Peugeot workshop manual Jet Force (756739) - Scootergrisen

SALES DIVISION 

NETWORK TECHNICAL INFORMATION 

WORKSHOP 

MANUAL

CONTENTS 

CONTENTS 

CONTENTS.......................................................................................................................................... 2 

CHARACTERISTICS......................................................................................................................... 5 

Engine............................................................................................................................................................. 5 

Capacities ....................................................................................................................................................... 5 

Chassis markings............................................................................................................................................ 5 

Engine markings............................................................................................................................................. 5 

Frame.............................................................................................................................................................. 6 

Dimensions and weight .................................................................................................................................. 6 

Tyres............................................................................................................................................................... 6 

SERVICE SCHEDULE AND COMMISSIONING ......................................................................... 7 

Check.............................................................................................................................................................. 7 

Change............................................................................................................................................................ 7 

Check and lubricate........................................................................................................................................ 7 

Reading the ECU fault codes ......................................................................................................................... 7 

Test machine................................................................................................................................................... 7 

SPECIAL IMPORTANT POINTS .................................................................................................... 8 

Oil and fuel..................................................................................................................................................... 8 

Starting up after overhauling the engine ........................................................................................................ 8 

Electricity ....................................................................................................................................................... 8 

Special features............................................................................................................................................... 8 

TIGHTENING TORQUES................................................................................................................. 9 

Body panels .................................................................................................................................................... 9 

Frame.............................................................................................................................................................. 9 

Standard.......................................................................................................................................................... 9 

SPECIAL TOOLS ............................................................................................................................. 10 

INSTRUMENT CLUSTER............................................................................................................... 11 

Instrument cluster description ...................................................................................................................... 11 

Description of the multi-function display .................................................................................................... 12 

MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS................................................ 12 

Changing from the total distance display to the daily display ..................................................................... 12 

Changing the distance unit ........................................................................................................................... 13 

Setting the clock ........................................................................................................................................... 13 

Maintenance function................................................................................................................................... 14 

Fuel gauge self-diagnostic............................................................................................................................ 14 

CONTROL CABLE AND HARNESS ROUTINGS....................................................................... 15 

ABS/PBS panel ............................................................................................................................................ 15 

Conventional braking panel.......................................................................................................................... 15 

Right-hand side 50 cc................................................................................................................................... 16 

Left-hand side 125 cc ................................................................................................................................... 17 

Rear right...................................................................................................................................................... 18 

Rear centre.................................................................................................................................................... 18 

LOCATION OF COMPONENTS.................................................................................................... 19 

50 cc ............................................................................................................................................................. 19 

125 cc ........................................................................................................................................................... 20 

BODY .................................................................................................................................................. 21 

Location of body components (50 and 125 cc) ............................................................................................ 21 

Body component sequence of disassembly (50 and 125 cc)........................................................................ 21 

Removal of front lower legshields (50 and 125 cc) Procedure 1............................................................... 22 

Removal of the headlight and sidelight assemblies (50 and 125 cc)............................................................ 22 

Method for fitting the lower legshield bracket (50 and 125 cc)................................................................... 22 

Page : 2 

Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles

CONTENTS 

Removal of the storage compartment (50 and 125 cc) Procedure 2........................................................... 23 

Removal of the shield)(50 and 125 cc) Procedure 3................................................................................... 23 

Removal of the rear cover assembly and mudflap (50 and 125 cc) Procedure 4 ....................................... 25 

Removal of the rear light / storage compartment trim (50 and 125 cc) ...................................................... 25 

FRAME............................................................................................................................................... 26 

Removal of the rear frame (50 cc)................................................................................................................ 26 

Removal of the frame (50 cc)....................................................................................................................... 27 

MISCELLANEOUS OPERATIONS ............................................................................................... 29 

Removal of the oil tank (50 cc) or oil separator (125 cc), the saddle lock (50 and 125 cc)......................... 29 

To remove the oil filter (50 cc) .................................................................................................................... 29 

To remove the header tank (50 and 125 cc) ................................................................................................. 29 

Removal of the radiator / radiator bracket (50 and 125 cc).......................................................................... 30 

Removal of the fuel gauge (50 cc) ............................................................................................................... 31 

Removal of the strainer (50 cc) .................................................................................................................... 32 

Removal of the fuel tank filler ring (50 and 125 cc).................................................................................... 33 

Removal of the fuel tank (50 cc).................................................................................................................. 33 

Removal of the central shock absorber / from the swingarm (50 and 125 cc)............................................. 34 

Removal of the radiator deflector (50 cc) .................................................................................................... 35 

Removal of the braking limiter (50 cc) ........................................................................................................ 35 

Removal of the saddle strut (50 and 125 cc)................................................................................................ 35 

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE (50 cc) .................... 36 

Removal of the inlet coupling and valves .................................................................................................... 36 

To remove the cylinder head Procedure 5 .................................................................................................. 37 

Removal of the cylinder / piston .................................................................................................................. 37 

Removal of the temperature sensor.............................................................................................................. 38 

Removal of the air compressor..................................................................................................................... 38 

SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE................. 39 

Procedure for reducing the fuel circuit pressure Procedure 6 (50 cc) ........................................................ 39 

Procedure for bleeding the fuel circuit Procedure 7 (50 and 125 cc)......................................................... 39 

Removal of the injection manifold (50 cc)................................................................................................... 40 

Removal of the air injector (50 cc)............................................................................................................... 40 

Removal of the thermostat (50 cc) ............................................................................................................... 41 

Removal of the ECU (50 and 125 cc) .......................................................................................................... 42 

Removal of the throttle unit (50 cc) ............................................................................................................. 42 

Removal of the oil pump (50 cc).................................................................................................................. 43 

Removal of the fuel gauge (50 cc) ............................................................................................................... 43 

ELECTRICITY.................................................................................................................................. 44 

Removal of the instrument cluster (50 and 125 cc)...................................................................................... 44 

Removal of the voltage regulator and saddle actuator (50 and 125 cc) ....................................................... 44 

Removal of the battery cover, battery, fuses (50 and 125 cc) ...................................................................... 44 

Removal of the starter motor and/or lighting relay (50 and 125 cc) and/or the fuel pump and/or 

ABS/PBS system relay (125 cc)................................................................................................................... 45 

Removal of the high tension coil (50 and 125 cc)........................................................................................ 45 

Removal of the horn, immobiliser module (50 and 125 cc)......................................................................... 45 

Removal of the transponder antenna (50 and 125 cc) .................................................................................. 46 

Removal of the starter motor (50 cc)............................................................................................................ 46 

ENGINE REMOVAL........................................................................................................................ 47 

Removal of the 50 cc engine ........................................................................................................................ 47 

125 cc SPECIFIC MISCELLANEOUS WORK ............................................................................. 48 

Removal of the idle valve............................................................................................................................. 48 

Removal of the thermostat ........................................................................................................................... 48 

Page : 3 


Page : 4 

CONTENTS 

Removal of the engine temperature sensor .................................................................................................. 48 

Removal of the fuel injector......................................................................................................................... 49 

Removal of the oil pressure switch .............................................................................................................. 49 

Removal of the throttle unit.......................................................................................................................... 49 

Removal of the fuel pump / of the fuel gauge.............................................................................................. 51 

Removal of the starter motor........................................................................................................................ 52 

Removal of the rear brake pads or caliper.................................................................................................... 53 

Removal of the suspension arm.................................................................................................................... 53 

Removal of the engine mounting twin linkrod............................................................................................. 54 

Method of fitting the engine mounting twin linkrod.................................................................................... 55 

Removal of the motor-driven fan heat switch.............................................................................................. 56 

Removal of the motor-driven fan ................................................................................................................. 56 

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL .................................................. 57 

Removal of the power unit Procedure 8 ..................................................................................................... 57 

Removal of the engine Procedure 9............................................................................................................ 58 

Removal of the rocker cover, setting the rockers, removal of the camshaft, removal of the rockers.......... 58 

Removal of the cylinder head, removal of the cylinder and/or piston, removal of the cylinder head or 

base gasket, removal of the timing chain, setting the timing ....................................................................... 58 

Removal of the connecting rod and/or LH bearing and/or changing the casings ........................................ 58 


CHARACTERISTICS 

Engine 


50 cc 125 cc 

Type 

Single cylinder 2-stroke direct 

injection 

Single cylinder 4-stroke indirect 

injection 

Cooling Liquid 

Bore x stroke 39.9 x 39.8 mm 57 x 48.9 mm 

Cubic capacity 49.9 cc 124.8 cc 

Max. power 

output 

3.6 kW at 7500 rpm 9.2 kW at 8750 rpm 

Max. torque at 6500 rpm 7250 rpm 

Fuel system 

Direct electronic injection 

(TSDI) 

Indirect electronic injection 

(EFI) 

Lubrication Electric oil pump Trochoidal pump 

Transmission 2 variable pulleys and Vee belt 

Clutch Centrifugal automatic 

Spark plug NGK CPR8E NGK CR7EB 

Exhaust Catalytic Non-catalytic 

Capacities 

Fuel tank 8 litres 95 or 98 lead-free 

Oil tank 1.2 litres semi-synthetic (API TC) 

Engine oil 1.25 litres SAE 10W40 

Relay box oil 0.12 litres SAE 80W90 Life lubricated 

Coolant* 1.3 l 1.6 l 

Fork 

* Peugeot coolant part number 754614 

Chassis markings 

1 – VIN number and manufacturer’s plate 

125 cc by tube Esso Univis 46 

or Agip H Lift 46 

Engine markings 

2 – Engine number 

Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles 

190 cc by tube Esso Univis 46 

or Agip H Lift 46 

Page : 5

Frame 


50 cc 125 cc 

Frame Direct Perimetric Frame 

Front suspension Ø 32 mm telescopic fork Ø 36 mm telescopic fork 

Travel 85 mm 95 mm 

Rear suspension Central shock absorber 

Travel 95 mm 90 mm 

Dimensions and weight 

Overall length 1914 mm 1918 mm 

Width at 

handlebar 

740 mm 

Height with rear 

view mirror 

1260 mm 1279 mm 

Wheelbase 1314 mm 1369 mm 

Ground clearance 137 mm 112 mm 

Saddle height: 820 mm 845 mm 

Unladen weight 115 kg 149 kg 

Tyres 

Front wheel 13-inch alloy 

Front tyre 130/60 - 13 

Front tyre 

2 bar 2 bar 

pressure 

Rear wheel 13-inch alloy 

Rear tyre 130/60 - 13 140/60 - 13 

Rear tyre pressure 2.2 bar 2.2 bar 

Page : 6 


SERVICE SCHEDULE AND COMMISSIONING 

SERVICE SCHEDULE AND COMMISSIONING 

Heavy duty servicing is for vehicles used under “harsh” conditions: door-to-door deliveries, intensive 

urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C. 

Service operations 500 kms Every 5000 kms Every 10000 kms 

or 1 months or 12 months 

Heavy duty servicing 

Check 

500 kms Every 2500 kms Every 5000 kms 

Throttle cable play X X X 

Steering column play X X X 

Operation of electrical equipment X X X 

Condition of front and rear brake hydraulic 

controls 

X X X 

Condition of fuel pipes X X X 

Condition of oil pipes X X X 

Tyre pressures X 

Tyre condition, pressure and wear X X 

Brake fluid level X X X 

Battery electrolyte level * X X X 

Coolant level X X X 

Engine oil level X 

Tightness of nuts and bolts X X X 

Change 

Spark plug X X 

Inlet silencer/air filter** 

Front brake pads# X 

Rear brake pads *# X 

Drive pulley bearings and guides # X X 

Transmission belt X 

Engine oil (+ clean strainer) X 

Engine oil filter X 

Brake fluid and coolant** 

Check and lubricate 

Driven pulley: moving flange and needle 

bush 

X 

Drive pulley: moving flange and rollers* X 

Reading the ECU fault codes 

Injection and ABS/PBS system* X X X 

Test machine 

On road X X X 

* depending on equipment 

# if necessary 

** every 20000 km for the 50 cc (10000 if harsh use servicing) and every 40000 for the 125 cc (20000 

km if harsh use servicing) 


Page : 7

SPECIAL IMPORTANT POINTS 

Page : 8 

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 oil used for the separate lubrication system is « Esso 2T Spécial » or « Esso 2T Spécial antifumée 

» recommended by the manufacturer 

Starting up after overhauling the engine 

The oil circuit bleed system (50 cc) must be checked with the diagnostic tool, the fuel pump bleeds itself 

automatically when the ignition is turned on 

Starting should not be with a 2-stroke mixture, as the fuel pump and injectors are not designed to 

operate with oil. 

When starting the engine hot or cold do not accelerate 

Check the coolant level in the header tank 

After road-testing the machine, check there are no fault codes left in the ECUs (read with diagnostic 

tool) 

Electricity 

All components of the electrical system are powered with 12 volts DC. 

The battery must not be disconnected while the engine is running and the voltage must be at least 8.5 

volts for the ECU to function and enable engine starting 

To avoid any risk of forgetting to turn off the ignition after opening the saddle, the ignition key 

should be removed after each job 

Special features 

After changing the injection ECU or the throttle, the initialisation procedure must be carried out with the 

diagnostic tool 

The ECU has a diagnostic function which via the instrument cluster Led or the diagnostic tool, enables 

reading of the faults in the memory 

The fuel inlet and injection manifold return pipes must only be replaced by genuine service parts. 

The fuel pressure of 8 bars requires special pipes. 

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 

Note: 

Before carrying out any work, leave the engine to cool for a minimum of 2 hours. 

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 TORQUES 

Body panels 

TIGHTENING TORQUES 

Front mudguard 0.8 to 1.2 mdaN 

Handlebar cover 0.2 to 0.4 m.daN 

Front legshields 0.2 to 0.4 m.daN 

Rear shield 0.2 to 0.4 m.daN 

Bottom panel 0.2 to 0.4 m.daN 

Footboard 0.4 to 0.6 m.daN 

Saddle storage compartment 0.4 to 0.6 m.daN 

Rear panels 0.2 to 0.4 m.daN 

Grab handle 2 to 2.5 m.daN 

Rear mudguard 0.2 to 0.4 m.daN 

Frame 

Front wheel spindle 6 to 7 m.daN 

Rear wheel bolt 8.5 to 9.5 m.daN 

Rear wheel spindle nut 10 to 12 m.daN 

Linkrod to engine pivot 4.3 to 5 m.daN 

Linkrod to swingarm 4.3 to 5 m.daN 

Engine-upper linkrod pivot 4.3 to 5 m.daN 

Shock absorber top mount 2.4 to 2.6 m.daN 

Shock absorber bottom mount 2.4 to 2.6 m.daN 

Front and rear frame mounting nut 2 to 2.5 m.daN 

Exhaust to cylinder mounting nut 1.5 to 1.8 m.daN 

Exhaust to cylinder head mounting nut (125 cc) 1.5 to 1.8 m daN 

Exhaust to casing mounting bolt 2 to 2.5 m.daN 

Upper cone (in 2 operations) 3.8/2.3 mdaN 

Upper cone locknut Tighten manually 

Steering locknut 7 to 8 m.daN 

Front brake caliper 2.5 to 3.5 m.daN 

Rear brake caliper 2 to 2.5 m.daN 

Front disc brake 0.9 to 1 m.daN 

Rear disc brake 0.9 to 1 m.daN 

Handlebar 2.5 to 3.5 mdaN 

Standard 

Nut and bolt 5 mm diameter 0.5 m.daN 

Nut and bolt 6 mm diameter 1 m.daN 





Page : 9

SPECIAL TOOLS 

Page : 10 

. Tool N° Description Used with 

68994 Torque wrench 8 

Nm to 54 Nm 

750539 Tie-wrap pliers 

SPECIAL TOOLS 

extension 

752235 

adapter 

752236 

752235 1/2 extension 69802 or 

753977 

752236 1/2-3/8 adapter 69802 or 

753978 

753977 Torque wrench 

30 Nm to 150 

Nm 

754086 Steering tool 

extension 

752235 

adapter 

752237 

755806 Cartridge France 755878 

755807 Cartridge Export 755878 

755878 Diagnostic tool 

(game boy 

colour) 

755806 

755807 


755990 Diagnostic tool 

update software 

755996 hose clamp 

756017 petrol injection 

power supply 

harness 

756715 Tank gauge spanner 

756449 ABS/PBS interface 

cable for diagnostic 

tool 

756575 Piston locking fork 

756716 Tank ring spanner 

756607 Fork seal fitting tool 

125 cc 

756608 Fork seal fitting tool 

50 cc 

755878 

755806 

755807

INSTRUMENT CLUSTER 

Instrument cluster description 


1. Multi-function display 

2. Rev counter 

3. Speedometer 

4. Engine temperature gauge 

5. Control button 

6. Injection system diagnostic warning light 

7. Transponder immobiliser dissuasion light 

8. ABS/PBS system diagnostic warning light (125 cc) 

9. Headlight warning light 

10. Low oil level (50 cc) or oil pressure (125 cc) warning light 

11. Direction indicator warning light 

12. Battery charge warning light 

When the ignition is turned on, the different functioning tests are carried out automatically for 5 

seconds: 

- Display of all of the multi-function display items (1) and the speed (3) 

- Lighting of all the warning lights (except ABS/PBS depending on version) 

- Test of rev counter stepper motors (2) and engine temperature (4) giving one sweep of the needles and 

zero reset where necessary 


Page : 11

Description of the multi-function display 

13. Tripmeter (total or daily) 

14. Tripmeter display 

15. Type of unit used by the tripmeter 

16. Clock 

17. Maintenance indicator (spanner symbol) 

18. Fuel gauge 

Page : 12 


MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS 

Setting and function change operations can only be carried out if the machine is stationary (engine 

not running) This is for safety reasons. 

Changing from the total distance display to the daily display 

The tripmeter (13) has two functions: 

- Total distance (15) displays and memorises the total distance covered by the machine 

- The tripmeter (14) displays and memorises the distance covered over a given period 

With the ignition on, changeover from the main to the daily distance and inversely is by briefly pressing 

the control button (5) 

With the ignition on, reset of the daily tripmeter is by pressing the control button for more than 3 

seconds 



Changing the distance unit 

Changing the distance unit (km or miles) is as follows: 

- Ignition off, hold down the control button (5) and turn on the ignition, the distance unit flashes 

- Select the unit by briefly pressing the control button, the distance unit changes from “km” to “miles” 

or inversely. 

-Turn off ignition to confirm 

Setting the clock 

The time can only be set in the tripmeter total distance position 

- Ignition on, press the button (5) until the time flashes 

- Set the time by successive pushes on the control button 

- To change the tenths of a minute, press the button until the minute tenths flash 

- Change the minute tenths by pressing as required on the button 

- Proceed in the same way to set the minutes 

- Press the button for more than 3 seconds to validate the clock setting 


Page : 13


Maintenance function 

Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service 

After servicing the machine, erase the spanner symbol as follows: 

- Ignition off, hold down the button (5) and turn on the ignition, the spanner symbol flashes 

- Release the control button 

- Press the button again for at least 5 seconds, the spanner symbol goes off 

Fuel gauge self-diagnostic 

If the fuel system is cut off from the fuel gauge, when the ignition is turned on, the display segments 

light one after the other 

Page : 14 


CONTROL CABLE AND HARNESS ROUTINGS 


ABS/PBS panel 

Conventional braking panel 

1. Main harness 

2. Throttle control 

3. Transponder antenna 

4. Speed sensor 

5. Brake light switch 

6. ABS/PBS brake module reservoir feed pipe 

7. Rear brake pipe 

8. Right master cylinder to module brake pipe 

9. Module brake pipe to front caliper 

10. Left master cylinder to module brake pipe 


2. Throttle control 



5. Brake light switch 

6. Front brake pipe 



Page : 15

Right-hand side 50 cc 

Page : 16 



2. Throttle cable (50 cc) 



5. Front brake pipe 


7. Fuel feed pipe 


Left-hand side 125 cc 



2. Throttle cable (125 cc) 


4. Fuel supply pipe 

5. Air pressure slave pipe 

6. Fuel overflow pipe 


Page : 17

Rear right 


Rear centre 


Page : 18 



LOCATION OF COMPONENTS 

50 cc 

1. Injection ECU 

2. Throttle unit 

3. Engine position and speed sensor 

4. Temperature sensor 

5. Battery 

6. Fuel injector 

7. Air injector 

8. Ignition coil 

9. Immobiliser module 

10. Fuel pump 


11. Oil pump 

12. Diagnostic light 

13. Diagnostic plug 

14. Air compressor 

15. Fuses 

16. Voltage regulator 

17. Horn 

18. Saddle lock 

19. Starter / lighting relay 


Page : 19

125 cc 

1. Injection ECU 

2. Throttle unit 

3. Engine position and speed sensor 

4. Temperature sensor 

5. Air pressure and air temperature sensor 

6. Battery 

7. Fuel injector 

8. Idle control valve 

9. Ignition coil 

10. Immobiliser module 

11. Fuel pump 

Page : 20 


12. Diagnostic light 

13. Diagnostic plug 

14. Fuel pump relay, ABS/PBS, lighting, 25A 

fuse 

15. Heat switch 

16. Motor-driven fan 

17. Starter relay, 15 A fuse 

18. Voltage regulator 

19. Horn 

20. Saddle lock 

21. ABS/PBS module 

22. Vehicle speed sensor and ABS/PBS 


BODY 

Location of body components (50 and 125 cc) 

BODY 

Body component sequence of disassembly (50 and 125 cc) 

WIND 

DEFLECTOR* AND 

HANDLBAR 

FRONT FAIRING(2) 

HANDLEBAR 

REAR FAIRING (3) 

LEGSHIELD TOP 

PANEL 

(1) 

* Depending on model 

FRONT LOWER 

LEGSHIELDS 

(4) 

MUDGUARD AND 

FORK GUARD 

(5) 

MUDGUARD 

(6) 

FOOTBOARDS 

(7) 

TUNNELS 

(8) 

BELLYPAN 

(9) 

LEGSHIELD REAR 

PANEL 

(10) 

RIDER SADDLE 

(11) 

STORAGE 

COMPARTMENT 

(12) 

FUEL TANK 

FAIRING 

(13) 

MUDFLAP AND 

NUMBER PLATE 

PANEL 

(14) 


PASSENGER 

SADDLE AND 

GRAB HANDLE 

(15) 

BATTERY COVER 

(16) 

REAR FAIRING 

AND 

IMMOBILISER 

UNIT (17) 

STORAGE 

COMPARTMENT 

TRIM PANELS 

(18) 

Page : 21

Removal of front lower legshields 

(50 and 125 cc) Procedure 1 

- Remove the ignition key 

- Remove the front upper legshield (1) (3 

screws) 

- Disconnect the lighting and direction 

indicator connections 

- Remove the front lower left legshield (2) (3 

screws), including the 2 fixing it to the RH 

legshield (3) 

- Remove the front lower RH legshield (3 

screws) 

Removal of the headlight and sidelight 

assemblies (50 and 125 cc) 

- Remove the front lower legshields (see 

procedure 1) 

- Remove the headlight and sidelight 

assemblies (3 screws each) 

Method for fitting the lower legshield bracket 

(50 and 125 cc) 

- Fit the support bracket (1) with its bolt (2) to 

the frame but do not tighten it 

- Fit the lower RH legshield (3) with the fixing 

screws 

- Adjust the support bracket to the legshield 

and tighten its frame fixing screw 

Page : 22 

BODY 


Removal of the storage compartment (50 and 

125 cc) Procedure 2 

- Open the saddle (1) 

- Remove the saddle strut upper securing nut 

(2) 

- Remove the saddle (1) (2 nuts) 

- Remove the storage compartment (3) (6 nuts) 

Removal of the shield)(50 and 125 cc) 

Procedure 3 


procedure 1) 

- Remove the storage compartment (see 

procedure 2) 

- Remove the tank cap trim (1) (3 screws) 

- Remove the tank cover (2) (5 screws) 

Note: When removing the trim 3 screws, take 

care not to release the 3 nuts held in place in the 

tank filler ring 

- To remove the footboards (3) (2 screws each) 

Method for removing the footboards 

- Unclip the outer part of the footboard starting 

at the rear (A) 

- Unclip the footboard from the frame bottom 

- Raise the footboard by levering on the front 

end (B) to release it from the rear shield 

BODY 


Page : 23

- Remove the tunnels (4) (3 screws each) by 

unclipping starting at the rear upper part 

- Remove the bottom panels (5) (3 screws) 

Page : 24 

BODY 


- Remove the rear shield (6) (3 screws) 

including 1 screw next to the filler cap 

Removal of the rear cover assembly and 

mudflap (50 and 125 cc) Procedure 4 


procedure 2) 


- Remove the passenger seat (2 bolts) 

- Remove the rear handle (3 nuts) 

- Remove the rear cover (1) 8 fixing screws 

- Disconnect the rear light and direction 

indicator connections (and number plate light 

depending on model) 

- Remove the rear cover assembly (unclip the 

rear cover from the storage compartment trim, 

fed one side of the panel under the battery 

bracket, pull the cover clear by turning it on the 

same side) 

Removal of the rear light / storage 

compartment trim (50 and 125 cc) 

- Remove the rear cover assembly (see procedure 

4) 

- Remove the rear light 

- Remove the storage compartment trim (1) 4 

screws 

- Unclip the compartment trim from the frame 

to remove it 

BODY 


Page : 25

FRAME 

Removal of the rear frame (50 cc) 


4) 

- Remove the battery cover 

- Disconnect and remove the battery 

- Unclip the battery bracket harness without 

disconnecting the components 

- Remove the battery bracket (1) 

- Remove the 2 storage compartment (2) trim 

pieces 

- Remove the regulator (3), the oil pump (4) 

after disconnecting it, and the saddle lock 

actuator (5) 

- Disconnect the oil level low switch (6) 

- Remove the oil tank (7) 

- Remove the 4 frame fixing nuts and bolts (8) 

- Remove the rear frame 

- Remove the nuts, the footboard with the caps 

and the saddle lock from the rear frame 

Note: When refitting, the storage compartment 

trim must be fitted in position before the rear 

cover panel assembly 

The regulator must be connected and its 

protection fitted before fixing to its bracket 

There must be no air bubbles in the feed pipe 

before connecting it to the oil pump 

Check: Using the diagnostic tool, check for 

fault codes, clear them if necessary 

Page : 26 

FRAME 


Removal of the frame (50 cc) 

This method is used only when changing the 

main frame, with the removal of several 

assemblies 

When changing the frame due to an accident, 

the method must be completed by the repair or 

replacement of damaged items 

- Remove the passenger seat 



- Remove the rear shield panel (see procedure 

3) 

- Remove the handlebar front and rear covers 

- Remove the fork guard 

- Remove the mudguard 

- Unclip and disconnect the main harness from 

the front part of the machine, and from the 

components around the engine 

- Disconnect the separate lubrication oil pipe 

from the engine casing 

- Remove the frame 4 fixing bolts 

- Remove the complete rear frame with the 

main harness 

- Remove the front caliper and braking limit 

but do not disconnect them 

- Remove the handlebar assembly without 

disconnecting the hydraulic controls 

- Remove the radiator/bracket/header tank 

assembly 

FRAME 


Page : 27

- Disconnect the fuel tank sender unit return 

pipe 

- Using tool part number 755996 clamp the fuel 

supply hose between the tank and the fuel pump 

- Remove the fuel tank 

- Remove the saddle pivot 

- Remove the high voltage coil 

- Remove the shock absorber upper mount 

- Remove the swingarm to frame mount 

- Pull back the power unit 

- Remove the fork assembly with the wheel 

Note: Self-lubricating captive balls are fitted in 

the lower race 

- Remove the remaining items from the frame, 

cage nuts, plastic inserts, ignition key switch, 

manufacturer’s plate, lower cover brackets, 

steering cups 

Page : 28 

FRAME 


MISCELLANEOUS OPERATIONS 

Removal of the oil tank (50 cc) or oil 

separator (125 cc), the saddle lock (50 and 

125 cc) 


4) 

- Unclip the harness from the battery bracket 

without disconnecting the components 



- Remove the battery bracket 

- Disconnect the oil level low switch 

- Disconnect the oil pump 

- Remove the oil tank (1) and/or the saddle lock 

(2) 

Note: When refitting the oil tank ensure there 

are no air bubbles in the pump feed pipe before 

connecting it 

To remove the oil filter (50 cc) 


procedure 2) 

- Remove the oil filter (1) 

Note: When refitting ensure there are no air 

bubbles in the oil filter in its feed pipes before 

reconnecting the to the oil pump 

To remove the header tank (50 and 125 cc) 


procedure 1) 

- Drain the cooling system 

- Disconnect the header tank pipes 

- Remove the upper fixing bolts 

- Clear the header tank (1) from the bracket 

guides and rear shield 

- Remove the header tank 

Note: When refitting, locate the header tank 

positioning pins (A) and the window (B) in the 

rear shield and in the radiator bracket 



Page : 29

Removal of the radiator / radiator bracket 

(50 and 125 cc) 


procedure 1) 


3) 

- Remove the fork guard (1) 2 fixing bolts 

without removing the guard 

- Remove the mudguard (2) 

- Drain off the coolant 

- Disconnect the radiator cooling system 4 

pipes (3) 

- Remove the radiator (4) (4 bolts) 

- Unclip the deflector (5) 

- Disconnect the horn and immobiliser unit 

- Unclip the harness 

- Remove the radiator bracket (3 bolts) with its 

components (immobiliser unit, horn and header 

tank) 

Page : 30 



Removal of the fuel gauge (50 cc) 


procedure 2) 

- Remove the tank cover panel (5 screws) 

- Remove the saddle pivot bracket 

(2 nuts) 

- Disconnect the fuel gauge (1) 

- Disconnect the return and vent pipes (2) from 

the sender unit 

- Unscrew and remove the fuel sender unit and 

its seal using plug wrench part number 756716 

Reassembly: Re-assemble in the reverse order 

to dismantling 

- Tighten the fuel sender unit using plug 

wrench part number 756716 in order to position 

the arrow (A) between the marks (B) on the 

tank 



Page : 31

Removal of the strainer (50 cc) 


procedure 2) 


- Remove the saddle pivot bracket (2 nuts) 

- Remove the footboard and the left tunnel 


- Disconnect the vent pipe (2) from the sender 

unit and put into a container in order to drain the 

tank 

- Disconnect the return pipe (3) from the sender 

unit 

- Unscrew and remove the sender unit and its seal 

using tool 756716 

- Remove the strainer (4) by passing one hand 

inside the sender unit, wearing a protective 

glove 

- Clean or change the strainer in accordance 

with the service instructions 

Note: When refitting tighten the sender unit 

using tool part number 756716 as described 

above 

Page : 32 



Removal of the fuel tank filler ring (50 and 

125 cc) 


procedure 2) 

- Remove the tank filler cap (3 screws) 

- Remove the filler cap trim 


- Remove the tank filler ring (1) (3 screws) 

Note: Mark the fitting position of the filler ring 

on the tank 

The filler ring is clipped into the tank, the 

assembly is sealed by 2 O-rings (2) 

When removing the trim 3 screws, take care not 

to release the 3 nuts held in place in the tank 

filler ring 

Removal of the fuel tank (50 cc) 

- Remove the front lower legshield assembly 

(see procedure 1) 


3) 

- Remove the radiator / deflector / bracket 

assembly 

- Remove the injection manifold 

- Using the injector actuator, drop the fuel 

pressure in the circuit (see procedure 6) 


- Disconnect the return pipe (2) from the sender 

unit 


- Disconnect the pump (4) from its bracket 

- Disconnect the fuel pump output hose (5) 



Page : 33

- Remove the tank upper fixing bolts (6) 

- Remove the tank to frame 2 fixing brackets 

(7) 

- Remove the tank with the fixing lugs, the fuel 

pump, the feed hoses and the cap 

Removal of the central shock absorber / from 

the swingarm (50 and 125 cc) 


procedure 2) 


- Remove the footboard (4 screws) 

- Remove the tunnels (4 screws) 

- Remove the bottom panels (7 bis) 

- Remove the saddle pivot bracket (1) 

(2 nuts) 

- Remove the shock absorber upper mount (2) 

- Remove the linkrod to swingarm (4) mount 

(3) 

- Remove the shock absorber lower mount (5) 

- Remove the shock absorber 

- Remove the swingarm to frame mount (6) 

- Remove the swingarm 

Note: We recommend greasing all needle 

bearings when refitting these parts 

Page : 34 



Removal of the radiator deflector (50 cc) 

- Remove the footboards (4 screws) 



- Unclip the deflector (1) from the radiator 

bracket and pull it downwards 

Removal of the braking limiter (50 cc) 




- Remove the limiter fixing bolts (1) 

- Disconnect and remove the limiter 

Note: The braking system should be bled each 

time the limiter is worked on 

Removal of the saddle strut (50 and 125 cc) 


procedure 2) 

- Remove the saddle strut lower mount (1) 

- Remove the saddle strut 

Note: Note the position of the saddle strut on 

the storage compartment 



Page : 35

Page : 36 

WORKING ON THE ENGINE WITHOUT REMOVING THE ENGINE 

WORKING ON THE ENGINE WITHOUT 

REMOVING THE ENGINE (50 cc) 

Removal of the inlet coupling and valves 

- Remove the transmission cover strip (1 screw) 

- Remove the air filter housing (2 screws) 

- Disconnect the throttle cable (1) from the 

throttle unit 

- Disconnect the throttle unit (2) 

- Remove the inlet coupling 2 fixing bolts 

- Remove the inlet coupling and the throttle 

unit (3) 

- Remove the clip from the throttle unit 

- Remove the inlet coupling 

- Remove the valves and paper gasket (4) 







To remove the cylinder head Procedure 5 




- Disconnect the lower pump from the coolant 

pump to drain the cooling system 

- Disconnect the coolant pipes from the 

cylinder head and cylinder 

- Remove the injection manifold (1) (2 bolts) 

- Disconnect the air injector (2), the 

temperature sensor and suppressor 

- Remove the spark plug 

- Working diagonally a few turns at a time, 

slacken the cylinder head/cylinder assembly 

fixing bolts 

- Remove the 4 bolts 

- Remove the cylinder head and the O-ring 

Note: Make sure to block the cylinder in the 

engine casing in order to avoid damage to the 

base gasket 

Do not remove the air injector if this is not 

necessary 

Removal of the cylinder / piston 


procedure 2) 

- Remove the exhaust 

- Remove the cylinder head (see procedure 4) 

- Remove the cylinder and the bottom seal 

- Remove the piston 

Note: When refitting the cylinder, we 

recommend locking the piston using the fork 

part number 756575 in order to facilitate 

assembly 


Page : 37

Page : 38 


Removal of the temperature sensor 


procedure 2) 

- Disconnect the temperature sensor (1) 

- Remove the sensor 

Note: Refit a sensor quickly to prevent loss of 

coolant 

Removal of the air compressor 



- Remove the compressor (1) 4 bolts 

- Remove the compressor with its hose 

- Remove the clip from the pipe (2) 

- Remove the compressor 

Note: On refitting, fit the compressor with its 2 

centring studs and a new lightly greased O-ring 

Tighten the 4 fixing bolts working diagonally a 

few turns at a time 


SPECIAL WORK AND PROCEDURES WITHOUT REMOVING THE ENGINE 

SPECIAL WORK AND PROCEDURES 

WITHOUT REMOVING THE ENGINE 

Procedure for reducing the fuel circuit pressure 

Procedure 6 (50 cc) 

Important: Wash the power unit 




- Disconnect the fuel injector (1) 

- Remove the 2 bolts from the injection 

manifold (2) 

- Remove the injection manifold without 

disconnecting the feed pipes 

- Connect the fuel injector power supply 

harness tool P/N 756017 to the fuel injector and 

the battery 

- Put the manifold into a container to recover 

the fuel 

- Operate the tool contactor 5 times for 5 

seconds with a 5 second pause between each 

operation, in order to lower the pressure in the 

injection manifold supply pipe 

Note: Secure the injection manifold in the 

container, the pressurised jet of fuel may be 

dangerous for the skin, do not expose the 

hands to the jet of fuel when opening the 

injector 

Procedure for bleeding the fuel circuit 

Procedure 7 (50 and 125 cc) 

- Operate the fuel pump by turning the key to 

the ignition position (turning on the ignition 

operates the fuel pump for 3 seconds) 

- Carry out this operation twice 


Page : 39

Page : 40 


Removal of the injection manifold (50 cc) 


- Carry out the procedure used to lower the 

pressure in the fuel system (see instruction 6) 

- Remove the clips from the 3 hoses (each time 

these clips are removed they must be changed 

for new genuine parts 

- Disconnect the 2 fuel pipes (1) 

- Disconnect the air pipe (2) from the 

compressor 

- Remove the injection manifold (3) 

- Remove the O-ring (4) from under the 

injection manifold (the O-ring must be renewed 

each time it is removed) 

Reassembly: Proceed in reverse order to 

disassembly and bleed the fuel system (see 

instruction 7) 

Removal of the air injector (50 cc) 


- Drift out the air injector (1) with drift part 

number 755989 

- Remove the O-ring from under the air injector 

(the O-ring must be renewed each time it is 

removed) 



Important: Put the injector in the holder tool 

P/N 755986 until ready for refitting 

Note: The injector may only be removed for a 

short instant from its housing in the cylinder 

head, as the air injector has a Teflon seal which 

expands if it is not held compressed 





Removal of the thermostat (50 cc) 


- Remove the circlip (1) from the thermostat (2) 

- Remove the thermostat 

When refitting, make sure the thermostat (2) 

circlip (1) is correctly fitted, as shown 

Note: The thermostat circlip must be changed 

each time it is removed 


Page : 41

Page : 42 


Removal of the ECU (50 and 125 cc) 


procedure 2) 


- Remove the ECU two fixing nuts 

- Remove and disconnect the ECU (1) 

Important: If the ECU is changed, the throttle 

unit must be initialised with the diagnostic tool 

(refer to diagnostic tool user documentation for 

the injection engine) 

Removal of the throttle unit (50 cc) 



- Disconnect the throttle cable (1) from the 

throttle unit 

- Disconnect the throttle unit (2) 

- Remove the inlet coupling 2 fixing bolts 


unit 

- Remove the clip from the throttle unit 

- Remove the throttle unit 

Important: If the throttle unit is changed it 

must be initialised with the diagnostic tool 

(refer to the diagnostic tool user documentation 

for the injection engine) 




disassembly ensuring: 

- the throttle unit positioning pin (A) is properly 

located in its housing (B) on the inlet coupling 

- the throttle cable is properly tensioned 

- the throttle unit is properly positioned on the 

air filter box 



Removal of the oil pump (50 cc) 


procedure 2) 

- Disconnect the engine casing separate 

lubrication pipe 

- Disconnect the oil pump (1) 

- Remove the oil pump fixing bolt 

- Disconnect the oil inlet pipe (2) from the 

pump 

- Remove the oil pump 

Important: Using the diagnostic tool bleed the 

oil pump (refer to the diagnostic tool user 

documentation for the injection engine) 



Removal of the fuel gauge (50 cc) 

- Remove the footboards (2 screws each) 

- Remove the tunnels (3 screws each) 

- Carry out the procedure used to lower the 

pressure in the fuel system (see instruction 6) 


- Remove the fuel pump (2) from its mounting 

- Clamp the fuel inlet hose with the hose clamp 

part number 755996 

- Disconnect the fuel inlet and outlet hoses (3) 

- Remove the fuel pump 


Page : 43

ELECTRICITY 

Removal of the instrument cluster (50 and 

125 cc) 

- Remove the front upper legshield (3 screws) 

- Remove the screen (depending on version) 

- Remove the handlebar front cover (6 bolts) 

- Remove the handlebar rear cover and 

instrument cluster (1) assembly (3 bolts) 

- Disconnect the instrument cluster (2) 

- Remove the instrument cluster (4 bolts) 

Note: When refitting, carefully connect the 

harness to the instrument cluster, with the 

rubber cover on the connector and correctly 

position the harness securing clip (A) 

Page : 44 

ELECTRICITY 

Removal of the voltage regulator and saddle 

actuator (50 and 125 cc) 


procedure 2) 

- Remove the regulator (1) or the saddle actuator (2) 

Note: When refitting the voltage regulator 

carefully connect the connector and its cover 

before fitting to the frame 

Removal of the battery cover, battery, fuses 

(50 and 125 cc) 

- Remove the passenger seat (2 bolts) 

- Remove the battery cover (1) (1 bolt) 

- Remove the battery and/or change the fuses 


Removal of the starter motor and/or lighting 

relay (50 and 125 cc) and/or the fuel pump 

and/or ABS/PBS system relay (125 cc) 


4) 

- Remove the relay concerned 

- lighting relay (1) (50 and 125 cc) and 

fuel pump relay (125 c) 

- starter motor relay (2) (50 cc) (on the 125 

cc the relay is on the other side 

- ABS/PBS system relay (depending on 

version) 

Removal of the high tension coil (50 and 125 

cc) 

- Remove the left footboard (2 screws) 

- Remove the left tunnel (2 screws) 

- Remove the 2 coil fixing bolts (1) 

- Disconnect the coil (2) and the spark plug 

lead 

- Remove the high tension coil 

Removal of the horn, immobiliser module (50 

and 125 cc) 

- Remove the front legshield assembly (see 

procedure 1) 

- On the 50 cc, the horn is mounted to the right 

of the radiator support bracket 

- On the 125 cc, the horn is mounted on the 

front legshield support bracket 

Note: If the immobiliser module is changed, the 

key programming procedure must be carried out 

ELECTRICITY 


Page : 45

Removal of the transponder antenna (50 and 

125 cc) 


procedure 1) 


3) 

- Unclip the antenna (1) from the steering lock 

- Disconnect the antenna from the transponder 

module 

- Remove the antenna from the transponder 

Removal of the starter motor (50 cc) 


procedure 2) 

- Disconnect the starter motor 

- Remove the starter motor (1) 2 bolts 

- Remove the starter motor 

Page : 46 

ELECTRICITY 


ENGINE REMOVAL 

Removal of the 50 cc engine 



- Remove the storage compartment 

- Remove the passenger seat 


- Disconnect the battery 

- Remove the 2 footboards 

- Remove the 2 tunnels 

- Remove the lower panel 

- Remove the transmission cover strip 

- Remove the air filter unit 

- Drain off the cooling system at the water pump hoses 

- Disconnect: 

- the magneto 

- the starter motor 

- the throttle unit 

- the air injector 

- the suppressor 

- the temperature sensor 

- the throttle cable 

- the crankcase separate lubricating oil inlet 

- Remove the injection manifold without disconnecting the fuel supply pipes (see relevant chapter), 

however disconnect the compressor air pipe 

- Pull clear the injection manifold and protect it from foreign matter with a clean rag 

- Remove the exhaust 

- Slacken off the wheel hub nut 

- Remove the wheel 

- Remove the 2 brake calipers but do not disconnect them 

- Remove the disc/hub assembly 

- Suspend the rear of the machine 

- Remove the linkrod to swingarm fixing pin 

- Remove the engine mounting upper pin 

- Remove the engine / stand / linkrod assembly 

- Remove the linkrod 

- Remove the stand 

- Remove the engine upper mount bush 


Page : 47

125 cc SPECIFIC MISCELLANEOUS 

WORK 

Removal of the idle valve 



- Disconnect the idle valve (2) 

- Disconnect the idle valve two hoses (3) 

- Remove the idle valve (4) 

Removal of the thermostat 


procedure 2) 


- Disconnect the idle valve (1) 

- Disconnect the engine casing cooling system 

inlet pipe in order to drain the system 

- Remove the top (2) from the thermostat (2 

screws) without disconnecting the hose 

- Remove the thermostat 

Note: After refitting, bleed the engine circuit 

hot and check the coolant level in the header 

tank (Peugeot approved coolant) 

Removal of the engine temperature sensor 


procedure 2) 


- Disconnect the fuel injector and the idle valve 

- Disconnect the temperature sensor (1) 

- Disconnect the engine casing cooling system 

inlet pipe in order to drain the system 

- Remove the sensor (1) and its seal 

Note: The seal must be changed each time it is 

removed 

After refitting, bleed the engine circuit hot and 

check the coolant level in the header tank 

Page : 48 

125 cc SPECIFIC MISCELLANEOUS WORK 


Removal of the fuel injector 


procedure 2) 



- Disconnect the fuel feed hose (2) (1 clip, to be 

changed each time it is removed) 

- Remove the fuel injector (3) (1 bolt) 

Inspection: Connect the diagnostic tool and 

check there are no fault codes, erase them if 

necessary 

Removal of the oil pressure switch 

- Remove the exhaust elbow (1) (2 bolts and 2 

nuts) 

- Disconnect the pressure switch (2) 

- Remove the cylinder to casing fixing bolt (3) 

- Remove the oil pressure switch (2) and its 

seal 

Removal of the throttle unit 


procedure 2) 


- Disconnect the atmospheric pressure sensor 

(1) 

- Disconnect the oil vapour return pipe (2) 

- Remove the air filter housing (3) (2 bolts) 



Page : 49

- Disconnect the throttle unit and the idle valve 

- Remove the throttle cable 

- Remove the throttle unit with the idle valve (1 

clip, to be changed each time it is removed) 

Important: If the throttle unit is changed it 

must be initialised with the diagnostic tool 

(refer to the diagnostic tool user documentation 

for the injection engine) 


disassembly ensuring: 

- the throttle unit positioning pin (A) is properly 

located in its housing (B) on the inlet coupling 

- the throttle cable is properly tensioned 

- the throttle unit is properly positioned on the 

air filter box 



necessary 

Page : 50 



Removal of the fuel pump / of the fuel gauge 


procedure 2) 


- Remove the saddle pivot bracket (1) (2 nuts) 




Note: Put a rag over the fuel pipe to catch any 

fuel splashes 

- Disconnect the fuel feed pipe (4) and the 

regulator vacuum pipe (5) 

- Remove the fuel gauge with its seal using the 

gauge wrench part number 756715 (and press 

on the tool in order to squash the rubber seal 

and unscrew one quarter of a turn) 

- Unscrew and remove the fuel pump assembly 

with its seal using tool 

P/N 756716 

Note: None of the components, fuel pump, 

pressure regulator and strainer are removable 

It is only possible to clean the outside of the 

strainer 



Page : 51



- Tighten the fuel pump using the plug wrench 

P/N 756716 in order to position the arrow (A) 

between the marks (B) on the tank 

- Fit the fuel gauge with a new seal using the 

gauge wrench 

P/N 756715 



necessary 

Removal of the starter motor 


- Disconnect the oil vapour return hose 



- Disconnect the starter motor (1) 

- Remove the starter motor (2) (2 bolts) 

Note: One of the starter motor fixing bolts is 

used for the battery engine earth (green wire) 

Page : 52 



Removal of the rear brake pads or caliper 

- Remove the pad 2 fixing pins 

- Remove the caliper 2 fixing bolts 

- Pull the caliper onto the disc to release the 

pads (1) 

- Remove the brake pads 

Note: After removing the pads, the caliper may 

be removed from the brake disc. If the caliper is 

to be changed, the hydraulic control must be 

slackened off before removal 

Removal of the suspension arm 

- Remove the exhaust (3 bolts and 2 bolts nuts) 

- Remove the wheel spindle nut and the 2 

washers 

- Remove the suspension arm (1) to casing 2 

fixing bolts 

- Remove the suspension arm 

Note: For re-assembly proceed in reverse order 

to removal as shown in the diagram 

1. Suspension arm 

2. Wheel spindle nut 

3. Plain washer 

4. Bearing flanges 

5. Bush 



Page : 53

Removal of the engine mounting twin linkrod 


procedure 2) 

- Remove the left-hand footboard and tunnel 


- Disconnect the oil vapour return pipe to the 

air filter 



- Disconnect the starter motor, the idle valve 

and the fuel injector 

- Disconnect the magneto harness and engine 

harness connections 

- Slacken off the upper mounts (1) of the 

engine mounting twin linkrod (2) 

- Slacken off and remove the twin linkrod 

lower securing pin (3) 

Note: Suspend the machine or wedge it under 

the swingarm twin linkrod 

- Remove the twin linkrod upper fixing pins 

- Remove the twin linkrod and the 2 rubber 

bump stops (4) 

Page : 54 



Method of fitting the engine mounting twin 

linkrod 

- Fit the 2 rubber bump stops (1) to the frame 

- Fit the twin linkrod (2) to the frame taking care it 

lines up with the rubber bump stops 

- Fit the twin linkrod upper fixing pins (3) 

- Fit the twin linkrod lower fixing pin (4) 



Page : 55

Removal of the motor-driven fan heat switch 


procedure 1) 


3) 




- Drain off the coolant 

- Disconnect the heat switch (1) 

- Remove the heat switch 

Removal of the motor-driven fan 


procedure 1) 


3) 




- Disconnect the fan (3) 

- Remove the header tank and the radiator but 

do not disconnect them 

- Remove the fan 

Page : 56 



125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL 

125 cc SPECIFIC WORK REQUIRING 


Removal of the power unit Procedure 8 

- Remove the storage compartment 

- Remove the left-hand footboard and tunnel 


- Disconnect the oil vapour return pipe to the 

air filter 



- Disconnect the starter motor, the idle valve 

and the fuel injector 

- Disconnect the magneto harness and engine 

harness connections 

- Disconnect the suppressor 

- Disconnect the throttle cable from the throttle 

unit 

- Disconnect the injector fuel feed hose 

- Disconnect the cylinder head air hose 

- Disconnect the oil vapour return hose to the 

rocker cover 

- Disconnect the oil filler pipe 

- Remove the pad fixing pins 

- Remove the caliper 2 fixing bolts 

- Rest the caliper on the disc to remove the 

pads 

- Remove the brake pads 

- Remove the caliper from the brake disc 

- Remove the hydraulic control from its guides 

on the engine casing 

- Disconnect the engine casing coolant inlet 

pipe to drain the circuit 

- Disconnect the coolant outlet to the 

thermostat 

Note: Suspend or wedge the machine frame 

before removing the power unit 

- Remove the engine 2 pins securing it to the 

frame linkrod and engine linkrod 

- Remove the power unit from the frame 


Page : 57

Page : 58 

125 cc SPECIFIC WORK REQUIRING ENGINE REMOVAL 

Removal of the engine Procedure 9 

- Remove the power unit (see 

procedure 8) 

- Remove the complete exhaust system 


unit 

- Remove the suspension arm 

- Remove the wheel hub assembly 

- Remove the stand 

Removal of the rocker cover, setting the 

rockers, removal of the camshaft, removal of 

the rockers 


procedure 8) and refer to the FD1 ENGINE 

workshop manual 

Removal of the cylinder head, removal of the 

cylinder and/or piston, removal of the 

cylinder head or base gasket, removal of the 

timing chain, setting the timing 


procedure 8) 

- Remove the exhaust and refer to the FD1 

ENGINE workshop manual 

Removal of the connecting rod and/or LH 

bearing and/or changing the casings 

- Remove the engine (see procedure 9) 

and refer to the FD1 ENGINE workshop 

manual 



REF: 756739 

RECOMMENDS 

For reasons of continuous improvement, Peugeot Motocycles reserves the right to modify, delete or add any part number quoted 

DC/PS/ATR printed in EU 02/2002 (photos non-contractual) 

Reproductions ou traductions, même partielles, interdites sans autorisation écrite de Peugeot Motocycles

Peugeot workshop manual Jet Force (756739) - Scootergrisen

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