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WORKSHOP MANUAL
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Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................... 1 PRODUCTS DANGER SYMBOLS USED......................................................................................................... 3 CHARACTERISTICS......................................................................................................................................... 5 Capacities ..................................................................................................................................................5 SPECIAL IMPORTANT POINTS....................................................................................................................... 6 Oil and fuel.................................................................................................................................................6 TIGHTENING TORQUE..................................................................................................................................... 7 SPECIAL TOOLS .............................................................................................................................................. 8 DISASSEMBLY ............................................................................................................................................... 11 Putting the engine on the stand. ..............................................................................................................11 To remove the magneto flywheel. ............................................................................................................11 Removal of the starter motor....................................................................................................................12 Removal of the starter motor (Depending on model)...............................................................................12 Removal of the gearbox output pinion. ....................................................................................................12 Removal of the clutch cover. ....................................................................................................................13 Removal of the clutch...............................................................................................................................14 Removal of the crank assembly and balance shaft pinions. ....................................................................16 To remove the inlet manifold and valve. ...................................................................................................16 To remove the cylinder head/cylinder assembly.......................................................................................17 Removal of the piston. .............................................................................................................................17 Removal of the thermostat.......................................................................................................................18 Opening the engine casings. ...................................................................................................................19 Removal of the gearbox and the gear-change system. ...........................................................................20 Removal of the transmission input shaft. .................................................................................................23 Removal of the balance shaft...................................................................................................................24 Removal of the crankshaft. ......................................................................................................................24 Checking the crankshaft and conrod assembly........................................................................................25 REFITTING SPECIFIC COMPONENTS.......................................................................................................... 26 Fitting the crank assembly bearings.........................................................................................................26 Replacing the RH engine casing bearings...............................................................................................27 Replacing the LH engine casing bearings. ..............................................................................................27 Replacing the RH engine casing caged needle bearings (depending on the model). .............................28 Replacing the LH engine casing caged needle bearings (depending on the model)...............................29 Fitting the box output seal. .......................................................................................................................30 Fitting the gear-change shaft seal............................................................................................................30 Fitting the clutch lever seal.......................................................................................................................30
1 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS To fit the balance shaft. ............................................................................................................................31 Fitting the conrod and crankshaft assembly. ............................................................................................31 Fitting the gearbox. ..................................................................................................................................31 Fitting the left side casing. .......................................................................................................................34 Checking the piston. ................................................................................................................................36 Checking the piston rings.........................................................................................................................36 Fitting the piston.......................................................................................................................................36 Fitting the cylinder. ...................................................................................................................................37 Fitting the cylinder head...........................................................................................................................37 Fitting the right side O-ring. .....................................................................................................................38 Fitting the crank assembly and balance shaft pinions..............................................................................38 Fitting the clutch.......................................................................................................................................40 Adjusting the clutch control lever..............................................................................................................42 Fitting the starter system (depending on model) and the clutch cover.....................................................42 To fit the magneto flywheel. .....................................................................................................................43 MISCELLANEOUS OPERATIONS ................................................................................................................. 44 Removal of the water pump. ....................................................................................................................44 Fitting the water pump..............................................................................................................................44 Removing the oil pump and its drive pinions............................................................................................45 Fitting the oil pump...................................................................................................................................45
2 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Mbius band
Recyclable.
Irritant
The product can irritate the skin, eyes and repiratory organs.
Flammable
Corrosive
Avoid contact with the skin and clothes. The product can damage living Wear gloves, safety glasses and tissues or other surfaces. appropriate clothes such as a cotton overall. Do not breath fumes. The product can explode under certain circumstances (flame, Avoid impacts, friction, sparks and heat. heat, impact, friction).
Explosive
The product affects fauna and The ideal solution is to bring this product Hazardous to flora. Do not dump it in to your nearest household waste recycling the environment garbage cans, sinks or nature. centre.
Toxic
The product can seriously Avoid direct contact with the body even by affect health if it is inhaled, inhalation. If you feel unwell, seek medical ingested or in contact with skin. advice immediately. One of the product's Do not throw the used product in the component is toxic and can be dustbin. Take it back to the trader or to a hazardous to environment. For specific waste disposal site. example: Used batteries. People's safety can be seriously affected if the recommendations are not fully respected. People's safety can be seriously affected if the recommendations are not fully respected.
Compulsory gloves
People's safety.
3 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Important
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
Serious damage to the vehicle and in Good operating The operation must be carried certain cases a cancellation of the condition of the out in strict compliance with the warranty can be involved if the vehicle documents. recommendations are not fully respected. Note Operation that can be difficult. Indicate a note which gives key information to make the procedure easier. Indicate the specific procedures that shall be followed in order not to damage the vehicle.
Lubricate
Grease
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
GLU
Glue
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
New part
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
4 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS
50 cc Marking Type Cooling Bore x stroke Cubic capacity Max. power output Max. torque rating Gearbox Clutch Lubrication circuit Exhaust Starter motor Spark plug Magneto flywheel Fuel supply Ducati 85 W Dellorto carburettor 1.82 kW at 5250 rpm 5250 rpm 6 speed mechanical gearbox multi-disc, oil bath, and manually controlled Separate lubrication by piston pump, synchronized with the throttle grip Catalytic With catalytic system and pulsair valve Ducati 85 W NGK BR9ES Motori Minarelli 85W Dellorto carburettor ECU-controlled carburetion system Moric AM6 Single cylinder 2 stroke with balance shaft Liquid 40.3 x 39 mm 49.7 cc 50 cc Power-Up
Capacities
Gearbox 0.75 l: SAE 10W30
5 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
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. Before carrying out any work, leave the engine to cool for at least 2 hours.
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TIGHTENING TORQUE
TIGHTENING TORQUE
Cylinder head Cylinder casings Transmission cover Water pump Inlet manifold Conrod and crankshaft assembly gear Balance shaft pinion Clutch housing Clutch pressure plate Clutch thrust bearing locknut Starter motor Rotor Stator Flywheel magneto cover Gearbox drain plug Spark plug 18 Nm 11 Nm 11 Nm 11 Nm 11 Nm 75 Nm 60 Nm 75 Nm 5 Nm 27 Nm 11 Nm 52 Nm 3 Nm 4 Nm 18 Nm 25 Nm
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SPECIAL TOOLS
SPECIAL TOOLS
Tool N Designation Used with Tool N Designation Used with
064706
750539
Tie-wrap pliers
064710
64706
752237
064765
Engine mount
753411
Flywheel puller
068007
753708
64706
069098
64706
753709
64765
069104
Pin nut
64706
753726
Crank assy lip seal fitting tool for primary transmission side
750069
64706
753728
8 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
Tool N
Designation
Used with
Tool N
Designation
Used with
753730
753729
753731
756039
754041
755585
757990
9 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
Standard tools
Heat gun
Intertia type extractor tool for bearings from 6 to 18 mm Type: Facom U.49PJ3
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DISASSEMBLY
- Fit protective cap P/N 068007 to the end of the crank assembly. - Tighten flywheel extractor P/N 753411 on the rotor. - Lock the flywheel extractor and turn the thrust bolt until the rotor is released.
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DISASSEMBLY
We recommend tapping the bolts with a hammer and drift to facilitate slackening. The 3 bolts must be renewed once removed.
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DISASSEMBLY
- Remove the 8 bolts that secure the cover. - Remove the cover. - Remove the 2 centring pillars and the paper gasket.
13 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
- Remove the assembly (3) of 4 lined discs and 3 smooth discs. - Remove the primary shaft: The pusher (4) The ball (5) The push rod (6)
- Remove the clutch operating lever (7) with its spring (8) and its washer (9).
8 9
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DISASSEMBLY
- Fold down the clutch nut (10) lockwasher tab (11). - Lock the clutch main shaft (12) with tool P/N 753731. - Remove the nut and the washer.
- Remove the clutch main shaft (12), the splined bush (13), the cover (14), the plain washer (15) and the tapered washer (16).
15 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
- Remove the 2 pinions (20 and 34 teeth) and the key (4) from the crank assembly. - Remove the 34 tooth pinion and the key (5) from the balance shaft.
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DISASSEMBLY
- Check that the valve assembly blades and support are in perfect condition.
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DISASSEMBLY
When refitting, ensure that the degassing hole (A) is at the highest point.
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DISASSEMBLY
- Fit the protective cap P/N 68007 to the crank. - Fit to casing with tool P/N 64706 fitted with plate P/N 753708.
- Fix the assembly to the casing using 4 bolts (1). - Remove the engine mount adapter 2 spring pins. - Tighten the tool centre screw until the casings separate.
When opening the 2 casings, so that they open evenly, use a plastic mallet to tap alternatively on the ends of the secondary shaft and the speed selector.
19 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
- To remove the left casing. - Remove the 2 centring pins (2). - Refit the engine mount adapter 2 spring pins.
Recover the friction washers which may have been retained by the oil in the left casing.
- Remove the selector shaft (1) fitted with its 2 friction washers.
20 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
- Remove the circlips (6). - When refitting, ensure each part is fitted in the right position and the right way round. 2. 3. 4. 5. 6. 7. 8. 9. Plain washer Gear change plate Gear change shaft Return spring Circlip Bush Spring Backed-up washer
2 6 7 8 9 6
- Remove the fork shaft (10) from the secondary shaft. - Remove the upper fork (11) from the secondary shaft.
11
10
- Turn the selector cylinder (12) to lower the primary shaft fork (13) into the cylinder lower groove. - Remove the selector cylinder. - Remove the secondary shaft 2nd fork (14).
14
13
12
21 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
- At the same time, remove the secondary shaft and primary shaft assembly fitted with its fork.
Model before 2008 - Remove the friction washer (15) from the secondary shaft which due to the oil may have remained stuck in the right casing. - Remove the locking ball (16) and its thrust spring.
Model 2008 - Remove the locking ball (16) and its thrust spring.
15 A A 16
Plain bearing (A)
16
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DISASSEMBLY
12
11
10
13
15
7
- Remove the circlips and pinions using circlips pliers. - When refitting, ensure each part is fitted in the right position and the right way round. 7. Secondary shaft. 8. 1st gear pinion.
14
15
14
9. 3rd gear pinion. 10. 4th gear pinion. 11. 6th gear pinion. 12. 2nd gear pinion. 13. 5th gear pinion. 14. Circlip. 15. Friction washer.
When changing a pinion, we recommend changing the opposite one on the other shaft. The circlips must be renewed each time they are removed.
23 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
24 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
DISASSEMBLY
The runout at the crankshaft ends shall not exceed 0.04 mm and shall be measured at: - 50 mm from the transmission side end. - 50 mm from the flywheel magneto end.
25 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
The bearings and crank seals must be changed each time the engine casings are opened.
- Remove the seal. - Place one of the crankcases on its gasket seat surface and heat it ( 80 to 90C) until the bearing falls out by itself. - While the casing is expanded fit the new bearing fully home in its housing. - Fit a new seal in the left casing using tool P/N 753726.
The right hand side seal should be fitted after closing the casings, fitting the O-ring and the bush, in order to prevent the seal lips from being damaged or from turning inside out.
26 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Place the crankcase on its gasket seat surface, heat it (80 to 90 C) until the bearings fall out by themselves. - While the crakcase is expanded: Fit the new bearing (2) fully home in its housing, using bearing drift P/N 755039. Fit the new bearing (3) fully home in its housing, using bearing drift P/N 757990.
27 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Replacing the RH engine casing caged needle bearings (depending on the model).
- Using a heat gun, heat the crankcase to a temperature between 80 and 90C. - Use an inertia type extractor Facom P/N U49PJ3 to remove the caged needle bearings. 1. Use Facom type pliers P/N U49P3 to remove 10 mm diameter caged needle bearings. 2. Use Facom type pliers P/N U49P4 to remove 14.5 mm diameter caged needle bearings.
- Position the clamp of the inertia type extractor tool under the needle cage before pulling it out.
- While the crakcase is expanded: Install a new caged needle bearings (3) flush with the casing using push tool P/N 754041. Install a new caged needle bearings (4) flush with the casing using push tool P/N 753730. Finish to fit the caged needle bearing (4) fully home in its housing, using push tool P/N 753729
4 3
28 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Replacing the LH engine casing caged needle bearings (depending on the model).
- Using a heat gun, heat the crankcase to a temperature between 80 and 90C. - Use an inertia type extractor Facom P/N U49PJ3 to remove the caged needle bearings. 1. Use Facom type pliers P/N U49P3 to remove 10 mm diameter caged needle bearings. 2. Use Facom type pliers P/N U49P4 to remove 10 mm diameter caged needle bearings. - While the crakcase is expanded: Install a new caged needle bearings (3) flush with the casing using push tool P/N 754041. Install a new caged needle bearings (4) flush with the casing using push tool P/N 753730. Finish to fit the caged needle bearing (4) fully home in its housing, using push tool P/N 755039.
29 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
30 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
2 1
31 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- At the same time fit the secondary shaft and primary shaft assembly with its selector fork (3) into the right side casing.
- Fit the elbow fork (4) and the 5th gear idler pinion to the secondary shaft.
Model before 2008 - Fit the selector cylinder and its 2 washers. - Position the fork guide (3) in the selector cylinder intermediate groove.
Model 2008 - Fit the selector cylinder and its top washer. - Position the fork guide (3) in the selector cylinder intermediate groove.
32 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit the fork (5) to the 6th gear idler pinion. - Position the fork guide (4) in the selector cylinder lower groove. - Position the fork guide (5) in the selector cylinder upper groove.
- Fit the fork shaft (6). - Position the selector cylinder in 4th gear, with the mcanindus pin opposite the fork shaft. - Fit the selector shaft (7) fitted with its 2 friction washers.
33 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
3
- Fit the left side casing. - Tighten pin P/N 750069 at the end of the crank assembly.
34 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit tool P/N 64706 fitted with plate P/N 753708 to the pin. - Centre the assembly to the casing using 4 bolts (5). - Fit centring tool P/N 64710 to tool P/N 64706. - Tighten pin nut P/N 69104 until the casings are fully closed.
35 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit and tighten the 13 clamping bolts. Tightening torque: 11 Nm. - Fit the gear selector without tightening it. - Turn the primary shaft manually and check the gears change correctly. - Lightly grease the crank assembly and bearings with 2 stroke oil.
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The circlips must be changed every time they are removed. The circlip gaps must face upwards or downwards (2), but under no circumstances to the side.
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- Using tool P/N 753726, fit a new seal (3) with its lip facing the outside.
38 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit the crank assembly pinion (3), with the marked tooth to the outside. - Fit the balance shaft pinion (4) by lining up the tooth gap marked with 2 spots ((A)) with the mark of on spot ((A)) on the crank assembly pinion. - Fit the nut but do not tighten it. - Lock the balance shaft using a bolt (B) inserted into one of the threaded holes. - Turn the balance shaft pinion to bring the bolt into contact with a ribbing on the casing. - Tight the balance shaft nut (5). Tightening torque: 60 Nm. - Fit the pinion (6), with the spotfacing towards the outside, and fit nut (7). - Tighten the crank assembly pinion. Tightening torque: 75 Nm.
39 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Lock the clutch main shaft with tool P/N 753731 - Tighten the nut. Tightening torque: 75 Nm. - Fold over the clutch nut washer locking tab. - Fit the clutch control lever with its spring and washer. - To the primary shaft, fit the piston (8), the ball (9) and thrust rod (10).
- Fit the clutch discs starting with a lined disc (11) and then alternate smooth and lined discs (12).
40 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- When re-assembling, ensure that the marks (A) on the smooth discs are offset by 120 from the others.
- Fit the pressure plate (13) lining up the arrow (B) on the plate with the round imprint (C) on the clutch main shaft. - Fit the pressure plate springs (14) and the 4 bolts and washers (15). Tightening torque: 5 Nm.
41 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Fitting the starter system (depending on model) and the clutch cover.
- Fit the spring (1) to the starter shaft. - Fit the starter dog (2), the starter release mechanisms (A) lining up with the return spring arm (B). - Fit the starter motor dog (3).
- Fit the 2 locating pins and a new paper gasket. - Fit the clutch cover. - Turn the crank assembly by hand, if necessary, to mesh the water pump pinion with the crank assembly pinion. - Fit the cover 8 fixing bolts. Tightening torque: 11 Nm. - Fit and gently operate the kickstart pedal and hold it in position. - Fit the kickstart shaft bump stop. Tightening torque: 30 Nm. - Release the kickstart pedal.
42 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit the rotor to the crank ensuring it is positioned on the key. - Lock the rotor with the adjustable pin wrench P/N 752237. - Fit and tighten the rotor nut. Tightening torque: 52 Nm. - Fit the gasket and the flywheel magneto cover. Tightening torque: 4 Nm.
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MISCELLANEOUS OPERATIONS
A new circlip and paper gasket must be used each time they are removed.
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MISCELLANEOUS OPERATIONS
- Remove: The (2) circlips. The pinion (3). The drive pin (4). The washer (5). The pump shaft and its washer (6). The pinion with its 2 washers(7). - Check the condition of the oil pump shaft. If it shows signs of wear, change the shaft.
New circlips and O-ring must be used each time they are removed.
45 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
P/N:757067
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. 06/2008 (non contractual pictures)