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2 0 4 Transmission
3 . 8 ~ Inspect the teeth (A) and the splines (6) on the kickstart
3.11 Quadrant should butt against stop (arrowed) on inside of
quadrant
case
and the quadrant bush, for signs of wear, and
inspect the splines on the end of the quadrant
shaft for damage (see illustration 3.8~).
Replace any components that are worn or
damaged with new ones. Note: The kickstart
driven gear is an integral part of the outer half
of the variator pulley. Peugeot list two types of
outer
pulley
halves
which
are
not
interchangeable. Consult a Peugeot dealer to
ensure you obtain the correct new part
9 Ensure the spring on the engaging pinion is
a firm fit and inspect the kickstart return
spring for cracks and wear at each end. When
fitted, the return spring should return the
3.13 Operate kickstart lever to draw
kickstart pinion into the case
4.3a Lock the crankshaft with the tool (A)
and undo the nut (6).
. .
kickstart lever to the rest position and hold it
there; if not, it has worn and should be
renewed.
Installation
10 Press the kickstart bush into the cover, then
install the return spring with its long end
innermost. Hook the long end around the post
on the inside of the cover (see illustration 3.6a).
11 Lubricate the kickstart shaft with a smear
of molybdenum disulphide grease and insert it
through the bush, then hook the outer end of
the return spring onto the quadrant. Rotate
the shaft anti-clockwise against the spring
4.2 Variator pulley teeth engage in notch
(arrowed)
4.3b
. . .
then remove the outer half of the
pulley
tension until the quadrant can be butted
against the stop on the inside of the case (see
illustration). Ensure the shaft is pressed all
the way into the case, then install the washer
(if fitted) and circlip (see illustrations 3.4a
and 3.4b).
12 Fit the kickstart lever in the rest position
and tighten the pinch bolt securely. Operate
the lever to check that it turns smoothly and
returns to its rest position under spring
pressure.
13 Lubricate the shaft of the engaging pinion
with a smear of grease and install the washer,
then fit the pinion into the case. Align the
spring with the detent in the case, then
operate the kickstart lever to engage the
pinion with the kickstart quadrant and draw
the pinion into the case (see illustration).
14 Check the operation of the mechanism,
then refit the cover (see Section 2).
4 Variator
-
removal, inspection
and installation
Removal
1 Remove the drive belt cover (see Section 2).
2 To remove the variator centre nut, the
crankshaft must be locked to stop it turning.
Peugeot produce a service tool (Pt. No.
752370) which bolts onto the engine case and
locates between the teeth on the variator
pulley. Alternatively a similar tool can be made
(see illustration).
3 Undo the nut and remove the outer half of
the variator pulley (see illustrations). Discard
the nut as a new one must be fitted on
reassembly. Move the drive belt aside. Note:
Unless you are removing the clutch assembly,
leave the belt on the clutch pulley. Mark the
belt with a directional a m w i f i t is removed so
that i t can be refitted the correct way round
(see illustration).
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