Peugeot Motorcycles Citystar 125i Workshop Manual
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Peugeot Motorcycles Citystar 125i Workshop Manual

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WORKSHOP MANUAL
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Summary of Contents for Peugeot Motorcycles Citystar 125i

  • Page 1 Sales division Technical network leadership WORKSHOP MANUAL...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS............................. 1 PRODUCTS DANGER SYMBOLS USED......................4 CHARACTERISTICS............................6 Engine................................6 Capacities ..............................6 Chassis ..............................7 Dimensions and weight ..........................7 Tyres ................................7 Brakes ................................8 SERVICE SCHEDULE AND COMMISSIONING ....................9 Battery preparation (Except battery without maintenance)* ..............11 Installing the battery..........................11 New machine preparation ........................12 SPECIAL IMPORTANT POINTS........................
  • Page 4 TABLE OF CONTENTS SERVICE OPERATIONS..........................28 Changing the engine oil and replacing the oil filter ..................28 Replacing the air filter ..........................30 Removal of the spark plug ........................31 Draining the cooling circuit ........................31 Transmission air filter ..........................33 Removal of the primary transmission cover .....................33 125 cc................................
  • Page 5 TABLE OF CONTENTS STEERING/FORK............................52 Changing the front fork seals ........................52 The fork and its components........................55 Removal of the fork ..........................59 Replacing the bearings of the steering system ..................60 Steering headset cups ............................60 Steering cone ..............................61 Installing the fork ............................62 FUEL SYSTEM ..............................

  • Page 6: Products Danger Symbols Used

    PRODUCTS DANGER SYMBOLS USED PRODUCTS DANGER SYMBOLS USED Protection of individuals and of the environment. Means that the product or the package can be recycled. However, this does not Möbius band Recyclable. guarantee that the product will be recycled. Avoid contact with skin and clothes. Wear The product can irritate the gloves, safety glasses and appropriate Irritant...
  • Page 7 PRODUCTS DANGER SYMBOLS USED People's safety can be seriously affected if Operation that can be People's safety the recommendations are not fully dangerous for people. respected. Indicate the specific procedures that shall Operation that can be Important be followed in order not to damage the hazardous to the vehicle.

  • Page 8: Characteristics

    CHARACTERISTICS CHARACTERISTICS Engine Citystar 125i 200i Marking FD6R 4-stroke single-cylinder. Horizontal cylinder Type Single overhead camshaft, 4 valves Cooling By a circulation of forced air by means of a turbine on the flywheel magneto Bore x stroke 57 x 48.9 mm 64 x 58.9 mm Cubic capacity 124.7 cc...

  • Page 9: Chassis

    CHARACTERISTICS Chassis Citystar 125i 200i Chassis Steel tube 37 mm Ø telescopic front fork Front suspension Travel: 95 mm Combined spring and hydraulically-damped shock absorber Rear suspension Travel: 96 mm Dimensions and weight 1985 mm Overall length 750 mm Width at handlebar 1300 mm Height.

  • Page 10: Brakes

    CHARACTERISTICS Brakes Citystar 125i 200i Front brake Single disc type, hydraulic control Disc diameter and 240 mm - 4 mm thickness Mini. thickness: 3.5 mm Front caliper Floating calliper equipped with 2 pistons Rear brake Single disc type, hydraulic control Disc diameter and 210 mm - 4 mm thickness...

  • Page 11: Service Schedule And Commissioning

    SERVICE SCHEDULE AND COMMISSIONING SERVICE SCHEDULE AND COMMISSIONING Heavy duty servicing is for vehicles used under "harsh" conditions: door-to-door deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C. Normal servicing in km 10000 20000 30000 40000...
  • Page 12 SERVICE SCHEDULE AND COMMISSIONING Normal servicing in km 10000 20000 30000 40000 5000 10000 15000 20000 Extensive servicing in km 24 mont 48 mont 72 mont 96 mont Minimum servicing 1 month Servicing for all models Freewheel. Starter drive gear needle bearing cage. Valve clearances.

  • Page 13: Battery Preparation (Except Battery Without Maintenance)

    SERVICE SCHEDULE AND COMMISSIONING Battery preparation (Except battery without maintenance)* Remove the battery. Remove the 6 filler caps and the vent plug. Fill all the battery cells with electrolyte to the upper level shown on the battery "UPPER LEVEL". Electrolyte: (35% sulfuric acid = 1.28g/cm3). 0.5 litre can P/N 739733. Leave the battery to stand for around half an hour.

  • Page 14: New Machine Preparation

    SERVICE SCHEDULE AND COMMISSIONING New machine preparation - Check the wheel nuts are tight. - Check nuts and bolts are tight. - Check brake adjustment and efficiency. - Check the tyre pressures cold. - Check operation of the lights, flashers, horn, and brake light. - Check the different warning lights work.

  • Page 15: Special Important Points

    SPECIAL IMPORTANT POINTS SPECIAL IMPORTANT POINTS This engine is designed to run on 95 or 98 lead-free petrol or on 95 E10 lead-free petrol. Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc. 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.

  • Page 16: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES Engine part 125 cc 200 cc Spark plug 12 Nm Engine drain plug 40 Nm Oil filter 10 Nm Cylinder head 6/15/25 Nm • Nut Ø8 mm 10 Nm • Screw Ø6 mm Cylinder head cover 10 Nm Camshaft gear 33 Nm...

  • Page 17: Body Panels

    TIGHTENING TORQUES Body panels Front mudguard 8 to 10 Nm Handlebar cover 1 to 2 Nm Front shield panels 1 to 2 Nm Rear shield 1 to 2 Nm Bottom panel 6 to 8 Nm Floor panel 8 to 10 Nm Saddle storage compartment 8 to 10 Nm Rear body panels...

  • Page 18: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS Used Used Tool N° Designation Tool N° Designation with with Adjustable Pressure 752237 757877 pin wrench gauge Clutch 46 mm pipe 754040 754040 758008 758008 compression wrench 801412 tool Bearing Driven pulley 755585 759492 extractor tool pin spanner Fuel injector Steeing head...
  • Page 19 SPECIAL TOOLS Used Used Tool N° Designation Tool N° Designation with with Fork Extraction 801760 extraction 802638* tool tool Spacer 801412* 758008 802809 TEP2010 adaptor SDO 1/0/ test (*) New or modified tool Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Standard Tools

    SPECIAL TOOLS Standard tools Wrenches with interchangeable end fittings for valve Set of shims clearance adjustment Type: Marolotest P/N 500140 Ω 200 m 200 m Slide calipers Multimeter 20 m 20 m Ω VΩ Automatic resetting type torque wrench 5 to Heat gun 25 Nm Type: Facom R.306A25...

  • Page 21: Location Of Components

    LOCATION OF COMPONENTS LOCATION OF COMPONENTS TEP 2005 test 1. Instrument panel 11. HT coil 2. Injection ECU 12. Kickstand contact switch 3. Battery 13. Transponder antenna 4. Fuses 14. Immobiliser module 5. Fuel pump relay/Lighting relay 15. Regulator 6. Fuel pump 16.

  • Page 22: Stroke Indirect Injection System Functional Diagram

    4 STROKE INDIRECT INJECTION SYSTEM FUNCTIONAL DIAGRAM 4 STROKE INDIRECT INJECTION SYSTEM FUNCTIONAL DIAGRAM VE-BE RG-NR RG-JN GR-RG GR-RG MR-BA JN-VE A1 B1 GR-RG BA-NR 4F 4G VE-BE GR-NR VE-BA RG-BA BE-NR JN-BE VE-NR BA-BE JN-NR GR-RG 1. Injection ECU 9.

  • Page 23: Body Panels

    BODY PANELS BODY PANELS Location of body components Description. 1. Front top cover panel 12. Lower handlebar cover 2. Radiator grille 13. Upper handlebar cover 3. Plastic cover 14. Rear shield 4. Headlight fairing 15. Floor panel 5. Wind protector 16.

  • Page 24: Body Component Sequence Of Disassembly

    BODY PANELS Body component sequence of disassembly 1. Front top cover panel* 12. Lower handlebar cover 2. Radiator grille 13. Upper handlebar cover* 3. Plastic cover* 14. Rear shield 4. Headlight fairing 15. Floor panel 5. Wind protector 16. Footrest* 6.

  • Page 25: Removal Of The Storage Compartment

    BODY PANELS Removal of the storage compartment Procedure 1. - Lift the saddle. - Remove the storage compartment. • 2 plastic screws (A). • 4 washer head screws Ø6 mm (B). Removal of the rear body cover Procedure 2. - Remove the storage compartment. See: Procedure 1.

  • Page 26: Removal Of Headlight Panels

    BODY PANELS Removal of headlight panels Procedure 4. - Remove the front top cover panel (1). • 1 plastic screws (A). - Remove the plastic cover (2). • 1 washer head screw Ø5 mm (B). - Remove the radiator grille. •...

  • Page 27: Removal Of Front Lower Shield Panels

    BODY PANELS Removal of front lower shield panels Procedure 5. - Remove the headlight panels. See: Procedure 2. page 23. - Remove the front lower shield panels. • 3 plastic screws (A). • 11 washer head screws Ø5 mm (B). - Disconnect the direction indicators.
  • Page 28 BODY PANELS - Remove the handlebar upper fairing. • 6 plastic screws. - Remove the instrument cluster fairing. • 4 plastic screws (D). • 2 washer head screws Ø5 mm (E). - Disconnect the instrument cluster. Procedure: • Press the locking system (X) to actuate the positioning lever (Y) of the instrument cluster's connector.

  • Page 29: Removal Of The Footboard

    BODY PANELS - Remove the header tank (2 screw) (Right side). - Remove the ingnition switch trim (1). - Remove the utility hanger (2) (2 screw). - Disconnect the accessory plug (3). - Remove the rear shield panel. • 1 washer head screws Ø5 mm (F). •...

  • Page 30: Service Operations

    SERVICE OPERATIONS SERVICE OPERATIONS Changing the engine oil and replacing the oil filter The engine must be drained when it is warm to allow the oil to run easier. Wear gloves in order not to get burnt. - Place the vehicle on its central stand on flat ground.
  • Page 31 SERVICE OPERATIONS - Put back the drainage cap and strainer cap, fitted with a new seal. Tightening torque: 40 Nm. - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole: • 0.92 I at oil change. •...

  • Page 32: Replacing The Air Filter

    SERVICE OPERATIONS Replacing the air filter - Remove the air filter cover (8 bolts) and its seal. - Remove the air filter (1) (3 screw). - Clean inside the air filter box. - Remove the inlet silencer drain plug to let humidity and oil drip out (2).

  • Page 33: Removal Of The Spark Plug

    SERVICE OPERATIONS Removal of the spark plug - The engine must be cold. - Remove the storage compartment. See: Procedure 1. page 23. 766062 - Disconnect the suppressor. - Remove the spark plug using tool P/N 766062. Tightening torque: 12 Nm. - Recommended spark plug: •...
  • Page 34 SERVICE OPERATIONS - Install the screw and its seal. - Fill the circuit with 0.9 L of coolant. - Loosen the bleeder screw (2) to remove air contained in the engine. - Close the bleeder screw. - Check and top up the coolant level in the radiator.

  • Page 35: Transmission Air Filter

    SERVICE OPERATIONS Transmission air filter - Remove the air filter cover (3 screw). Tightening torque: 10 Nm. - Remove the air filter (1). - Clean or replace the air filter if it is dirty. Removal of the primary transmission cover 125 cc - Remove the plastic cover.

  • Page 36: 200 Cc

    SERVICE OPERATIONS - Remove the tapered washer (1). - Remove the clutch cover (2). 200 cc - Remove the under-saddle panels. See: Procedure 2. page 23. - Remove the fastening screw from the intake silencer (A) - Remove the transmission cover (8 screw). Tightening torque: 10 Nm.

  • Page 37: Removal Of The Primary Drive

    SERVICE OPERATIONS Removal of the primary drive - Hold the fixed flange with tool P/N 752237. - Remove the nut. - Remove the fixed flange. Tightening torque: • 125 cc: 70 Nm. • 200 cc: 110 Nm. 752237 - Pull the belt aside. - Remove the drive pulley (1) with the guide hub (2).

  • Page 38: 200 Cc

    SERVICE OPERATIONS 200 cc - Hold the cover with the pin wrench P/N 752237. Tightening torque: 70 Nm. 752237 - Remove the clutch and driven pulley assembly together with the belt. Removal of the overrunning clutch - Remove the kick starter stopper (1) (1 screw). Tightening torque: 10 Nm.

  • Page 39: Checking The Overrunning Clutch

    SERVICE OPERATIONS 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. Separate the overrunning clutch from the ring gear.

  • Page 40: Changing The Drive Pulley Bearings

    SERVICE OPERATIONS Changing the drive pulley bearings - Remove the holder (1) and its 3 plastic guides (2). - Remove the moving flange (4) 6 bearings (3). The bearings must be changed if they show major signs of wear. The guides shall be replaced if they show signs of wear.

  • Page 41: 200 Cc

    SERVICE OPERATIONS 200 cc When refitting, respect the way the rollers are installed. Checking the drive belt - Measure the width of the belt (A). Minimum width: 125 cc: 20.5 mm. 200 cc: 23 mm. - Make sure the belt is not cracked. Removal of the clutch lining assembly - Using the depth calliper, measure the thickness of the clutch linings.

  • Page 42: Refitting The Clutch Lining Assembly

    SERVICE OPERATIONS - Compress the clutch and driven pulley assembly using tool 758008 equipped with the protection spacer P/N 801412. - Remove nut (1) using spanner P/N 754040. - Slacken tool P/N 758008. 754040 801412 758008 - Remove the clutch linings (2), the upper centring sleeve (3), the spring (4), and the lower centring sleeve (5).

  • Page 43: Fitting The Overrunning Clutch

    SERVICE OPERATIONS - Compress the clutch and driven pulley assembly using tool 758008 equipped with the protection spacer P/N 801412. - Tighten the nut (1). Tightening torque: 60 Nm. 754040 801412 758008 Fitting the overrunning clutch - Fit the starter ring. - Fit the spacer (1).
  • Page 44 SERVICE OPERATIONS - Lightly grease the caged needle bearing of the kick starter (2). - Fit the starter motor dog. - Fit the kick starter stopper (3) (2 screw). Tightening torque: 10 Nm. Use lithium soap grease. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 45: Installing The Primary Drive

    SERVICE OPERATIONS Installing the primary drive Before fitting the clutch drive pulley and driven pulley to the input shaft, fit the belt into the pulley bottom by opening the flanges by hand. Respect the direction of rotation of the belt which is shown by an arrow. - Lightly grease the drawn cup needle roller bearing of the driven pulley.

  • Page 46: 125 Cc

    SERVICE OPERATIONS 125 cc - Fit the clutch cover (4). - Fit the spacer (5) (Chamfer facing you). 200 cc - Fit the clutch cover. - Hold the cover with the pin wrench P/N 752237. - Fit and tighten the nut. 752237 Tightening torque: 70 Nm.

  • Page 47: Fitting The Primary Transmission Cover

    SERVICE OPERATIONS Fitting the primary transmission cover 125 cc - Install the transmission cover (8 screw). Tightening torque: 10 Nm. - Lock the clutch drum with the pin wrench P/N 759492. - Fit and tighten the nut. 759492 Tightening torque: 70 Nm. - Fit the plastic cover.

  • Page 48: Installing The Valve Clearance

    SERVICE OPERATIONS Installing the valve clearance - Remove the storage compartment. See: Procedure 1. page 23. - Remove the under-saddle panels. See: Procedure 2. page 23. - Remove the transmission air filter cover. - Disconnect the oil vapour return hose to the rocker cover.

  • Page 49: Checking The Valve Clearance

    SERVICE OPERATIONS - If the clearance is not correct, adjust by means of the cam follower screw. - Use a wrench to adjust the valve clearance: Type: Marolotest, P/N 500140. Checking the valve clearance - At the intake a 0.15 mm feeler gauge shouldn't go.

  • Page 50: Brake Pad Wear

    SERVICE OPERATIONS Brake pad wear Front brake A = 1.5mm - If one of the 2 brake pads is worn down to the minimum dimensions (A), the 2 brake pads must be changed. A. Mini. thickness: 1.5 mm. Rear brake - If one of the 2 brake pads is worn down to the minimum dimensions (A), the 2 brake pads must be changed.
  • Page 51 SERVICE OPERATIONS - Remove the 2 pins from the caliper. Tightening torque: 18 Nm. - Remove the brake pads (1). 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.

  • Page 52: Checking The Brake Fluid Level

    SERVICE OPERATIONS - Remove the brake pad clips and pin (1). - Remove the brake pads. 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.

  • Page 53: Draining The Front Fork

    SERVICE OPERATIONS Draining the front fork - Remove the fork tubes. See chapter: Changing the front fork seals, page 52. - Remove the spring (1). - Turn the fork tube upside down to drain the oil into a recipient. - Pour 0.18 l SAE10W hydraulic oil into the fork tube.

  • Page 54: Steering/Fork

    STEERING/FORK STEERING/FORK Changing the front fork seals - Remove the front lower shield panels. See: Procedure 2. page 23. - Suspend or immobilize the machine securely. - Remove the front brake caliper from the fork tube (2 screw). Tightening torque: 10 Nm. - Loosen the wheel spindle clamping screw (1).
  • Page 55 STEERING/FORK - Remove the calibrated hydraulic tube (7). - Remove the expansion stop spring (8). - Remove the dust cover (9). - Remove the retaining clip (10). Extraction of the tube assembly, seals and rings - Screw the pin (A) of tool ref. 801760 onto the fork tube (11) in place of the cap.
  • Page 56 STEERING/FORK - Place the flanged tube (B) of tool ref. 801760 on the hollow shaft. - Install the split washer (C) ref. 801760 under the washer. - Secure the pin (A) and screw the nut (D) on the pin as far as the separation of the shaft (12) and fork tube.

  • Page 57: The Fork And Its Components

    STEERING/FORK The fork and its components 1. Fork tube cap. 2. Spring. 3. Screw and copper seal. 4. Hollow shaft. 5. End of compression cone. 6. Fork upper tube. 7. Washer. 8. Retaining clip. 9. Balk rings 10. Tightness seal. 11.
  • Page 58 STEERING/FORK - Fit the fork sleeve (5) to the slightly oiled fork tube (6). - Install the stanchion assembly screw and its seal (7). Tightening torque: 25 Nm. - Install a new guiding ring (8). - Fit washer (9). - Using the marolotest lip seal installation kit tool, partially push the guiding balk ring.
  • Page 59 STEERING/FORK - Install the retaining ring (11). - Fit a new, lightly greased dust cover (12). - Pour 0.18 l SAE10W hydraulic oil into the fork tube. - Install the spring (3). - Fit the fork tubes into the fork triple clamps. - Tighten the lower screws on the fork tee (13).
  • Page 60 STEERING/FORK - Fit the front mudguard. - Fit the speedometer drive gear assembly to the wheel drive pins. - Fit the wheel, matching the speedometer drive gear assembly to the pin (A) on the fork stanchion. - Fit the wheel spindle and tighten. Tightening torque: 60 Nm.

  • Page 61: Removal Of The Fork

    STEERING/FORK Removal of the fork - Suspend or immobilize the machine securely. - Remove the front mudguard (4 screw). - Remove the front brake caliper from the fork tube (2 screw). Tightening torque: 30 Nm. - Remove the front wheel. Tightening torque: 60 Nm.

  • Page 62: Replacing The Bearings Of The Steering System

    STEERING/FORK - Using tool P/N 757860 remove the steering locknut. 757860 - Remove: • The brake washer (2). • The nut (3). • The rubber washer (4). • The adjustable cone (5). • Remove the fork. • Remove the caged ball bearings. Replacing the bearings of the steering system Steering headset cups...

  • Page 63: Steering Cone

    STEERING/FORK - Using push tool P/N 756607, fit a new upper cup into the steering tube. - Using push tool P/N 759788, fit a lower cup into the steering tube. 759788 Steering cone - Using a drift, remove the steering headset cone.

  • Page 64: Installing The Fork

    STEERING/FORK Installing the fork - Grease the cup bearing races. - Install new ball cage bearings (7) (respect the right way of installation). - Fit the fork into the steering column. - Install new ball cage bearings (8) (no special direction).

  • Page 65: Fuel System

    FUEL SYSTEM FUEL SYSTEM Procedure for reducing the fuel circuit pressure Procedure 8 756017 - Remove the storage compartment. See: Procedure 1. page 23. - Disconnect the fuel injector. - Remove the fuel injector without disconnecting the supply hose. - Connect the fuel injector power supply harness tool P/N 756017 to the fuel injector and the battery.

  • Page 66: Measuring The Petrol Flow

    FUEL SYSTEM - Carry out the procedure for lowering the pressure in the fuel system. See: Procedure 8. 757877 page 63. - Disconnect the pump fuel feed hose. - Insert the pressure gauge P/N 757877 between the gauge well and the supply hose. - Turn the ignition on 3 times to bleed the fuel system.

  • Page 67: Removal Of The Fuel Pump

    FUEL SYSTEM Removal of the fuel pump - Remove the footboard. See: Procedure 7. page 27. - Carry out the procedure for lowering the pressure in the fuel system. See: Procedure 8. page 63. - Disconnect the fuel pump output hose (1). - Disconnect the fuel pump (2).

  • Page 68: Power Unit

    POWER UNIT POWER UNIT Removal of the power unit Note: To remove the cylinder head, remove the power propulsion unit. For removal of the cylinder head, cylinder and piston, see the workshop manual: • Engine 125/200cc. 4 valves. - Remove the under-saddle panels. See: Procedure 2. page 23. - Disconnect the battery.
  • Page 69 POWER UNIT • The oil pressure (7). • The throttle box (8). • The fuel injector (9). • The suppressor (10). Disconnect: • The fuel inlet pipe (11). • The throttle control (12). - Disconnect the water pump and cylinder head hoses (13).
  • Page 70 POWER UNIT - Remove the exhaust (1 collar and 3 screws). - Remove the suspension arm (5 screws and 1 nut). - Remove the wheel (3 screw). - Remove the rear brake caliper (2 screw). Tightening torque: 30 Nm. - Temporarily reinstall the wheel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 71 POWER UNIT - Suspend the rear of the machine. - Remove the shock absorber lower mount (14). Tightening torque: 22 Nm. - Remove the linkrod-to-engine connecting pin (15). Tightening torque: 70 Nm. When re-installing, use a new nut. - Remove the power propulsion unit from the frame.
  • Page 72 P/N MA0024GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/PS/APV 12/7/11 (non contractual pictures)

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