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Ludix 4T
Workshop Manual
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PEUGEOT Ludix 4T Workshop Manual

Sales division Technical network leadership
WORKSHOP MANUAL
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TABLE OF CONTENTS
1
TABLE OF CONTENTS
TABLE OF CONTENTS . ... .......................................... ... ... .... ... .......................................... ... ... ... .......................1
PRODUCTS DANGER SYMBOLS USED........ .... ... ... ............................................. ... .... ... ... ............................. 3
CHARACTERISTICS......................................................................................................................................... 5
Engine........................................................................................................................................................5
Capacities..................................................................................................................................................5
Chassis......................................................................................................................................................5
Dimensions and weight................ .... ... ... ... .... .......................................... ... ... ... ... .......................................6
Tyres ..........................................................................................................................................................6
Brakes........................................................................................................................................................6
SERVICE SCHEDULE AND COMMISSIONING...............................................................................................7
To be checked at each service...................................................................................................................7
Service operations .....................................................................................................................................8
Time required for maintenance........................................ ... ... .... ... .......................................... ...................8
Battery preparation (Except battery without maintenance)* ......................................................................9
New machine preparation..........................................................................................................................9
SPECIAL IMPORTANT POINTS.....................................................................................................................10
Fuel..........................................................................................................................................................10
TIGHTENING TORQUES .............................. ... .... ... ... ............................................. ... ..................................... 11
Engine part ..............................................................................................................................................11
Body panels .............................................................................................................................................12
Cycle part.................................................................................................................................................12
Standard ..................................................................................................................................................12
SPECIAL TOOLS............................................................................................................................................13
STANDARD TOOLS................... ... .................................................................................................................. 14
LOCATION OF COMPONENTS...................................................................................................................... 15
BODY PANELS ...............................................................................................................................................16
Removal of the front shield panel.............................................................................................................16
Removal of the rear shield panel .............................................................................................................16
Removal of the footboard.........................................................................................................................17
Removal of the under body panel............................................................................................................17
Removal of the fuel tank ..........................................................................................................................18
Removal of handlebar fairing...................................................................................................................19
TABLE OF CONTENTS
2
SERVICE OPERATIONS................................................................................................................................. 20
Changing the engine oil ...........................................................................................................................20
Draining the relay box..............................................................................................................................21
Replacing the air filter ..............................................................................................................................22
Removal of the spark plug .......................................................................................................................23
Transmission............................................................................................................................................23
Installing the valve clearance........................... ... ... ............................................. .... ... ... ...........................27
Idle setting................................................................................................................................................28
Removal of the fuel filter ..........................................................................................................................28
Brake inspection ........................................... ... ........................................................................................28
Replacing the brake pads ........................................................................................................................29
Checking the brake fluid level..................................................................................................................29
Rear brake linings....................................................................................................................................30
MISCELLANEOUS OPERATIONS .................................................................................................................33
Removal of the fork..................................................................................................................................33
Replacing the bearings of the steering system........................................................................................33
Steering system tightening method..........................................................................................................35
Wheel bearing replacement............................................. ... ... .......................................... .... ... .. ...............36
ELECTRICITY.................................................................................................................................................. 37
Ignition principle schematic/Car buretor hea ter ............. ... ... ... .......................................... .... ... ... ... ... ........37
Checking the ignition system ...................................................................................................................38
Checking the carburettor heating circuit...................................................................................................39
Regulator/Starter motor relay/Ignition unit/Starter resistor/HT coil...................................................................40
Checking the starter motor relay..............................................................................................................40
Checking the starter resistance ...............................................................................................................41
Checking the high tension coil .................................................................................................................41
Vacuum-operated cock............................................................................................................................42
FUEL SYSTEM................................................................................................................................................43
Removal of the carburettor.......................................................................................................................43
The carburettor and its components ........................................................................................................49
POWER UNIT.......................................... ... .....................................................................................................50
PRODUCTS DANGER SYMBOLS USED
3
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 glasses and appropriate clothing such as a cotton overall. Do not breath fumes. 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 glasses and appropriate clothing such as a cotton overall. Do not breath fumes.
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.
Toxic
The product can seriously affect health if it is inhaled, ingested or in contact with skin.
Av oid direct contact with the body, even b y inhalation. If you fee l unwell, seek medical advice immediately.
Do not throw aw ay into a garbage can
One of the product's component is toxic and can be hazardous to environment. i.e.:. Used batteries.
This symbol informs the consumer that the used product shall not be thrown awa y 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 saf ety can be seriously aff ected if the recommendations are not fully respected.
PRODUCTS DANGER SYMBOLS USED
4
People's safety
Operation that can be dangerous for people.
People's saf ety can be seriously aff ected 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
5
CHARACTERISTICS
Engine
Capacities
Chassis
Engine marking XS1P37QMA-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 37 x 46 mm
Cubic capacity 49 cc
Max. power output 3 kW at 8300 rpm
Max. torque rating 3.7 Nm at 6500 rpm
Compression
9.5 bars at 550 rpm 7bars Minimum
Fuel supply Carburettor. KEIHIN NCV Lubrication
Pressurised wet sump lubrication.
Trochoid pump driven by a chain from the crankshaft
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Catalytic
Starter motor By kick starter or electric starter
Spark plug
NGK CR6HSA
Electrode gap: 0.6 - 0.7 mm
Magneto flywheel 80 W
Standards Euro 2
Relay box
0.1 l SAE 80W90
Minimum grade: API GL4
(0.09 I at oil change)
Crankcase
0.8 l SAE 5W40
Minimum grade: API SL/SJ
(0.65 I at oil change)
Fuel tank 5.3 l
Chassis Tubular chassis
Front suspension
Upside down telescopic front fork
Travel: 73 mm
Rear suspension
Combined spring and hydraulically-damped shock absorber
Travel: 65 mm
CHARACTERISTICS
6
Dimensions and weight
Tyres
Brakes
Overall length 1750 mm
Width at handlebar 670 mm
Height (without rear-view
mirrors)
1080 mm
Wheelbase 1280 mm
Unladen weight 78 kg
Front wheel rim 14 inch aluminium alloy
Front tyre 80/80 - 14
Front tyre pressure 2.5 bars
Rear wheel rim 14 inch aluminium alloy
Rear tyre 170/70 - 14
Rear tyre pressure 2.8 bars
Front brake
Single disc type, hydraulic control
Fixed calliper with 2 pistons
Disc diameter and
thickness
190 mm - 3 mm
Rear brake Single-cam drum type, controlled by cable
Brake drum diameter 110 mm
Brake lining thickness 4mm
Chassis markings Engine marking
(1) number and manufacturer's plate Engine number (2)
X
X
XXXXXXX
XXXXXXXX
1
XXXXXX
*XXXXXXXXX*
2
SERVICE SCHEDULE AND COMMISSIONING
7
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.
Service operations 500 2000 5000 10000 15000 20000
Heavy duty servicing 500 1000 2500 5000 7500 10000
Minimum servicing
1 months 6 months 12 months 24 months 36 months 48 months
To be checked at each service
Steering column play V V V V V V Wheel bearing play C C C C C C Throttle cable play V V V V V V Operation of electrical equipment V V V V Condition of the front brake hydraulic
control
VVV V VV
Brake fluid level V V V V V V Front brake pad wear C C C C C C Rear brake lining wear C C C C C C Condition of petrol pipes C C C C C C Tyre condition, pressure and wear C C C C C C State of front suspension. State of rear
suspension
VVV V VV
Battery electrolyte level. Battery charge V V V V V V Engine oil level Every 1000 kms Headlight height adjustment V V V V V V Tightness of nuts and bolts V V V V V V Overall operation. Road test V V V V
V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment.
SERVICE SCHEDULE AND COMMISSIONING
8
Service operations 500 2000 5000 10000 15000 20000
Heavy duty servicing 500 1000 2500 5000 7500 10000
Minimum servicing
1 months 6 months 12 months 24 months 36 months 48 months
Service operations
Spark plug V R R R R Air filter R R Intake silencer drain N N N N Drive pulley bearings and guides V C V C Transmission belt R R R R Driven pulley caged needle bearing G G G G Kick starter mechanism G G Valve clearances V V V V V Setting the carburettor V V Joints. (Central stand, Brake levers) G G G G Petrol filter R Engine oil (+ clean strainer) R R R R R R Relay box oil R R R R R Petrol pipe Once every 5 years Brake fluid Once every 2 years
Time required for maintenance
Code 9100 9150 9300 9400 9500 9600 Servicing time in tenths of an hour
(0.5 h = 30 mn)
1.3 2.2 3.3 4.0 3.3 4.2
V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment.
SERVICE SCHEDULE AND COMMISSIONING
9
Battery preparation (Except battery without maintenance)*
Remove the battery. Remove the 6 filler caps and the vent plug. Fill all the battery cells with electrolyte to the upper level shown on the battery " UPPER LEVEL ". Electrolyte: (35% sulfuric acid = 1.28g/cm3). 0.5 litre can P/N 739733. 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 0.4 A. Refit the battery and connect the vapour vent pipe. Connect the red wire lug to the battery's + terminal, and the green wire lug to the battery's - terminal. Then, the battery level should be topped up if necessary, after fully charging, using distilled water only.
* Depending on equipment.
New machine preparation
Check the tightness of the carburettor float chamber drain screw. 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.
SPECIAL IMPORTANT POINTS
10
SPECIAL IMPORTANT POINTS
Fuel
This engine is designed to run on 95 or 98 unleaded fuel only.
Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc... The air pipe between the air pump and the exhaust is specific owing to its heat resistance
properties. Should it be changed, replace it with a genuine pipe.
Petrol is highly inflammable, do not smoke in the working area and avoid pr oximity to flames or sparks.
Before carrying out any work, leave the engine to cool for at least 2 hours.
TIGHTENING TORQUES
11
TIGHTENING TORQUES
Engine part
Spark plug 12 Nm Engine drain plug 20 Nm Screen 15 Nm Cylinder head
•Nut
•Screw
20 Nm
12 Nm Camshaft gear cover 10 Nm Camshaft gear 20 Nm Valve clearance covers 15 Nm Automatic tensioner 10 Nm Automatic tensioner plug 8 Nm Chain tensioner 10 Nm Inlet manifold 10 Nm Crankcase 12 Nm RH casing cover 12 Nm Freewheel 90 Nm Oil pump 10 Nm Transmission cover 10 Nm Relay box cover 22 Nm Relay box drain plug 10 Nm Relay box filler cap 10 Nm Starter motor 10 Nm Rotor 50 Nm Turbine 10 Nm Stator 10 Nm Engine speed sensor 10 Nm Drive pulley 55 Nm Driven pulley 55 Nm Clutch plate and shoes 55 Nm
TIGHTENING TORQUES
12
Body panels
Cycle part
Standard
Floor panel 4 Nm Handlebar cover 1 Nm Front shield panel 1 Nm Rear shield 1 Nm Side panels 1 Nm Front mudguard 8 Nm
Front wheel spindle 65 Nm Rear wheel spindle nut 110 Nm Linkrod to engine pivot 50 Nm Linkrod to frame pivot 50 Nm Shock absorber top mount 45 Nm Shock absorber bottom mount 22 Nm Exhaust to cylinder head mounting nut 15 Nm Exhaust to casing mounting bolt 20 Nm Upper cone (in 2 operations) 40/23 Nm Upper cone locknut Hand tightened Steering locknut 70 Nm Front brake caliper 30 Nm Front brake disc 22 Nm Handle bar 40 Nm Fuel tank 22 Nm Luggage carrier 25 Nm
Nut and bolt 5 mm diameter 6 Nm Nut and bolt 6 mm diameter 10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm
SPECIAL TOOLS
13
SPECIAL TOOLS
Tool N° Designation Used with Tool N° Designation Used with
752127
Clutch
compression
tool
756607
Steeing head cup push tool
752237
Adjustable pin
wrench
757860
Steering tool
752361
39 mm pipe
wrench
759788
Steeing head cup push tool
755996 766062
Spark plug
spanner
STANDARD TOOLS
14
STANDARD TOOLS
Wrenches with
interchangeable end fittings f or
valve clearance adjustment.
Type: Marolotest P/N 500140
Set of shims
Slide calipers Multimeter
Automatic resetting type
torque wrench
5 to 25 Nm
Type:
Facom R.306A25
Automatic resetting type
torque wrench
40 to 200 Nm
Type:
Facom S.208A200
Automatic resetting type
torque wrench
10 to 50 Nm
Type:
Facom J.208A50
Inertia extraction tool and
sockets with internal grip
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
LOCATION OF COMPONENTS
15
LOCATION OF COMPONENTS
1. CDI unit
2. Battery
3. Magneto flywheel
4. Fuse
5. HT coil
6. Regulator
7. Starter motor relay
8. Switch "Reserve"
9. Horn
10.Starter resistor
11.Resistor warming carburator
12.Temperature control unit
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U
P
P
E
R
L
E
V
E
L
L
O
W
E
R
L
E
V
E
L
5
11
1
2
9
8
6
7
3
4
12
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