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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP MANUAL
CONTENTS
CONTENTS |
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CONTENTS ..................................................................................................................................................... |
2 |
CHARACTERISTICS .................................................................................................................................... |
4 |
Engine characteristics .................................................................................................................................... |
4 |
Engine markings ............................................................................................................................................ |
4 |
Frame characteristics ..................................................................................................................................... |
5 |
Capacities....................................................................................................................................................... |
5 |
Machine markings ......................................................................................................................................... |
5 |
SERVICE SCHEDULE AND COMMISSIONING ..................................................................................... |
6 |
Check: ............................................................................................................................................................ |
6 |
Change: .......................................................................................................................................................... |
6 |
Check and remove carbon: ............................................................................................................................ |
6 |
Check and lubricate: ...................................................................................................................................... |
6 |
Clean and adjust:............................................................................................................................................ |
6 |
Test machine:................................................................................................................................................. |
6 |
Battery preparation (except for maintenance-free battery)*.......................................................................... |
7 |
Checks before handing over to the customer................................................................................................. |
7 |
SPECIAL IMPORTANT POINTS ................................................................................................................ |
8 |
Oil and fuel .................................................................................................................................................... |
8 |
TIGHTENING TORQUES AND SPECIAL TOOLS.................................................................................. |
9 |
Tightening torques ......................................................................................................................................... |
9 |
Body panels: .............................................................................................................................................. |
9 |
Frame: ........................................................................................................................................................ |
9 |
Standard: .................................................................................................................................................... |
9 |
Special tools:.................................................................................................................................................. |
9 |
CONTROL CABLE AND HARNESS ROUTINGS .................................................................................. |
10 |
Ludix basic version...................................................................................................................................... |
10 |
Ludix luxury version.................................................................................................................................... |
12 |
Caption for Ludix basic and luxury versions............................................................................................... |
14 |
BODY PANELS ............................................................................................................................................. |
15 |
Removal of the front leg shield Procedure 1.............................................................................................. |
15 |
Removal of the rear leg shield Procedure 2 ............................................................................................... |
15 |
Removal of the floor assembly Procedure 3 .............................................................................................. |
16 |
Removal of the lower panel......................................................................................................................... |
17 |
FRAME........................................................................................................................................................... |
18 |
Removal of the handlebar Procedure 4 ...................................................................................................... |
18 |
Removal of the fork or cone, cups, lower ball cage .................................................................................... |
19 |
Steering composition ................................................................................................................................... |
19 |
MISCELLANEOUS OPERATIONS........................................................................................................... |
20 |
Removal of the front brake hydraulic hose.................................................................................................. |
20 |
Removal of the rear brake cable .................................................................................................................. |
20 |
Removal of the oil and fuel tank assembly or the tap.................................................................................. |
21 |
Removal of the headlight bulb, instrument panel, speedometer cable ........................................................ |
22 |
Removal of the ignition switch.................................................................................................................... |
22 |
Removal of the voltage regulator or high-tension coil ................................................................................ |
22 |
Removal of the starter motor relay or CDI module, fuse, oil pump control unit ........................................ |
23 |
Removal of the throttle cable....................................................................................................................... |
23 |
Removal of the horn .................................................................................................................................... |
23 |
Removal of the exhaust Procedure 5.......................................................................................................... |
24 |
Removal of the oil pump ............................................................................................................................. |
24 |
Oil pump bleeding procedure on LUDIX with battery................................................................................ |
25 |
Page: 2 |
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Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles |
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CONTENTS |
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Oil pump bleeding procedure on LUDIX without battery........................................................................... |
26 |
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE.................................................... |
27 |
Removal of the magneto flywheel armature................................................................................................ |
27 |
Removal of the starter motor ....................................................................................................................... |
27 |
Removal of the carburettor Procedure 6 .................................................................................................... |
27 |
Removal of the inlet coupling and valves.................................................................................................... |
28 |
Removal of the cylinder and piston ............................................................................................................. |
28 |
Removal of the engine mounting linkrod .................................................................................................... |
29 |
ELECTRICITY ............................................................................................................................................. |
30 |
Removal of the main harness....................................................................................................................... |
30 |
ENGINE REMOVAL.................................................................................................................................... |
31 |
Removal of the power unit .......................................................................................................................... |
31 |
Removal of the engine ................................................................................................................................. |
31 |
FRAME........................................................................................................................................................... |
32 |
Removal of the frame .................................................................................................................................. |
32 |
Frame fitting ................................................................................................................................................ |
33 |
Page : 3
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS
Engine characteristics
Engine |
2-stroke, exhaust air injection (I.A.E.) |
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Air cooling |
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Bore x stroke |
39.9 X 39.8 |
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Cubic capacity |
49.9 cc |
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Max. power output |
3.2 kW |
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Max. torque engine |
6800 rpm |
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speed |
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Maximum power |
7100 rpm |
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output engine speed |
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Ignition |
CDI |
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Spark plug |
NGK BR7HS |
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Eyquem R850 |
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Carburettor |
Gurtner PY 12 |
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Oil pump control |
Dell'Orto |
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unit |
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Air pump |
Dell'Orto |
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Oil pump |
Dell'Orto |
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Magneto |
Kokusan 89 W |
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Starter motor |
Mitsuba 150 W ou Moric 160 W |
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Exhaust |
Catalytic |
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Engine markings |
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Engine type |
HA1 |
1. Engine number
Page: 4
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
CARACTERISTICS
Frame characteristics
Capacities
Fuel tank |
5.5 litres |
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Lead-free 95 or 98 |
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Oil tank |
1.2 litre |
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Semi-synthetic oil |
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0.12 litre |
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Transfer box |
Oil SAE 80W90 |
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Life lubricated |
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Fork |
Mechanical |
Machine markings
1.Manufacturer’s plate
2.VIN number
Page : 5
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing is for machines used under “harsh” conditions: door-to-door deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.
Service operations |
500 kms |
Every 5000 kms |
Every 10000 kms |
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or 1 months |
or 12 months |
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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 |
Functioning of electrical devices |
X |
X |
X |
Condition and adjustment of front and rear |
X |
X |
X |
brake cables * |
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Condition of fuel pipes |
X |
X |
X |
Condition of oil pipes |
X |
X |
X |
Condition of front brake fluid pipe |
X |
X |
X |
Tyre pressures |
X |
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Tyre condition, pressure and wear |
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X |
X |
Brake fluid level |
X |
X |
X |
Battery electrolyte level * |
X |
X |
X |
Tightness of nuts and bolts |
X |
X |
X |
Change: |
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Spark plug |
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X |
X |
Inlet silencer |
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X |
Front brake pads or linings # |
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X |
X |
Rear brake linings * # |
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X |
Drive pulley rollers # |
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X |
X |
Transmission belt |
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X |
Check and remove carbon: |
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Piston |
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X |
Cylinder head |
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X |
Exhaust port |
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X |
Check and lubricate: |
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Expanding flange driven pulley and needle |
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X |
cages |
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Drive pulley / expanding flange |
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X |
X |
Kickstart drive gear and kickstart shaft |
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X |
X |
Front and rear brake cam |
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X |
X |
Clean and adjust: |
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Carburettor |
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|
X |
Test machine: |
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On road |
X |
X |
X |
* Depending on equipment |
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# If necessary |
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Page: 6
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING
Battery preparation (except for maintenance-free battery)*
-Remove the battery
-Remove the 6 filler caps and the vent plug
-Fill the battery with electrolyte to the level marked UPPER LEVEL
-Electrolyte: (35% sulphuric acid = 1.28g/cm3) 1 litre can ref: 752740, 5 litre can ref: 752741.
-Leave the battery to stand for around half an hour
-Top up if necessary
-Charge the battery for at least 2 hours with a current of 400 mA (0.4A)
-Refit the battery and connect the vapour vent pipe
-Connect the red wires to the + terminal and the green wire to the - terminal
-Then, the battery level should be topped up if necessary, after fully charging, using distilled water only.
Checks before handing over to the customer
-Check the wheel nuts are tight
-Check nuts and bolts are tight
-Check brake adjustment and efficiency
-Check the tyre pressures cold
-Check operation of the lights, flashers *, horn, and brake light
-Check the different warning lights work
-Carry out a road test
*Depending on equipment
Page : 7
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
SPECIAL IMPORTANT POINTS
Oil and fuel
This machine is designed to run on super 95 or 98 unleaded fuel
The oil to use for the separate lubrication system is semi-synthetic oil
The oil pump must be bled according to the methods specified depending on the models.
The air pipe between the air pump and the exhaust has specific heat resistance properties. In case of replacement, an original pipe must be fitted.
For machines equipped with a battery, the instrument panel oil warning light comes on when the ignition is turned on and then goes off when the engine starts ; this means that the lubrication system warning light and electrical circuit are operational
Page: 8
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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TIGHTENING TORQUES AND SPECIAL TOOLS |
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TIGHTENING TORQUES AND SPECIAL TOOLS |
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Tightening torques |
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Body panels: |
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Bottom panel |
0.4 m.daN |
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Floor |
0.4 m.daN |
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Handlebar cover |
0.1 m.daN |
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Front panel |
0.1 m.daN |
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Rear shield |
0.1 m.daN |
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Side fairings |
0.1 m.daN |
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Front mudguard |
0.8 m.daN |
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Grab handle |
1.2 m.daN |
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Frame: |
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Front wheel spindle nut |
6 m.daN |
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Rear wheel spindle nut |
10 m.daN |
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Engine to rod pivot |
5.2 m.daN |
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Frame to rod pivot |
5.2 m.daN |
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Shock absorber top mount |
4.3 m.daN |
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Shock absorber bottom mount |
2 m.daN |
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Exhaust to cylinder mounting nut |
1.5 m.daN |
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Exhaust fixing bolt on engine casing |
2 m.daN |
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Upper cone (in 2 operations) |
4 and 2.3 m.daN |
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Steering locknut |
7 m.daN |
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Front brake caliper |
2.5 m.daN |
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Front brake disc |
1 m.daN |
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Standard: |
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Nut and bolt 5 mm diameter |
0.5 m.daN |
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Nut and bolt 6mm diameter |
1 m.daN |
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Nut and bolt 8mm diameter |
2.2 m.daN |
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Nut and bolt 10mm diameter |
3.5 m.daN |
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Nut and bolt 12mm diameter |
5.5 m.daN |
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Special tools: |
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Designation |
Reference |
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Hose clamp |
755996 |
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Steering column wrench |
757860 |
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Oil circuit bleeding harness |
757854 |
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Page : 9
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
CONTROL CABLE AND HARNESS ROUTINGS
CONTROL CABLE AND HARNESS ROUTINGS
Ludix basic version
Page: 10
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
CONTROL CABLE AND HARNESS ROUTINGS
Page : 11
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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