Related Manuals for PEUGEOT 125 CC
Summary of Contents for PEUGEOT 125 CC
- Page 1 WORKSHOP MANUAL TECHNICAL NETWORK LEADERSHIP WORKSHOP MANUAL 125 CC/150 CC 4-STROKE ENGINE...
- Page 2 Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 3: Table Of Contents
Removal of the RH crankcase half..................22 Removal of the oil discharge valve..................23 Removal of the water pump....................23 Removal of the crankshaft....................24 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 4 Fitting the drive pulley assembly..................40 Changing the drive pulley bearings................... 40 Removal of the clutch lining assembly................41 Refitting the clutch lining assembly..................42 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 5: Characteristics
235 W/330 W Fuel supply Carburettor Indirect electronic injection (EFI) Capacities Engine oil 1.25 l SAE 10W40 Relay box oil 0.12 l SAE 80W90 life lubricated Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 6: Special Important Points
Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a clear and well-ventilated area. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 7: Tightening Torque
7 m.daN Stator 1 m.daN Engine speed sensor 0.7 m.daN Drive pulley 7 m.daN Driven pulley 7 m.daN Spark plug 1 m.daN Camshaft gear 2.3 m.daN Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 8: Special Tools
753977 Extensi Torque 68994 wrench 68994 752235 752236 8 N.m to 3/8 adapter Adapter 753977 54 N.m 752236 External Adjustable 69092 752237 circlips pliers pin wrench Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 9 755585 seal drift extractor tool Engine Water pump mount 754008 756717 64765 seal drift adapter Jetforce Water pump Fixed flange 754009 757035 pin drift locking tool Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
- Page 10 SPECIAL TOOLS Water pump Water pump 757988 757989 bearing drift bearing drift Crankcase seal 757990 installation buffer Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 11: Disassembly
Removal of the primary transmission cover. - Remove the 8 bolts that secure the cover. - Remove the transmission cover and the 2 centring pillars. - Tightening torque: 1 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 12: Removal Of The Drive Pulley
P/N 752237 or the flywheel clamp P/N 68570. - Remove the nut. - Remove the clutch drum and the clutch and drive pulley assembly. - Tightening torque: 7 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 13: Removal Of The Rocker Cover
Removal of the chain tensioner. - Remove the screw and spring from the tensioner (1). - Remove the 2 mounting screws (2) from the tensioner body. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 14: Removal Of The Rh Cover / Ignition Coil And Sensor
- Remove the 8 bolts that secure the RH cover. - Remove the cover. - Tightening torque: 1 m.daN. - Remove the paper gasket (1) and the 2 locating pins (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 15: Removal Of The Rotor
P/N 754041. Removal of the rotor. 68570 - Immobilize the rotor (1) using the flywheel clamp P/N 68570 - Remove the nut. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 16: Removal Of The Cylinder Head
- Rotate the engine by hand in the direction of operation (clockwise) by means of the fixed plate in order to bring the rocker pads over the camshaft's cam lobes.. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 17 - Remove the 4 nuts and washers and the 2 washer screws. - Remove the cylinder head, the metal seals (5) and the 2 centring pillars (6). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 18: Removal Of The Temperature Sensor
- Tightening torque: 0,7 m.daN. Note: The stopper plate has two functions. to provide: - proper positioning of the camshaft. - flow of oil inside the rocker shafts. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 19: Removal Of The Valves Or Valve Stem Seals
- Compress the spring of one of the valves using the valve lifter P/N 754035. - Remove the 2 half cones. - Uncompress the spring and remove the tool. 754035 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 20 (use a Molykote type grease). Seals and valve stems must be lubricated. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 21: Removal Of The Cylinder
2 centring pillars (3). Removal of the piston. - Remove one of the circlips (1) with pliers P/N 752000. - Remove the gudgeon pin. - Remove the piston. 752000 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 22: Removal Of The Oil Pump
- Remove the plastic gears and the 2 pins (4). - Remove the 2 screws which secure the 2nd anti-splash plate (5). - Remove the plate. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 23 - Remove the oil pump. - Tightening torque: 1 m.daN. Note: Before re-assembling, lubricate the oil pmup by dipping it into a pan con- taining clean motor oil. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 24: Removal Of The Rh Crankcase Half
RH casing, as the bearing is secured to the cranshaft and conrod ass'y. - Tightening torque: 1 m.daN. Check and if necessary clean the water pump drain hole (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 25: Removal Of The Oil Discharge Valve
- Drive out the seal 6 from the turbine side. - Drive out the caged needle bearing (7) from the turbine side. All the components must be changed every time the pump is serviced.. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 26: Removal Of The Crankshaft
- Removing the the cranshaft and conrod assembly. Note: When the casings are opened, if the bearings stay on the crank, use tool P/N 755585 to remove them. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 27: Checking The Crankshaft And Conrod Assembly
5/100 mm and must be measured: - 30 mm from the transmission side end. - 35 mm from the flywheel magneto end. 30 mm 35 mm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 28: Removal Of The Secondary Transmission Cover
In case the gasket is damaged, oil will flow through the casing's drain hole (A) located between the gasket (on the wheel side) and the bearing. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 29 DISASSEMBLY - Remove the intermediate shaft and its second friction washer (6) located behind it. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 30: Refitting Specific Components
P/N 754009. - Fit the seal (2) using the drift P/N 754008, the seal's lips shall be directed towards the caged 754008 needle bearing.. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 31 - Fit the drive shaft and bearing assembly by the outer cage using the bearing drift P/N 757989. 757989 - Install the circlip (5) on the bearing side. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 32: Assembly Of The Engine Casings
Note: Hold the crank assembly by the RH side using the rotor fitted on the key. 754006 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 33 4 stroke oil. - Place the inlet pipe and the O-ring (check the condition of the O-ring and if necessary change it).. - Tightening torque: 1 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 34: Installing The Piston Rings On The Piston
Note: The circlips must be changed every time they are removed. The circlip gaps (1) must face upwards or downwards, but under no circumstances to the side. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 35: Fitting The Cylinder
- Fit the 2 guiding pillars (1) and the metal gasket (2) on the cylinder. - Fit the timing chain through the cylinder head timing well. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 36 28 Nm in a crosswise order. - Tighten the 2 washer screws to 8 Nm. You must set the timing every time you remove the cylinder head when servicing. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 37: Setting The Timing
- Insert the pin P/N 754034 into the cylinder 754034 head gauging hole. - Rotate the camshaft until the pin enters the camshaft gauging hole. - Remove the camshaft gear. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 38 - Fit once again the pins in order to make sure timing is set correctly. - If the pins do not enter reset the timing. - Fit the plug over the cylinder head gauging hole. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
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Page 39: Installing The Valve Clearance
- At the intake a 15/100 feeler gauge shouldn't go. - At the exhaust a 30/100 feeler gauge shouldn't go On the contrary, if the fealer gauge goes, reset the clearances. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 40: Refitting The Rocker Cover
- Install the rocker cover and its 5 scews. - Tightening torque: 1 m.daN. If you forget to fit the plug (1) the oil pressure will be low and some components could seize. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 41: Miscellaneous Operations
- Remove the water inlet pipe and the O-ring (2) (check the condition of the O-ring and change it if necessary). - Tightening torque: 1 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 42: Fitting The Drive Pulley Assembly
- Remove the nut (2) of the fixed flange. - Remove the fixed flange. - Remove the belt. - Remove the guide hub and the drive pulley. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 43: Removal Of The Clutch Lining Assembly
P/N 754005 754005 754040 clamped in the jaws of a vice. - Remove nut (1) using spanner P/N 754040 - Slacken tool P/N 754005. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... -
Page 44: Refitting The Clutch Lining Assembly
- Fit and tighten the nut. - Tightening torque: 7 m.daN. - Install the transmission cover. - Fit and tighten the cover 8 fixing bolts. - Tightening torque: 1 m.daN. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles... - Page 45 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
- Page 46 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
- Page 47 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
- Page 48 RECOMMENDS P/N 757904 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/PS/APV Printed in the E.U. 07/2004 (non contractual pictures) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...