Sales division
Technical network leadership
WORKSHOP MANUAL
-
ADDITION TO THE MA0020 ENGINE WORKSHOP MANUAL
FOR THE SYM EVO 2 VALVE 4 STROKE 125/151 CC ENGINE
Sales division
Technical network leadership
Reproduction or translation, even partial, is forbidden without the written consent of Pe ugeot Motocycles
TABLE OF CONTENTS
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
TABLE OF CONTENTS.....................................................................................................................................1
PRODUCTS DANGER SYMBOLS USED.........................................................................................................2
CHARACTERISTICS.........................................................................................................................................4
Capacities ..................................................................................................................................................4
SPECIAL IMPORTANT POINTS.......................................................................................................................5
Oil and fuel.................................................................................................................................................5
TIGHTENING TORQUES ..................................................................................................................................6
SPECIAL TOOLS ..............................................................................................................................................7
Standard tools............................................................................................................................................9
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Putting the engine on the stand...............................................................................................................10
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Removal of the driven pulley....................................................................................................................10
Checking the drive belt.............................................................................................................................10
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Removal of the secondary transmission..................................................................................................11
Removal of the cylinder head...................................................................................................................11
Removal of the camshaft and/or rockers..................................................................................................11
Checking the cylinder...............................................................................................................................16
Checking the piston..................................................................................................................................16
Checking the piston rings.........................................................................................................................17
Setting the timing .....................................................................................................................................13
Checking the timing..................................................................................................................................14
Installing the valve clearance...................................................................................................................15
Checking the valve clearance ..................................................................................................................15
Checking the crankshaft and conrod assembly .......................................................................................15
PRODUCTS DANGER SYMBOLS USED
2
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
PRODUCTS DANGER SYMBOLS USED
Protection of individuals and of the environment.
Möbius band Recyclable.
Means that the product or the package
can be recycled. However, this does not
guarantee that the product will be
recycled.
Irritant
The product can irritate the
skin, eyes and respiratory
organs.
Avoid contact with skin and clothes. Wear
gloves, safety goggles and cotton overalls.
Do not breath in the vapour. If in contact,
wash thoroughly with water.
Flammable The product is flammable.
Keep it away from flames or any heat
source (barbecue, radiator, heating, etc.).
Do not leave the product in the sun.
Corrosive
The product can damage living
tissues or other surfaces.
Avoid contact with skin and clothes. Wear
gloves, safety goggles and cotton overalls.
Do not breath in the vapour.
Explosive
The product can explode under
certain circumstances (flame,
heat, impact, friction).
Avoid impacts, friction, sparks and heat.
Hazardous to
the environment
The product affects fauna and
flora. Do not dump it in
dustbins, sinks or in the
environment.
The ideal solution is to bring this product
to your nearest household waste recycling
centre.
Tox ic
The product can seriously
affect health if it is inhaled,
ingested or in contact with skin.
Avoid direct contact with the body, even by
inhalation. If you feel unwell, seek medical
advice immediately.
Do not throw
away into a
garbage can
One of the product's
component is toxic and can be
hazardous to environment.
Example: Used batteries.
This symbol informs the consumer that the
used product shall not be thrown away into
a garbage can, but shall be brought back
to the merchant or dropped at a specific
collection point.
Compulsory
gloves
Operation that can be
dangerous for people.
People's safety can be seriously affected if
the recommendations are not fully
respected.
PRODUCTS DANGER SYMBOLS USED
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
People's safety
Operation that can be
dangerous for people.
People's safety can be seriously affected if
the recommendations are not fully
respected.
Important
Operation that can be
hazardous to the vehicle.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Good operating
condition of the
vehicle
The operation must be carried
out in strict compliance with the
documents.
Serious damage to the vehicle and in
certain cases a cancellation of the
warranty can be involved if the
recommendations are not fully respected.
Note Operation that can be difficult.
Indicate a note which gives key
information to make the procedure easier.
Lubricate
Lubricate the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Grease
Grease the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Glue
Glue the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
New part Use a new part.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
GLUE
N
CHARACTERISTICS
4
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Capacities
125 cc 151 cc
Marking XS1P52QMI-3B XS1P57QMJ-2
Type
4-stroke single-cylinder
2 valves per cylinder with chain driven overhead camshaft
Cooling By a circulation of forced air by means of a turbine on the flywheel magneto
Bore x stroke 52.4 x 57.8 mm 57.4 x 58.2 mm
Cubic capacity 124.6 cc 150.6 cc
Max. power output 7.5 kW at 8500 rpm 8.3 kW at 8000 rpm
Max. torque rating 8.9 Nm at 7000 rpm 11 Nm at 6000 rpm
Compression
11.4 bars at 380 rpm
7 bars Minimum.
Lubrication Trochoid pump driven by a chain from the crankshaft
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Catalytic
Spark plug NGK CR7HSA
Magneto flywheel 80 W
Fuel supply Deni DPD24J carburettor
Standards Euro3
Crankcase
0.95 L(0.7 l at oïl change)
SAE 5W40 Synthetic
Minimum grade: API SJ
Relay box
0.18 L (0.17 l at oïl change)
SAE 80W90
Minimum grade: API GL4
SPECIAL IMPORTANT POINTS
5
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
Oil and fuel
Checking the engine oil level
This engine is designed to run on 95 or 98 unleaded fuel only.
Never run the machine with a petrol/oil mixture.
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.
Too much oil will noticeably restrict the
vehicle's performance
- Place the vehicle on its central stand on flat
ground.
- Start the engine, let it run for a few minutes and
then stop it.
- Wait a few minutes for the oil to stabilise.
- Remove the engine's oil filler cap/gauge (1).
- Wipe dry the filler cap/gauge and fit it back {but
do not screw it} into the filler hole.
- Remove the filler cap/gauge and check the oil
level.
- The oil level shall not be between the
minimum (A) and maximum (B) level marks
without exceeding the latter.
- Add oil if necessary.
B
A
1
TIGHTENING TORQUES
6
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TIGHTENING TORQUES
Quantity Dimension
Tightening
torque
125/151 cc
Note
Spark plug 1 M10-1.5 10 to 12 Nm
Engine drain plug 1 M12 35 to 45 Nm
Screen 1 M30 10 to 20 Nm
Cylinder head
Nut Ø8 mm
Screw Ø6 mm
4
2
M8-1.25
M6-1.0
18 to 22 Nm
7 to 11 Nm
Cylinder head cover 4 M6-1.0 8 to 12 Nm
Camshaft gear 2 M6-1.0 10 to 15 Nm
Camshaft stopper plate 1 M6-1.0 10 to 15 Nm
Installing the valve clearance 2 M5-0.8 7 to 11 Nm
Automatic tensioner 2 M6-1.0 8 to 12 Nm
Automatic tensioner plug 1 M6-1.0 8 to 12 Nm
Chain tensioner 1 M6-1.0 8 to 12 Nm
Inlet manifold 2 M6-1.0 8 to 12 Nm
Cylinder casings 2 M6-1.0 8 to 12 Nm
RH casing cover 10 M6-1.0 7 to 11 Nm
Freewheel 1 M22 90 to 100 Nm
Oil pump 2 M6-1.0 8 to 12 Nm
Anti-splash plate 2 M6-1.0 8 to 12 Nm
Transmission cover 8 M6-1.0 8 to 12 Nm
Relay box cover 7 M8-1.25 26 to 30 Nm
Relay box drain plug 1 M8-1.25 10 to 15 Nm
Relay box filler cap 1 M8-1.25 10 to 15 Nm
Starter motor 2 M6-1.0 7 to 11 Nm
Rotor 1 M12 50 to 60 Nm
Turbine 4 M6-1.0 8 to 12 Nm
Stator 2 M6-1.0 8 to 12 Nm
Engine speed sensor 2 M5-0.8 4 to 6 Nm
Drive pulley 1 M12 55 to 60 Nm
Driven pulley 1 M12 50 to 60 Nm
Clutch plate and shoes 1 M28 55 to 60 Nm
SPECIAL TOOLS
7
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
64765
Engine
mount
802349 757990
Lip seal push
tool
750016
Flywheel
puller
758008
Clutch
compression
tool
752361
801682
752237
Adjustable
pin wrench
758596
Valve stem
seal drift
752361
39 mm pipe
wrench
758008 759788
Lip seal push
tool
754035 Valve lifter 801682
Spacer
adaptor
758008
SPECIAL TOOLS
8
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
755585
Bearing
extractor tool
802349
Engine mount
adapter
64765
802833
756575
Piston locking
fork
802833
Engine mount
adapter
802349
64765
756668
Lip seal push
tool
SPECIAL TOOLS
9
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Standard tools
Wrenches with
interchangeable end
fittings for valve clearance
adjustment
Type: Marolotest
Reference: 500140
Set of shims
Slide calipers Multimeter
Heat gun
Automatic resetting type
torque wrench
5 to 25 Nm
Type: Facom R.306A25
Intertia type extractor tool
for bearings from 6 to
18 mm
Type: Facom U.49PJ3
Automatic resetting type
torque wrench
10 to 50 Nm
Type: Facom J.208A50
Automatic resetting type
torque wrench
40 to 200 Nm
Type: Facom S.208A200
OFF
OFF
V
DC
DC
V
AC
AC
Ω
20 m
20 m
200 m
200 m
DC
DC
10A
10A
V
Ω
COM
COM
mA
mA
Ω
SPECIFIC POINT FOR OPERATION
10
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIFIC POINT FOR OPERATION
Refer to the MA0020 Engine workshop manual.
Putting the engine on the stand
- Use the ref. 802833 bracket to fit the (1) engine
onto the ref. 802349 adaptor.
- Put the assembly on stand ref. 064765 clamped in
the jaws of a vice.
Removal of the driven pulley
- Lock the clutch drum (1) with the pin wrench
ref. 752237.
- Remove the nut (2).
- Remove washer (3).
- Remove the clutch drum, the clutch drive pulley
and driven pulley assembly and belt.
Tightening torque:
55 Nm.
Checking the drive belt
- Measure the width of the belt (A).
Minimum width: 18.5 mm
- Make sure the belt is not cracked.
802349
064765
802833
1
1
2
752237
3
A
SPECIFIC POINT FOR OPERATION
11
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Removal of the secondary transmission
- Remove the paper gasket (1) and the 2 locating
pins (2).
- Remove the countershaft (3).
- Remove the secondary shaft (4).
- Remove washer (5).
Make a note of the way the secondary shaft
pinion is installed.
Removal of the cylinder head
- Remove the 2 bolts (7).
- Gradually loosen in a crosswise order the 4 nuts
which secure the cylinder head (8).
- Remove the 4 nuts and the 4 washers (8).
Removal of the camshaft and/or rockers
- Remove the cylinder head.
- Remove the stopper plate (1).
Tightening torque: 10 Nm.
1
2
2
4
3
5
7
8
1
SPECIFIC POINT FOR OPERATION
12
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Remove the pins from the rockers using a 5 mm
screw (2).
- Remove the inlet (3) and exhaust (4) rockers.
- Remove the springs.
- Remove the camshaft (6).
- Make sure the rocker pins and rockers are not
worn (A).
- Turn the rollers of the rockers; they must turn
freely and silently (B).
- Make sure the cams on the camshaft are not
worn (C).
- Turn the ball bearings on the camshaft; they must
turn freely and silently (D).
4
3
2
6
ADM
ECH
A
A
A
A
B
C
D
SPECIFIC POINT FOR OPERATION
13
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- When refitting, position the cam shaft mark (E) as
shown in the illustration.
- When re-installing the rocker pins, position the
indentation of the axles towards the outside of the
cylinder head to fit the cylinder studs.
- To assemble the holder plate, position the rocker
pins with the screwdriver slits vertical.
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 lithium soap grease). Seals and valve stems must be lubricated.
- Install the cylinder head.
- Fit the 4 washers.
- Screw up the 4 nuts (4) and 2 screws (5) slightly.
- Tighten the cylinder head securing 4 nuts working
(5) diagonally in 2 or 3 steps.
Tightening torque: 20 Nm.
- Tighten the 2 screws (5).
Tightening torque: 12 Nm.
Setting the timing
- Turn the magnetic wheel to line up the "T" mark
with the the crankcase boss (A).
E
5
4
A
SPECIFIC POINT FOR OPERATION
14
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Fit the timing chain on the camshaft gear.
- Make sure the camshaft marks (B) are parallel
with the gasket seat surface (C).
- If necessary, dislodge the gear from the camshaft
without removing it and move the chain around
the gear on the required side.
- Fit the 2 screws.
Tightening torque: 12 Nm.
- Fit the chain tensioner gasket.
- Install the chain tensioner and the 2 attachment
screws (1).
Tightening torque: 10 Nm.
- Using a flat blade screwdriver, unlock the chain
tensioner screw.
- Fit the O-ring.
- Install the tensioner cap.
Tightening torque: 8 Nm.
Checking the timing
- Rotate the engine twice: 2 revolutions in the
engine's operating direction.
- Turn the magnetic wheel to line up the "T" mark
with the the crankcase boss (A).
- Make sure the camshaft marks (B) are parallel
with the gasket seat surface.
- If the marks are not alined, reset the valve timing.
B
C
1
A
B
SPECIFIC POINT FOR OPERATION
15
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Installing the valve clearance
- Remove the rocker cover.
Tightening torque: 8 Nm.
- Using a wrench, turn the crankshaft in the
direction of operation to as to line up the marks on
the camshaft gear (B) with the cylinder head
gasket face.
.
- Using the set of feeler gauges, measure the
clearance of each valve.
Clearances:
• 0.12 ± 0.02 mm at the intake.
• 0.12 ± 0.02 mm at the exhaust.
- If the clearance is not correct, adjust by means of
the cam follower screw.
- Tighten the nock nut.
Tightening torque: 10 Nm.
Checking the valve clearance
• At the intake a 0.15 mm feeler gauge shouldn't go.
• At the exhaust a 0.15 mm feeler gauge shouldn't go.
- On the contrary, if the fealer gauge goes, reset the clearances.
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: 0.55 mm.
B
SPECIFIC POINT FOR OPERATION
16
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
The out-of-roundness values measured at the ends
of the crankshaft must be measured at:
- 90 mm on the transmission side and must not
exceed 0.030 mm.
- 60 mm on the flywheel magneto side and must
not exceed 0.035 mm.
Checking the cylinder
- The cylinder should show no traces of scoring or
seizure.
125 cc 151 cc
Cylinder diameter
52.395 to 52.415 mm 57.395 to 57.415 mm
Utilisation limit
52.5 mm 57.5 mm
Checking the piston
- The piston should show no traces of scoring or
seizure.
- The rings must be free in their grooves.
- Measure the piston diameter at 9 mm from the
piston skirt.
125 cc 151 cc
Piston diameter
52.385 to 52.405 mm 57.385 to 57.405 mm
Utilisation limit
52.29 mm 57.29 mm
90 mm 60 mm
9 mm
SPECIFIC POINT FOR OPERATION
17
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Checking the piston rings
- Carefully remove the piston rings.
- Place a ring in the bore parallel to it and measure
the gap using a feeler gauge.
Piston ring gap:
• Top compression ring gap: 0.2 to 0.4 mm.
• Compression ring gap: 0.25 to 0.4 mm.
• Oil control ring gap: 0.2 to 0.7 mm.
P/N. MA0050GB
Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add
any reference mentioned in this manual.
DC/APV 07/2014 (non contractual pictures)
/
