moteur 125-150cc 4t-04b

WORKSHOP MANUALTECHNICAL NETWORK LEADERSHIP

WORKSHOP MANUAL

-

125 CC/150 CC 4-STROKE ENGINE

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

Workshop manual

Technical network leadership


TABLE OF CONTENTS

1Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS

TABLE OF CONTENTS........................................................................................................ 1

CHARACTERISTICS............................................................................................................ 3

Capacities............................................................................................................................ 3

SPECIAL IMPORTANT POINTS.......................................................................................... 4

Oil and fuel .......................................................................................................................... 4

TIGHTENING TORQUE........................................................................................................ 5

SPECIAL TOOLS ................................................................................................................. 6

DISASSEMBLY .................................................................................................................... 9

Putting the engine on the stand........................................................................................... 9

Removal of the primary transmission cover......................................................................... 9

Removal of the drive pulley................................................................................................ 10

Removal of the driven pulley.............................................................................................. 10

Removal of the rocker cover. ............................................................................................. 11

Removal of the chain tensioner. ........................................................................................ 11

Removal of the RH cover / ignition coil and sensor. .......................................................... 12

Removal of the rotor. ......................................................................................................... 13

Removal of the cylinder head. ........................................................................................... 14

Removal of the temperature sensor. ................................................................................. 16

Removal of the thermostat. ............................................................................................... 16

Removal of the camshaft and/or rockers. .......................................................................... 16

Removal of the valves or valve stem seals. ....................................................................... 17

Removal of the cylinder. .................................................................................................... 19

Removal of the piston........................................................................................................ 19

Removal of the oil pump. ................................................................................................... 20

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

TABLE OF CONTENTS


Checking the crankshaft and conrod assembly. ................................................................ 25

Removal of the secondary transmission cover. ................................................................. 26

Removal of the secondary transmission............................................................................ 26

REFITTING SPECIFIC COMPONENTS............................................................................. 28

Installing the crankshaft LH bearing. ................................................................................. 28

Installing the water pump inside the RH crankcase........................................................... 28

Assembly of the engine casings. ....................................................................................... 30

Installing the piston rings on the piston. ............................................................................ 32

Fitting the piston. ............................................................................................................... 32

Fitting the cylinder ............................................................................................................. 33

Fitting the cylinder head. ................................................................................................... 33

Setting the timing............................................................................................................... 35

Installing the valve clearance............................................................................................. 37

Checking the valve clearance............................................................................................ 37

Refitting the rocker cover. .................................................................................................. 38

MISCELLANEOUS OPERATIONS .................................................................................... 39

Removal of the oil filter. ..................................................................................................... 39

Removal of the water inlet pipe. ........................................................................................ 39

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

CHARACTERISTICS


CHARACTERISTICS

Capacities

125 cc 150 cc 125 cc EFI 150 cc EFI

Marking FD1 FD2 FD4/FD5 FD4

Type 4-stroke single-cylinder

Cooling Liquid

Bore x stroke 57 x 48,9 mm 57 x 58,9 mm 57 x 48,9 mm 57 x 58,9 mm

Cubic capacity 124,8 cc 150 cc 124,8 cc 150 cc

Max. power output 9 kW at 8750 rpm 10 kW at 8450 rpm 9 kW at 8750 rpm 10 kW at 8450 rpm

Max. torque rating 7250 rpm 6500 rpm 7250 rpm 6500 rpm

Lubrication Trochoidal pump

Transmission By 2 variable pulleys and V-type belt

Clutch Centrifugal automatic

Exhaust Non-catalytic

Starter motor Mitsuba 440 W Mitsuba 470 W Mitsuba 440 W Mitsuba 470 W

Spark plug NGK CR7E NGK CR7EB

Magneto flywheel Mitsuba 235 WMitsuba

235 W/330 WMitsuba 235 W

Fuel supply Carburettor Indirect electronic injection (EFI)

Engine oil 1.25 l SAE 10W40

Relay box oil 0.12 l SAE 80W90 life lubricated

SPECIAL IMPORTANT POINTS


SPECIAL IMPORTANT POINTS

Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

Never run the machine with a petrol/oil mixture.

The fuel pipes must be changed if they show 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 orsparks. Work in a clear and well-ventilated area.

TIGHTENING TORQUE


TIGHTENING TORQUE

Cylinder head 1.8/2.3 m.daNCylinder casings 1 m.daNTransmission cover 1 m.daNRH casing cover 1 m.daNAutomatic tensioner 1 m.daNOil control valve 4 m.daNTemperature sensor 1 m.daNStarter motor 1 m.daNRotor 7 m.daNStator 1 m.daNEngine speed sensor 0.7 m.daNDrive pulley 7 m.daNDriven pulley 7 m.daNSpark plug 1 m.daNCamshaft gear 2.3 m.daN

SPECIAL TOOLS


SPECIAL TOOLS

64706Casing extractor and opening tool

Casing opening plate + pin

69098Protective end-piece large model

64706

64710Shouldered centering tool

64706 69104 Pin nut

750 + 64711 + 64712 + 64754

64712Pin Ø12 pitch 125 69104 750539

Tie-wrap pliers

64765Engine mount

Engine mount adapter

752000Piston circlip pliers

68570Flywheel clamp

752235 1/2 extension68994 or 753977

68994

Torque wrench 8 N.m to 54 N.m

Extension 752235Adapter 752236

7522361/2 3/8 adapter

68994 or 753977

69092External circlips pliers

752237Adjustable pin wrench

SPECIAL TOOLS


753711

Engine mount adapterElyseoElystar

64765 754033Crankshaft locking pin

753977

Torque wrench 30 N.m to 150 N.m

752235extensi

on752236adapte

r

754034Camshaft locking pin

754003Flywheel puller

69098 754035 Valve lifter

754005Clutch compression tool

754046 75404046 mm pipe wrench

754005

754006Casing opening plate

64706 754041Timing casing seal drift

754007Mechanical seal drift

755585Bearing extractor tool

754008Water pump seal drift

756717

Engine mount adapterJetforce

64765

754009Water pump pin drift

757035Fixed flange locking tool

SPECIAL TOOLS


757988Water pump bearing drift

757989Water pump bearing drift

757990

Crankcase seal installation buffer

DISASSEMBLY


DISASSEMBLY

Putting the engine on the stand.

- Put the engine on the jig:

P/N 753711 for engines FD1, FD2 and FD4.

P/N 756717 for engines FD5.

- Put the assembly on stand P/N 64765 clamped in the jaws of a vice.

- Empty the oil from the engine

Note: Every time oil is changed, the filter must be cleaned and the copper seal changed.

- Tightening torque: 4 m.daN.

Removal of the primary transmission cover.

- Remove the 8 bolts that secure the cover. - Remove the transmission cover and the

2 centring pillars.


.

756717753711

64765

DISASSEMBLY


Removal of the drive pulley.

- Remove the starter dog. - Hold the fixed flange with tool P/N 757035.- Remove the nut (1) and washer (2) from the

fixed flange- Remove the fixed flange.


- Remove the belt (3). - Remove the drive pulley (4) with the guide

hub (5).

Removal of the driven pulley.

- Immobilize the clutch drum using the ajustable pin wrench P/N 752237 or the flywheel clamp P/N 68570.

- Remove the nut. - Remove the clutch drum and the clutch and

drive pulley assembly.


757035

2 1

5

4 3

1

68570

DISASSEMBLY


Removal of the rocker cover.

- Remove the 5 fixing bolts. - Remove the rocker cover. - Remove the paper gasket.


Note: The O-ring must be changed every time it is removed.

Every time the rocker cover is removed and re-installed, make sure the plug (1) is over the gauge hole of the cylinder head.

Removal of the chain tensioner.

- Remove the screw and spring from the tensioner (1).

- Remove the 2 mounting screws (2) from the tensioner body.

1

1

2

DISASSEMBLY


- Remove the chain tensioner and slacken it by pressing the ratchet tooth (A).

- Remove the paper gasket.


Removal of the RH cover / ignition coil and sensor.

- Remove the 8 bolts that secure the RH cover. - Remove the cover.


- Remove the paper gasket (1) and the 2 locating pins (2).

A

21

DISASSEMBLY


- Remove the engine speed sensor 2 fixing bolts (3) and the stator assembly 3 fixing bolts (4).

- Remove the stator and sensor assembly (3).

- Setting the engine speed sensor gap: 0.3 to 1.4 mm.


Note: The oil flowing inside the cover and the crankshaft stem shall lubricate the conrod big end..

The tighteness of the oil lubrication system between the cover and the RH stem of the crankshaft is provided by a seal

The seal is placed in the casing with its lip on the casing side.

A circlip (5) holds the seal in its housing

The condition of the seal shall be checked every time the cover is removed. And if necessary it shall be replaced using the timing casing seal drift P/N 754041.

Removal of the rotor.

- Immobilize the rotor (1) using the flywheel clamp P/N 68570

- Remove the nut.

3

4

5

168570

DISASSEMBLY


- Fit protective cap P/N 69098 to the end of the crank assembly.

- Tighten flywheel extractor P/N 754003 on the rotor.

- Lock the flywheel extractor and turn the thrust bolt until the rotor is released.

- Remove the rotor.


.

Note: When re-installing, make sure the key (1) is properly positioned on the crankshaft stem as shown in the figure.

Removal of the cylinder head.

- Remove the spark plug. - 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..

69098

754003

1

DISASSEMBLY


- Immobilize the camshaft gear (1) using the adjustable pin wrench P/N 752237.

- Remove the camshaft gear bolt. - Remove the camshaft gear. - Hang the timing chain.

- Remove the chain guide pad (2) (which is fitted inside the cylinder head on the exhaust side).

- Loosen the 2 washer screws (3). - Gradually loosen in a crosswise order the 4

nuts which secure the cylinder head (4).- 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).

1

752237

3

2

4

5

6

DISASSEMBLY


Removal of the temperature sensor.

- The temperature sensor (1) is screwed into the cylinder head.


Removal of the thermostat.

- Remove the 2 bolts and the thermostat valve (1).

- Remove the thermostat (2).


Note: The drain bolt is located on the cover. Tighteness of the bolt is provided by a fiber seal.

Removal of the camshaft and/or rockers.

- Remove the 3 screws which secure the stopper plate (1).

- Remove the stopper plate. - Remove the camshaft (2). - 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.

1

21

2

1

DISASSEMBLY


-

- Remove the 2 rocker shafts (3). - Remove the inlet (4) and exhaust (5) rockers.

When re-installing, the lubrication holes (A) of the shafts shall be directed towards the stopper plate.

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.

5

4

3

A

754035

DISASSEMBLY


Remove:

- The upper cup (1).- The spring (2) (when dismantling notice in

which direction it is so that you will replace it in its initial position when reassembling).

- The lower washer (3). - The valve (4). - Remove the 2nd valve in the same way.

Note: When re-installing, lubricate the 2 half cones (5) so as to hold them in the groove of the valve's stem.

Do not place the 2 half cones into the cup forcefully with the tool when decom-pressing the spring.

In case you remove the seal of a valve stem (6), replace it with a new seal after removing all the carbon residues which could remain inside the cylinder head.

Important: When re-installing, the camshaft bearings, the rocker shafts and the contact between the rockers and the valves shall well lubricated in order to avoid any risk of seizure when starting the engine (use a Molykote type grease). Seals and valve stems must be lubricated.

2

3

4

1

5

5

6

DISASSEMBLY


Removal of the cylinder.

- Remove the front bolt (1) of the cylinder (located beside the oil pressure swich).

- Remove the cylinder.

- Remove the base gasket (2) and the 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.

1

3

2

1

752000

DISASSEMBLY


Removal of the oil pump.

- Remove the 2 screws which secure the 1st anti-splash plate (1).

- Remove the plate.

.

- Remove the 2 circlips (2) from the plastic gears (3) which drive the water pump and 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.

1

2

3

4

5

DISASSEMBLY


- Remove the 3 screws which secure the oil pump (6).

- Remove the oil pump.


Note: Before re-assembling, lubricate the oil pmup by dipping it into a pan con-taining clean motor oil.

6

DISASSEMBLY


Removal of the RH crankcase half.

- Remove the screw which secures (1) the chain tensioner slipper (2).

- Remove the chain tensioner slipper.


- Remove the timing chain and notice its direction of rotation.

- Remove the 2 bolts that secure the starter motor (3)

- Remove the starter motor.


Note: Check the condition of the starter motor O-ring.

- Remove the 8 bolts. One of which is located on the LH casing..

- Remove the RH casing. - Remove the 2 centring pillars and the paper

gasket.

Note: No tools are necessary to remove the RH casing, as the bearing is secured to the cranshaft and conrod ass'y.


Check and if necessary clean the water pump drain hole (A).

1

2

3

A

DISASSEMBLY


Removal of the oil discharge valve.

- The discharge valve (1) is screwed without any seal in the casing.


Removal of the water pump.

- Unscrew the turbine (1) from the drive shaft (2) while immobilizing it using a 2 mm diameter drift in (A).

- Remove the circlip (3) located on the bearing side.

- Drive out the bearing (4) on the timing side by pushing it out over the pump drive shaft.

- Drive out the mechnical joint (5) from the turbine side.

- 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..

1

1

245

6

7

3 A

DISASSEMBLY


Removal of the crankshaft.

- Remove the 2 screws which secure the water inlet pipe (1).

- Remove the water inlet pipe and the O-ring.


- Fit the protective cap P/N 69098 to the crank. - Fit to casing with tool P/N 64706 fitted with

plate P/N 754006.

- Fix the assembly to the casing using 4 bolts (2).

- Tighten the tool centre screw holding the crank with one hand on the other side until it is fully extracted.

- 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.

1

64706

75400669098

2

2

DISASSEMBLY


Checking the crankshaft and conrod assembly.

- Using a set of shims, check the big end side play.

- The maximum side play on the conrod end must not exceed: 7/10 mm.

The out-of-round values measured on the ends of the crank should not exceed 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

DISASSEMBLY


Removal of the secondary transmission cover.

Note: Use a drip pan to catch the transfer box oil when the cover is removed.

Filling and checking the transfer box oil level is through the cap (1).

- Remove the transmission cover 5 fixing bolts. - Remove the cover with the primary shaft (2). - Tightening torque: 1 m.daN.

Note: The primary shaft can be drifted out of the cover using a mallet.

Removal of the secondary transmission.

- Remove the 2 centring pillars and the paper gasket (1).

- Remove the first friction washer (3) from the intermediate shaft (4).

- Remove the secondary shaft (5).

Note: Make sure not to damage the gasket on the wheel side when removing the secondary shaft.

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.

21

21

54 3

A

DISASSEMBLY


- Remove the intermediate shaft and its second friction washer (6) located behind it. 6

REFITTING SPECIFIC COMPONENTS



Installing the crankshaft LH bearing.

- The bearing is positioned into the casing by means of a press.

- Fit the seal into the casing using the installation buffer P/N 757990.

Installing the water pump inside the RH crankcase.

- Fit the caged needle bearing (1) into the casing on the turbine side using the pin drift P/N 754009.

- Fit the seal (2) using the drift P/N 754008, the seal's lips shall be directed towards the caged needle bearing..

757990

1

754009

2

754008



- Install the bearing (3) on the drive shaft (4) by pushing it by the inner cage using bearing drift P/N 757988.

- Fit the drive shaft and bearing assembly by the outer cage using the bearing drift P/N 757989.

- Install the circlip (5) on the bearing side.

3

4

757988

757989

5



- Fit the mechanical joint (6) using the seal drift P/N 754007.

- Install the turbine.

Note: The new mechanical joint is delivered with a blocking product coated on the surface which is in contact with the casing. Make sure not to damage this product when handling the joint.

Assembly of the engine casings.

- Insert the crank assembly into the LH casing bearing.

- Tighten pin P/N 64712 at the end of the crank assembly.

- Fit tool P/N 64706 fitted with plate P/N 754006 to the pin.

- Centre the assembly to the casing with 4 bolts (1).

- Fit centring tool P/N 64710 to tool P/N 64706. - Tighten pin nut P/N 69104 on pin P/N 64712

in order to bring the crankshat assembly into contact with the bearing ensuring that the crank is pointing towards the cylinder side.

Note: Hold the crank assembly by the RH side using the rotor fitted on the key.

6

754007

64712

69104

6470664710

754006



- Fit the 2 centring pins (2) to the LH casing and a new paper gasket (3) do not use oil or grease.

- Place the RH casing over the LH casing assembly.

Note: No tools are necessary for assem-bling the casings, which shall be car-ried out without effort.

- Fit and tighten the 8 fixing bolts .


- Check the crank assembly turns freely in the casings.

- Trim the casing gasket in (A). - Lightly grease the crank assembly and

bearings with 4 stroke oil.

- Place the inlet pipe and the O-ring (check the condition of the O-ring and if necessary change it)..


2

3

2

A



Installing the piston rings on the piston.

Proceed in the following order in order to install the oil control rings.

- Install the spring (1) (no special direction).- Install the 2 piston rings (2) on each side of

the spring by offsetting the gap of each ring (no special direction).

- Install the compression ring (3) by placing the"TOP" mark upwards.

- Install the top compression ring (4) by placing the "0" mark upwards.

Fitting the piston.

- Install the piston with the arrow engraved on the piston crown, on the timing side.

Note: Lubricate the piston pin.

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.

4

3

2

1

1



Fitting the cylinder

- Install the cylinder base gasket and the 2 guiding pillars on the crankcase.

- Position the piston ring gap as follows.1. Top compression ring gap.2. Compression ring gap.3. Upper oil control ring gap.4. Lower oil control ring gap.

Note: Lubricate the cylinder.

- Fit the timing belt through the cylinder timing well.

- Compress the piston rings and fit them manually one after the other into the cylinder barrel.

- Fit the cylinder front screw (beside the oil temperature switch).

- Install the the chain tensioner slipper (2).

Note: The cylinder skirt is chamfered in order to fit the piston rings easily.

Fitting the cylinder head.

- Fit the 2 guiding pillars (1) and the metal gasket (2) on the cylinder.

- Fit the timing chain through the cylinder head timing well.

120°

90°

90°

1

4

2

3

2

1

1

2



-

- Install the cylinder head. - Install the chain guiding slipper on the

crankcase pin (A) and the housing (B) in the crankcase on the exhaust port side.

Method for tightening the cylinder head.

Standard nut (A).This is carried out in two steps:

• 1st step: - Fit the 4 washers. - Tighten the 4 nuts (1) and the 2 washer

screws (2) slightly. - Pre-tighten the 4 nuts in a crosswise order to

18 Nm and the 2 washer screws to 8 Nm. • 2nd step:

- Torque the 4 nuts in a crosswise order to 23 Nm and the 2 washer screws to 10 Nm.

Collar nut (B).This operation is carried out in several steps:

- Slightly lubricate the studs.- Fit the 4 washers.- Tighten the 4 nuts (1) and the 2 washer

screws (2) slightly.- Torque the nuts to 6 Nm.- Pre-tighten the 4 nuts in a crosswise order to

15 Nm and the 2 washer screws to 8 Nm.- Loosen each nut by 90° and re-tighten them to

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.

A

B

B

A

12



Setting the timing.

Every time you set the timing you must:

- Empty the oil from the engine. - Remove the RH cover. - Remove the flywheel magneto rotor. - Remove the automatic tensioner.

- Fit the locking pin P/N 754033 in the crankcase gauge hole.

- Rotate the crankshaft until the pin enters the crankshaft gauging hole.

- Install the camshaft gear (1) on the camshaft. - Immobilize the camshaft gear using the

adjustable pin wrench P/N 752237. - Tighten the camshaft gear screw.

- Remove the cylinder head gauging hole plug. - Insert the pin P/N 754034 into the cylinder

head gauging hole. - Rotate the camshaft until the pin enters the

camshaft gauging hole. - Remove the camshaft gear.

754033

1

754034



- Place the camshaft gear (1) in the timing chain so that you can immobilize it using the adjustable pin wrench P/N 752237.

- Fit the camshaft gear screw but do not tighten it.

- Fit the chain tensioner seal (respect the position of installation).

- Install the chain tensioner and the 2 attachment screws.

- Install the spring and its screw.

- Tightening torque: 1 m. daN.

- Immobilize the camshaft gear using the adjustable pin wrench P/N 752237.

- The lower strand of the chain shall be kept taut.

- Tighten the camshaft gear screw.

- Tightening torque: 2.3 m.daN.

Checking the timing:

- Remove the 2 timing pins. - Rotate the engine twice: 2 revolutions in the engine's operating direction (clockwise). - 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.

1



Installing the valve clearance.

- Rotate the engine manually either by means of the pulley or the rotor (as appplicable) in the direction of operation (clockwise) so as to bring the rocker pads over the cam lobes.

- Loosen the lock nut of the rocker adjustment screw.

- By means of feeler gauges, adjust the clearance of every valve by acting on the rocker set screw.

Clearances:

• 10/100 at the intake. • 25/100 at the exhaust.

- Immobilize the rocker set screw. - Tighten the nock nut.

Checking 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.



Refitting the rocker cover.

Important:

Make sure you fit the plug (1) over the cylinder head gauging hole.

- Install a new paper gasket. - Install the rocker cover and its 5 scews.


If you forget to fit the plug (1) the oil pressure will be low and some components could seize.

1

MISCELLANEOUS OPERATIONS



Removal of the oil filter.

- Remove the 2 screws which secure the oil filter cover (1).

- Remove the cover and the O-ring (2) (check the condition of the O-ring and change it if necessary).

- Remove the oil filter (3).

Note: The oil filter has no installing direc-tion.


Removal of the water inlet pipe.

- Remove the 2 screws which secure the water inlet pipe (1).

- Remove the water inlet pipe and the O-ring (2) (check the condition of the O-ring and change it if necessary).


1

3

2

2

1



Fitting the drive pulley assembly.

- Fit the drive pulley with its guide hub (1) onto the crank assembly.

- Fit the belt (2) to the guide hub. - Fit the fixed flange (3) to the crank assembly

checking it is properly positioned on the crank assembly splines.

- Fit the washer (4) and the nut and hand tighten.

- Hold the fixed flange with tool P/N 757035. - Tighten the nut.


It is forbidden to use a power driver, this may upset the crank position.

Precautions when refitting the drive pulley: Drive pulley components shall neither be suppressed nor have their size reduced. Any modifications may cause the nut to tighten against the crankshaft splines instead of thefixed flange and damage the crankshaft splines.

Changing the drive pulley bearings.

- Remove the 8 screws which secure the primary transmission cover.

- Remove the transmission cover. - Lock the fixed flange (1) with tool P/N 757035.- Remove the nut (2) of the fixed flange. - Remove the fixed flange. - Remove the belt. - Remove the guide hub and the drive pulley.

4

2

3 1

1

757035

2



- Remove the holder (3) and its (4) plastic guides.

- Remove the moving flange (6) 6 bearings (5).

Note: The bearings must be changed if they show major signs of wear.

Re-assembly:

Proceed in reverse order to disassembly and do not grease the bearings.

Grease the moving flange bore lightly (high temperature grease).

Removal of the clutch lining assembly.

- Remove the transmission cover 8 fixing bolts. - Removal of the primary transmission cover. - Lock the clutch drum with the pin wrench

P/N 752237. - Remove the nut. - Clamp the 2 strands of the belt to lower it

between the flanges. - Remove the clutch drum, the clutch drive

pulley and driven pulley assembly and belt.

- Compress the clutch drive pulley and driven pulley assembly with the tool P/N 754005 clamped in the jaws of a vice.

- Remove nut (1) using spanner P/N 754040 - Slacken tool P/N 754005.

4

35

6

754040754005

1



- Remove the clutch linings (2), the upper centring sleeve (3), the spring (4), and the lower centring sleeve (5).

- Remove the 3 pins (6) from the variable speed drive seat

- Separate the fixed (7) and rotating (8) flanges.

Refitting the clutch lining assembly.

- After checking the 2 lip seals (1) and the 2 O-rings (2) of the rotating flange (7) are in good condition, grease the governor seat 3 pins (6) (high temperature grease) and assemble the parts in reverse order to removal.

- Compress the clutch drive pulley and driven pulley assembly with the tool P/N 754005.

- Tighten the nut. - Tightening torque: 4.5 m.daN.

Before fitting the clutch drive pulley and driven pulley to the input shaft, fit the belt into the pulleybottom by opening the flanges by hand.

- Fit the clutch drive pulley and driven pulley assembly. - Fit the clutch cover. - 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.

4 52 3

6 87

7

1

2


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)

moteur 125-150cc 4t-04b

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