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PEUGEOT MOTOR ENGINE Workshop Manual

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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
MOTOR
ENGINE

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Summary of Contents for PEUGEOT MOTOR ENGINE

  • Page 1 SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP MANUAL MOTOR ENGINE...

  • Page 2: Table Of Contents

    To change clutch shoes..........................37 To remove the drive pulley sprocket......................37 To remove and fit a coil ..........................39 To change the decompressor assembly ......................40 Page: 4 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 3: Characteristics

    Peugeot electronic 12 V 4- flywheel pole or 6V 6-pole Engine markings T059 (version H) T055 (version F.G) Engine type T051 (version A) T054 (version B.C) Page: 5 Reproductions ou traductions, même partielles, interdites sans autorisation écrite de Peugeot Motocycles...

  • Page 4: Special Tools

    750369 Governor removal/refitting support 750411 1.5 mm base washer 750495 Piston clip pliers 752000 RCX/SPX driven pulley sprocket removal tool 754269 Adjustable pin wrench 755586 Page: 6 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 5: Identification

    Differences between the 3 types of assembly - Type 1 without governor and kickstart - Type 2 with governor and without kickstart - Type 3 with governor and with kickstart Page: 7 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 6: Disassembly

    - Remove the nut (2) from the end of the crank assembly - Remove the drive pulley not forgetting the washer (3) under the drum Page: 8 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 7: To Remove The Governor - Type 3

    - Remove the chain guard (3) and the RH footrest (4) - Remove the quick-link and the chain (5) - Remove the circlip (6), the sprocket (7) and its plastic washer Page: 9 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 8 - Remove the LH footrest (9) - Slacken the engine tension spring (1) - Remove the belt (11) - Remove the clutch/transmission shaft assembly (12) Page: 10 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 9: To Remove The Magneto Flywheel

    - Remove the 2 bolts (3) from the coil assembly (5) and the 2 bolts (4) from the sensor (6) - Remove the coil assembly Page: 11 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 10: To Remove The Coil Assembly Plate

    - Remove the coil assembly (5) To remove the coil assembly plate - Remove the 2 bolts (7) from the stator plate - Remove the stator plate (8) Page: 12 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 11: To Remove The Cylinder Head And Cylinder/Piston

    To remove the inlet manifold and valve - Remove the inlet manifold (2) 4 bolts (1) Remove: - the inlet manifold - the inlet valve and its seals Page: 13 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 12: Opening The Casings

    - On the RH casing, on the magneto flywheel side, fit: - bush P/N 69137 (large diameter side) - protector P/N 69098 on the end of the crank assembly Page: 14 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 13: To Remove The Crank Assembly

    2 bolts (5) (Ø 6 x 80 mm) using the casing assembly holes - Tighten the tool screw P/N 64706 until the crank assembly is withdrawn completely Page: 15 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 14: To Remove The Bearings And Seals

    Note: the bearing external diameter of 47 mm is on the drive pulley side The bearing 40 mm external diameter is on the magneto flywheel side Page: 16 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Reassembly

    - Remove the fitting tool and seal guide - Fit the bearing to guide P/N 69108 and push it fully home into the casing half using tool P/N 69109 (large diameter side) Page: 17 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 16 REASSEMBLY Page: 18 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 17: To Fit The Bearing And Seal In The Rh Casing

    P/N 69115 (Ø 17 - Fit the bearing to guide P/N 69115 and push it fully home into the casing using tool P/N 69114 (large diameter side) Page: 19 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 18: To Fit The Crank Assembly In The Lh Casing

    - Centre assembly with 2 nuts and bolts (5) Ø 6 x 80 mm - Fit the shoulder centring tool P/N 64710 and butterfly nut P/N 69104 to tool P/N 64706 Page: 20 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Assembling The Casings

    (8) at (A) and also the other 2 bolts (9) to fit the gasket correctly - Tighten the rod P/N 64711 on the crank assembly - Fit bush P/N 69137 the large diameter side against the casing Page: 21 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 20: To Assemble The Engine Bottom End And Engine Mount

    - Tighten to the recommended torque - Trim the paper gasket in the casing at (A) and (B) - Lubricate the crank assembly and check it rotates freely Page: 22 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 21: To Fit The Valve And Inlet Manifold

    - Fit the piston to the connecting rod little end, with the arrow pointing towards the exhaust side - Fit the gudgeon pin (3) - Fit the circlips Page: 23 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 22: To Fit The Cylinder

    - Fit the cylinder head - Fit the 4 lockwashers and the 4 nuts - Tighten the 4 nuts working diagonally, to the recommended torque Page: 24 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 23 - Fit the cylinder head - Fit the 4 lockwashers and the 4 nuts - Tighten the 4 nuts working diagonally, to the recommended torque Page: 25 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Type 1 - Drive Pulley Without Governor, Without Kickstart

    - the washer (2) (the chamfer (A) facing the casing side) - the drum (3) - the adjuster washer (4) - the 4-leg spring (5) - the lining (6) Page: 26 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 25 (6) - Fit the spring washer (13) - Fit the washer (14) - Fit the nut (15) - Tighten the nut to the recommended torque Page: 27 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 26: Type 2 - Drive Pulley With Governor, Without Kickstart

    - the drum (3) - the adjuster washer (4) - the 2-leg spring (5B) - the 4-leg spring (5A) - the lining (6) Page: 28 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 27 (1) with the lining drive notches (6) - Remove tool P/N 69142 - Fit the nut (15) and tighten to the recommended torque Page: 29 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Type 3 - Drive Pulley With Governor, With Kickstart

    - the plain washer (8) - the nut (9) - Lock the bobweight support with pin wrench P/N 755586 - Tighten to the recommended torque Page: 30 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 29: To Fit The Magneto Flywheel

    (6) two bolts (4) To remove the coil assembly and the stator Type 2: 4-pole assembly - Fit the coil assembly (5) and its 2 bolts (3) Page: 31 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 30 - Tighten the nut (2) with the chamfered side facing inwards - Immobiliser le rotor avec l’outil réf 755586 - Tighten the nut to the recommended torque Page: 32 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Miscellaneous Operations

    MISCELLANEOUS OPERATIONS MISCELLANEOUS OPERATIONS Drive pulley assembly Composition of the drive pulley without governor Composition of the drive pulley with governor Page: 33 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Clutch Adjustment (With And Without Governor) Types 1 And 2

    - 7 and 9/10 de mm for the drive pulley without governor (type 1) -3 and 5/10 mm for the drive pulley with governor (type 2) After adjustment, check the functional clearance Page: 34 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Changing The Starting Jaws (With And Without Governor) Types 1 And 2

    - Rotating flange (1G) - Fixed flange (1A) - Nylon washers (12 and 13) Special tooling required - Governor fitting and removal support P/N 750411 Page: 35 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 34 (1F) Re-assembly Proceed in reverse order to disassembly Note: tighten the 32 mm nut to the recommended torque and close the washer locking tab Page: 36 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 35: Drive Pulley Assembly

    - Remove the 3 shoes (8) and the springs (9) Re-assembly Proceed in reverse order to disassembly To remove the drive pulley sprocket Special tooling required - Drive pulley sprocket removal tool P/N 754269 Page: 37 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 36 - Remove the nut (5) with the wrench - Remove the sprocket (2) Re-assembly Proceed in reverse order to disassembly Fit the nut locking plate (4) Page: 38 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 37: To Remove And Fit A Coil

    - Unsolder the harness connection wire (2) - Remove the clip (3) - Remove the coil (4) Note: The rest of the coil assembly coils cannot be serviced. Page: 39 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...

  • Page 38: To Change The Decompressor Assembly

    - Remove the spring (2) from the compressor body - Remove the decompressor casing (5) from the cylinder head Note: Do not remove the copper seal (6) from the cylinder head Page: 40 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 39 - Fit the spring (2), the valve (4) - Fit the lever (3) and the pin (1) - Flatten the end of the pin (1) with tool P/N 68048 and a drift Page: 41 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
  • Page 40 REF: 755903 www.peugeot-motocycles.com With a constant concern for improvement Peugeot Motocycles reserves the right to delete, modify, or add any quoted reference DC/PS/ATR printed in E.U. 07/2001 (photos non- contractual) Reproductions ou traductions, même partielles, interdites sans autorisation écrite de Peugeot Motocycles...

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