Workshop Manual: Sales Division Technical Network Leadership

Sales division
Technical network leadership
WORKSHOP MANUAL
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TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................... 1
PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4
CHARACTERISTICS......................................................................................................................................... 6
Engine........................................................................................................................................................6
Capacities ..................................................................................................................................................6
Chassis ......................................................................................................................................................6
Dimensions and weight..............................................................................................................................7
Tyres ..........................................................................................................................................................7
Brakes ........................................................................................................................................................8
SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 9

To be checked at each service...................................................................................................................9
Service operations ...................................................................................................................................10
Time required for maintenance ................................................................................................................10
Battery preparation (Except battery without maintenance)* ....................................................................11
New machine preparation ........................................................................................................................11
SPECIAL IMPORTANT POINTS..................................................................................................................... 12

Oil and fuel...............................................................................................................................................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
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
BODY PANELS ............................................................................................................................................... 18

Location of body components ..................................................................................................................18
Body component sequence of disassembly.............................................................................................19
Removal of the rear storage compartment ..............................................................................................20
Removal of the rear cover assembly and mudflap ...................................................................................20
Removal of the RH or LH central cover panel..........................................................................................21
Removal of the instrument cluster ...........................................................................................................22
Removal of the RH or LH under body panel ............................................................................................22
Removal of the front top shield panel.......................................................................................................23
Removal of the rear shield panel .............................................................................................................23
Removal of the front lower shield pannel .................................................................................................24
Removal of the footboard.........................................................................................................................25
SERVICE OPERATIONS................................................................................................................................. 26
Changing the engine oil ...........................................................................................................................26
Draining the relay box ..............................................................................................................................27
Removal of the spark plug .......................................................................................................................28
Replacing the air filter ..............................................................................................................................28
Transmission ............................................................................................................................................29
Installing the valve clearance ...................................................................................................................34
Idle setting................................................................................................................................................35
Removal of the fuel filter ..........................................................................................................................36
Brake inspection ......................................................................................................................................36
Replacing the brake pads ........................................................................................................................36
Checking the brake fluid level ..................................................................................................................37
Rear brake linings ....................................................................................................................................38
Draining the front fork ..............................................................................................................................41
MISCELLANEOUS OPERATIONS ................................................................................................................. 44

Removal of the fork ..................................................................................................................................44
Replacing the bearings of the steering system ........................................................................................44
Steering system tightening method..........................................................................................................46
Changing the front fork seals ...................................................................................................................48
The fork and its components....................................................................................................................48
2
TABLE OF CONTENTS
ELECTRICITY.................................................................................................................................................. 53
Ignition principle schematic......................................................................................................................53
Regulator/Ignition unit ..............................................................................................................................54
Checking the ignition system ...................................................................................................................54
Removal of the fuel gauge .......................................................................................................................55
Removal of the high tension coil ..............................................................................................................55
FUEL SYSTEM ................................................................................................................................................ 56

Removal of the fuel tank ..........................................................................................................................56
Removal of the carburettor.......................................................................................................................56
The carburettor and its components ........................................................................................................62
POWER UNIT .................................................................................................................................................. 63

Removal of the power unit .......................................................................................................................63
Removal of the cylinder head...................................................................................................................64
Removal of the camshaft and/or rockers .................................................................................................66
Removal of the valves or valve stem seals ..............................................................................................67
Fitting the cylinder head...........................................................................................................................68
Method for tightening the cylinder head ...................................................................................................68
Setting the timing .....................................................................................................................................69
Checking the timing .................................................................................................................................70
3
PRODUCTS DANGER SYMBOLS USED
Protection of individuals and of the environment.

Means that the product or the package
can be recycled. However, this does not
Möbius band Recyclable.
guarantee that the product will be
recycled.
Avoid contact with skin and clothes. Wear

The product can irritate the gloves, safety glasses and appropriate
Irritant skin, eyes and respiratory clothing such as a cotton overall. Do not
organs. breath fumes. If in contact, wash
thoroughly with water.
Keep it away from any flame or heat

Flammable The product is flammable. source (barbecue, radiator, heating, etc.).
Do not leave the product in the sun.
Avoid contact with skin and clothes. Wear

The product can damage living gloves, safety glasses and appropriate
Corrosive
tissues or other surfaces. clothing such as a cotton overall. Do not
breath fumes.
The product can explode under

Explosive certain circumstances (flame, Avoid impacts, friction, sparks and heat.
heat, impact, friction).
The product affects fauna and

The ideal solution is to bring this product
Hazardous to the flora. Do not dump it in
to your nearest household waste recycling
environment dustbins, sinks or in the
centre.
environment.
The product can seriously Avoid direct contact with the body, even by
Toxic affect health if it is inhaled, inhalation. If you feel unwell, seek medical
ingested or in contact with skin. advice immediately.
This symbol informs the consumer that the

One of the product's
Do not throw used product shall not be thrown away into
component is toxic and can be
away into a a garbage can, but shall be brought back
hazardous to environment.
garbage can to the merchant or dropped at a specific
i.e.:. Used batteries.
collection point.
People's safety can be seriously affected if

Compulsory Operation that can be
the recommendations are not fully
gloves dangerous for people.
respected.
4
People's safety can be seriously affected if

Operation that can be
People's safety the recommendations are not fully
dangerous for people.
respected.
Indicate the specific procedures that shall

Operation that can be
Important be followed in order not to damage the
hazardous to the vehicle.
vehicle.
Serious damage to the vehicle and in

Good operating The operation must be carried
certain cases a cancellation of the
condition of the out in strict compliance with the
warranty can be involved if the
vehicle documents.
recommendations are not fully respected.
Indicate a note which gives key

Note Operation that can be difficult.
information to make the procedure easier.

Lubricate the parts to be
Lubricate be followed in order not to damage the
assembled.
vehicle.

Grease the parts to be
Grease be followed in order not to damage the
assembled.
vehicle.

GLU
E Glue the parts to be
Glue be followed in order not to damage the
assembled.
vehicle.

New part Use a new part. be followed in order not to damage the
vehicle.
5
CHARACTERISTICS
CHARACTERISTICS
Engine
Marking 139 QMB-E

4-stroke single-cylinder
Type
2 valves per cylinder with chain driven overhead camshaft
By a circulation of forced air by means of a turbine on the flywheel
Cooling
magneto
Bore x stroke 39 x 41.4 mm
Cubic capacity 49 cc
Max. power output 2.7 kW at 7200 rpm
Max. torque rating 3.6 Nm at 7000 rpm
Compression 8.95 bars 500 rpm
Pressurised wet sump lubrication.
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
NGK CR7HSA
Spark plug
Electrode gap: 0.6 to 0.7 mm
Magneto flywheel 90 W
Fuel supply Carburettor. Deni DPD 18J
Standards Euro 2
Capacities
0.8 l SAE 5W40

Crankcase
Minimum grade: API SL/SJ
0.12 l SAE 80W90
Relay box
Minimum grade: API GL4
Fuel tank 6.8 l 95 or 98 lead-free
Fork 0.035 l per tube (Hydraulic oil SAE 10W)
Chassis
Chassis Steel tube

Hydraulic telescopic fork. Ø27 mm
Front suspension
Travel: 68 mm
Combined spring and hydraulically-damped shock absorber
Rear suspension
Travel: 68 mm
6
CHARACTERISTICS
Dimensions and weight
Overall length 1849 mm

Width at handlebar 667 mm
Height (without rear-view 1156 mm
mirrors)
Wheelbase 1256 mm
Saddle height 760 mm
Unladen weight 95 kg
Tyres
Front wheel rim 12 inch aluminium alloy

Front tyre 110/70 - 12
Front tyre pressure 1.6 bars
Rear wheel rim 12 inch aluminium alloy
Rear tyre 110/70 - 12
Rear tyre pressure 1.8 bars
7
CHARACTERISTICS
Brakes
Front brake Single disc type, hydraulic control

Disc diameter and
170 mm - 4 mm
thickness
Front caliper Floating caliper equipped with one piston
Rear brake cable-controlled, single cam drum type
Brake drum diameter 110 mm
Brake lining thickness 4 mm
Chassis markings Engine marking
2
XXXXXX-X
*XXXXXXXX*
Manufacturer's plate (1) Engine number (2)
xxxxxxxxxxxxxxxxx
Chassis no. (3)
8
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.
Service operations 500 2000 5000 10000 15000 20000

Heavy duty servicing 500 1000 2500 5000 7500 10000
Minimum servicing 1 month 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
V V V V V V
control
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
Joints. (Central stand. Brake levers. Rear
G G G G
brake cam...)
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
V V V V V V
suspension
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
V: Check, clean, adjust. N: Clean.

R: Change. C: Inspect and change if necessary.
G: Check, clean, lubricate.
9
Service operations 500 2000 5000 10000 15000 20000

Heavy duty servicing 500 1000 2500 5000 7500 10000
Minimum servicing 1 month 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
Drive pulley bearings and guides V C V C
Transmission belt R R
Kick starter mechanism G G
Valve clearances V V V V V
Setting the carburettor V V
Joints. (Central stand. Brake levers. Rear
G G G G
brake cam)
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 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
1.2 1.8 2.6 3.3 2.6 4.6
(0.5 h = 30 min)
V: Check, clean, adjust. N: Clean.

R: Change. C: Inspect and change if necessary.
G: Check, clean, lubricate.
10
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.
11
SPECIAL IMPORTANT POINTS
SPECIAL IMPORTANT POINTS
Oil and 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 proximity to flames or
sparks.
Before carrying out any work, leave the engine to cool for at least 2 hours.
12
TIGHTENING TORQUES
TIGHTENING TORQUES
Engine part
Spark plug 18 Nm
Filler cap 20 Nm
Screen 30 Nm
Relay box drain plug 12 Nm
Relay box filler cap 12 Nm
Cylinder head cover 10 Nm
Cylinder head
• 7 mm diameter nut 18 Nm
• 6 mm diameter screw 8 Nm
Crankcase 10 Nm
RH casing cover 10 Nm
Automatic tensioner 10 Nm
Automatic tensioner plug 8 Nm
Starter motor 10 Nm
Rotor 50 Nm
Stator 8 Nm
Engine speed sensor 6 Nm
Transmission cover 10 Nm
Turbine 10 Nm
Drive pulley 50 Nm
Driven pulley 50 Nm
Clutch plate and shoes 50 Nm
Inlet manifold 10 Nm
Body panels
Front mudguard 8 to 10 Nm
Handlebar cover 2 to 4 Nm
Front shield panel 2 to 4 Nm
Rear shield 2 to 4 Nm
Bottom panel 2 to 4 Nm
Floor panel 6 to 8 Nm
Saddle storage compartment 8 to 10 Nm
Rear body panels 6 to 8 Nm
Grab handle 20 to 25 Nm
Rear mudguard 2 to 4 Nm
13
TIGHTENING TORQUES
Cycle part
Front wheel spindle 60-70 Nm
Rear wheel spindle nut 110-130 Nm
Linkrod to engine pivot 57±5 Nm
Linkrod to frame pivot 57±5 Nm
Shock absorber top mount 43-50 Nm
Shock absorber bottom mount 20-25 Nm
Exhaust to cylinder head mounting nut 15-18 Nm
Exhaust to casing mounting bolt 20-25 Nm
Upper cone (in 2 operations) 38-42 Nm
15-19 Nm
Upper cone locknut Hand tightened
Steering locknut 70-80 Nm
Handle bar 35-45 Nm
Front brake caliper 27-32 Nm
Front brake disc 27-32 Nm
Fastening screw for brake linkrod on cam 8-11 Nm
Fastening screw for fork stanchion on tee 30-40 Nm
Standard
Nut and bolt 5 mm diameter 5 Nm
14
SPECIAL TOOLS
SPECIAL TOOLS
Used Used
Tool N° Designation Tool N° Designation
with with
64765 Engine mount 755982 754035 Valve lifter 758595
Protective
Engine mount
68007 end-piece 750806 755982 64765
adapter
small model
Flywheel
750806 68007 755996 Hose clamp
puller
Clutch
Lip seal push
752127 compression 756725 756668
tool
tool
Adjustable pin 38 mm pipe

752237 756725 752127
wrench wrench
Steeing head
753726 757860 Steering tool
cup push tool
15
STANDARD TOOLS
Used Used
Tool N° Designation Tool N° Designation
with with
Steeing head Valve stem

757990 758596
cup push tool seal drift
Valve spring Fixed flange

758595 754035 759467
lifter adapter locking tool
STANDARD TOOLS
Wrenches with interchangeable Ω
end fittings for valve clearance DC

200 m
20 m
10A
Ω
VAC
VDC
OFF
Multimeter
adjustment VΩ COM
mA
Type: Marolotest P/N 500140
Automatic resetting type torque

wrench
Set of shims
5 to 25 Nm
Type: Facom R.306A25

wrench
wrench
10 to 50 Nm
40 to 200 Nm
Type: Facom S.208A200
Type: Facom J.208A50
16
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
3 6
1 2
7
8
4 5
14
NC
12
EL
V
EL
LE V
ER LE
PP ER
U W
LO
X
XX
X.X X
11 XX X.X
X
9
10
13
1. Fuel gauge 9. Battery

2. CDI unit 10. HT coil
3. Regulator 11. Ignition sensor
4. Starter motor relay 12. Carburetor heater
5. Fuse 13. Carburettor heater thermo-switch
6. Flasher unit 14. Drive sensor
7. Starter resistor
8. Horn
17
BODY PANELS
BODY PANELS
Location of body components

Description.
13
14
3
2
4
8
11
6
12
NC
15 10 9 7
5
1. Handlebar front fairing 9. Bottom panel

2. Handlebar rear fairing 10. Central bottom panel
3. Legshield top panel 11. Floor panel
4. Rear shield 12. Mudflap
5. Front lower legshields 13. Saddle and storage compartment
6. Front mudguard 14. Rear body panels
7. Front wheel 15. Central panels
8. Mudguard
18
BODY PANELS
Body component sequence of disassembly
1* 3* 12* 13*
2 4 9*
14
6* 5
15
7* 8 10 11
1. Handlebar front fairing 9. Bottom panel

2. Handlebar rear fairing 10. Central bottom panel
3. Legshield top panel 11. Floor panel
4. Rear shield 12. Mudflap
5. Front lower legshields 13. Saddle and storage compartment
6. Front mudguard 14. Grab handle
7. Front wheel 15. Rear body panels
8. Mudguard 16. Central panels
* This item may be removed on its own.
19
BODY PANELS
Removal of the rear storage

compartment
Procedure 1.
- Lift the saddle.
- Remove the tank filler cap.
- Remove the storage
compartment (6 screw).
Removal of the rear cover assembly and

mudflap
Procedure 2.
- Remove the rear storage compartment.
See: Procedure 1. page 20.
- Remove the splash guard (6 screw).
- Remove the grab handle (3 screw).

- Remove the rear cover assembly (4 screw).
- Disconnect the taillight.
20
BODY PANELS
- Remove the taillight (4 screw).

- Remove the fastening screw on the fairings.
- Separate the 2 fairings.
Removal of the RH or LH central cover

panel
Procedure 3.
- Remove the rear cover assembly. See:
Procedure 2. page 20.
- Remove the battery access door (1 screw).

- Remove the complete footrest
assembly (1 screw).
- Remove the 5 screws from the central
fairing.
21
BODY PANELS
Removal of the instrument cluster

Procedure 4.
- Remove the handlebar front

cover (4 screw).
- Disconnect the instrument cluster.

- Unscrew the speedometer cable.
- Remove the handlebar rear cover and
instrument cluster assembly (4 screw).
- Remove the instrument cluster (4 screw).
Removal of the RH or LH under body

panel
Procedure 5.
- Remove the 2 screws from the bottom
panel.
- Remove the bottom panel.
22
BODY PANELS
Removal of the front top shield panel

Procedure 6.
- Remove the 2 screws that secure the front
shield panel.

shield panel.
- Remove the front upper shield panel.
- Disconnect the headlight and the indicator
lights.
Removal of the rear shield panel

Procedure 7.
- Remove the handlebar front and rear
covers. See: Procedure 4. page 22.
- Remove the front upper shield panel. See:
- Remove the ingnition switch trim.
23
BODY PANELS
- Remove the 2 screws that secure the rear

shield panel.
- Remove the 4 screws that secure the rear

shield panel.
- Pull upwards the lower part of the shield
panel in order to separate it from the
footboard.
Removal of the front lower shield pannel

Procedure 8.
- Remove the rear shield panel. See:
A
Procedure 7. page 23. A
- Remove the RH and LH under body panel.
See: Procedure 5. page 22. A
A
- Remove the 4 fastening screws from the B
mudguard (A). B
shield panel (B).
24
BODY PANELS
Removal of the footboard

Procedure 9.
- Remove the rear shield panel.
See:Procedure 7. page 23.
- Remove the right and left central
fairings. Procedure 3. page 21.
- Remove the RH and LH under body panel.
- Remove the battery.

- Remove the starter relay.
- Remove the fuse holder.
- Remove the footboard (4 screw).
25
SERVICE OPERATIONS
SERVICE OPERATIONS
Changing the engine oil
The engine must be drained when it is

warm to allow the oil to run easier.
Put on protective gloves. 1
- Place the vehicle on its central stand on flat
ground.
- Remove the engine's oil filler cap (1).
Remove the drainage cap and its

seal (2) and allow the oil to drip into a
recipient.
XXXXXX-X
- Remove the strainer cap (3) and clean the
strainer. *XXXXXXXX*
- Insert the drain plug fitted with a new seal.
Tightening torque: 20 Nm.
- Re-install the filter cap fitted with a new seal.
- Pour the required quantity of oil

corresponding to the manufacturer's
standards into the filler hole.
Quantity: 0.8 l.
- Start the engine and let it run for a short

3
while.
26
SERVICE OPERATIONS
- Remove the engine's oil filler cap/gauge.

- Wipe dry the filler cap/gauge and fit it back
but do not screw it into the filler hole.
- Remove the filler cap/gauge and check the
oil level.
- The oil level shall not be between the
minimum (A) and maximum (B) level marks
without exceeding the latter.
- Add oil if necessary. B
A
Draining the relay box
The gearbox must be drained when the

engine is warm so that the oil will run 1
easier.
Put on protective gloves.
- Place the vehicle on its central stand on flat

ground.
- Remove the relay box filler cap (1).
Remove the drainage cap and its

seal (2) and allow the oil to drip into a
recipient. 2
- Insert the drain plug fitted with a new seal.
- Pour the required quantity of oil

corresponding to the manufacturer's
standards into the filler hole.
Quantity: 0.12 l.
- Fit the filler cap (1).
27
SERVICE OPERATIONS
Removal of the spark plug

- Disconnect the suppressor (1).
- Remove the spark plug access hatch (A).

- Remove the spark plug.
Essential precautions: When re-installing,

srew in the spark plug (a few turns)
by hand. A
- Tighten the spark plug.
Replacing the air filter

- Remove the 6 screws from the air filter
cover.
28
SERVICE OPERATIONS
- Remove the air filter.

- Clean inside the air filter box.
Fit a new air filter.
- Remove the inlet silencer drain plug to let

humidity and oil drip out (A).
Transmission
Removal of the primary transmission cover B

- Lift the air filter box to reach the transmission
cover (1 screw) (B).
- Remove the transmission sensor (2 screw).
- Remove the transmission cover (9 screw).
- Remove the paper gasket and the two 2

centering pins.
29
SERVICE OPERATIONS
Removal of the drive pulley
- Hold the fixed flange with tool P/N 759467. 2 1

- Remove the fixed flange nut and washer.
- Remove the starter hub (1) and the

turbine (2).
- Remove the fixed flange.
759467
- Remove the belt.

- Remove the drive pulley (3) together with
the guide hud.
Removal of the driven pulley
- Lock the clutch drum with the pin wrench

P/N 752237.
- Remove the clutch drum and the clutch and
drive pulley assembly.
752237
30
SERVICE OPERATIONS
Checking the drive pulley
- Remove the holder (2) and its 3 plastic

2
guides. 4 3
- Remove the moving flange (4)
6 bearings (3).
The bearings must be changed if they
show major signs of wear.
The guides shall be replaced if they
show signs of wear.
Reassembly
- Proceed in reverse order to disassembly

and do not grease the bearings.
- When refitting, respect the way the rollers
are installed.
- Grease the moving flange bore lightly (high
temperature grease).
Checking the drive belt
- Measure the width of the belt (A). A

Minimum width: 16.3 mm.
- Make sure the belt is not cracked.
31
SERVICE OPERATIONS
Checking the clutch linings
- Using the depth calliper, measure the

thickness of the clutch linings.
Mini. thickness 2 mm.
- Make sure surface of the plates in contact

with the belt does not show any cracks or
signs of abnormal wear.
Replacing the clutch lining assembly
- Compress the clutch drive pulley and driven

pulley assembly with the tool P/N 752127 756725
clamped in the jaws of a vice.
- Remove nut (1) using spanner P/N 756725. 1
- Slacken tool P/N 752127.
752127
- Remove the clutch linings (2), the upper

centring sleeve (3), the spring (4), and the 2 3 4 5
lower centring sleeve (5).
- Remove the 3 pins (6) from the variable
speed drive seat.
- Separate the fixed (7) and rotating
(8) flanges.
- Make sure surface of the plates in contact
with the belt does not show any cracks or 7
signs of abnormal wear.
6
8
32
SERVICE OPERATIONS
Reassembly
- After checking the 2 lip seals (9) and the

2 O-rings (10) of the rotating flange (8) are
in good condition, grease the governor seat
3 pins (6) (high temperature grease) and
assemble the parts in reverse order to
removal.
- Compress the clutch drive pulley and driven 9
pulley assembly with the tool P/N 752127
clamped in the jaws of a vice.
- Tighten the nut (1).

Before fitting the clutch drive pulley and
driven pulley to the input shaft, fit the
belt into the pulley bottom by opening 10
the flanges by hand. 8
- Fit the clutch drive pulley and driven pulley
assembly.
- Fit the clutch cover.
- Fit and tighten the nut.
33
SERVICE OPERATIONS
Installing the valve clearance

- Remove the central cover panel. See:
- Disconnect the oil vapour return pipe (1).
- Disconnect the pipe from the pulsair reed
1
valve (2).
- Remove the 2 screws that secure the pulsair
pipe (3).
- Remove the cylinder head cover and its O-

ring (4 screw). 2
3
The O-ring must be changed every time

it is removed.
- Remove the turbine on the the flywheel

magneto side (4 screw).
- Rotate the engine by hand in the operating
direction in order to align the (A) mark on the
pinion with the mark on the cylinder head.
34
SERVICE OPERATIONS
- Using the set of feeler gauges, measure the

clearance of each valve.
- Clearances:
• 0.10 mm ±0.02 at the intake.
• 0.10 mm ±0.02 at the exhaust.
- If the clearance is not correct, adjust by

means of the cam follower screw.
- Use a wrench to adjust the valve clearance.
Type: Marolotest, P/N 500140.
Checking the valve clearance
• At the intake a 0.15 mm feeler gauge

shouldn't go.
• At the exhaust a 0.15 mm feeler gauge
shouldn't go.
- On the contrary, if the fealer gauge goes,
reset the clearances.
Idle setting
- The engine must be at its operating 1

temperature.
- Switch off the engine.
- Park the vehicle on its stand.
- Check the operating clearance in the
throttle.
- Start the engine.
- Screw or unscrew the engine speed adjuster
screw (1) to alter the idle speed.
- The rear wheel should not turn.
Idle speed: 1600 to 2000 rpm.
35
SERVICE OPERATIONS
Removal of the fuel filter

- Remove the splash guard. See:
3 1
- Empty the reservoir.
- Disconnect the fuel supply hose (1).
- Disconnect the vacuum hose (2).
- Loosen the collar (3).
- Remove the vacuum-operated cock (4).
4
2
Brake inspection
- If one of the 2 brake pads is worn down to
the minimum dimensions (A), the 2 brake
pads must be changed.
A. Mini. thickness: 1.5 mm.
A = 1.5mm
Replacing the brake pads

- Remove the calliper (2 screw).
Tightening torque: 27-32 Nm.
36
SERVICE OPERATIONS
- Squeeze the caliper holder in order to

remove the first brake pad (1).
- Remove the second brake pad (2).
- Remove the brake pad spring (3).
When refitting the brake pads, push the 3

piston all the way into its housing.
2
After refitting, actuate the brake levers 1
several times to bring the brake pads
against the brake disc.
Checking the brake fluid level

- Position the handlebars so that the master
A
cylinder will be horizontal.
- Check the brake fluid level and if necessary B
top up in the master cylinder.
A. Maximum brake fluid level.

B. Minimum brake fluid level.
- Remove the handlebar front cover

(6 screw). See: Procedure 4. page 22.
- Remove the cover and the diaphragm from
the master cylinder (2 screw).
- Add brake fluid until it reaches the maximum
level.
37
SERVICE OPERATIONS
Rear brake linings
Check
- Actuate the brake control lever and check

the position of the wear mark on the cam A
tierod (A) compared to the mark (B) on the
engine housing.
- If the cam tierod mark is lined up with or B
passes the wear mark on the engine
housing, the brake lining must be replaced.
Disassembly
- Remove the 2 screws that secure the

muffler.
Use a new exhaust gasket.
- Remove the 2 screws fastening the

mudguard.
- Remove the 2 screws from the exhaust.
- Remove the exhaust.
38
SERVICE OPERATIONS
- Remove the wheel spindle nut and washer

(1).
When re-installing, use a new nut.
- Remove the rear wheel. 1
- Remove the brake linings (4).

- Remove the adjusting nut, the barrel (5) and
the brake control cable (6).
- Remove the brake arm (7), the brake 4
cam (8) and the spring (9).
7 8
6 9
5
Reassembly
Lubricate the brake cam spindle and fit

it into the casing.
- Fit the brake arm onto the cam and align the
punched marks (A).
39
SERVICE OPERATIONS
- Slightly lubricate the brake cam and pin.

- Install the brake linings (4).
- Install the spring (9).
- Install the brake control cable, the barrel and
the adjusting nut (5).
- Refit the other items in the reverse order to
4
disassembly.
5
9
- Measure the free travel of the rear brake
control lever.
- Ajust the lever free travel using the adjusting B
nut.
B. Brake control free travel: 10 to 20 mm.
40
SERVICE OPERATIONS
Draining the front fork

- Remove the front upper shield panel.
- Turn the handlebars to the right to reveal
the fork nut (1) in the hold in the
mudguard.
- Before, loosen the fork tube caps (1).
- Repeat this operation by turning the
handlebars to the left.
1
- Suspend or immobilize the machine

securely. 2
- Remove the caliper 2 fixing bolts.
- Remove the front wheel.
- Removal of the front mudguard (4 screw).
- Unscrew and remove the 2 upper
screws (2) from the fork Tee.
- Unscrew the 2 lower screws (3) from the
fork Tee.
- Remove the fork stanchions.
3
- Remove the fork tube cap (1).

- Remove the spring (4).
1
41
SERVICE OPERATIONS
Turn the fork tube upside down to

drain the oil into a recipient.
- Pour new oil into the fork tube.

Type: SAE10W. 1
Quantity: 0.035 l.
- Install the spring (4).

- Fit and screw the cap home (1). 4
- Insert the fork stanchions into the fork tee.

- Fit and tighten the 4 clamping bolts.
- Fit the front shield panel.
42
SERVICE OPERATIONS
- Fit the front mudguard.

- Fit the speedometer drive gear assembly
to the wheel drive pins.
- Fit the wheel, matching the speedometer
drive gear assembly to the pin (A) on the
fork stanchion.
A
- Fit the wheel spindle and tighten.
- Refit the other items in the reverse order

to disassembly.
43
MISCELLANEOUS OPERATIONS
Removal of the fork
Replacing the bearings of the steering

system
- Remove the handlebars from the fork tube
(1 screws and 1 nut) (1).
1

securely.
- Remove the front brake caliper from the fork
tube.

2
- Remove the front mudguard.

- Remove the brake control cable grommet
and the speed sensor located under the fork
triple clamp (2) (2 screw).
- Using tool P/N 757860 remove the steering
locknut.
- Remove: 757860
• The brake washer.
• The nut.
• The rubber washer.
• The nut.
• The dust cover.
• The upper cone.
- Remove the fork.

- Remove the caged ball bearings.
44
- Using a drift, remove the steering head

cups.
- Using a chisel, pry the steering head cup off

by pressing the tool behind the dust cover.
Reassembly
- Install the following new parts:

• The dust cover (1).
• The fork cone (2).
1 2
45
Steering system tightening method

- Using push tool P/N 753726, fit a new upper 753726
cup into the steering tube.
- Using push tool P/N 757990, fit a lower cup
into the steering tube.
- Grease the cup bearing races.

- Install new ball cage bearings (3).
- Fit the fork into the steering column.
- Grease the cup bearing races.

- Install new ball cage bearings (4).
- Install the upper cone (5). 7 6
- Install the dust cover (6).
- Fit and tighten the nut (7).
5 4
- Loosen and re-tighten the nut.
46
- Install the rubber washer (4).

- Fit and finger tighten the nut (5) so that its
notches are aligned with those of the nut.
- Fit the lock washer (6) in the notches of the
2 nuts. 6
- Install the steering head locknut and tighten

it (7).
47
Changing the front fork seals
The fork and its components 1

1. Fork tube cap. 5
2. Spring.
2
3. Calibrated hydraulic tube. 6
4. Expansion stop spring.
5. Dust cover.
7
6. Retaining clip. 3
7. Tightness seal.
8. Fork tube.
9. End of compression cone. 4
10. Hollow shaft.
11. Stanchion assembly screw.
10
11 9
Disassembly

securely. A
- Remove the front brake caliper from the fork
tube (2 screw).
- Remove the front mudguard (4 screw).
B
- Before, loosen the fork tube caps (1).
- Unscrew and remove the 2 upper
screws (A) from the fork Tee.
- Unscrew the 2 lower screws (B) from the
fork Tee.
- Remove the fork stanchions.
48
- Remove the fork tube cap (1).

- Remove the spring (2). 1
Turn the fork tube upside down to drain

the oil into a recipient.
- Remove the stanchion assembly screw (11)

and its seal.
- If necessary use a mallet to dislodge the
screws.
11
- Separate the fork's tube (8) from the
cover (10). 8
10
49
The compression stop cone may remain

inside the shaft.
- Remove the compression stop cone (9).

8
- Remove the calibrated hydraulic tube (3).
- Remove the expansion stop spring (4).
3
9
4
- Remove the dust cover (5).

- Remove the retaining clip (6).
- Remove the seal (7). 5
6
50
Pre-assembly checks
- Clean all the parts with a degreasing agent:
• Biosane type ref. 754748.
• Or use an ultrasonic cleaning tank.
- Check the condition of the fork tube, there shall be no corrosion or impact marks, and the tube shall
be perfectly straight and clean.
Reassembly
- Fit a new lightly greased lip seal using push 757893

tool P/N 757893 (7).
- Install the retaining ring.
- Install the dust cover.
7
- Install the expansion stop spring (4).

- Install the calibrated hydraulic tube (3).
- Install the compression stop cone (9) on the 8
calibrated hydraulic tube.
3
9
4
- Fit the fork sleeve (10) to the slightly oiled

fork tube (8).
- Install the stanchion assembly screw and its 8
seal (11).
11
10 10
51
- Pour 0.035 l SAE10W hydraulic oil into the

fork tube. 1
- Fit the spring (2) with the close coils
upwards.
- Fit and screw the cap home (1).
Tightening torque: 18-20 Nm. 2
- Fit the fork tubes into the fork triple clamps.

- Fit and tighten the (4) clamping bolts.
- Re-install all the fork equipment.

- Refit the fairings in reverse order to removal.
52
ELECTRICITY
ELECTRICITY
Ignition principle schematic
OFF 2 VE
ON
-
U
PP ER
LO
W
L
VE L
LE VE
ER LE
3
1 VE BA-NR NR RG
BE
7,5A RG
RG-NR NR 13
BA-NR VE
JN-BE
JN-NR 4
RG-NR VE JN
JN
JN-BE JN-BA VE JN
VE
JN
VE
VE-NR 6 R
5
12
10 XXXX.XXX
XX.XX
9 8
7 11
1. Ignition switch 8. Automatic starter

2. Battery 9. Magneto flywheel
3. CDI unit 10. Voltage regulator
4. Spark plug socket 11. Carburetor heater
5. Spark plug 12. Carburettor heater thermo-switch
6. HT coil 13. Drive sensor
7. Starter resistor
53
ELECTRICITY
Regulator/Ignition unit
- Remove the rear cover assembly. See:
- Removal: 1
• Regulator (1).
• The ignition module (2). 2
Checking the ignition system

Ω
Disconnect the ignition unit and perform the

measurements on the harness
side (3 Connectors). B
xx xxx
xx
xx xx
xx
xx xx
xx xxx
x
xx
If the values are correct, replace the ignition
module.
If the values are incorrect, check:
- The harness.
- The ignition switch. C
- The high voltage coil. A
- The magneto.
- The transmission sensor.
Component Connector Wire colours Standard values

Ground A Green_Ground R=0:
Ignition switch:
Ignition on A Black_Green V = 12 Volt (Battery voltage)
Ignition off A Black_Green V = 0 Volt
Ignition on: f :
Engine cut-off B White/black_Green
Ignition off: :
Drive sensor C Blue_Green R = 145 :±20%
Ignition sensor A Yellow/blue_Green R = 145 :±20%

Low voltage coil B Red/black_Green R = 517 :
HT coil:
Primary A Yellow/black_Green R = 0.5 :±20%
Secondary High voltage wire_Green R = 3.7 K:±20%
Spark plug socket R = 5 K:
54
ELECTRICITY
Removal of the fuel gauge

- Remove the rear storage compartment. 1
- Disconnect the fuel gauge (1).
- Remove the fuel gauge (4 screw) (when
dismantling notice in which direction it is so
that you will replace it in its initial position
when reassembling).
- Remove the rubber gasket.
When re-installing, use a new gasket.
Check:
A. Full fuel tank: 8 :±20%. Ω
B. Empty fuel tank: 95 :±20%.
B
Removal of the high tension coil
See: Procedure 1. page 20. 2
- Disconnect the suppressor (1).
- Disconnect and remove the high voltage
coil (2) (1 screw).
55
FUEL SYSTEM
FUEL SYSTEM
Removal of the fuel tank

- Remove the rear cover assembly. See: 1
- Disconnect the fuel supply hose.

- Disconnect the vacuum hose.
- Disconnect the fuel gauge (1).
- Remove the 3 screws on the rear support.

- Remove the fuel tank (3 screw).
Removal of the carburettor

- Remove the rear storage compartment. 2
4
- Disconnect: 3
• The throttle control (1).
• The fuel supply hose (2).
- Disconnect:
• The choke (3).
• The carburettor heater (2 Connectors) (4).
56
FUEL SYSTEM
- Remove the carburettor (2 collars) (5 / 6).
5 6
Disassembly
Removal of the choke
- Remove the choke cap. 3

- Remove the screw (1) and the holder
plate (2).
- Locate the position of the choke (3) and then
remove it.
2 1
- Remove the choke holder and its gasket

(2 screw).
Check the condition of the O-ring.
57
FUEL SYSTEM
Removal of the carburetor heater
- Remove the carburator warming 5

resistor (4).
- Remove the heater earthing connection (5).
Removal of the throttle valve
- Remove the 2 screws that secure the

chamber cap.
- Remove the chamber cap (6).
- Remove the spring. 6
- Remove the needle, valve and membrane
assembly.
Check that the membrane is in good

condition.
- Remove the needle stop (7).

- Remove the needle (9). 7
The height oif the needle is factory set 8
and cannot be modified.
58
FUEL SYSTEM
Removal of the float, needle valve and jets
- Remove the 3 screws that secure the float

chamber (10).
- Remove the float chamber and its O-ring. 10
Check the condition of the float
chamber O-ring.
- Remove the float (11), its pin (12) and the

needle valve (13).
13
12
11
- Remove the idle jet (14).

- Remove the main jet (15). 15
- Remove the needle well (16).
16
14
59
FUEL SYSTEM
- Check the condition of the needle valve and

the needle valve seat (A).
Removal of the engine speed adjuster screw

and mixture control screw
- Remove the 2 screws from the sheathing

holder plate.
- Turn clockwise the mixture control

screw (15) while counting the number of
turns until it is screwed home.
Do not turn the screw home forcefully.
- Remove the mixture screw and its

spring (17).
When re-fitting, this operation allows

you to put it back to its initial 17
adjustment position.
60
FUEL SYSTEM
Removal of the deceleration enrichment

device
- Remove the 2 bolts that secure the cover.

- Remove the cover (18).
18

- Remove the membrane (20).
Check that the membrane is in good

condition. 20
19
- Clean the carburettor body with Biosane

cleanser ref. 754748 or use an ultrasonic
cleaning tank.
- Blow into every jet and duct of the
carburettor body with compressed air.
Do not use any metal tool which can

damage the ducts of these items.
- Re-install all the other components and, if

necessary, when starting the engine,
readjust according to the values indicated
on the technical data card.
61
FUEL SYSTEM
The carburettor and its components
6
18 19
4
16
15
2
17
21 1
22 11
13 14
12 10
8 9
20
1. Starter support 12. Main jet

2. Choke 13. Needle well
3. Carburettor chamber cap 14. Mixture screw
4. Needle 15. Choke cover
5. Spring 16. Spring
6. Needle stop 17. Diaphragm
7. Sump 18. Idle screw
8. Float 19. Piston
9. Float pin 20. Float chamber gasket
10. Needle valve 21. Carburetor heater
11. Idle jet 22. Heater earth connection
62
POWER UNIT
POWER UNIT
Removal of the power unit
Note: To remove the cylinder head, remove 1

the power propulsion unit.
- Disconnect the battery.

- Remove the rear cover assembly. See: 2 6
- Remove the RH and LH under body panel. 5
4
- Disconnect: 3
• The magneto (3 Connectors) (1).
• The choke (2).
• The carburettor heater (3).
• The suppressor (4).
• Starter power supply wires.
A.The power wire (5).
B.Starter earth wire.
• The transmission sensor (6).
- Disconnect:
• The throttle control (7). 8
• The fuel inlet pipe (8).
• The vacuum pressure hose (9).
7 9
63
POWER UNIT
- Disconnect the rear brake control cable.

- Suspend the rear of the machine.
- Remove the 2 pins which secure the engine 11
to the linkrod (10).
Tightening torque: 57±5 Nm.

10
- Remove the shock absorber upper

mount (11).

- Lift the rear of the machine.
- Remove the power propulsion unit from the
frame.
Removal of the cylinder head

- Remove the inlet pipe and the carburettor.
- Remove the exhaust.

- Remove the cooling volutes. (7 screw).
- Remove the spark plug.
- Removal of the chain tensioner.

- Remove the screw, the O-ring and the
tensioner spring (1). 1
- Remove the 2 mounting screws (2) from the 2

tensioner body.
A
- Remove the chain tensioner and slacken it

by pressing the ratchet tooth (A).
64
POWER UNIT
- Disconnect the oil vapour return pipe (3).

- Disconnect the pipe from the pulsair reed
valve (4).
- Remove the 2 screws that secure the pulsair
pipe (5). 3
- Remove the cylinder head cover and its O-

ring (4 screw).

4
5
The O-ring must be changed every time

it is removed.
- Rotate the engine manually in the direction

of operation in order to bring the rocker pads B
over the cam lobes (B).
- Remove the rubber plug (6).
65
POWER UNIT
- Hold the magnetic wheel to unscrew the

2 fastening screws from the camshaft
pinion.
- Remove the camshaft gear (7).
- Tie a wire to the timing chain in order to
prevent it from falling into the crankcase.
- Loosen the 2 washers screws (8).

- Gradually loosen in a crosswise order the 4 9
nuts which secure the cylinder head (9).
- Remove the cylinder head.
Removal of the camshaft and/or rockers

- Remove the pins from the rockers using a 3 1
5 mm screw.
- Remove the inlet (1) and exhaust (2) 2
rockers.
- Remove the stopper plate (3).
- Remove the camshaft (4).

4
66
POWER UNIT
Removal of the valves or valve stem

seals
- Compress the spring of one of the valves
using the valve lifter P/N 754035.
- Remove the 2 half cones (1). 1
- Uncompress the spring and remove the tool.
Use the valve lifter provided with

adaptor P/N 758595 .
754035
- Remove:
• The upper cup (2).
• The spring (3).
5
• The lower washer (4).
• The valve (5).
• Remove the 2nd valve in the same way.
3
2
1
4
When re-installing, fit the valve springs, the closest coils against the cylinder head.
When removing a valve, always change the valve stem seal. Using tool P/N 758596, fit a new
valve stem seal.
When re-installing, lubricate the 2 half

cones (1) so as to hold them in the
groove of the valve's stem.
- Placing the 2 half cones (1) into the cup

using the tool shall not be done forcefully
when decompressing the spring (3). 1
67
POWER UNIT
When re-installing, the camshaft bearings, the rocker shafts and the contact between the
rockers and the valves shall well lubricated in order to avoid any risk of seizure when starting
the engine (Use lithium soap grease). Seals and valve stems must be lubricated.
Fitting the cylinder head

- Fit the 2 guiding pillars and the metal
gasket (6) on the cylinder.
- Fit the timing chain through the cylinder
head timing well.
- Install the cylinder head.
You must set the timing every time you remove the cylinder head when servicing.
Method for tightening the cylinder head

- Fit the 4 washers. 1
- Tighten the 4 nuts (1) and the 2 washer
screws (2) slightly.
- Torque the 4 nuts in a crosswise order to
18 Nm and the 2 washer screws to 8 Nm.
68
POWER UNIT
Setting the timing

- Rotate the flywheel magneto (1) to bring the
"T" mark in front of the crankcase boss (A).
- Fit the timing chain on the camshaft gear.

- Install the camshaft gear.
- Make sure the mark (B) of the camshaft
gear is aligned with the mark (C) of the C
cylinder head.
- If necessary, dislodge the gear from the
camshaft without removing it and move the
chain around the gear on the required side.
- Fit the 2 screws.

- Immobilise the magnetic wheel using a
wrench and tighten the camshaft pinion.
69
POWER UNIT
- Install a new paper gasket.

- Install the chain tensioner and the 4
2 attachment screws (2).
Tightening torque: 10 Nm. 5 2

- Install the spring (3). 3
- Fit the chain tensioner gasket (5).
2
Check the condition of the O-ring and
change it if necessary.
- Install the tensioner cap (4).
Checking the timing

- Rotate the engine twice: 2 revolutions in the
engine's operating direction.
- Rotate the flywheel magneto (1) to bring the
"T" mark in front of the crankcase boss (A).
- Make sure the mark (B) of the camshaft
gear is aligned with the mark (C) of the
cylinder head.
A
If the marks are not alined, reset the
valve timing.
70
P/N MA0016GB
In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add
any reference mentioned.
DC/PS/APV Printed in the E.U. 07/2010 (non contractual pictures)

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PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4

SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 9

SPECIAL IMPORTANT POINTS..................................................................................................................... 12

TIGHTENING TORQUES ................................................................................................................................ 13

SPECIAL TOOLS ............................................................................................................................................ 15

BODY PANELS ............................................................................................................................................... 18

MISCELLANEOUS OPERATIONS ................................................................................................................. 44

FUEL SYSTEM ................................................................................................................................................ 56

POWER UNIT .................................................................................................................................................. 63

PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.

Avoid contact with skin and clothes. Wear

Keep it away from any flame or heat

Avoid contact with skin and clothes. Wear

The product can explode under

The product affects fauna and

This symbol informs the consumer that the

People's safety can be seriously affected if

People's safety can be seriously affected if

Indicate the specific procedures that shall

Serious damage to the vehicle and in

Indicate a note which gives key

Indicate the specific procedures that shall

Indicate the specific procedures that shall

Indicate the specific procedures that shall

Indicate the specific procedures that shall

Marking 139 QMB-E

0.8 l SAE 5W40

Chassis Steel tube

 Dimensions and weight

Overall length 1849 mm

Front wheel rim 12 inch aluminium alloy

Front brake Single disc type, hydraulic control

Chassis markings Engine marking

Manufacturer's plate (1) Engine number (2)

Chassis no. (3)

SERVICE SCHEDULE AND COMMISSIONING

Service operations 500 2000 5000 10000 15000 20000

V: Check, clean, adjust. N: Clean.

Service operations 500 2000 5000 10000 15000 20000

V: Check, clean, adjust. N: Clean.

 Battery preparation (Except battery without maintenance)*

SPECIAL IMPORTANT POINTS

 Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

64765 Engine mount 755982 754035 Valve lifter 758595

Adjustable pin 38 mm pipe

Steeing head Valve stem

Valve spring Fixed flange

Wrenches with interchangeable Ω

end fittings for valve clearance DC

Type: Marolotest P/N 500140

Automatic resetting type torque

Automatic resetting type torque

1. Fuel gauge 9. Battery

 Location of body components

Dimensions and weight

Battery preparation (Except battery without maintenance)*

Oil and fuel

Location of body components

Body component sequence of disassembly

Removal of the rear storage

Removal of the rear cover assembly and

Removal of the RH or LH central cover

Removal of the instrument cluster

Removal of the RH or LH under body

Removal of the front top shield panel

Removal of the rear shield panel

Removal of the front lower shield pannel

Removal of the footboard

Changing the engine oil

Draining the relay box

Removal of the spark plug

Replacing the air filter