Related Manuals for PEUGEOT XS1P37QMA-2
Summary of Contents for PEUGEOT XS1P37QMA-2
- Page 1 Direction commerciale Animation technique réseau WORKSHOP MANUAL 50 CC ENGINE 4 STROKE 2 VALVES...
- Page 2 Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 3: Table Of Contents
Fitting the starter system .........................16 SECONDARY TRANSMISSION........................17 Removal of the secondary transmission ....................17 Replacing the bearings of the relay box....................18 Crankcase................................. 18 Relay box cover ..............................18 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 4 Installing the valve clearance ........................40 Checking the valve clearance ........................40 CRANKCASE ..............................41 Removal of the crankshaft ........................41 Checking the crankshaft and conrod assembly ..................42 Fitting the conrod and crankshaft assembly.....................43 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 5: Products Danger Symbols Used
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 ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 6 Indicate the specific procedures that shall New part Use a new part. be followed in order not to damage the vehicle. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 7: Characteristics
Centrifugal automatic Exhaust Catalytic Spark plug NGK CR6HSA Magneto flywheel 80 W Fuel supply Carburettor Keihin NVC18 (c/d) Standards Euro 3 Capacities Crankcase 0.7 l Relay box 0.1 l Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 8: Special Important Points
The clips are specific, they must always be changed each time they are removed and replaced with new genuine parts clips. Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 9: Tightening Torques
Rotor 55 Nm Turbine 10 Nm Stator 10 Nm Engine speed sensor 10 Nm Drive pulley 55 Nm Driven pulley 55 Nm Clutch plate and shoes 55 Nm Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 10: Special Tools
752361 756668 Seal piston tool Adjustable 752237 757990 Seal piston pin wrench 39 mm pipe Freewheel 752361 752127 800673 wrench nut tool (*) New or modified tool Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 11: Standard Tools
6 torque wrench to 18 mm 10 to 50 Nm Type: Facom U.49PJ3 Type: Facom J.208A50 Automatic resetting type torque wrench 40 to 200 Nm Type: Facom S.208A200 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 12: Operation
- Remove the strainer cap (1) and clean the strainer (2). Tightening torque: 15 Nm. Every time oil is changed, the filter (2) must be cleaned and the O-ring changed (3). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 13: Primary Transmission
- Remove the fixed flange. Tightening torque: 55 Nm. - Remove the belt (3). - Remove the plastic spacer (4). - Remove the drive pulley (5) with the guide hub (6). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 14: Removal Of The Driven Pulley
Checking the drive belt - Measure the width of the belt (A). Minimum width: 17.2 mm. - Make sure the belt is not cracked. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 15: Removal Of The Clutch Lining Assembly
752127 pulley assembly with the tool P/N 752127 clamped in the jaws of a vice. - Remove nut (1) using spanner P/N 752361. - Slacken tool P/N 752127. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 16: Refitting The Clutch Lining Assembly
Tightening torque: 55 Nm. - Fitting the drive pulley assembly. - Fit and tighten the nut. Tightening torque: 55 Nm. - Install the transmission cover. (10 screw). Tightening torque: 10 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 17: Removal Of The Starter System
(2) and washer. - Remove the lock ring (3), using circlip pliers. - Remove the washer, the starter gear sector (1) and the spring (4) of the drive train cover. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 18: Fitting The Starter System
(2). - Position the pin (6) of the kick starter drive piece around the boss (D) of the housing. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 19: Secondary Transmission
- Remove the secondary shaft (5). Make a note of the way the secondary shaft pinion is installed. - The primary shaft can be drifted out of the casing using a mallet (6). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 20: Replacing The Bearings Of The Relay Box
- While the casing is expanded fit the new bearing fully home in its housing. - Using fitting tool P/N 757990, fit a new lightly greased gasket (2). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 21: Carburettor
- Locate the position of the choke (1) and then remove it. Removal of the starter holder and its gasket - Remove the 2 screws that secure the choke (1). - Remove the O ring. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 22: Removal Of The Throttle Valve
Removal of the float, needle valve and jets - Remove the 4 screws that secure the float chamber (1). - Remove the float chamber and its O-ring. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 23 - Remove the main jet (7). - Remove the needle well (8). Check the condition of the needle valve and the needle valve seat (A). Check the condition of the float chamber O-ring. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 24: Removal Of The Mixture Screw
Check the condition of the bushing and the rubber protection. - Remove the piston (3). Removal of the pick-up pump suction valve - Remove the jet. - Remove the spring. - Remove the ball. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 25: Removal Of The Deceleration Enrichment Device
- Re-install all the other components and, if necessary, when starting the engine, readjust according to the values indicated on the technical data card Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 26: Removal Of The Intake Pipe
- Remove the inlet coupling (2 nuts). Tightening torque: 10 Nm. - Remove the plastic spacer. Check the condition of the O-ring. The paper gasket must be changed each time it is removed. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 27: Magneto Flywheel/Freewheel
- Remove the turbine (4 screw). Tightening torque: 10 Nm. - Lock the rotor with the adjustable pin wrench 752237 P/N 752237. - Remove the nut. Tightening torque: 55 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 28: Removal Of The Overrunning Clutch
- Remove the 8 bolts that secure the RH cover. A. Screw Length: 50 mm B. Screw Length: 95 mm C. Screw Length: 100 mm - Remove the RH cover. Tightening torque: 12 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 29: Checking The Overrunning Clutch
- Rotate the overrunning clutch by hand: • It must rotate in direction (A). • It must be block in direction (B). - If it doesn't, replace the overrunning clutch. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 30 MAGNETO FLYWHEEL/FREEWHEEL - Using fitting tool P/N 756668, fit a new lightly greased gasket (1). 756668 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 31: Cylinder Head/Cylinder/Piston
(B) on the cylinder head. - Removal of the chain tensioner (3) plug (2). - Remove the seal. - Remove the tension spring. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 32 - Remove the 2 bolts (5). - Gradually loosen in a crosswise order the 4 nuts which secure the cylinder head (6). - Remove the 4 nuts and the 4 washers (6). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 33: Removal Of The Camshaft And/Or Rockers
(2). Apply the correct tightening torque to the valve clearance adjustment covers. Tightening torque: 15 Nm - Remove the pins from the rockers using a 8 mm screw. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 34: Removal Of The Valves Or Valve Stem Seals
• The upper cup (2). • The spring (3). • The valve (4). • The valve stem seal (5). - Remove the 2nd valve in the same way. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 35 (Use lithium soap grease). Seals and valve stems must be lubricated. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 36: Removal Of The Cylinder / Piston
- Remove the base gasket (2) and the 2 centring pillars (3). - Remove one of the circlips (4) with pliers. - Remove the gudgeon pin. - Remove the piston. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 37: Checking The Cylinder
(no special direction). - Install the compression ring (3) by placing the 2R mark upwards. - Install the top compression ring (4) by placing the 1R mark upwards. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 38: Fitting The Piston
- Position the piston ring gap as follows: A. Top compression ring gap. B. Compression ring gap. C. Upper oil control ring gap. D. Lower oil control ring gap. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 39 - Tighten the cylinder head securing 4 nuts working diagonally in 2 or 3 steps (4). Tightening torque: 20 Nm. - Fit and tighten the 2 fixing bolts (5). Tightening torque: 12 Nm. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 40: Setting The Timing
(B) of the cylinder head. - If necessary, dislodge the gear from the camshaft without removing it and move the chain around the gear on the required side. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 41: Checking The Timing
(C) of the cover, and of the camshaft gear with the mark (B) of the cylinder head. - If the marks are not alined, reset the valve timing. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 42: Installing The Valve Clearance
• At the intake a 0.10 mm feeler gauge shouldn't go. • At the exhaust a 0.15 mm feeler gauge shouldn't go. - On the contrary, if the fealer gauge goes, reset the clearances. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 43: Crankcase
- Remove the pin. - Remove the 2 screws that secure the RH half casing. - Remove the RH casing. - Remove the 2 centring pillars and the paper gasket. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 44: Checking The Crankshaft And Conrod Assembly
0.1 mm and shall be measured at: - 90 mm from the transmission side end. - 60 mm from the flywheel magneto end. 90 mm 60 mm Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 45: Fitting The Conrod And Crankshaft Assembly
- Fit the 2 guiding bushes (3) to the LH casing and a new paper gasket (4), do not use oil or grease. - Place the RH casing over the LH casing assembly. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 46 CRANKCASE - Fit and tighten the 2 clamping bolts. Tightening torque: 12 Nm. - Trim the casing gasket in (A). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 48 P/N. MA0010GB Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add any reference mentioned in this manual. DC/APV 05/2009 (non contractual pictures)