and rule out the possibility
of dirt falling into some vital component.
4 Disconnect the battery negative terminal
(see Chapter 9). Pull the spark plug cap off the
plug and disconnect the wire to the
temperature sender on the cylinder head (see
illustration).
5 Drain the cooling system and disconnect
the coolant hoses from the unions on the
water pump and cylinder head (see Chapter 3).
6 Trace the wiring from the alternator/ignition
pulse generator and the starter motor on the
right-hand side of the engine and disconnect
it a the connectors. Free the wiring from any
clips on the frame.
7 Remove the air filter housing and the air
intake duct (see Chapter 4).
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