Peugeot 150 CC Workshop Manual

WORKSHOP MANUAL

TECHNICAL 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

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

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

2

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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

3

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

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 W

Mitsuba

235 W/330 W

Mitsuba 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

4

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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 or

sparks. Work in a clear and well-ventilated area.

TIGHTENING TORQUE

5

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

TIGHTENING TORQUE

Cylinder head 1.8/2.3 m.daN

Cylinder casings 1 m.daN

Transmission cover 1 m.daN

RH casing cover 1 m.daN

Automatic tensioner 1 m.daN

Oil control valve 4 m.daN

Temperature sensor 1 m.daN

Starter motor 1 m.daN

Rotor 7 m.daN

Stator 1 m.daN

Engine speed sensor 0.7 m.daN

Drive pulley 7 m.daN

Driven pulley 7 m.daN

Spark plug 1 m.daN

Camshaft gear 2.3 m.daN

SPECIAL TOOLS

6

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

SPECIAL TOOLS

64706

Casing

extractor and

opening tool

Casing

opening

plate +

69098

Protective

end-piece

large model

64706

64710

Shouldered

centering

tool

64706 69104 Pin nut

750 +

64711

+

64712

+

64754

64712

Pin Ø12

pitch 125

69104 750539

Tie-wrap

pliers

64765

Engine

mount

Engine

mount

adapter

752000

Piston circlip

pliers

68570

Flywheel

clamp

752235 1/2 extension

68994

or

753977

68994

Torque

wrench

8 N.m to

54 N.m

Extensi

on

752235

Adapter

752236

1/2

3/8 adapter

68994

or

753977

69092

External

circlips pliers

752237

Adjustable

pin wrench

SPECIAL TOOLS

7

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

753711

Engine

mount

adapter

Elyseo

Elystar

64765 754033

Crankshaft

locking pin

753977

Torque

wrench

30 N.m to

150 N.m

752235

extensi

on

752236

adapte

r

754034

Camshaft

locking pin

754003

Flywheel

puller

69098 754035 Valve lifter

754005

Clutch

compression

tool

754046 754040

46 mm pipe

wrench

754005

754006

Casing

opening

plate

64706 754041

Timing

casing seal

drift

754007

Mechanical

seal drift

755585

Bearing

extractor tool

754008

Water pump

seal drift

756717

Engine

mount

adapter

Jetforce

64765

754009

Water pump

pin drift

757035

Fixed flange

locking tool

SPECIAL TOOLS

8

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

757988

Water pump

bearing drift

757989

Water pump

bearing drift

757990

Crankcase

seal

installation

buffer

DISASSEMBLY

9

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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.

- Tightening torque: 1 m.daN.

.

756717

753711

64765

DISASSEMBLY

10

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 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.

- Tightening torque: 7 m.daN.

- 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.

- Tightening torque: 7 m.daN.

757035

2

1

5

4 3

1

68570

DISASSEMBLY

11

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 Removal of the rocker cover.

- Remove the 5 fixing bolts.

- Remove the rocker cover.

- Remove the paper gasket.

- Tightening torque: 1 m.daN.

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

2

DISASSEMBLY

12

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- Remove the chain tensioner and slacken it by

pressing the ratchet tooth (A).

- Remove the paper gasket.

- Tightening torque: 1 m.daN.

 Removal of the RH cover / ignition coil

and sensor.

- Remove the 8 bolts that secure the RH cover.

- Remove the cover.

- Tightening torque: 1 m.daN.

- Remove the paper gasket (1) and the

2 locating pins (2).

A

2

1

DISASSEMBLY

13

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- 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.

- Tightening torque: 1 m.daN.

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

1

68570

DISASSEMBLY

14

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- 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.

- Tightening torque: 7 m.daN.

.

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

15

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- 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

16

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 Removal of the temperature sensor.

- The temperature sensor (1) is screwed into

the cylinder head.

- Tightening torque: 1 m.daN.

 Removal of the thermostat.

- Remove the 2 bolts and the thermostat

valve (1).

- Remove the thermostat (2).

- Tightening torque: 1 m.daN.

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

2

1

2

1

DISASSEMBLY

17

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-

- 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

18

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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

6

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