PEUGEOT BLASTER Workshop Manual
Sales division
Technical network leadership
WORKSHOP MANUAL
-
Sales division
Technical network leadership
Reproduction or translat ion, even partial, is forbi dden without the written co nsent of Peugeot Motocyc les
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
Engine........................................................................................................................................................3
Capacities. .................................................................................................................................................3
Chassis......................................................................................................................................................4
Dimensions and weight................................................. ... ... ... .... ... ....................................... ......................4
Tyres. .........................................................................................................................................................4
Chassis markings.......................................................................................................................................4
Engine marking..........................................................................................................................................4
SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 5
Check.........................................................................................................................................................5
Change. .....................................................................................................................................................5
Check and lubricate. ..................................................................................................................................6
Clean and adjust........................................................................................................................................6
Test machine..............................................................................................................................................6
Battery preparation (Except battery without maintenance)*. .....................................................................7
Checks before handing over to the customer.............................................................................................7
SPECIAL IMPORTANT POINTS....................................................................................................................... 8
Oil and fuel.................................................................................................................................................8
Starting up after overhauling the engine....................................................................................................8
TIGHTENING TORQUES ................................. .... ... ... ... ... .......................................... .... ... ................................ 9
Body panels. ..............................................................................................................................................9
Cycle part...................................................................................................................................................9
Standard. ...................................................................................................................................................9
SPECIAL TOOLS ............................................................................................................................................ 10
LOCATION OF COMPONENTS...................................................................................................................... 11
BODY PANELS ............................................................................................................................................... 12
Removal of the front top shield panel.......................................................................................................12
Removal of the radiator covers. ...............................................................................................................12
Removal of the front lower shield pannel.................................................................................................13
Removal of the dirt shield. .......................................................................................................................13
Removal of the rear shield panel. ............................................................................................................13
Removal of the footboard.........................................................................................................................14
Removal of the under body panel............................................................................................................14
Installing the under body panel................................................................................................................15
TABLE OF CONTENTS
2
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Installing the footboard.............................................................................................................................15
Installing the front lower shield panel.......................................................................................................16
MISCELLANEOUS OPERATIONS ................................................................................................................. 18
Removal of the radiator top connecting pipe............................................................................................18
Removal of the header tank.....................................................................................................................18
Removal of the radiator lower connecting pipe........................................................................................18
Removal of the RH and LH radiators. ......................................................................................................19
Removal of the cylinder / piston...............................................................................................................19
Removal of the engine temperature sensor.............................................................................................20
Removal of the regulator..........................................................................................................................20
CHARACTERISTICS
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Engine.
Capacities.
Blaster.
Type. 2-stroke single-cylinder.
Cooling. Liquid.
Bore x stroke. 39.9 x 39.8 mm.
Cubic capacity. 49.9 cc.
Max. power output. 3.6 kW at 7300 rpm.
Max. torque rating. 7000 rpm.
Fuel supply. Carburettor Gurtner PY15.
Lubrication. Electric oil pump.
Transmission. By 2 variable pulleys and V-type belt.
Clutch. Centrifugal automatic.
Spark plug. NGK CR7EB.
Exhaust. Catalytic.
Fuel tank. 5.5 l 95 or 98 lead-free.
Oil tank.
1.2 l.
Semi synthetic for 2 stroke engines with separate oiling.
Relay box. 0.12 l SAE 80W90 life lubricated.
Coolant.
1.3 l.
Peugeot coolant part number 754614.
CHARACTERISTICS
4
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Chassis.
Dimensions and weight.
Tyres.
Front suspension. Upside down telescopic front fork.
Travel. 73 mm.
Rear suspension. Combined spring and hydraulically-damped shock absorber.
Travel. 65 mm.
Overall length.
1720 mm.
Width at handlebar.
705 mm.
Height (without rear-view
mirrors)
110 mm.
Wheelbase.
1210 mm.
Ground clearance.
135 mm.
Unladen weight.
81.5 kg.
Front wheel rim. 10 inch aluminium alloy.
Front tyre. 120/90 - 10.
Front tyre pressure. 1.7 bars.
Rear wheel rim. 10 inch aluminium alloy.
Rear tyre. 130/90 - 10.
Rear tyre pressure. 2 bars.
Chassis markings. Engine marking.
1. VIN number and manufacturer's plate. 2. Engine number.
1
XXXXXXXXXXXX
2
SERVICE SCHEDULE AND COMMISSIONING
5
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing is for vehicles used under "harsh" conditions: door-to-door deliveries, intensive
urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.
* Depending on equipment.
# Change if necessary.
Service operations.
500 kms or
1 months.
Every 5000 kms
or 12 months.
Every
10000 kms.
Heavy duty servicing. 500 kms Every 2500 kms. Every 5000 kms.
Check.
Idle setting. X X X
Throttle cable play. X X X
Steering column play. X X X
Operation of electrical equipment. X X X
Condition of front and rear brake hydraulic
controls *.
XXX
Condition of petrol pipes. X X X
Condition of oil pipes. X X X
Tyre pressures. X
Tyre condition, pressure and wear. X X
Brake fluid level. X X X
Battery electrolyte level. X X X
Coolant level. X X X
Tightness of nuts and bolts. X X X
Change.
Spark plug. X X
Intake silencer. X
Front brake pads #. X X
Rear brake linings #. X
Drive pulley bearings and guides #. X X
Transmission belt. X
Brake fluid and coolant. Once every 2 years
SERVICE SCHEDULE AND COMMISSIONING
6
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
* Depending on equipment.
# Change if necessary.
Service operations.
500 kms or
1months.
Every 5000 kms
or 12 months.
Every
10000 kms.
Heavy duty servicing. 500 kms. Every 2500 kms. Every 5000 kms.
Check and lubricate.
Driven pulley: Moving flange and needle b ush. X
Kick lever boss/Kick starter control shaft. X X
Rear brake cam. X
Clean and adjust.
Carburettor. X
Test machine.
On road. X X X
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