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ENGINE FD1
GB
CONTENTS
DISMANTLING AND REASSEMBLY PROCEDURE Removing engine from vehicle .............................. 7 Placing engine on its support ................................ 7 Cylinder head ..................................................... 8-9 Cylinder - Piston ............................................. 10-11 Primary transmission assembly...................... 11-12 Relay box ....................................................... 12-13 Opening of housings ...................................... 13-18 - right hand cover - oil pump - right hand housing - crankshaft assy Closing of housings ........................................ 18-19 Carburettor - choke assembly ............................. 19
SPECIFIC POINTS Timing setting ...................................................... 20 Adjustment of valve clearance ............................ 21 Dismantling of the cylinder head ................... 22-23 Replacement of the water pump ......................... 24
Information
Before dismantling, get rid of any dirt by cleaning the chassis - engine assembly. When dismantling, keep together all parts originally paired together or paired due to wear. Paired parts must be reused together or replaced together; they will have been placed in the order they were dismantled in, thus making refitting easier. Any parts which are changed must be replaced with original PEUGEOT parts. Check the state of the tightness seals, O rings and paper seals each time a dismantling operation is carried out. Lubricate all paired parts and bearings correctly when reassembling.
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INTRODUCTION
This workshop manual concerns the FD1 engine which equips the Elyso 125 cm 4-stroke model. It is intended to be used by dealers and their qualified mechanics. Bearing in mind that it is not possible to group together in one document all that a mechanic needs to know, the person who uses this manual should have a basic knowledge of mechanical concepts and repair operations, in order to carry out interventions under the best conditions of efficiency and safety.
4-stroke oil
Coolant (Peugeot) .................................................................................. Procor 3000 or equivalent (type : degree of protection up to -25)
CHARACTERISTICS
Main characteristics
ENGINE MARKING
Chassis
identification marking VIN number (17 characters)
Number Type
XXXXXXXXX FD1
o 0, il 12 L
manufacturers plate
- ENGINE
4 stroke water cooled Bore x stroke ....................................................... 57 X 48,9 Displacement ....................................................... 124,8 cm3 Compression ratio ........................................................ 11,7 Maximum power : ......................... 9 kW at 8750 rpm Maximum torque : .................... 10,2 Nm at 7500rpm Diagrams ................................ AOA = 10 ........ AOE = 40 ................................................ RFA = 40 ......... RFE = 10 Lubrication .......................... oil pump type trochoid MIKUNI
Identification : VGAG2AB . . . . . . . . . .
FT tyre .............................................................. 120/70 x 12 RR tyre ............................................................. 130/70 x 12 Pressure when cold : front ..................................... 1,5 bar rear ...................................... 1,8 bar
- Timing :
Capacities (litre)
Petrol tank ..................................................................... 8,5 Engine oil sump ........................................................... 1,25 . with filter change ..................................................... 1,1 . without filter change ................................................ 1,0 Relay box .................................................................... 0,12
- Ignition :
Advance ........................................................ mapping type Spark plug ................................................. 5 K resistance . normal use...................................................... NGK CR7E . severe use ...................................................... NGK CR8E Electrode gap ......................................................... 0.6 mm
Dimensions (mm)
Overall length .............................................................1 900 Overall width (without mirrors) ...................................... 720 Overall height (without mirrors) ................................... 1 230 Wheelbase .................................................................1 368
- Carburettor :
.......................................................... MIKUNI with vacuum Idling speed ............................................... 1 600 rpm +100 Initial position of the air screw ................... Unscrew: 2 turns 5-notch needle ....................... 4CZ3 2nd notch from the top Main jet ......................................................................... 125 Idling jet .......................................................................... 35
Weight (kg)
Kerb weight .................................................................. 140
Transmission
Clutch assy ................................ centrifugal, automatic type Primary transmission .............................. by trapezoidal belt Reduction gear ........................................ with 2 gear trains
MAINTENANCE PLAN
MAINTENANCE OPERATION
Battery / electrolyte level Spark plug Air filter Oil filter Clutch shoe Brake fluid * Brake pad wear Coolant * Engine oil Relay box oil Inflation pressure / Tyres Rear brake cables and cam Front suspension rear shock absorber Valve play Steering play Engine fixation Tightening bolt, screw, nut Variator : belt(1) , rollers(2) , slides(2) Carburettor : idle speed adjustment Stands Fuel pipework
20000 kms
V C N C V
V V V V V V C
C C
G V V V V V V A V+G V
V = Check
N = Clean
C = Change
A = Adjust
G = Grease or lubricate
These service operations must be carried out more frequently if the vehicle is used in so-called severe conditions : - Wet, dusty, areas, intensive urban use, ...etc.
SETTING UP
1. Preparation of the battery
Charging a dry battery: - Take out the battery. - Remove the six filling caps and the air vent plug. - Fill with electrolyte (35 % sulphuric acid = 1,28 g / cm) up to the level marked UPPER LEVEL Reference ...................................... 752740 ................... 1 L ...................................................... 752741 ................... 5 L - Leave the battery to settle for approximately half an hour. Top up the level if necessary. - Charge the battery for at least 7 hours with a current of 1.2 A, using a regulated charger or for 2 hours maximum using a non-regulated charger. - Put the battery back in its place and connect the vapour evacuation pipe to it. - Connect the red wire connector to + and the green wire earth connector to - . - From then on, the battery level should be topped up if necessary using distilled water only.
2. Fuel
- Capacity ............................................................. 8.5 Litres - Lead free petrol 95 or 98.
3. Checking of levels
Relay box oil :
- Put the vehicle on its stand on a level surface - Loosen and remove the filling screw and make sure that the oil level comes up to the filling neck. Capacity ........................................................................ 0,12 L - Tighten the screw to 12 Nm.
Coolant :
- Check that the level is level with the top of the screw thread in the expansion valve. Capacity .......................................................................... 1.5 L
Maxi
Mini
Tightening torques
Special tools
- Engine support ............................................ 64765 - Adaptation for engine support * ................ 753711 - Flywheel clamp ........................................... 68570 - Piston snap ring pliers ............................... 752000 - Tool for removing and opening housing ...... 64706 - Protective end piece lar ge modelfor opening housing .......................................................... 69098 - Retaining dowel pin ..................................... 64710 - Nut with spindle ........................................... 69104 - Clutch assy compression tool * ................. 754005 - Adjustable lug wrench ............................... 752237 - Torque wrench + extension + reduction part 69802 - Torque wrench + extension + reduction part ......... ................................................................ 753977 - Flywheel remover * ................................... 754003 - Immobilisation tool * .................................. 754004 - Circlips pliers ............................................... 69117 - Spindle ........................................................ 64712 - Housing plate * .......................................... 754006 - Crankshaft adjustment pin * ...................... 754033 - Camshaft adjustment pin * ........................ 754034 - Valve compressor * ................................... 754035 - Mechanical seal pusher * .......................... 754007 - Water pump seal pusher * ........................ 754008 - Water pump bushing pusher* ................... 754009 - Ignition housing seal pusher * ................... 754036 - Crankshaft assy bearing remover * .......... 754037 - Clamp with clip .......................................... 750539 * specific tools 125cm
Engine part Assembly screws of : - Housings .....................................................10 Nm - Covers .........................................................10 Nm - Starter ......................................................... 10 Nm - Stator ..........................................................10 Nm - Sensor .........................................................10 Nm - Oil pump ......................................................10 Nm - Cylinder head ..............................................23 Nm - Drive pulley .................................................70 Nm - Driven pulley ...............................................70 Nm - Rotor ...........................................................70 Nm - Engine housing plug.................................... 40 Nm - Relay box cap .............................................12 Nm - Spark plug ...................................................10 Nm - Camshaft support ..........................................7 Nm
Cycle part - Front wheel axis nut ....................................65 Nm - Rear wheel nut .......................................... 110 Nm - Engine articulation on bracket pivot ............ 60 Nm - Rod articulation on chassis ........................ 60 Nm - RR shock absorber upper fixation ...............45 Nm - RR shock absorber lower fixation ...............23 Nm - Exhaust nuts on cylinder ............................. 16 Nm - Handlebar nut .............................................40 Nm - Steering counter nut .................................... 70 Nm - Front brake calliper ..................................... 30 Nm
- Screw and nut 5 mm ..................................... 7 Nm - Screw and nut 6 mm ................................... 10 Nm - Screw and nut 8 mm ................................... 22 Nm - Screw and nut 10 mm ................................. 35 Nm - Screw and nut 12 mm ................................. 60 Nm
- Drain
. engine . cooling circuit (disconnect the pipe on the inlet tube and the pipe on the cylinder head in order to facilitate draining)
- Disconnect
. vacuum take off on cylinder head, breather, carburettor, oil filler, rear brake control
- Disconnect
. interference suppresser, starter , oil pressure sensor, coolant temperature sensor, flywheel outlet connector, choke, throttle control, remove the carburettor
Note The rubber stops may be removed in order to avoid oil spillage on dismantling
Cylinder head
- Remove the 5 screws from the cylinder head cover - Take it off - Tightening torque : 10 Nm
- Remove the 8 screws from the housing cover - Take it off - Tightening torque : 10 Nm
- Run the engine in its operating direction by the fixed face in order to bring the dumper friction pads A onto the back B of the camshaft cams
- Remove the screw and the spring from the automatic tensioner - Remove the 2 fixation screws from the automatic tensioner - Tightening torque : 10 Nm - Remove the automatic tensioner and release it A by pressing the stop tooth B
- Immobilise the camshaft pinion using the lug wrench ref. 752237 or ref. 64651
Warning
Do not press on the mating face with the wrench
64651
- Remove the screw from the camshaft pinion - Tightening torque : 23 Nm - Remove the pinion - Suspend the timing chain
- Loosen the 2 washer screws - Progressively loosen the 4 nuts in crossed order - Remove the 4 nuts with their washers and the 2 washer screws - Remove the cylinder head, the metal seal and the two centring guides - Remove the guide rail of the chain (exhaust side slotted into the cylinder head)
On reassembling
- Systematically replace the cylinder head gasket and the cylinder head cover seal - Set the timing setting and adjust valve clearance
Cylinder - piston
- Next to the oil pressure switch A - Tightening torque : 10 Nm - Remove 1 screw CHC B - Tightening torque : 12 Nm - Remove the cylinder - Free the piston carefully - Suspend the chain once again - Remove the base seal and the two centring guides of the engine housing
- Tip the engine onto its side - Remove the ring - Push the piston pin - Remove the piston
Warning
The timing chain must be passed through the timing well and suspended when refitting the cylinder
Reassembly
The arrow engraved on the piston top must be pointing towards the timing side The piston pin and the cylinder well must be lubricated, the snap rings and the seals must be replaced (base and cylinder head). The cylinder must be lowered with care by compressing the rings one at a time after having already positioned them on the piston (see assembly of rings page 11).
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The cylinder skirt is chamfered in order to make it easier to put the rings on.
A B
120 120 120
Drive pulley
- Having removed the cover, remove the drive gear assembly - Immobilise the primary drive face with the tool ref. 754004 - Unscrew the fixation nut of the primary drive face of the drive pulley - Tightening torque : 70 Nm - Remove the nut and the primary drive face - Remove the belt and take out the drive pulley assembly
754004
Warning
Do not discard any stacking element or reduce the dimensions in any way as this could lead to the nut being tightened onto the crankshaft assy grooves instead of on the primary drive face, which could result in the possible destruction of the crankshaft assy.
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- Remove the guide hub and the 3 screws for holding down the cover using a screwdriver. - Remove the cover, the ramp, the 3 guides (one assembly orientation, the guide must be fully inserted into the ramp) and the 6 rollers. - After cleaning check the rollers in particular; they must not show any traces of wear.
Reassembly
- Reverse procedure to dismantling after having lubricated the rollers, the ramp and the bore of the movable drive face using high temperature grease ref. 752093
Note
The rollers should be checked every 5000 kms. The belt must be changed every 10 000 kms.
64651
Driven pulley
- Immobilise the clutch assy drum using the lug wrench ref. 752237 or ref. 64651 - Unscrew the nut and remove the clutch drum and the driven pulley assembly - Tightening torque : 70 Nm
Note
The clutch shoes should be checked every 5000 Kms
- Immobilise the assembly using the tool ref. 754005 in a vice - Loosen the special nut using a socket wrench 6 socket M 46 - Remove in order . the clutch shoe assembly, the spring, the centring sleeve of the spring - Tightening torque : 50 Nm
Relay box
- Having drained the relay box - Tightening torque : 12 Nm - Purge screw C (page 13) - Remove the 5 fixation screws from the cover - Tightening torque : 10 Nm
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- Remove the cover with the primary shaft, the seal and the two centring guides . the primary shaft is removed from the cover using a mallet, taking care to turn the shaft - Remove the friction washer from the countershaft 15 x 30 x 0.5 - Remove the secondary shaft, taking care not to damage the seal - Check that the air vent pipes A are not blocked - If the seal is damaged in any way, oil will run out through the evacuation slit located behind it - Remove the countershaft as well as its 2nd friction washer 15 x 30 x 0.5
Cover side
Note
Check the state of all these parts and replace if necessary
COUNTERSHAFT
metal washer
metal washer
Note
Fill the box with 0.12 litre ESSO GX 80 W 90 ref. 753009 Tightening torque for the level screw: 12 Nm
A B
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- Immobilise the rotor using tool ref. 68570 - Remove the nut - Tightening torque : 70 Nm - Place the protective end piece on the end of the crankshaft ref. 69098 - Screw the flywheel remover ref. 754003 onto the rotor and work on the push screw of the flywheel remover until the rotor comes free
68570
754003
- Remove the 1st deflector (2 screws) - Tightening torque : 10 Nm - Remove the chain tensioning pad (1 screw) - Tightening torque : 10 Nm
- Take the 2 circlips off the plastic pinions, remove them and remove the 2 shafts - When reassembling systematically replace the 2 circlips - Remove the 2nd deflector (2 screws) - Tightening torque : 10 Nm
Important Remove the timing chain making note of its rotation direction
Oil pump
It is only accessible at this stage in dismantling - Remove 3 screws - Tightening torque : 10 Nm - Remove the oil pump
Note
Before reassembly immerse the pump in engine oil
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Coil - sensor
- Remove the 2 screws from the sensor and the 3 screws from the coil - Remove the assembly - Tightening torque : 10 Nm
Note
The right hand cover also ensures lubrication of the conrod big end via the crankshaft end.
Tightness is ensured by a lip seal on the outer side, in contact with the housing shoulder and held in place by a circlips on the other side. - Systematically check that the seal is in good condition and replace it if necessary. - Lubricate the housing before putting it in place with the pusher ref. 754036
- Remove the 8 screws from the right hand half housing including : . 2 outer . 1 right side A ! . 1 left side B necessitating removal of the transmission cover - Tightening torque : 10 Nm
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- Remove right hand half housing, the 2 centring guides and the housing seal - Evacuation hole A of the water pump, to be checked and cleaned if necessary
Note
No tool is necessary to remove the housing, the bearing remains attached to the crankshaft assy.
Crankshaft assy
- Place the protective end piece on the end of the crankshaft ref. 69098
69098
- Place the tool ref. 64706 on the housing equipped with the plate ref. 754006 - Extract the crankshaft by screwing the central screw on the tool
64706
754006
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Comment
If the crankshaft bearing on the left hand side remains in place, use the extraction tool ref. 754037
Position of V
Oil filter
- Remove the 2 screws from the cover - Take it off with its O ring seal, check the state of it and replace it if necessary - Remove the filter - Tightening torque : 10 Nm (no specific assembly orientation).
Regulation valve
The oil regulation valve and the anti-degauging plate are only accessible after having removed the right hand housing - Tightening torque : 40 Nm View of drain plug and strainer - Tightening torque : 40 Nm
Warning
It is essential that the strainer be cleaned every time the oil is changed and the copper seal is replaced.
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- The tightness of the water inlet tube is ensured by an O ring seal (2 screws) - Tightening torque : 10 Nm
Closing of housings
Assembly of crankshaft in the left housing - Insert the crankshaft into the bearing - Screw the spindle ref. 64712 onto the end of the crankshaft - Insert the tool ref. 64706 fitted with the plate ref. 754006 onto the spindle
64712 64706
754006
69104
- Centre the assembly on the housing by putting 4 screws in place - Place the centring device ref. 64710 - Screw the nut spindle ref. 69104 onto the spindle whilst supporting the crankshaft assy
64710
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To facilitate holding the crankshaft assy, use the rotor inserted into its cotter on the right hand side. Continue to screw the nut spindle in order to bring the crankshaft into contact with the bearing whilst keeping the conrod positioned in the direction of the cylinder studs - Put the two centring guides in position on the left hand housing - Put the housing seal in place (without oil or grease)
- Present the right hand housing paying attention to insert the antidegauging plate into position in the left hand housing The joining of the 2 housings should not require any effort - Position the 8 screws (2 of which are external) - Tightening torque : 10 Nm - Level off the housing seal, lubricate the crankshaft assy Once this operation is complete, proceed with reassembly in reverse order of the timing chain, the deflectors and drive gears of the water pump and the oil pump and of the cylinder / piston / cylinder head assembly.
Idling screw
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SPECIFIC POINTS
Timing setting
This operation is necessary after having removed the cylinder head, the cylinder / piston assy and opened the housings - Remove the cylinder head cover, the right hand cover, the automatic tensioner screw - The automatic tensioner in order to release it (see page 8) - Insert the pin ref. 754033 into the housing - Turn the crankshaft assy until it clicks into the cottering hole
754034 754033
- Put the camshaft gear screw in position - Remove the indexing cap - Insert the pin ref. 754034 - Turn the camshaft until it clicks into place - Remove the camshaft gear screw
- Check that the timing chain is correctly placed on the crankshaft assy gear - Position the chain on the camshaft gear - Position the camshaft gear in such a way as to be able to immobilise it using the lug wrench ref. 752237 or ref. 64651 - Put the chain tensioner and the spring with its screw in position - Tighten the screw by exerting a force in an anticlockwise direction on the lug wrench, taking care not to press on the mating face with the wrench - Tightening torque : 23 Nm - Remove the pins - Turn the engine twice in its normal rotation direction - Carry out a check using the pins
64651
Important
Put the cap back into place on the indexing hole in the cylinder head. If it is forgotten, this may disrupt the lubrication circuit and may cause certain parts to seize up.
20
- Turn the engine manually either by the drive pulley or by the rotor in its normal rotation direction - Bring the dumper friction pads A onto the back B of the cams
- Adjust the clearance for each valve by acting on the dumper screw - Clearances : .......................................... 10/100 for intake ....................................... 25/100 for exhaust
21
Any work on the cylinder head requires the water temperature sensor and the thermostatic valve to be removed - Remove the water temperature sensor A - Tightening torque : 10 Nm - Remove the 2 screws from the cover of the thermostatic valve B and take it off - Tightening torque : 10 Nm - The drain screw C is located on the cover with a fibre seal
Camshaft
- Remove the 3 screws and take off the stop plate - Tightening torque : 7 Nm - Remove the camshaft
Comment
The stop plate has 2 functions : - Positioning of the camshaft - Passage of oil between the 2 axes of the dumpers
Dumpers
- Remove the 2 axes of the dumpers, lubrication hole on the plate side - Remove the intake and exhaust dumpers
22
Valves
- Compress the valve with the tool ref. 754035 - Remove the two half cones - Release the spring - Remove the tool
754035
- Remove the upper cup - Remove the spring, (note the sense in which it was removed in order to replace it in its initial position) - Remove the lower washer - Remove the valve - Repeat the operation for the second valve
Warning
When reassembling, put the two half cones in place with grease in the valve stem groove; do not slide the two half cones with the cup by releasing the tool.
Before reassembly
It is essential to check that oil passages are not obstructed and to remove any carbonised deposits from all parts.
On reassembly
All parts removed such as the camshaft, valves, dumper shafts, dumpers must be lubricated thoroughly in order to avoid any risk of seizing when the vehicle is started (spray with a grease such as Molykote with MoS2 for assembly)
Comment
No do not reuse a valve stem seal which has been removed
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- Open the housings - Remove the right hand housing - Unscrew the fan
Note
Any work carried out on the water pump necessitates systematic replacement of all parts.
- Remove the circlips on the bearing side - Take off the bearing on the timing side by pushing it with the pump control shaft - Take off the mechanical seal on the fan side - Take off the seal on the fan side - Take off the needle bearing cage on the fan side
Reassembly procedure
- Force fit the needle bearing cage level with the chamfer in the housing on the fan side with the pusher ref. 754009 - Assemble the pump control shaft with its bearing - Force fit the pump control shaft assembly, with the bearing resting against the housing shoulder - Put the circlips in place in the groove - Force fit the seal, with the lips resting against the housing shoulder with the pusher ref. 754008 - Force fit the mechanical seal with the special tool ref. 754007
754007
Note
The new mechanical seal is delivered coated with a blocking product on the surface in contact with the housing. Take care not to damage this product when handling it.
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In the aim of constant improvement, Peugeot Motocycles reserves the right to modify, delete or add to the references mentioned. DC/PS/DOC/SH Imp. in U.E. I3R 15/04/99 ed1 (Non contractual photos)
recommande
N 11.754014.00
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