PEUGEOT Tweet Workshop Manual
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PEUGEOT Tweet Workshop Manual

PEUGEOT Tweet Workshop Manual

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Sales division
Technical network leadership
WORKSHOP MANUAL
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Summary of Contents for PEUGEOT Tweet

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

  • Page 3: Table Of Contents

    Removal of the front top shield panel.......................21 Removal of the front lower shield pannel ....................21 Removal of the rear shield panel ......................22 Removal of the footboard .........................23 Removal of handlebar fairing ........................23 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 4 Removal of the fork ..........................45 Replacing the bearings of the steering system ..................46 Steering headset cups ..........................46 Fork cone ..............................46 Installing the fork ............................47 Steering system tightening method......................47 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 5 FUEL SYSTEM ..............................54 Removal of the carburettor........................54 Vacuum-operated cock ..........................54 Removal of the fuel gauge ........................52 POWER UNIT ..............................55 Removal of the power unit ........................55 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 6: 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 or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 7 Indicate the specific procedures that shall New part Use a new part. be followed in order not to damage the vehicle. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 8: Characteristics

    0.18 L (0.17 at the oil change) Relay box SAE 80W90 Minimum grade: API GL4 Fuel tank 5.7 l 95 or 98 lead-free Fork oil 0.1 l per tube. SAE 10W Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Chassis

    90/80 - 16 Front tyre pressure 1.75 bars Rear wheel rim 16 inch aluminium alloy Rear tyre 90/80 - 16 110/70 - 16 Rear tyre pressure 2.25 bars Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Brakes

    Rear caliper Fixed calliper with 2 pistons Chassis markings Engine marking xxxxxxx 1. The VIN number and the manufacturer's 2. Engine number plate are under the seat Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 11: Service Schedule And Commissioning

    After 20000 km, resume the service schedule again from 5000 km. a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high temperature, exclusively town use, etc.. b.Depending on model. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 12 Servicing time in tenths of an hour (0.5 h = 30 min) Tweet Peugeot a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high temperature, exclusively town use, etc.. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

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

    - Check the tyre pressures cold. - Check operation of the lights, flashers, horn, and brake light. - Check the different warning lights work. - Carry out a road test. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 14: Special Important Points

    Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Before carrying out any work, leave the engine to cool for at least 2 hours. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Tightening Torques

    6 to 8 Nm Floor panel 8 to 10 Nm Saddle storage compartment 8 to 10 Nm Rear panels 1 to 2 Nm Grab handle 20 to 25 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Cycle Part

    10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm Nut and bolt 12 mm diameter 55 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Special Tools

    125/151 cc 39 mm pipe Steeing head 752361 759788 wrench cup push tool Steeing head 755039 801682 Spacer adaptor 758008 cup push tool 755996 Hose clamp Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Standard Tools

    5 to 25 Nm 40 to 200 Nm Type: Facom R.306A25 Type: Facom S.208A200 Automatic resetting type torque wrench 10 to 50 Nm Type: Facom J.208A50 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Location Of Components

    3. Battery 10. Fuel gauge 4. Fuses 11. Opening the saddle 5. HT coil 12. Horn 6. Magneto flywheel 13. Flasher unit 7. Starter motor relay Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Body Panels

    14. Battery access door 6. Front mudguard 15. Rear panels/Mudflap 7. Legshield top panel 16. Saddle and storage compartment 8. Front lower legshields 17. Grab handle 9. Mudguard Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 21: Body Component Sequence Of Disassembly

    7. Legshield top panel* 16. Saddle and storage compartment* 8. Front lower legshields 17. Grab handle* 9. Mudguard* *This item may be removed on its own. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Removal Of The Storage Compartment

    Range 1. page 20. - Remove the grab handle. • 3 screw Ø8 mm (A). - Remove the battery access door. • 5 plastic screws (B). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 23: Removal Of The Front Top Shield Panel

    - Remove the front upper shield panel. See: Range 3. page 21. - Remove the RH and LH under body panel. • 4 screw Ø6 mm (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Removal Of The Rear Shield Panel

    Range 4. page 21. - Remove the ingnition switch trim. - Remove the utility hanger (1). - Remove the rear shield panel. • 2 plastic screws (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Removal Of The Footboard

    • The brake light switches (3). • The horn (2). • The flasher unit (2). - Remove the handlebar rear cover and instrument cluster assembly. • 3 plastic screws (C). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 26: Service Operations

    - Remove the strainer cap (2) and clean the strainer (3). Tightening torque: 15 Nm. Every time oil is changed, the filter (3) must be cleaned and the O-ring changed (4). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Draining The Relay Box

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. - Quantity: 0.17 l - Fit the filler cap. Tightening torque: 10 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Replacing The Air Filter

    - Fit the gasket. - Install the air filter cover. - Remove the oil vapour return drain plug to let humidity and oil drip out (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 29: Removal Of The Spark Plug

    - Remove the transmission cover. • 50 cc: 10 screw • 125/151 cc: 8 screw Tightening torque: 10 Nm. - Remove the paper gasket and the two 2 centering pins. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Removal Of The Drive Pulley

    - Remove the clutch drum, the clutch drive pulley and driven pulley assembly and belt. Make a note of the direction of rotation of the belt. Tightening torque: 55 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Changing The Drive Pulley Bearings

    - When refitting, respect the way the rollers are installed. - Grease the moving flange bore lightly (high temperature grease). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Checking The Thickness Of The Clutch Linings

    - Remove nut (1) using spanner - Remove nut (1) using spanner P/N 752361. P/N 752361. - Slacken tool P/N 752127. - Slacken tool P/N 758008. 758008 752361 752127 801682 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Refitting The Clutch Lining Assembly

    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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 34: Installing The Valve Clearance

    (B) with the - Turn the magnetic wheel to line up the "T" cylinder head gasket face. mark with the the crankcase boss (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 35: Checking The Valve Clearance

    - On the contrary, if the fealer gauge goes, - On the contrary, if the fealer gauge goes, reset the clearances. reset the clearances. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 36: Brake Pad Wear

    A. Mini. thickness: 1.5 mm. Replacing the brake pads Front brake - Loosen the brake pad pin first (1). - Remove the calliper (2 screw). Tightening torque: 30 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 37 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 38: Checking The Brake Fluid Level

    - Remove the screw fastening the rear mudguard on right (2). Tightening torque: 10 Nm. - Remove the 2 screws from the exhaust (3). Tightening torque: 30 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 39 - Install the spring (8). - Install the brake control cable, the barrel and the adjusting nut (4). - Install the wheel. Tightening torque: 110 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 40: Removal Of The Fuel Filter

    - Remove the fuel filter (1). When re-installing, respect direction of installation of the filter shown by the arrow which indicates in which direction the fuel flows. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 41: Draining The Front Fork

    - Remove the spring (3). - Turn the fork tube upside down to drain the oil into a recipient. - Pour 0.1 l SAE10W hydraulic oil into the fork tube. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 42 SERVICE OPERATIONS - Install the spring (3). - Install the cap. - Push the fork tube cap to install the retaining spring clip. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 43: Steering/Fork

    Remove the tightening screw from the internal tube and its seal (4). - If necessary use a mallet to dislodge the screws. - Separate the fork tube from the fork stanchion (5). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 44: The Fork And Its Components

    6. End of compression cone. 7. Calibrated hydraulic tube. 8. Expansion spring. 9. Dust cover. 10. Circlip. 11. Tightness seal. 12. Fork upper tube. 13. Fork triple clamp Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 45 - Fit the fork sleeve (5) to the slightly oiled fork tube (12). - Install the stanchion assembly screw (4) and its seal. Tightening torque: 25 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 46 - Fit the wheel spindle and tighten. When re-installing, use a new nut. Tightening torque: 60 Nm. - Refit the other items in the reverse order to disassembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 47: Removal Of The Fork

    Tightening torque: 45 Nm. When re-installing, use a new nut. - Remove the steering locknut (1) (2). - Remove the adjustment cone (3). Remove the fork. Remove the balls. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 48: Replacing The Bearings Of The Steering System

    - Remove the fork tubes. - Remove the front mudguard (3 screw). - Using a drift, remove the steering headset cone. - Remove the dust cover. - Remove the washer. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 49: Installing The Fork

    - Turn the fork from left to right to check that there are no tight spots. - Refit the other items in the reverse order to disassembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 50: Electricity

    9. Starter motor switch b.Ignition sensor 10. Starter motor relay 4. Ignition switch 11. Stop light switch 5. HT coil 12. Stop/tail bulb 6. Resistive spark plug and suppressor Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 51: Checking The Ignition System

    Emergency stop To the ground voltage) switch ON position Ignition switch OFF position Red/black Battery positive power Emergency stop U=0V To the ground switch OFF position Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 52: Ignition Principle Schematic/Starting Off (125/151 Cc)

    8. Starter motor switch b.Ignition sensor 9. Starter motor relay 3. Ignition switch 10. Stop light switch 4. HT coil 11. Stop/tail bulb 5. Resistive spark plug and suppressor Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 53: Checking The Ignition System

    ON position Emergency stop switch OFF position Ignition switch ON position Emergency stop White/black switch To the ground Emergency stop switch ON position Ignition switch ON position Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 54: Removal Of The Regulator/Starter Resistor

    - Disconnect the fuel gauge. - Unscrew the fuel gauge locking plate (1). - Remove the fuel gauge. - Remove the rubber gasket. When re-installing, use a new gasket. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 55 ELECTRICITY Check: A. Full fuel tank: 8 ±20%. B. Empty fuel tank: 95 ±20%. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 56: Fuel System

    - Disconnect the vacuum hose, taking note of its location (1). - Disconnect the fuel supply hose . - Remove the vacuum-operated cock. When re-installing, use a new gasket. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 57: Power Unit

    • The starter motor (A). • The power supply wire from the starter to the relay (B). • The suppressor. • The suppressor. - Disconnect: - The engine ground (1). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 58 - Disconnect the pipe from the pulsair reed valve (5). - Remove the exhaust assembly (4 screws and 2 nuts). - Remove the exhaust assembly (3 screws and 2 nuts). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 59 - Remove the rear brake caliper (2 screw). Tightening torque: 30 Nm. - Suspend the rear of the machine. - Remove the shock absorber lower mounts (8). Tightening torque: 28 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 60 When re-installing, use a new nut - Lift the rear of the machine. - Remove the power propulsion unit from the frame. - Remove the covers from the power unit. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 64 P/N. MA0019GB Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add any reference mentioned in this manual. Printed in the E.U. DC/PS/APV 04/2010 (non contractual pictures)

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