How it Works
PEUGEOT
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LOOXOR
Owner's Manual
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User Manual
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PEUGEOT LOOXOR User Manual

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Page 1
SALES DIVISION NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
Page 2
CONTENTS
CONTENTS
SOMMAIRE .................................................................................................................................................... 2
TECHNICAL DATA....................................................................................................................................... 4
SERVICE SCHEDULE AND COMMISSIONING ..................................................................................... 5
SPECIAL IMPORTANT POINTS ................................................................................................................ 7
TIGHTENING TORQUES AND SPECIAL TOOLS.................................................................................. 8
BODY PANELS ............................................................................................................................................... 9
FRAME........................................................................................................................................................... 21
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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CONTENTS
MISCELLANEOUS OPERATIONS........................................................................................................... 25
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE.................................................... 32
ELECTRICITY ............................................................................................................................................. 35
REMOVING THE ENGINE ........................................................................................................................ 40
FRAME........................................................................................................................................................... 42
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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TECHNICAL DATA
TECHNICAL DATA
Machine markings
50cc 100cc
Type approval n° B1AAAA B2ABAA
Technical data
50cc 100cc
Engine
2-stroke 2-stroke Bore x stroke 40 x 39.1 50.6 x 49.7 Cubic capacity 49.1 cc 99.9 cc Max. power 2.9 kw 6.9 kw Max. torque 4,4 Nm 9,5 Nm Gross compression
10.96 12.19
ratio
Ignition
Spark plug NGK BR7HS
CDI ACI 100
NGK BR8ES
Eyquem R850
Eyquem R1000L
Carburettor
Idle speed Air screw initial
Gurtner PA 358 Gurtner PY 15
1800
±200
rpm 1800
±200
1 + 1/2 turns 1 + 3/4 turns setting Needle L 3035F L 3035F Main jet 52 88 Idle jet 36 45
Magneto Starter motor
GF4 276 55W GF10 232 90W
150W SM
300W SM5
10254
Frame
1- Manufacturer's plate 2- VIN number
rpm
Capacities
Fuel tank 8 litres
unleaded 95 or 98
Oil tank 1.2 litres
semi-synthetic oil
Relay box 0.12 litres
SAE 80W90 oil Life lubricated
Fork 2 X 0.11 litres
Esso Univis 46 Agip H Lift 46
Dimensions
50cc 100cc Length 1925 mm 1925 mm Width 716 mm 716 mm Height without rear
1126 mm 1126 mm view mirror Ground clearance 130 mm 125 mm Wheelbase 1311 mm 1311 mm
Weight
50cc 100cc Weight 100 kg 107 kg
Tyres
50cc 100cc Front wheel 1.85 "x 16" 1.85" x 16" Front tyre 80/80-16 80/80-16 Front pressure 1.8 bar 1.8 bar Rear wheel 2.50" x 16" 2.50" x 16" Rear tyre 100/70-16 100/70-16 Rear pressure 2 bar 2 bar
Engine markings
Engine type FC1-FC3 FC2
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
50cc 100cc
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SERVICE SCHEDULE AND COMMISSIONING
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing is aimed at machines used under "harsh" conditions: door-to-door deliveries, intensive urban use (courier), short trips with cold engine, dusty regions, ambient temperature of over 30°c.
Service operation 500 kms
or 1 month
Every 5000 kms or 12 months
Every 10000 kms
Harsh conditions 500 kms Every 2500 kms Every 5000 kms
Check:
Idle speed X X X Throttle control X X X Oil pump operation * X X X Functioning of electrical equipment X X X Front and rear brake operation * X X X Fuel pipe X X X Oil pipe X X X Front brake fluid pipe 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 Tightness of nuts and bolts X X X
Change:
Spark plug X X Inlet silencer filter element X X Front brake pad # X Rear brake pad * # X Rear brake lining * # Drive pulley bushes # X X Transmission belt X
Check and decarbonize:
Piston X Cylinder head X Exhaust port X
Check and grease:
Idle flange pulley and needle bushes X Drive pulley: idle flange and rollers * X Kickstart drive gear and shaft bush X
Clean and set:
Carburettor X
Test the machine:
On the road X X X
* depending on equipment # if necessary
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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SERVICE SCHEDULE AND COMMISSIONING
Battery preparation (unless maintenance-free battery)
Remove the battery Remove the 6 filler caps and the vent cap Fill with electrolyte up to the level marked UPPER LEVEL Electrolyte: (35% sulphuric acid = 1.28g/cm3) 1 litre P/N: 752740, 5 litres P/N: 752741 Leave the battery to stand for approximately half an hour Top up again if necessary Charge the battery for at least 2 hours with a current of 400mA (0.4A) Refit the battery and connect the vent pipe Connect terminal with the red wires to the + and the terminal with the green wire to the -. Then the battery should be topped up again if necessary, after fully charging, using distilled water only
Filling the fuel and oil systems
Put in the tank 1 litre of 95 or 98 unleaded fuel mixed with 3 % of 2-stroke semi-synthetic oil Top up the oil with 2-stroke semi-synthetic oil Start the engine and disconnect the oil feed pipe to the carburettor on the 50 cc model and to the inlet pipe on the 100 cc model, that the oil is supplied in drops (the frequency of the drops increases with engine speed) Top up the tank with pure fuel only
Checks before handing over to customer
Check tightness of wheel nuts
Front wheel: 6 m.daN
Rear wheel 10 m.daN Check all nuts and bolts are tight Check brake adjustment and efficiency Check tyre pressures cold
Front wheel: 1.8 bar
Rear wheel 2 bar Check operation of lighting, direction indicators, horn, and brake light Check operation of the different warning lights Carry out a road test
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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SPECIAL IMPORTANT POINTS
SPECIAL IMPORTANT POINTS
Tyres:
This machine is fitted with special tyres manufactured by Hutchinson. When replacing tyres, it is essential to fit tyres of the same type and same dimensions
To open the saddle:
The saddle on this machine is opened electrically. This is carried out by turning the ignition key fully to the right When the saddle opens, the ignition key automatically returns to the ignition on position Important do not forget to turn off the ignition after opening the saddle
Oil and fuel:
This machine is designed to run on unleaded 95 or 98 fuel The oil to use for separate lubrication is semi-synthetic oil
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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TIGHTENING TORQUES AND SPECIAL TOOLS
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
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N
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N
TIGHTENING TORQUES AND SPECIAL TOOLS
Tightening torques
Body panels:
Main fairings 0,4 m.da Foot panel 0,4 m.da Speedo cover 0,1 m.da Saddle locker 0,6 m.da Legshield panel front 0,1 m.da Legshield panel rear 0,1 m.da Engine side panels 0,1 m.da Front mudguard 0,8 m.da Rear mudguard * 0,8/0,1 m.da Mudflap * 0,8/0,1 m.da Grab handle 1,2 m.da Steering lock 0,6 m.da Saddle opening control 0,1 m.da
Frame:
Front wheel spindle nut 6 m.da Rear wheel spindle nut 10 m.da Linkrod engine pivot 5,2 m.da Frame engine pivot 5,2 m.da Shock absorber upper mount 4,3 m.da Shock absorber lower mount 2 m.da Exhaust nut on cylinder 1,5 m.da Exhaust nut on engine 2 m.da Top cone 3,8 m.da Top cone locknut 2,1 m.da Steering locknut 7 m.da Front brake caliper 2,5 m.da Rear brake caliper 2,5 m.da Front brake disc 1 m.da Rear brake disc 1 m.da Stand on engine 1,9 m.da
Standard:
Screw and nut diameter 5 mm 0,5 m.da Screw and nut diameter 6mm 1 m.da Screw and nut diameter 8mm 2,2 m.da Screw and nut diameter 10mm 3,5 m.da Screw and nut diameter 12mm 5,5 m.da
Special tools:
Description Part Number Steering column wrench 754086
* depending on size of screw
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
BODY PANELS
Removal of instrument panel upper cover Operation 1
Remove the 4 screws (1) Remove the instrument panel upper cover (2)
Removal of instrument panel cover Operation 2
Remove the instrument panel upper cover (see operation 1) Disconnect the instrument panel connector (1) Remove the handlebar 4 fixing screws (2) Remove the cover (3) and instrument panel assembly
Remove the 3 screws (4) fixing the instrument panel to the cover Remove the instrument panel (5)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
Removal of saddle/storage compartment assembly
Operation 3
Remove the 4 fixing nuts (1) Withdraw the saddle/storage compartment assembly (2)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
Removal of legshield rear panel Operation 4
Remove the instrument panel upper cover (see operation 1) Remove the ignition key
Remove the legshield rear panel 8 screws (1) Separate the legshield front and rear panels Unclip the legshield rear panel, from the footboard at (A), and the two guides in the legshield front panel at (B) Withdraw the legshield rear panel from the right hand side of the machine, by pivoting it downwards
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
Removal of legshield front panel Operation 5
Remove the legshield rear panel (see operation 4) Remove the fork (see operation 9) Remove the screw (1) fixing the legshield front panel to the main fairings
Remove the 2 upper screws (2) fixing the legshield front panel to the frame
Disconnect the headlight connector (3)
Remove the 2 lower screws (4) fixing the legshield front panel to the frame by pushing the footboard lug (A) to one side
Unclip the 4 points (5) securing the legshield front panel to the main fairings
Tilt the legshield front panel forwards Remove the 2 screws (6) fixing the ACI 100 ignition module, disconnect and remove the module Remove the 4 screws (7) fixing the headlight and remove it
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BODY PANELS
Removal of rear RH and LH covers Operation 6
Remove the saddle/storage compartment assembly (see operation 3) Remove the grab handle (2 nuts (1A) and 1 screw (1B))
Remove the battery cover (1 screw) Remove the 2 side screws (2) Remove the screw (3) under the battery cover Remove the plastic rivet (4) over the battery cover
Disconnect the number plate lighting harness (5) (100cc)
Remove the rear mudflap 4 screws (6)
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Unclip and remove the rear mudflap (7)
Pull the rear cover assembly towards the rear Disconnect the rear light Remove the rear cover assembly
BODY PANELS
Remove the complete rear light (2 screws (8))
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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Remove the rear cover assembly 2 screws (9) Unclip the covers
Removal of footboard
BODY PANELS
Remove the legshield rear panel (see operation 4) Draw back the rear cover assembly (see operation 6) Disconnect the battery + terminal Remove the battery, disconnect the battery - terminal Remove the footboard 4 fixing screws (1) Unclip fuse holder and the starter motor relay Remove the footboard (2)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
Removal of main fairings Operation 7
Remove the legshield rear panel (see operation 4) Remove the footboard 4 screws (1) Remove the lower screw (2) fixing the legshield to the main fairings
Remove the two screws (3) fixing the main fairings to the legshield front panel by holding apart the main fairing clip (A) Unclip the 4 points (4) securing the main fairings to the legshield
Raise one side of the footboard, to release the clips (5) securing the main fairing to the frame Proceed in the same way for the other side Remove the main fairing
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
, The main fairings are joined together by 2 screws
lengthways and a clip system at the front
, Check the two main fairings are properly joined at
(B) before fitting Position the main fairings fitted to the frame lugs under the footboard Clip the 4 securing points to the legshield front panel Fit the legshield front panel lower screw first Complete assembly by inserting the two lower screws on the legshield front panel Then fit the footboard 4 screws
Removal of front mudguard
Remove the front fork (see operation 9)
Remove the front mudguard 3 screws (1) Remove the front mudguard (2)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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BODY PANELS
Removal of rear mudguard and the mud flap
Operation 8
Remove of the saddle/storage compartment assembly (see operation 3) Remove the battery cover (1 screw) From the rear covers remove the screw and the plastic rivet over the battery cover and the 2 side screws Remove grab handle (2 nuts (1A) and one screw (1B))
Remove the rear mudflap 4 screws (2) Disconnect the number plate light connector (3)
Remove the rear mudflap (4)
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BODY PANELS
Remove the mudguard (5) (1 centre screw (6) and 2 side screws (7))
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BODY PANELS
Removal of headlight, sidelight, and front direction indicator bulb
Remove the legshield rear panel (see operation 4)
, This gives access to the direction indicator bulbs
(1)
Remove the 2 upper screws (2) from the legshield front panel
, Tilt the legshield front panel forwards to access
the headlight and sidelight bulbs Remove headlight cover
Unclip the headlight bulb holder Remove the bulb
, The bulb holder has a locator for fitting to the
headlight
To release the sidelight bulb holder press on the bulb holder tabs and remove it
Removal of headlight
The front direction indicators are built into the headlight
Remove the legshield front panel (see operation 5) Remove the headlight (1), 4 screws (2)
Removal of rear light
Remove the RH and LH rear covers (see operation 6) Remove the rear light (1), 2 screws (2)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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FRAME
FRAME
Removal of fork Operation 9
Remove the legshield rear panel (see operation 4) Slacken the front wheel spindle nut Remove the front brake caliper 2 screws Hang the front caliper from the machine without disconnecting it Remove the handlebar to pivot tube screw and nut (1) Unclip the antenna (2) in order not to damage it
Protect the legshield front panel and tilt the handlebar forward Remove the front wheel
Disconnect the speed sensor 3-pin connector (3)
Remove the steering nut (4) and its shimming use tool P/N: 754086
Remove the fork (5)
, there is a ball-bearing cage at the top of the
steering head (6) (no special fitting position) and at the bottom 21 balls of Ø6.4mm
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FRAME
Removal of fork lower and upper races
Remove the fork (see operation 9) Drift out the races (1)
, The races must be changed every time they are
removed
Removal of fork lower cone
Remove the fork (see operation 9) Remove the front mudguard (3 screws (1)) Drift out the cone (2)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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Dismantling the fork
Removal of fork stanchions
Remove the fork (see operation 9) Remove the end plugs (1) from the stanchions (2)
, The end plugs are fitted with a sealing washer
which must be changed each time it is removed.
Drain the oil from the stanchions Operate the stanchions several times to completely drain off all the oil Remove the stanchions
Removal of seals
Remove the dust cover (3) Remove the circlips (4) Remove the seal (5) Remove the compression limit cone (6)
FRAME
, After changing the dust covers, the circlips, and
the seals, pour into the fork tubes fork 110 cc of oil for the 100 cc model and 70 cc of oil for the 50cc model. Insert the stanchions into the tubes and refit the end plugs with new seals
Oil Esso Univis 46 P/N: 754697 for 5-litre can
Or Agip H Lift 46
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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FRAME
Removal of steering lock
Remove the legshield rear panel (see operation 4) Unclip the lock antenna (1) (100cc) Disconnect the lock connector (2) Remove the lock shear screw with a punch (3) Remove the lock (4)
, For the 100cc if the steering lock is to be changed,
the transponder (5) in the master key (red) must be retained and reinstalled in the new master key. Then the key learning program must be carried out (see SI N° 96)
Removal of rear brake hose
Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Open the brake fluid reservoir (1) Connect a tube leading into a jar to the rear caliper bleed screw Operate the brake lever to drain the circuit Remove the banjo bolts (4) and (5) from the caliper and the master cylinder Unhook the brake hose (6) at the stand at (A) Remove the brake hose (6)
After refitting, bleed the circuit (see bleed operation in Manuals and Methods document N°10)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
MISCELLANEOUS OPERATIONS
Removal of handlebar
Remove the instrument panel cover (see operation 1) Remove the legshield rear panel (see operation 4) Remove the RH and LH control switch modules (2 screws each)
Make an alignment mark at (A) (in rotation and longitudinally) on the front and rear brake master cylinders and remove them (2 screws each)
Remove the RH grip (2 screws (1)) Release the throttle control (2) by turning it ¼ turn
, If the position of the master cylinders has not been
marked position them at 12mm from the control switch modules in a standard operating position. The control switch modules are indexed to the handlebar
Unclip the steering lock antenna (3) (100cc) Remove the screw and nut (4) securing the handlebar to the pivot tube Remove the handlebar (5)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
Removal of RH and LH control switch modules
Remove the legshield rear panel (see operation 4) Disconnect the control switch module connector involved from the main harness Remove the control switch module, 2 screws
, The control switch modules are indexed to the
handlebar
Removal of throttle and oil controls
Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Removal of saddle/storage compartment assembly Remove the air intake (1 screw) Remove the air filter module (2 screws) Remove the RH grip (2 screws (1) ) Release the throttle control cable (2) by turning it ¼ of a turn.
Remove the oil pump cable (3) Remove the carburettor chamber top (4) Remove the slide valve Unclip the control cable from the frame under the footboard Remove the control cable
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MISCELLANEOUS WORK
Removal of exhaust Operation 10
Remove the saddle/storage compartment assembly (see operation 3) Remove the air intake (2) screw (1) and push it slightly away
Remove the 2 exhaust nuts (3) from the cylinder end
Remove the exhaust trim, 3 screws Remove the exhaust 3 fixing screws (4) The 2 screws (4A) are coated with locking compound and therefore must be replaced each time they are removed
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
Removal of saddle opening control
Remove the rear RH and LH covers (see operation 6) Remove the oil tank (see operation 12) Disconnect the opening control connector (1) Unhook the lock control linkage (2)
Remove the opening control fixing screw (3) Unhook the opening control (4) from the frame and remove it
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
Removal of fuel tank and its valve
Operation 11
Remove the saddle/storage compartment assembly (see operation 3) Remove the battery cover Remove the screw (1) and the plastic rivet (2) over the battery cover Remove the side cover 2 screws (3)
Open out the side covers above the battery Remove the fuel tank 2 fixing nuts (4) and the two washers Disconnect the fuel gauge (5) Remove the fuel tank (6) Disconnect the fuel valve
, Note the position of the valve in relation to the
tank before removing it
Removal of oil tank Operation 12
, The oil gauge cannot be removed
Remove the rear RH and LH covers (see operation 6) without removing the rear light Remove the oil tank bracket (1), 3 screws Disconnect the oil dipstick Disconnect the oil pipe Remove the oil tank (2)
, The oil pump circuit must be bled each time
work is carried out on the lubrication system (see relevant engine workshop manual)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
Removal of oil pipes
Removal of pipe between tank and pump
Remove the exhaust (see operation 10) Remove the fuel tank (see operation 11) Remove the engine air intake (1 screw) Remove the oil pump tension bracket (1) Disconnect the pipe (2) Drain the oil tank
Remove the rear mudguard and mudflap (see operation 8) Remove the assembly, filter tank pipe (3) /filter (4) /oil pump filter pipe (2)
, On reassembly, before connecting the pipe, put
a little oil in the tank and let the pipes and filter fill up
Removal of pipe between the oil pump and inlet pipe (100cc) or carburettor (50cc)
Remove the exhaust al of the exhaust (see operation 10) Remove the engine air intake (1 screw) (50cc) Remove the oil pump tension bracket (1) Disconnect the pipe (5)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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MISCELLANEOUS WORK
Removal of fuel gauge
Remove the saddle/storage compartment assembly (see operation 3) Disconnect the fuel gauge connector (1) Turn the gauge 1/8 of a turn towards the left
Remove the gauge
Removal of rear shock absorber
Remove the rear RH and LH cover assembly (see operation 6) Remove the air filter module air, 2 screws Remove the shock absorber upper fixing bolt (1) Remove the shock absorber lower fixing bolt (2) Remove the shock absorber (3)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
Removal of magneto coil
Remove the legshield rear panel (see operation 4) Remove the exhaust pipe (see operation 10) Remove the main fairing (see operation 7) Disconnect the coil connector (1) from the main harness (in the main fairing) Remove the cooling volute, the magneto rotor, and the coil, see relevant engine workshop manual
Removal of starter motor
Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 5) Disconnect starter motor connector (2) from the main harness (in the main fairing) Remove the starter motor 2 screws (3) Remove the starter motor (4)
Removal of carburettor
Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Remove the air filter module, 2 screws Remove the air filter air intake Disconnect the fuel (1) and vacuum (2) pipes Make a
note of the position of each pipe
Disconnect the choke connector from the main harness (in the main fairing) Remove the rubber sleeve (3) Disconnect the throttle control, 1 screw (4) Slacken the clip (5) Remove the carburettor (6)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
Removal of cylinder and the piston
Remove the fuel tank (see operation 11) Remove the exhaust (see operation 10) Remove the cylinder outer casing (1), 4 screws Remove the spark plug To remove the cylinder head, the cylinder, the piston, see the relevant engine workshop manual
Removal of inlet manifold and valves
Remove the fuel tank (see operation 11) Remove the exhaust (see operation 10) On the 100cc engine remove the cylinder Disconnect the oil injection hose (1) (100cc) or vacuum pickoff (50cc) from the inlet manifold Remove the 4 screws (2) from the inlet manifold, one of which is a shear screw on the 50cc model Remove the inlet manifold and carburettor assembly (3) Remove the valves
Removal of oil pump
Remove the exhaust (see operation 10) Unhook the oil pump control cable (1) (100cc) Remove the oil pump 2 screws (2) Remove the pump/tension bracket assembly Disconnect the oil hoses (3)
, Refitting:
Feed the 2 hoses (3) through protective sleeve (4) Connect the hoses to the oil pump Put the oil pump in position Put the tension bracket (5) in position Fit the two fixing screws (2) Fit the control cable to the oil pump (1) Check the cable adjustment (see relevant workshop manual)
, The oil pump system must be bled after any
work on the lubrication system
(see relevant engine workshop manual)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
Removal of engine mounting linkrod and rubber thrust bush
Remove the saddle/storage compartment assembly (see operation 3) Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Remove the engine mounting linkrod 2 nuts (1) Suspend the machine Remove the 2 engine mounting linkrod shafts Remove the engine mounting linkrod from the top
, On reassembly, check the rubber bush (2) is
correctly positioned in the frame. The 2 rubber locators (A) must be inserted in the 2 locating holes (B) in the frame
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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ELECTRICITY
ELECTRICITY
Removal of ACI 100 ignition module (100cc)
Remove the main fairing (see operation 7) Remove the ACI 100 ignition module , 2 screws (1) Disconnect the ACI 100 ignition module
Removal of transponder antenna (100cc)
Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Remove the ACI 100 ignition module , 2 screws Disconnect the transponder antenna Unclip the transponder antenna (1) from the steering lock Remove the transponder antenna
Removal of high tension coil
Remove the fuel tank (see operation 11) Disconnect the 2 wires (1) Remove the high tension coil, 1 screw (2)
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ELECTRICITY
Removal of voltage regulator Removal of horn Removal of lighting and choke resistors
Remove the legshield rear panel (see operation 4) The voltage regulator, horn and resistors are fixed to the frame
Removal of CDI ignition module (50cc)
Remove the legshield rear panel (see operation 4) Remove the CDI module (1)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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ELECTRICITY
Removal of instrument panel
Remove the instrument panel cover (see operation 2) Remove the instrument panel 3 screws (1) fixing it to the cover
Removal of speed sensor
Remove the legshield rear panel (see operation 4) Disconnect the speed sensor connector (1) from the main harness
Remove the front wheel (2) Remove the speed sensor and its cable (3)
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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ELECTRICITY
Removal of main harness
Remove the rear RH and LH covers (see operation 6) Remove the battery Disconnect: the fuel gauge, the oil gauge, the saddle opening control, the high tension coil Remove the footboard (4 screws)
Remove the ACI 100 module (1), 2 screws (100cc) Disconnect the ACI 100 module Remove the protective rubber cap (2) and disconnect the antenna (100cc) Remove the CDI module (50cc) Disconnect:
- the starter motor connector (3)
- the magneto coil connector (4)
- the choke connector (5)
- the starter motor relay (6)
- the horn (7)
- the regulator (8)
- the lighting and choke resistors (9)
- the resistor earth wires (10)
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ELECTRICITY
Remove the 2 upper screws (11) from the legshield front panel and tilt it forwards
Remove the legshield fixing bracket (12) on lower RH side
Disconnect:
- the headlight (13)
- the steering lock (14)
- the speed sensor connector (15)
- the RH and LH control switch module connectors from the main harness (16)
- the instrument panel
- the brake light switches
Remove the main harness
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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REMOVING THE ENGINE
REMOVING THE ENGINE
Removal of power unit
Remove the saddle/storage compartment assembly (see operation 3) Remove the legshield rear panel (see operation 4) Remove the main fairing (see operation 7) Remove the air filter module 2 screws (1) Remove the air intake 1 screw (2)
Disconnect the choke control, coil, starter motor, connectors (3), located under the footboard
On the engine, disconnect the suppressor, the carburettor throttle cable, the carburettor fuel feed and vacuum pipes (note the position of each pipe), disconnect the oil pump cable (100cc)
Slacken the rear wheel nut On the 100cc model, remove the rear brake caliper without opening the circuit On the 50cc model, disconnect the rear brake cable
Remove the nut from the engine mounting linkrod (4) Slacken the shock absorber lower fixing bolt Suspend the machine Remove the engine mounting bolt from the mounting bracket linkrod and the shock absorber bolt
Move the engine slightly out of the frame Disconnect the oil pump feed pipe
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REMOVING THE ENGINE
Stripping down the power unit
Remove the exhaust Remove the rear wheel Remove the stand Remove the kickstart pedal Remove the exhaust third mounting bracket Remove the carburettor sleeve Remove the oil hose plastic protective sleeve
, When refitting the power unit, the first operation is
to connect the oil pump pipes (1) (2) which have already been inserted in the plastic protective sleeve (3)
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FRAME
FRAME
Removal of frame
This method enables changing of the frame only If a frame is changed following an accident, the operation must be completed by the repair or replacement of any other damaged parts
At the rear:
Remove the saddle/storage compartment assembly Remove the battery cover Disconnect the battery Remove the grab handle Remove the rear mudflap Remove the rear RH and LH covers Disconnect the rear light Disconnect the fuel gauge Remove the fuel tank Disconnect the fuel tap Disconnect the oil low switch Remove the bracket and oil tank without disconnecting the pipe Remove the saddle lock Remove the saddle opening control Remove and disconnect the high tension coil Remove the mudguard
At the front:
Remove the speedo upper cover Remove the legshield rear panel Remove the footboard Remove the main fairing Unclip the steering lock antenna (100cc) Remove the handlebar pin from the pivot tube Tilt the handlebar assembly to the front of the machine Disconnect the speed sensor from the harness Remove the front caliper without disconnecting it
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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FRAME
Remove the complete fork Disconnect the headlight Remove the ACI 100 module without disconnecting it (100cc) Remove the legshield front panel Remove the horn, regulator, resistors and CDI module (50cc) without disconnecting them
Unclip the harness from the frame and cut the plastic ties
On the engine:
Remove the engine mounting bracket shaft from the frame side Remove the shock absorber upper mount
Remove the frame
Stripping the frame
Remove the manufacturer's plate (A) Remove the steering lock Remove the legshield front panel two stiffeners Remove the mounting bracket clips and rubber
, On the bench, there should be the power unit, the
main harness and its non-disconnected components, and the handlebar assembly
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FRAME
Refitting the frame
Preparing the frame
Engrave the VIN number at (B) Refit the manufacturer's plate at (A) (1 rivet) Fit the lower and upper steering ball races Fit the steering lock Fit the linkrod rubber thrust bush Fit the two legshield front panel stiffeners at (C)
Rear part 1:
Position the frame on the power unit Position the shaft on the engine mounting linkrod Position the shock absorber upper mounting shaft Fit the saddle opening control (1 screw) Fit the oil tank with its bracket (3 screws) Connect the oil low switch Fit and connect the high tension coil (1 screw) Connect the starter motor and magneto coil connectors Fix the main harness to the RH side of the frame (clips and plastic ties)
Front part 1:
Fit the voltage regulator and horn Fix the brake and throttle cables and also the choke harness on the LH side of the frame (clips and plastic ties) Fit the horn, the regulator, the CDI module (50cc), the choke and lighting resistors and the earth wire to the resistor mountings Connect the choke on the footboard
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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FRAME
Rear part 2:
Fit the saddle lock (2 screws) Fit the saddle lock / open control linkage Fit the mudguard (1 centre screw and 2 side screws) Connect the fuel tap and fuel tank overflow pipes Fit the fuel tank (2 nuts) and two washers Connect the fuel gauge Fit the main fairing assembly to the frame
Front part 2:
Connect the steering lock Fit the ACI 100 module to the legshield front panel, 2 screws (100cc) Feed the front brake caliper through the legshield Attach the legshield front panel with the 2 upper screws Feed the transponder antenna through the legshield front panel without clipping it to the lock (100 cc) Clip the legshield front panel to the main fairings Fix the front panel to the lower crossmember, 2 screws, and to the main fairings, 1 centre screw Grease the lower race and fit the 21 ball bearings Grease the upper race Engage the complete fork into the fork tube Fit the ball cage in the upper race Fit the stack of steering nuts and washers
, Check that the steering play is correct
Fit the handlebar assembly and fit and tighten the handlebar fixing bolt Clip the antenna to the steering lock (100cc) Fit the front brake caliper to the fork tube (2 screws and 2 washers) Connect the speed sensor to the main harness Fix the sensor to the upper crossmember with a clip Fit the footboard with the battery box Position the starter motor relay and the battery harness in the footboard Fit the rear cover assembly but do not tighten it Connect the rear light Fit and connect the battery
, Test all of the machine electrical functions
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FRAME
End of reassembly:
Fit the rear mudflap (4 screws) 2 side screws and 2 screws which also secure the mudguard Connect the number plate light (100cm3)
Secure the footboard to the frame (4 screws) Fit the rear cover screws (2 side screws, 1 screw and one plastic rivet above the battery cover) Fit the grab handle (2 nuts and 1 screw with washer) Fit the battery cover (1 screw) Fit the legshield rear panel (8 screws) and speedo upper cover (4 screws) Refit the saddle/storage compartment assembly Carry out a road test to check the whole of the machine
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
Page 48
RECOMMENDED
C/PS/
ISO 9001
QUALITY SYSTEM S
CERTIFICATION
CERTIFICATE N° SQ/766
REF: 11.754721.00
Ever aiming at improvement, Peugeot Motocycles reserves the right to delete, modify or add all part numbers listed in
D
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
ATR printed in EU 12/2000
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