PEUGEOT XS1P52QMI-3B, XS1P57QMJ-2 Workshop Manual
Sales division
Technical network leadership
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WORKSHOP MANUAL
ADDITION TO THE MA0020 ENGINE WORKSHOP MANUAL
FOR THE SYM EVO 2 VALVE 4 STROKE 125/151 CC ENGINE
Sales division
Technical network leadership
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocy cles
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS.....................................................................................................................................1
PRODUCTS DANGER SYMBOLS USED......................................................................................................... 2
CHARACTERISTICS.........................................................................................................................................4
Capacities ..................................................................................................................................................4
SPECIAL IMPORTANT POINTS...... ... ... .... ... ... .......................................... .......................................................5
Oil and fuel.................................................................................................................................................5
TIGHTENING TORQUES ..................................................................................................................................6
SPECIAL TOOLS ................ ... ... ....................................... ... .... ... ... ....................................... . ............................7
Standard tools........................................... ... .... ... ... ....................................... ... ... ... ....................................9
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Putting the engine on the stand...............................................................................................................10
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Removal of the driven pulley....................................................................................................................10
Checking the drive belt........................... ..................................................................................................10
SPECIFIC POINT FOR OPERATION..............................................................................................................10
Removal of the secondary transmission ..................................................................................................11
Removal of the cylinder head...................................................................................................................11
Removal of the camshaft and/or rockers..................................................................................................11
Checking the cylinder................................... .... ... ... ... ... ....................................... ... .... ... ... ... .....................16
Checking the piston............................. ... ... ... ....................................... ... .... ... ...........................................16
Checking the piston rings................................. ...................................... .... ... ... ... .....................................17
Setting the timing .....................................................................................................................................13
Checking the timing............................. ... ... ....................................... ... ... .... ..............................................14
Installing the valve clearance...................................................................................................................15
Checking the valve clearance............................. ... ... ... .... ... ....................................... ... ... ... .....................15
Checking the crankshaft and conrod assembly ..................................... ....................................... ... ... .. ...15
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
1
PRODUCTS DANGER SYMBOLS USED
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.
The product can irritate the
Irritant
skin, eyes and respiratory
organs.
Flammable The product is flammable.
Corrosive
The product can damage living
tissues or other surfaces.
The product can explode under
Explosive
certain circumstances (flame,
heat, impact, friction).
The product affects fauna and
Hazardous to
the environment
flora. Do not dump it in
dustbins, sinks or in the
environment.
Avoid contact with skin and clothes. Wear
gloves, saf ety goggles and cotto n ov eralls .
Do not breath in the vapour. If in contact,
wash thoroughly with water.
Keep it away from flames or any heat
source (barbecue, radiator, heating, etc.).
Do not leave the product in the sun.
Avoid contact with skin and clothes. Wear
gloves, saf ety goggles and cotto n ov eralls .
Do not breath in the vapour.
Avoid impacts, friction, sparks and heat.
The ideal solution is to bring this product
to your nearest household waste recycling
centre.
Toxic
Do not throw
away into a
garbage can
Compulsory
gloves
The product can seriously
affect health if it is inhaled,
ingested or in contact with skin.
One of the product's
component is toxic and can be
hazardous to environment.
Example: Used batteries.
Operation that can be
dangerous for people.
Av oid direct contact with the body, even by
inhalation. If you f eel unw ell, seek medical
advice immediately.
This symbol informs the consumer that the
used product shall not be thrown aw ay into
a garbage can, but shall be brought back
to the merchant or dropped at a specific
collection point.
People's saf ety can be seriously aff ected if
the recommendations are not fully
respected.
2
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
PRODUCTS DANGER SYMBOLS USED
N
People's safety
Important
Good operating
condition of the
vehicle
Note Operation that can be difficult.
Lubricate
Grease
Operation that can be
dangerous for people.
Operation that can be
hazardous to the vehicle.
The operation must be carried
out in strict compliance with the
documents.
Lubricate the parts to be
assembled.
Grease the parts to be
assembled.
People's saf ety can be seriously aff ected if
the recommendations are not fully
respected.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Serious damage to the vehicle and in
certain cases a cancellation of the
warranty can be involved if the
recommendations are not fully respected.
Indicate a note which gives key
information to make the procedure easier.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
GLUE
Glue
New part Use a new part.
Glue the parts to be
assembled.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
Indicate the specific procedures that shall
be followed in order not to damage the
vehicle.
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS
125 cc 151 cc
Marking XS1P52QMI-3B XS1P57QMJ-2
Type
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 52.4 x 57.8 mm 57.4 x 58.2 mm
Cubic capacity 124.6 cc 150.6 cc
Max. power output 7.5 kW at 8500 rpm 8.3 kW at 8000 rpm
Max. torque rating 8.9 Nm at 7000 rpm 11 Nm at 6000 rpm
Compression
Lubrication Trochoid pump driven by a chain from the crankshaft
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
4-stroke single-cylinder
11.4 bars at 380 rpm
7 bars Minimum.
Exhaust Catalytic
Spark plug NGK CR7HSA
Magneto flywheel 80 W
Fuel supply Deni DPD24J carburettor
Standards Euro3
Capacities
0.95 L(0.7 l at oïl change)
Crankcase
SAE 5W40 Synthetic
Minimum grade: API SJ
0.18 L (0.17 l at oïl change)
Relay box
Minimum grade: API GL4
SAE 80W90
4
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
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