PEUGEOT satelis 125 cc Gebrauchsanweisung
WORKSHOP MANUAL
TECHNICAL NETWORK LEADERSHIP
WORKSHOP MANUAL
-
125 CC/150 CC 4-STROKE ENGINE
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Workshop manual
Technical network leadership
Reproduction or translation, evenpartial, is forbidden without thewritten consent of Peugeot Motocycles
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
CHARACTERISTICS............................................................................................................3
Capacities............................................................................................................................ 3
SPECIAL IMPORTANT POINTS..........................................................................................4
Oil and fuel .......................................................................................................................... 4
TIGHTENING TORQUE........................................................................................................5
SPECIAL TOOLS.................................................................................................................6
DISASSEMBLY ....................................................................................................................9
Putting the engine on the stand........................................................................................... 9
Removal of the primary transmission cover......................................................................... 9
Removal of the drive pulley................................................................................................ 10
Removal of the driven pulley.............................................................................................. 10
Removal of the rocker cover.............................................................................................. 11
Removal of the chain tensioner......................................................................................... 11
Removal of the RH cover / ignition coil and sensor........................................................... 12
Removal of the rotor.......................................................................................................... 13
Removal of the cylinder head............................................................................................ 14
Removal of the temperature sensor. ................................................................................. 16
Removal of the thermostat. ............................................................................................... 16
Removal of the camshaft and/or rockers........................................................................... 16
Removal of the valves or valve stem seals........................................................................ 17
Removal of the cylinder..................................................................................................... 19
Removal of the piston........................................................................................................ 19
Removal of the oil pump.................................................................................................... 20
Removal of the RH crankcase half.................................................................................... 22
Removal of the oil discharge valve.................................................................................... 23
Removal of the water pump............................................................................................... 23
Removal of the crankshaft................................................................................................. 24
TABLE OF CONTENTS
2Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Checking the crankshaft and conrod assembly................................................................. 25
Removal of the secondary transmission cover.................................................................. 26
Removal of the secondary transmission............................................................................ 26
REFITTING SPECIFIC COMPONENTS.............................................................................28
Installing the crankshaft LH bearing.................................................................................. 28
Installing the water pump inside the RH crankcase........................................................... 28
Assembly of the engine casings........................................................................................ 30
Installing the piston rings on the piston. ............................................................................ 32
Fitting the piston................................................................................................................ 32
Fitting the cylinder ............................................................................................................. 33
Fitting the cylinder head. ................................................................................................... 33
Setting the timing............................................................................................................... 35
Installing the valve clearance............................................................................................. 37
Checking the valve clearance............................................................................................ 37
Refitting the rocker cover................................................................................................... 38
MISCELLANEOUS OPERATIONS ....................................................................................39
Removal of the oil filter...................................................................................................... 39
Removal of the water inlet pipe. ........................................................................................ 39
Fitting the drive pulley assembly........................................................................................ 40
Changing the drive pulley bearings................................................................................... 40
Removal of the clutch lining assembly............................................................................... 41
Refitting the clutch lining assembly.................................................................................... 42
CHARACTERISTICS
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Capacities
125 cc 150 cc 125 cc EFI 150 cc EFI
Marking FD1 FD2 FD4/FD5 FD4
Type 4-stroke single-cylinder
Cooling Liquid
Bore x stroke 57 x 48,9 mm 57 x 58,9 mm 57 x 48,9 mm 57 x 58,9 mm
Cubic capacity 124,8 cc 150 cc 124,8 cc 150 cc
Max. power output 9 kW at 8750 rpm 10 kW at 8450 rpm 9 kW at 8750 rpm 10 kW at 8450 rpm
Max. torque rating 7250 rpm 6500 rpm 7250 rpm 6500 rpm
Lubrication Trochoidal pump
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Non-catalytic
Starter motor Mitsuba 440 W Mitsuba 470 W Mitsuba 440 W Mitsuba 470 W
Spark plug NGK CR7E NGK CR7EB
Magneto flywheel Mitsuba 235 W Mitsuba
235 W/330 W Mitsuba 235 W
Fuel supply Carburettor Indirect electronic injection (EFI)
Engine oil 1.25 l SAE 10W40
Relay box oil 0.12 l SAE 80W90 life lubricated
SPECIAL IMPORTANT POINTS
4Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
Oil and fuel
This engine is designed to run on 95 or 98 unleaded fuel only.
Never run the machine with a petrol/oil mixture.
The fuel pipes must be changed if they show signs of wear, cracks, etc.
The clips are specific, they must always be changed each time they are removed
and replaced with new genuine parts clips.
Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or
sparks. Work in a clear and well-ventilated area.
TIGHTENING TORQUE
5
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TIGHTENING TORQUE
Cylinder head 1.8/2.3 m.daN
Cylinder casings 1 m.daN
Transmission cover 1 m.daN
RH casing cover 1 m.daN
Automatic tensioner 1 m.daN
Oil control valve 4 m.daN
Temperature sensor 1 m.daN
Starter motor 1 m.daN
Rotor 7 m.daN
Stator 1 m.daN
Engine speed sensor 0.7 m.daN
Drive pulley 7 m.daN
Driven pulley 7 m.daN
Spark plug 1 m.daN
Camshaft gear 2.3 m.daN
SPECIAL TOOLS
6Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
64706 Casing
extractor and
opening tool
Casing
opening
plate +
pin
69098 Protective
end-piece
large model 64706
64710 Shouldered
centering
tool 64706 69104 Pin nut
750 +
64711
+
64712
+
64754
64712 Pin Ø12
pitch 125 69104 750539 Tie-wrap
pliers
64765 Engine
mount
Engine
mount
adapter 752000 Piston circlip
pliers
68570 Flywheel
clamp 752235 1/2 extension 68994
or
753977
68994
Torque
wrench
8N.m to
54 N.m
Extensi
on
752235
Adapter
752236
752236 1/2
3/8 adapter
68994
or
753977
69092 External
circlips pliers 752237 Adjustable
pin wrench
SPECIAL TOOLS
7
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
753711
Engine
mount
adapter
Elyseo
Elystar
64765 754033 Crankshaft
locking pin
753977
Torque
wrench
30 N.m to
150 N.m
752235
extensi
on
752236
adapte
r
754034 Camshaft
locking pin
754003 Flywheel
puller 69098 754035 Valve lifter
754005 Clutch
compression
tool 754046 754040 46 mm pipe
wrench 754005
754006 Casing
opening
plate 64706 754041 Timing
casing seal
drift
754007 Mechanical
seal drift 755585 Bearing
extractor tool
754008 Water pump
seal drift 756717
Engine
mount
adapter
Jetforce
64765
754009 Water pump
pin drift 757035 Fixed flange
locking tool
SPECIAL TOOLS
8Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
757988 Water pump
bearing drift 757989 Water pump
bearing drift
757990
Crankcase
seal
installation
buffer
Dieses Handbuch passt für folgende Modelle
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