125_cc SATELIS.pdf

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WORKSHOP MANUAL
TECHNICAL NETWORK LEADERSHIP
WORKSHOP MANUAL
-
125 CC/150 CC 4-STROKE ENGINE
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Workshop manual
Technical network leadership
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Downloaded from
www.Manualslib.com
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TABLE OF CONTENTS
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
1
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TABLE OF CONTENTS
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
2
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CHARACTERISTICS
CHARACTERISTICS
125 cc
Marking
Type
Cooling
Bore x stroke
Cubic capacity
Max. power output
Max. torque rating
Lubrication
Transmission
Clutch
Exhaust
Starter motor
Spark plug
Magneto flywheel
Fuel supply
Mitsuba 440 W
57 x 48,9 mm
124,8 cc
9 kW at 8750 rpm
7250 rpm
57 x 58,9 mm
150 cc
10 kW at 8450 rpm
6500 rpm
FD1
150 cc
FD2
125 cc EFI
FD4/FD5
150 cc EFI
FD4
4-stroke single-cylinder
Liquid
57 x 48,9 mm
124,8 cc
9 kW at 8750 rpm
7250 rpm
57 x 58,9 mm
150 cc
10 kW at 8450 rpm
6500 rpm
Trochoidal pump
By 2 variable pulleys and V-type belt
Centrifugal automatic
Non-catalytic
Mitsuba 470 W
Mitsuba 440 W
Mitsuba
235 W/330 W
Mitsuba 470 W
NGK CR7E
Mitsuba 235 W
Carburettor
NGK CR7EB
Mitsuba 235 W
Indirect electronic injection (EFI)
Capacities
Engine oil
Relay box oil
1.25 l SAE 10W40
0.12 l SAE 80W90 life lubricated
3
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Downloaded from
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