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WORKSHOP MANUAL
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Workshop manual
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TABLE OF CONTENTS.
TABLE OF CONTENTS.
TABLE OF CONTENTS..................................................................................................................................... 1
PRODUCTS DANGER SYMBOLS USED......................................................................................................... 3
CHARACTERISTICS......................................................................................................................................... 5
Engine........................................................................................................................................................5
Capacities ..................................................................................................................................................5
Chassis ......................................................................................................................................................5
Dimensions and weight..............................................................................................................................6
Tyres ..........................................................................................................................................................6
Brakes ........................................................................................................................................................6
SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 7
To be checked at each service...................................................................................................................7
Service operations .....................................................................................................................................7
Battery preparation (Except battery without maintenance)* ......................................................................8
Installing the battery vent hose. .................................................................................................................8
New machine preparation ..........................................................................................................................8
SPECIAL IMPORTANT POINTS....................................................................................................................... 9
Oil and fuel.................................................................................................................................................9
Starting up after overhauling the engine ....................................................................................................9
TIGHTENING TORQUES ................................................................................................................................ 10
Engine part ..............................................................................................................................................10
Body panels .............................................................................................................................................10
Cycle part.................................................................................................................................................11
Standard ..................................................................................................................................................11
SPECIAL TOOLS ............................................................................................................................................ 12
LOCATION OF COMPONENTS...................................................................................................................... 14
1
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TABLE OF CONTENTS.
BODY PANELS ............................................................................................................................................... 15
Location of body components ..................................................................................................................15
Body component sequence of disassembly.............................................................................................16
Removal of the rear storage compartment ..............................................................................................17
Removal of the rear cover assembly and mudflap ...................................................................................17
Removal of the front storage compartment..............................................................................................19
Removal of the rear shield panel .............................................................................................................19
Removal of the front shield panel.............................................................................................................20
Removal of the footboard.........................................................................................................................21
Removal of the instrument cluster ...........................................................................................................22
SERVICE OPERATIONS................................................................................................................................. 23
Removal of the spark plug .......................................................................................................................23
Replacing the air filter ..............................................................................................................................23
Front brake pads ......................................................................................................................................24
Replacing the brake pads ........................................................................................................................24
Checking the brake fluid level ..................................................................................................................25
Rear brake linings ....................................................................................................................................26
Transmission ............................................................................................................................................29
Checking the drive belt ............................................................................................................................31
Checking the clutch linings.......................................................................................................................31
Replacing the clutch lining assembly .......................................................................................................32
Removal of the fuel filter ..........................................................................................................................33
MISCELLANEOUS OPERATIONS ................................................................................................................. 34
Removal of the fork ..................................................................................................................................34
Replacing the bearings of the steering system ........................................................................................34
Steering system tightening method..........................................................................................................36
Removal of the fuel pump ........................................................................................................................38
Removal of the fuel gauge .......................................................................................................................38
Removal of the fuel tank ..........................................................................................................................38
Removal of the carburettor.......................................................................................................................40
Removal of the float, needle valve and jets....................................................................................................... 41
Removal of the engine speed adjuster screw and mixture control screw. ........................................................ 42
Reassembly .............................................................................................................................................43
Removal of the power unit .......................................................................................................................45
2
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Mbius band
Recyclable.
Irritant
Flammable
Corrosive
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
Do not throw
away into a
garbage can
Compulsory
gloves
3
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People's safety
Important
E
GLU
Note
Lubricate
Grease
Glue
New part
4
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CHARACTERISTICS
CHARACTERISTICS
Engine
Marking
Type
Cooling
B1E400MB
2-stroke single-cylinder
Horizontal cylinder
By a circulation of forced air by means of a turbine on the flywheel
magneto
Bore x stroke
39.9 x 39.8 mm
Cubic capacity
49.9 cc
3 kW at 7000 rpm
4 Nm at 5800 rpm
Compression
Fuel supply
Carburettor. PZ12
Lubrication
Transmission
Clutch
Centrifugal automatic
Exhaust
Catalytic
Starter motor
Spark plug
NGK BPR7HS
Electrode gap: 0.6 mm
Magneto flywheel
90 W
Capacities
Relay box oil
Fork oil
Fuel tank
8.5 l
Oil tank
1.3 l
Chassis
Chassis
Front suspension
Rear suspension
Steel tube
Hydraulic telescopic fork. 32 mm
Travel: 75 mm
Combined spring and hydraulically-damped shock absorber
Travel: 65 mm
5
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CHARACTERISTICS
1923 mm
Width at handlebar
670 mm
1170 mm
Wheelbase
Saddle height
1337 mm
786 mm
Unladen weight
95 kg
Tyres
Front wheel rim
Front tyre
120/70 - 12
1.8 bars
Rear tyre
120/70 - 12
2 bars
Brakes
Front brake
200 mm - 3.5 mm
Rear brake
110 mm
4 mm
Engine marking
1
B
M X
00 X
E4 XX
B1 XX
XX
*VGAV
1AAAA
0JXXX
XXX*
Chassis markings
2
(1) number and manufacturer's plate
6
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Service operations
500 kms or
1 months
Every
5000 kms
Every
10000 kms
Every
20000 kms
500 kms
Every
2500 kms
Every
5000 kms
Every
10000 kms
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
V
C
V
V
V
C
V
V
V
C
V
V
V
C
V
V
V
R
V
C
V
R
R
R
R
G
V
R
R
R
R
G
V
R
R
Service operations
Spark plug
Air filter
Drive pulley bearings and guides
Transmission belt
Kick starter mechanism
Setting the carburettor
Petrol filter
Fork oil
Brake fluid
Code
Time required for maintenance
9100
9300
9400
9600
0.5
1.3
1.4
7
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8
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Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc.
The air pipe between the air pump and the exhaust is specific owing to its heat resistance
properties.
Should it be changed, replace it with a genuine pipe
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.
9
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TIGHTENING TORQUES
TIGHTENING TORQUES
Engine part
Drive pulley
Driven pulley
Clutch plate and shoes
Transmission cover
Relay box cover
Stator
Engine speed sensor
Rotor
Turbine
Starter motor
Spark plug
Cylinder head
Inlet manifold
Crankcase
40 Nm
45 Nm
40 Nm
10 Nm
10 Nm
10 Nm
5 Nm
40 Nm
7 Nm
10 Nm
20 Nm
12 Nm
10 Nm
10 Nm
Body panels
Front mudguard
Handlebar cover
Front shield panel
Rear shield
Bottom panel
Floor panel
Saddle storage compartment
Rear panels
Grab handle
Rear mudguard
8 to 10 Nm
2 to 4 Nm
2 to 4 Nm
2 to 4 Nm
2 to 4 Nm
6 to 8 Nm
8 to 10 Nm
6 to 8 Nm
20 to 25 Nm
2 to 4 Nm
10
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TIGHTENING TORQUES
Cycle part
Front wheel spindle
Rear wheel spindle nut
Linkrod to engine pivot
Linkrod to frame pivot
Shock absorber top mount
Shock absorber bottom mount
Exhaust to cylinder mounting nut
Exhaust to casing mounting bolt
Upper cone (in 2 operations)
Upper cone locknut
Steering locknut
Front brake caliper
Front brake disc
Handle bar
65 Nm
100 Nm
60 Nm
60 Nm
45 Nm
22 Nm
15 Nm
20 Nm
40/23 Nm
Hand tightened
70 Nm
25 Nm
22 Nm
25 Nm
Standard
Nut and bolt 5 mm diameter
Nut and bolt 6 mm diameter
Nut and bolt 8 mm diameter
Nut and bolt 10 mm diameter
Nut and bolt 12 mm diameter
5 Nm
10 Nm
22 Nm
35 Nm
55 Nm
11
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SPECIAL TOOLS
SPECIAL TOOLS
Tool N
64706
Designation
Used
with
Casing
754006
extractor and
750069
opening tool
Tool N
Designation
750539
Tie-wrap
pliers
Used
with
64710
Shouldered
centering
tool
64706
750808
Thrust
washer
64765
Engine
mount
755982
752000
Piston circlip
pliers
68007
Protective
end-piece 755985
small model
752127
Clutch
compression 756725
tool
69098
Protective
end-piece
large model
64706
752237
Adjustable
pin wrench
69104
Pin nut
750069
753726
Steeing head
cup push tool
750069
Pin 10
pitch 125
754006
Modified
casing
opening
plate
69104
12
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64706
67706
SPECIAL TOOLS
Used
with
Designation
756668
Crank
assembly lip
seal tool
64765
756725
38 mm pipe
752127
wrench
Casing
68007
opening tool
757860
Steering tool
757990
Steeing head
cup push tool
Designation
755585
Bearing
extractor tool
755982
Engine
mount
adapter
755983
Used
with
Tool N
Tool N
755985
Flywheel
puller
755996
Hose clamp
68007
13
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LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
7
14
2
R
PE
UP ER
W
L
VE L
LE VE
LE
LO
11
4
12
8
NC
13
5
3
1.
2.
3.
4.
5.
6.
7.
10
8. Regulator
9. Starter motor relay
10. Fuel gauge
11. Horn
12. Outside temperature sensor
13. Speed sensor
14
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BODY PANELS
BODY PANELS
2
1
12
13
8
10
6
1.
2.
3.
4.
5.
6.
7.
NC
14
11
15
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BODY PANELS
1*
14*
3*
6*
7*
1.
2.
3.
4.
5.
6.
7.
9*
10
5*
12*
11
13
16
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BODY PANELS
17
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BODY PANELS
3
- Remove the splash guard. (6 screw)
- Separate the 3 fairings. (4)
4
4
18
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BODY PANELS
19
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BODY PANELS
20
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BODY PANELS
21
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BODY PANELS
22
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SERVICE OPERATIONS
SERVICE OPERATIONS
1
2
23
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SERVICE OPERATIONS
A = 1.5mm
24
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SERVICE OPERATIONS
A
B
25
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SERVICE OPERATIONS
B
Disassembly.
- Disconnect the air hose from the exhaust.
(1)
- Remove the exhaust holder plate.
(2)(2 screw)
26
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SERVICE OPERATIONS
4
8
7
5
27
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SERVICE OPERATIONS
Reassembly.
8
Lubricate the brake cam and fit it into
the casing.
28
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SERVICE OPERATIONS
Transmission
752237
29
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SERVICE OPERATIONS
752237
B
- When refitting, respect the way the rollers
are installed.
- Grease the moving flange bore lightly (high
temperature grease).
30
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SERVICE OPERATIONS
A
B
31
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SERVICE OPERATIONS
752127
32
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SERVICE OPERATIONS
755996
When re-installing, respect the direction of installation of the filter shown by the arrow which
indicates in which direction the fuel flows.
33
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MISCELLANEOUS OPERATIONS
MISCELLANEOUS OPERATIONS
1
When re-installing, use a new nut.
757860
757860
34
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MISCELLANEOUS OPERATIONS
Reassembly.
- Install the following new parts:
The dust cover.(1)
The fork cone.(2)
35
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MISCELLANEOUS OPERATIONS
753726
4
3
36
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MISCELLANEOUS OPERATIONS
6
5
4
37
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MISCELLANEOUS OPERATIONS
755996
38
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MISCELLANEOUS OPERATIONS
755996
39
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MISCELLANEOUS OPERATIONS
6
- Dismantle the needle (7) by pushing it out in
order to remove the clips (8).
40
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MISCELLANEOUS OPERATIONS
A
9
10
13
12
11
41
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MISCELLANEOUS OPERATIONS
15
14
16
18
42
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17
MISCELLANEOUS OPERATIONS
Reassembly
-
15
14
16
C
11
43
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MISCELLANEOUS OPERATIONS
10
8
61
72
4
16
6
13
7
17
8
18
5
15
3
14
12
11
44
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MISCELLANEOUS OPERATIONS
5
6
7
8
The pulsair reed valve hose. (9)
The rear brake control cable.
45
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MISCELLANEOUS OPERATIONS
10
11
12
46
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MISCELLANEOUS OPERATIONS
15
47
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P/N.
MA0003GB
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)