PEUGEOT Tweet Workshop Manual
Sales division
Technical network leadership
WORKSHOP MANUAL
-
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
PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4
CHARACTERISTICS.........................................................................................................................................6
Engine........................................................................................................................................................6
Capacities ..................................................................................................................................................6
Chassis ......................................................................................................................................................7
Dimensions and weight..............................................................................................................................7
Tyres ..........................................................................................................................................................7
Brakes........................................................................................................................................................8
SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 9
Battery preparation (Except battery without maintenance)* ....................................................................11
New machine preparation........................................................................................................................11
SPECIAL IMPORTANT POINTS.....................................................................................................................12
TIGHTENING TORQUES ................................................................................................................................13
Engine part ..............................................................................................................................................13
Body panels .............................................................................................................................................13
Cycle part.................................................................................................................................................14
Standard ..................................................................................................................................................14
SPECIAL TOOLS ............................................................................................................................................15
Standard tools..........................................................................................................................................16
LOCATION OF COMPONENTS......................................................................................................................17
BODY PANELS ...............................................................................................................................................18
Location of body components..................................................................................................................18
Body component sequence of disassembly.............................................................................................19
Removal of the storage compartment......................................................................................................20
Removal of the rear cover assembly........................................................................................................20
Removal of the front top shield panel.......................................................................................................21
Removal of the front lower shield pannel.................................................................................................21
Removal of the rear shield panel .............................................................................................................22
Removal of the footboard.........................................................................................................................23
Removal of handlebar fairing...................................................................................................................23
TABLE OF CONTENTS
2
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SERVICE OPERATIONS.................................................................................................................................24
Changing the engine oil ...........................................................................................................................24
Draining the relay box..............................................................................................................................25
Replacing the air filter ..............................................................................................................................26
Removal of the spark plug .......................................................................................................................27
Idle setting................................................................................................................................................27
Transmission............................................................................................................................................27
Removal of the drive pulley......................................................................................................................28
Removal of the driven pulley....................................................................................................................28
Changing the drive pulley bearings..........................................................................................................29
Checking the drive belt.............................................................................................................................29
Checking the thickness of the clutch linings.............................................................................................30
Removal of the clutch lining assembly.....................................................................................................30
Refitting the clutch lining assembly..........................................................................................................31
Installing the valve clearance...................................................................................................................32
Checking the valve clearance..................................................................................................................33
Brake pad wear........................................................................................................................................34
Replacing the brake pads ........................................................................................................................34
Checking the brake fluid level..................................................................................................................36
Rear brake linings 50 cc...........................................................................................................................36
Removal of the fuel filter ..........................................................................................................................38
Draining the front fork...............................................................................................................................39
STEERING/FORK............................................................................................................................................41
Changing the front fork seals...................................................................................................................41
The fork and its components....................................................................................................................42
Removal of the fork..................................................................................................................................45
Replacing the bearings of the steering system........................................................................................46
Steering headset cups .............................................................................................................................46
Fork cone.................................................................................................................................................46
Installing the fork......................................................................................................................................47
Steering system tightening method..........................................................................................................47
TABLE OF CONTENTS
3
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ELECTRICITY..................................................................................................................................................48
Ignition principle schematic/Starting off (50 cc).......................................................................................48
Checking the ignition system ...................................................................................................................49
Ignition principle schematic/Starting off (125/151 cc)..............................................................................50
Checking the ignition system ...................................................................................................................51
Removal of the regulator/Starter resistor.................................................................................................52
Removal of the starter motor relay...........................................................................................................52
FUEL SYSTEM................................................................................................................................................54
Removal of the carburettor.......................................................................................................................54
Vacuum-operated cock............................................................................................................................54
Removal of the fuel gauge.......................................................................................................................52
POWER UNIT ..................................................................................................................................................55
Removal of the power unit .......................................................................................................................55
PRODUCTS DANGER SYMBOLS USED
4
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
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 goggles and appropriate
clothes 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, heater, 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 goggles and appropriate
clothes 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.
Avoid direct contact with the body, even by
inhalation. If you feel unwell, seek medical
advice immediately.
Do not throw
away 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 away 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 safety can be seriously affected if
the recommendations are not fully
respected.
5
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
People's safety
Operation that can be
dangerous for people.
People's safety can be seriously affected 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
CHARACTERISTICS
6
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Engine
Capacities
50 cc 125 cc 151 cc
Marking XS1P37QMA-2 XS1P52QMI-4 XS1P57QMJ-2
Type
4-stroke single-cylinder. Horizontal cylinder
Single overhead camshaft, 2 valves
Cooling By a circulation of forced air by means of a turbine on the flywheel magneto
Bore x stroke 37 x 46 mm 52.4 x 57.8 mm 57.4 x 58.2 mm
Cubic capacity 49.5 cc 124.6 cc 150.6 cc
Max. power output 2.3 kW at 7500 rpm 6.5 kW at 7500 rpm 7.7 kW at 7500 rpm
Max. torque rating 3.1 Nm at 6500 rpm 9 Nm at 6000 rpm 10.6 Nm at 6000 rpm
Compression
9.5 bars at 550 rpm
7 bars. Minimum
11.8 bars at 380 rpm
7 bars. Minimum
Lubrication Trochoid pump driven by a chain from the crankshaft
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Catalytic
Spark plug
NGK CR6HSA
Electrode gap: 0.7 - 0.8 mm
NGK CR7HSA
Electrode gap: 0.7 - 0.8 mm
Magneto flywheel 80 W
Fuel supply Keihin NCV carburettor DENI DPD24J carburettor
Standards Euro2 Euro3
Crankcase
0.8 L (0.65 L at the oil
change)
SAE 5W40 Synthetic
Minimum grade: API SJ
0.95 L (0.7 L at the oil change)
SAE 5W40 Synthetic
Minimum grade: API SJ
Relay box
0.18 L (0.17 at the oil change)
SAE 80W90
Minimum grade: API GL4
Fuel tank 5.7 l 95 or 98 lead-free
Fork oil 0.1 l per tube. SAE 10W
CHARACTERISTICS
7
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Chassis
Dimensions and weight
Tyres
50 cc 125 cc 151 cc
Chassis Steel tube
Front suspension
Upside down telescopic front fork. Ø30 mm
Travel: 100 mm
Rear suspension
Combined spring and
hydraulically-damped
shock absorber Travel:
80 mm
Combined spring and hydraulically-damped shock
absorber Travel: 75 mm
Overall length 2000 mm
Width at handlebar 690 mm
Height (without rear-view
mirrors)
1125 mm
Wheelbase 1330 mm
Unladen weight 97 kg 106 kg
Front wheel rim 16 inch aluminium alloy
Front tyre 90/80 - 16
Front tyre pressure 1.75 bars
Rear wheel rim 16 inch aluminium alloy
Rear tyre 90/80 - 16 110/70 - 16
Rear tyre pressure 2.25 bars
CHARACTERISTICS
8
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Brakes
50 cc 125 cc 151 cc
Front brake Single disc type, hydraulic control
Disc diameter and
thickness
226 mm - 4 mm
Mini. thickness: 3.5 mm
Front caliper Floating calliper equipped with 2 pistons
Rear brake
cable-controlled, single
cam drum type
Single disc type, hydraulic control
Drum diameter 130 mm
Disc diameter and
thickness
226 mm - 4 mm
Mini. thickness: 3.5 mm
Rear caliper
Fixed calliper with 2 pistons
Chassis markings Engine marking
1. The VIN number and the manufacturer's
plate are under the seat
2. Engine number
*VGAXXXXXXXXXXXXXX*
1
2
xxxxxxx
SERVICE SCHEDULE AND COMMISSIONING
9
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING
Heavy duty servicing applies to vehicles used under rugged operating conditions: door-to-door deliveries,
intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature
over 30°C.
Normal servicing in km 500 2000 5000 10000 15000 20000
Extensive servicing in km
a
a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high
temperature, exclusively town use, etc..
500 1000 2500 5000 7500 10000
Minimum servicing
1 months 6 months 12 months 24 months 36 months 48months
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 V V
Condition of front and rear brake hydraulic
controls.
b
b.Depending on model.
V V V V V V
Brake fluid level.
b
V V V V V V
Brake pad wear. C C C C C C
Rear brake lining wear.
b
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.
V V V V V V
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 V
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 50 cc. R R
Transmission belt 125/151 cc. R R R R
Kick starter mechanism. G G
V:Check, clean, adjust. R: Change. G: Check, clean, lubricate. C: Inspect and change if necessary. N:
Clean.
After 20000 km, resume the service schedule again from 5000 km.
SERVICE SCHEDULE AND COMMISSIONING
10
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Normal servicing in km 500 2000 5000 10000 15000 20000
Extensive servicing in km
a
500 1000 2500 5000 7500 10000
Minimum servicing
1 months 6 months 12 months 24 months 36 months 48months
Service operations
Valve clearances. V V V V V
Setting the carburettor. V V
Joints. (Central stand, Brake levers, Brake cams). 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
Fork oil. R
Petrol pipe. R Once every 5 years.
Brake fluid. R Once every 2 years.
V:Check, clean, adjust. R: Change. G: Check, clean, lubricate. C: Inspect and change if necessary. N:
Clean.
After 20000 km, resume the service schedule again from 5000 km.
Code 9000 9100 9150 9300 9400 9500 9600
Normal servicing in km 0 500 2000 5000 10000 15000 20000
Extensive servicing in km
a
a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high
temperature, exclusively town use, etc..
0 500 1000 2500 5000 7500 10000
Servicing time in tenths of an hour (0.5 h = 30 min)
Tweet Peugeot 1.4 1.3 1.8 2.6 3.1 2.6 3.9
SERVICE SCHEDULE AND COMMISSIONING
11
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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
12
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SPECIAL IMPORTANT POINTS
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 proximity to flames or
sparks.
Before carrying out any work, leave the engine to cool for at least 2 hours.
TIGHTENING TORQUES
13
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TIGHTENING TORQUES
Engine part
Body panels
50 cc 125/151 cc
Spark plug 12 Nm
Engine drain plug 20 Nm
Screen 15 Nm
Cylinder head
• Nut
• Screw
12 Nm
12 Nm
22 Nm
12 Nm
Camshaft gear cover 10 Nm
Cylinder head cover 10 Nm
Camshaft gear 20 Nm 10 Nm
Valve clearance covers 10 Nm
Automatic tensioner 10 Nm
Automatic tensioner plug 8 Nm
Chains guide 10 Nm
Inlet manifold 10 Nm
Cylinder casings 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
Starter motor 10 Nm
Rotor 45 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
Front mudguard 8 to 10 Nm
Handlebar cover 1 to 2 Nm
Front shield panels 1 to 2 Nm
Rear shield 1 to 2 Nm
Bottom panel 6 to 8 Nm
Floor panel 8 to 10 Nm
Saddle storage compartment 8 to 10 Nm
Rear panels 1 to 2 Nm
Grab handle 20 to 25 Nm
TIGHTENING TORQUES
14
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Cycle part
Standard
Front wheel spindle 60 Nm
Fork tube 28 Nm
Rear wheel spindle nut 110 Nm
Linkrod to engine pivot 50 Nm
Linkrod to frame pivot 50 Nm
Shock absorber top mount 40 Nm
Shock absorber bottom mount 28 Nm
Exhaust to cylinder head mounting nut 15 Nm
Exhaust to casing mounting bolt 30 Nm
Adjustment cone Hand tightened
Steering locknut 20Nm
Front brake caliper 30 Nm
Front brake disc 40 Nm
Rear brake caliper 30 Nm
Rear brake disc 40 Nm
Handle bar 45 Nm
Nut and bolt 5 mm diameter 5 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
Nut and bolt 12 mm diameter 55 Nm
SPECIAL TOOLS
15
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SPECIAL TOOLS
Tool N° Designation Used with Tool N° Designation Used w ith
752127
Clutch
compression
tool
50 cc
756057
Fork seal push
tool
752237
Adjustable pin
wrench
758008
Clutch
compression
tool
125/151 cc
801682
752361
39 mm pipe
wrench
759788
Steeing head
cup push tool
755039
Steeing head
cup push tool
801682
Spacer adaptor
758008
755996
Hose clamp
SPECIAL TOOLS
16
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Standard tools
Wrenches with interchangeable
end fittings for 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
OFF
V
DC
V
AC
Ω
20 m
200 m
DC
10A
V
Ω
COM
mA
Ω
LOCATION OF COMPONENTS
17
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LOCATION OF COMPONENTS
1. Instrument panel
2. CDI unit
3. Battery
4. Fuses
5. HT coil
6. Magneto flywheel
7. Starter motor relay
8. Regulator
9. Starter resistor
10.Fuel gauge
11.Opening the saddle
12.Horn
13.Flasher unit
-
U
PP
ER
LE
VEL
LOW
ER LEVEL
12
8
1
10
11
3
4 2
7
5
9
13
6
ODOTRIP
T
IM
E
BODY PANELS
18
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
Location of body components
Description
1. Rearview mirrors
2. Handlebar front fairing
3. Handlebar rear fairing
4. Front wheel
5. Fork tube
6. Front mudguard
7. Legshield top panel
8. Front lower legshields
9. Mudguard
10.Bottom panel
11.Central bottom panel
12.Rear shield
13.Floor panel
14.Battery access door
15.Rear panels/Mudflap
16.Saddle and storage compartment
17.Grab handle
17
2
1
11
13
15
7
9
8
16
6
5
4
12
3
10
14
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