Tweet Workshop Manual

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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 ......................................................................................................................................................7
Dimensions and weight ..............................................................................................................................7
Tyres ..........................................................................................................................................................7
Brakes ........................................................................................................................................................8
SERVICE SCHEDULE AND COMMISSIONING ............................................................................................... 9
Battery preparation (Except battery without maintenance)* ....................................................................11
New machine preparation ........................................................................................................................11
SPECIAL IMPORTANT POINTS..................................................................................................................... 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
BODY PANELS ............................................................................................................................................... 18
Location of body components ..................................................................................................................18
Body component sequence of disassembly.............................................................................................19
Removal of the storage compartment ......................................................................................................20
Removal of the rear cover assembly........................................................................................................20
Removal of the front top shield panel.......................................................................................................21
Removal of the front lower shield pannel .................................................................................................21
Removal of the rear shield panel .............................................................................................................22
Removal of the footboard .........................................................................................................................23
Removal of handlebar fairing ...................................................................................................................23
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS
SERVICE OPERATIONS................................................................................................................................. 24
Changing the engine oil ...........................................................................................................................24
Draining the relay box ..............................................................................................................................25
Replacing the air filter ..............................................................................................................................26
Removal of the spark plug .......................................................................................................................27
Idle setting................................................................................................................................................27
Transmission ............................................................................................................................................27
Removal of the drive pulley ......................................................................................................................28
Removal of the driven pulley ....................................................................................................................28
Changing the drive pulley bearings..........................................................................................................29
Checking the drive belt.............................................................................................................................29
Checking the thickness of the clutch linings.............................................................................................30
Removal of the clutch lining assembly .....................................................................................................30
Refitting the clutch lining assembly ..........................................................................................................31
Installing the valve clearance ...................................................................................................................32
Checking the valve clearance ..................................................................................................................33
Brake pad wear ........................................................................................................................................34
Replacing the brake pads ........................................................................................................................34
Checking the brake fluid level ..................................................................................................................36
Rear brake linings 50 cc...........................................................................................................................36
Removal of the fuel filter ..........................................................................................................................38
Draining the front fork...............................................................................................................................39
STEERING/FORK............................................................................................................................................ 41
Changing the front fork seals ...................................................................................................................41
The fork and its components....................................................................................................................42
Removal of the fork ..................................................................................................................................45
Replacing the bearings of the steering system ........................................................................................46
Steering headset cups .............................................................................................................................46
Fork cone .................................................................................................................................................46
Installing the fork ......................................................................................................................................47
Steering system tightening method..........................................................................................................47
2
TABLE OF CONTENTS
ELECTRICITY.................................................................................................................................................. 48
Ignition principle schematic/Starting off (50 cc) .......................................................................................48
Checking the ignition system ...................................................................................................................49
Ignition principle schematic/Starting off (125/151 cc) ..............................................................................50
Checking the ignition system ...................................................................................................................51
Removal of the regulator/Starter resistor .................................................................................................52
Removal of the starter motor relay...........................................................................................................52
FUEL SYSTEM ................................................................................................................................................ 54
Removal of the carburettor.......................................................................................................................54
Vacuum-operated cock ............................................................................................................................54
Removal of the fuel gauge .......................................................................................................................52
POWER UNIT .................................................................................................................................................. 55
Removal of the power unit .......................................................................................................................55
3
PRODUCTS DANGER SYMBOLS USED
PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.
Mbius band
Recyclable.
Means that the product or the package

can be recycled. However, this does not
guarantee that the product will be
recycled.
Irritant
The product can irritate the

skin, eyes and respiratory
organs.
Avoid contact with skin and clothes. Wear

gloves, safety goggles and appropriate
clothes such as a cotton overall. Do not
breath fumes. If in contact, wash
thoroughly with water.
Flammable
The product is flammable.
Keep it away from flames or any heat

source (barbecue, radiator, heater, etc.).
Do not leave the product in the sun.
Corrosive
Avoid contact with skin and clothes. Wear

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

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.
Toxic
The product can seriously

Avoid direct contact with the body, even by
affect health if it is inhaled,
inhalation. If you feel unwell, seek medical
ingested or in contact with skin. advice immediately.
Do not throw
away into a
garbage can
This symbol informs the consumer that the

One of the product's
used product shall not be thrown away into
component is toxic and can be
a garbage can, but shall be brought back
hazardous to environment.
to the merchant or dropped at a specific
i.e.:. Used batteries.
collection point.
Compulsory
gloves
Operation that can be

dangerous for people.
People's safety can be seriously affected if

the recommendations are not fully
respected.
4
E
GLU
People's safety

dangerous for people.
People's safety can be seriously affected if

the recommendations are not fully
respected.
Important

hazardous to the vehicle.
Indicate the specific procedures that shall

be followed in order not to damage the
vehicle.
Good operating
condition of the
vehicle
Serious damage to the vehicle and in

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

information to make the procedure easier.
Lubricate
Lubricate the parts to be

assembled.

vehicle.
Grease
Grease the parts to be

assembled.

vehicle.
Glue
Glue the parts to be

assembled.

vehicle.
New part
Use a new part.

vehicle.
5
CHARACTERISTICS
CHARACTERISTICS
Engine
Marking
50 cc
125 cc
151 cc
XS1P37QMA-2
XS1P52QMI-4
XS1P57QMJ-2
Type
4-stroke single-cylinder. Horizontal cylinder

Single overhead camshaft, 2 valves
Cooling
By a circulation of forced air by means of a turbine on the flywheel magneto
Bore x stroke
37 x 46 mm
52.4 x 57.8 mm
57.4 x 58.2 mm
Cubic capacity
49.5 cc
124.6 cc
150.6 cc
Max. power output
2.3 kW at 7500 rpm
6.5 kW at 7500 rpm
7.7 kW at 7500 rpm
Max. torque rating
3.1 Nm at 6500 rpm
9 Nm at 6000 rpm
10.6 Nm at 6000 rpm
Compression
9.5 bars at 550 rpm

7 bars. Minimum
11.8 bars at 380 rpm

7 bars. Minimum
Lubrication
Trochoid pump driven by a chain from the crankshaft
Transmission
By 2 variable pulleys and V-type belt
Clutch
Centrifugal automatic
Exhaust
Catalytic
Spark plug
NGK CR6HSA
Electrode gap: 0.7 - 0.8 mm
Magneto flywheel
NGK CR7HSA
Electrode gap: 0.7 - 0.8 mm
80 W
Fuel supply
Keihin NCV carburettor
DENI DPD24J carburettor
Standards
Euro2
Euro3
0.8 L (0.65 L at the oil

change)
SAE 5W40 Synthetic
Minimum grade: API SJ
0.95 L (0.7 L at the oil change)

SAE 5W40 Synthetic
Minimum grade: API SJ
Capacities
Crankcase
Relay box
0.18 L (0.17 at the oil change)

SAE 80W90
Minimum grade: API GL4
Fuel tank
5.7 l 95 or 98 lead-free
Fork oil
0.1 l per tube. SAE 10W
6
CHARACTERISTICS
Chassis
50 cc
Chassis
Front suspension
Rear suspension
151 cc
Steel tube
Upside down telescopic front fork. 30 mm
Travel: 100 mm
Combined spring and
Combined spring and hydraulically-damped shock
hydraulically-damped
shock absorber Travel:
absorber Travel: 75 mm
80 mm
Dimensions and weight

Overall length
2000 mm
Width at handlebar
690 mm
Height (without rear-view

mirrors)
Wheelbase
Unladen weight
125 cc
1125 mm
1330 mm
97 kg
106 kg
Tyres
Front wheel rim
16 inch aluminium alloy
Front tyre
90/80 - 16
Front tyre pressure
1.75 bars
Rear wheel rim
16 inch aluminium alloy
Rear tyre
Rear tyre pressure
90/80 - 16
110/70 - 16
2.25 bars
7
CHARACTERISTICS
Brakes
50 cc
125 cc
151 cc
Front brake
Single disc type, hydraulic control
Disc diameter and

thickness
226 mm - 4 mm
Mini. thickness: 3.5 mm
Front caliper
Floating calliper equipped with 2 pistons
Rear brake
cable-controlled, single
cam drum type
Drum diameter
130 mm
Single disc type, hydraulic control
Disc diameter and

thickness
226 mm - 4 mm
Mini. thickness: 3.5 mm
Rear caliper
Fixed calliper with 2 pistons
*VGAXXXXXXXXXXXXXX*
Chassis markings
Engine marking
1. The VIN number and the manufacturer's

plate are under the seat
xxxxxxx
2
2. Engine number
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 30C.
Normal servicing in km
Extensive servicing in km
Minimum servicing
To be checked at each service
Steering column play.
Wheel bearing play.
Throttle cable play.
Operation of electrical equipment.
Condition of front and rear brake hydraulic
controls. b
Brake fluid level. b
Brake pad wear.
500
500
2000
1000
5000
2500
10000
5000
15000
7500
20000
10000
1 months 6 months 12 months 24 months 36 months 48 months
V
C
V
V
V
C
V
V
V
C
V
V
V
C
V
V
V
C
V
V
V
C
V
V
V
C
V
C
V
C
V
C
V
C
V
C
C
C
C
C
C
C
Rear brake lining wear. b
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
Service operations
Spark plug.
V
R
R
R
R
Air filter.
R
R
Intake silencer drain.
N
N
N
N
Drive pulley bearings and guides.
V
C
V
C
Transmission belt 50 cc.
R
R
Transmission belt 125/151 cc.
R
R
R
R
Kick starter mechanism.
G
G
V:Check, clean, adjust. R: Change. G: Check, clean, lubricate. C: Inspect and change if necessary. N:
Clean.
After 20000 km, resume the service schedule again from 5000 km.
a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high
temperature, exclusively town use, etc..
b.Depending on model.
9
Extensive servicing in km
Minimum servicing
500
500
2000
1000
5000
2500
10000
5000
15000
7500
20000
10000
1 months 6 months 12 months 24 months 36 months 48 months
Service operations
Valve clearances.
V
V
V
V
V
Setting the carburettor.
V
V
Joints. (Central stand, Brake levers, Brake cams).
G
G
G
G
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.
R Once every 5 years.
Brake fluid.
R Once every 2 years.
V:Check, clean, adjust. R: Change. G: Check, clean, lubricate. C: Inspect and change if necessary. N:
Clean.
After 20000 km, resume the service schedule again from 5000 km.
Code
9000
0
0
Extensive servicing in km a
Servicing time in tenths of an hour (0.5 h = 30 min)
Tweet Peugeot
1.4
9100
500
500
9150
2000
1000
9300
5000
2500
1.3
1.8
2.6
9400 9500 9600

10000 15000 20000
5000 7500 10000
3.1
2.6
3.9
a.Carry out this servicing if the vehicle is used in "severe" conditions: damp or dusty environment, high
temperature, exclusively town use, etc..
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
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
50 cc
Spark plug
Engine drain plug
Screen
Cylinder head
Nut
Screw
Camshaft gear cover
Cylinder head cover
Camshaft gear
Valve clearance covers
Automatic tensioner
Automatic tensioner plug
Chains guide
Inlet manifold
Cylinder casings
RH casing cover
Freewheel
Oil pump
Transmission cover
Relay box cover
Relay box drain plug
Starter motor
Rotor
Turbine
Stator
Engine speed sensor
Drive pulley
Driven pulley
Clutch plate and shoes
125/151 cc
12 Nm
20 Nm
15 Nm
12 Nm
12 Nm
22 Nm
12 Nm
10 Nm
10 Nm
10 Nm
20 Nm
10 Nm
10 Nm
8 Nm
10 Nm
10 Nm
12 Nm
12 Nm
90 Nm
10 Nm
10 Nm
22 Nm
10 Nm
10 Nm
45 Nm
10 Nm
10 Nm
10 Nm
55 Nm
55 Nm
55 Nm
Body panels
Front mudguard
Handlebar cover
Front shield panels
Rear shield
Bottom panel
Floor panel
Saddle storage compartment
Rear panels
Grab handle
8 to 10 Nm
1 to 2 Nm
1 to 2 Nm
1 to 2 Nm
6 to 8 Nm
8 to 10 Nm
8 to 10 Nm
1 to 2 Nm
20 to 25 Nm
13
TIGHTENING TORQUES
Cycle part
Front wheel spindle
Fork tube
Rear wheel spindle nut
Linkrod to engine pivot
Linkrod to frame pivot
Shock absorber top mount
Shock absorber bottom mount
Exhaust to cylinder head mounting nut
Exhaust to casing mounting bolt
Adjustment cone
Steering locknut
Front brake caliper
Front brake disc
Rear brake caliper
Rear brake disc
Handle bar
60 Nm
28 Nm
110 Nm
50 Nm
50 Nm
40 Nm
28 Nm
15 Nm
30 Nm
Hand tightened
20 Nm
30 Nm
40 Nm
30 Nm
40 Nm
45 Nm
Standard
Nut and bolt 5 mm diameter
5 Nm
10 Nm
22 Nm
35 Nm
55 Nm
14
SPECIAL TOOLS
SPECIAL TOOLS
Tool N
Designation
Used with
Tool N
Designation
Used w ith
752127
Clutch
compression
tool
50 cc
756057
Fork seal push

tool
752237
Adjustable pin
wrench
758008
Clutch
compression
801682
tool
125/151 cc
752361
39 mm pipe
wrench
759788
Steeing head
cup push tool
755039
Steeing head
cup push tool
801682
755996
Hose clamp
Spacer adaptor 758008
15
SPECIAL TOOLS
Standard tools
Wrenches with interchangeable
end fittings for valve clearance
adjustment
Type: Marolotest P/N. 500140
Set of shims
DC
Slide calipers
Multimeter
VAC
VDC
OFF
Automatic resetting type torque

wrench
5 to 25 Nm
Type: Facom R.306A25
10A
200 m
20 m
COM
mA

wrench
40 to 200 Nm
Type: Facom S.208A200

wrench
10 to 50 Nm
Type: Facom J.208A50
16
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
1
13
TIME
ODO TRIP
5
7
10
3
L
VE L
LE VE
R LE
PE
ER
UPW
LO
12
11
1.
2.
3.
4.
5.
6.
7.
Instrument panel
CDI unit
Battery
Fuses
HT coil
Magneto flywheel
Starter motor relay
8. Regulator
9. Starter resistor
10. Fuel gauge
11. Opening the saddle
12. Horn
13. Flasher unit
17
BODY PANELS
BODY PANELS
Location of body components
Description
1
2
3
7
16
17
12
15
6
14
5
4
13
11
9
10
1.
2.
3.
4.
5.
6.
7.
8.
9.
Rearview mirrors
Handlebar front fairing
Handlebar rear fairing
Front wheel
Fork tube
Front mudguard
Legshield top panel
Front lower legshields
Mudguard
10. Bottom panel

11. Central bottom panel
12. Rear shield
13. Floor panel
14. Battery access door
15. Rear panels/Mudflap
16. Saddle and storage compartment
17. Grab handle
18
BODY PANELS
Body component sequence of disassembly
1*
7*
14*
16*
17*
2*
9*
15
10*
12
13
4*
11*
1.
2.
3.
4.
5.
6.
7.
8.
9.
Rearview mirrors*
Handlebar front fairing*
Handlebar rear fairing
Front wheel*
Fork tube
Front mudguard
Legshield top panel*
Front lower legshields
Mudguard*
10. Bottom panel*

11. Central bottom panel*
12. Rear shield
13. Floor panel
14. Battery access door*
15. Rear panels/Mudflap
16. Saddle and storage compartment*
17. Grab handle*
*This item may be removed on its own.
19
BODY PANELS
Removal of the storage compartment
Range 1.
- Lift the saddle.
- Remove the storage compartment.
1 plastic screw (A).
4 screw. 6 mm (B).
- Disconnect the cutout switch.
Removal of the rear cover assembly

Range 2.
- Remove the storage compartment. See:
Range 1. page 20.
A
A
- Remove the grab handle.

3 screw 8 mm (A).
- Remove the battery access door.

5 plastic screws (B).
B
B
B
B
20
BODY PANELS
- Remove the rear cover assembly.

3 screw 6 mm (C).
6 plastic screws (D).
D
- Disconnect the taillight.
C
C
D
Removal of the front top shield panel

Range 3.
- Remove the front upper shield panel.
4 plastic screws (A).
A
A
A
A
Removal of the front lower shield pannel
Range 4.
- Remove the front upper shield panel. See:
Range 3. page 21.
- Remove the RH and LH under body panel.
4 screw 6 mm (A).
21
BODY PANELS
- Remove the mudguard (B).

4 plastic screws.
- Remove the front lower shield panel.

4 plastic screws (C).
1 Screw 6 mm (D).
- Disconnect the direction indicators.
Removal of the rear shield panel

Range 5.
- Remove the front lower shield panel. See:
Range 4. page 21.
OFF
IGNITION
ON
H
PUS
- Remove the ingnition switch trim.
LO
- Remove the utility hanger (1).

- Remove the rear shield panel.
CK
22
BODY PANELS
Removal of the footboard

Range 6
- Remove the rear cover assembly. See:
Range 2. page 20.
- Remove the rear shield panel. See: Range 5.
page 22.
A
- Disconnect and remove the battery.
- Remove the footboard.
4 washer head screws. 6 mm (A).
Removal of handlebar fairing

Range 7
- Remove the rearview mirrors.
- Remove the handlebar front cover.
1 Screw 6 mm. (Under the headlight) (B).
- Disconnect the lighting.
A
B
- Remove the front upper shield panel. See:

Range 3. page 21.
1
C
- Disconnect the speedometer cable (1).

- Disconnect:
The main harness (2).
The brake light switches (3).
The horn (2).
The flasher unit (2).
- Remove the handlebar rear cover and
instrument cluster assembly.
3 plastic screws (C).
3
C
1
3
23
SERVICE OPERATIONS
SERVICE OPERATIONS
Changing the engine oil

The engine must be drained when it is
warm to allow the oil to run easier.
Wear gloves in order not to get burnt.
- Place the vehicle on its central stand on flat

ground.
- Remove the engine's oil filler cap.
Remove the drainage cap and its

seal (1) and allow the oil to drip into a
recipient.
Tightening torque: 20 Nm.
Replace the copper seal every time you

change oil.
- Remove the strainer cap (2) and clean the

strainer (3).
Every time oil is changed, the filter (3)
must be cleaned and the O-ring
changed (4).
4
2
24
SERVICE OPERATIONS
- Put back the drainage cap and strainer cap,

fitted with a new seal.
- Pour the required quantity of oil corresponding
to the manufacturer's standards into the filler
hole:
50 cc: 0.65 l
125/151 cc: 0.7 l
- Start the engine and let it run for a short while.
- 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.
A. Oil level low.
B. Oil level high.
- Add oil if necessary.
B
A
Check the level with the machine

parked on its centre stand, on level
ground.
Draining the relay box

The gearbox must be drained when the
engine is warm so that the oil will run
easier.
Wear gloves in order not to get burnt.
- 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.
- Re-install the plug with a new seal.

- Pour the required quantity of oil corresponding
to the manufacturer's standards into the filler
hole.
- Quantity: 0.17 l
- Fit the filler cap.
25
SERVICE OPERATIONS
Replacing the air filter

- Remove the air filter cover (9 bolts) and its
seal.
- Remove the air filter (1) (3 screw).

- Clean inside the air filter box.
- Clean the oil vapour return filter (2).
Reassembly
- Fit a new air filter.
- Fit the gasket.
- Install the air filter cover.
2
- Remove the oil vapour return drain plug to let
humidity and oil drip out (3).
26
SERVICE OPERATIONS
Removal of the spark plug

-
The engine must be cold.

Remove the battery access door (5 screw).
Disconnect the suppressor (1).
Remove the spark plug.

- Recommended spark plug:
50 cc: NGK CR6HSA.
125/151 cc: NGK CR7HSA.
Electrode gap: 0.7 to 0.8 mm.
Essential precautions: When reinstalling, srew in the spark plug (a few
turns) by hand.
Idle setting
- The engine must be at its operating

temperature.
- Switch off the engine.
- Check the operating clearance in the throttle.
- Remove the rubber plug .
- Start the engine.
- Screw or unscrew the engine speed adjuster
screw (1) to alter the idle speed.
Idle speed:
50 cc: 2000 to 2200 rpm.
125/151 cc: 1700 to 1900 rpm.
LO
CK
UN
LO
CK
Transmission
- Lift the air filter box to reach the transmission
cover (2 screw).
- Disconnect the transmisson cooling air
intake (1).
- Remove the transmission cover.
50 cc: 10 screw
125/151 cc: 8 screw

- Remove the paper gasket and the two 2
centering pins.
27
SERVICE OPERATIONS
Removal of the drive pulley

- Hold the fixed flange with tool
P/N 752237.
- Remove the nut and the washer.
- Remove the fixed flange.
752237
- Pull the belt aside (1).

- Remove the plastic spacer (50 cc).
- Remove the drive pulley (2) together with
the guide hud (3).
3
2
Removal of the driven pulley

- Lock the clutch drum (1) with the pin
wrench P/N 752237.
- Remove the nut and the washer.
- Remove the clutch drum, the clutch drive
pulley and driven pulley assembly and
belt.
752237
Make a note of the direction of rotation

of the belt.
28
SERVICE OPERATIONS
Changing the drive pulley bearings

- Remove the ramp (1) and its 3 guides (2).
- 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.
Checking the drive belt

- Measure the width of the belt.
A. Minimum width:
50 cc: 17.2 mm.
125/151 cc: 17.5 mm.
- Make sure the belt is not cracked.
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).
29
SERVICE OPERATIONS
Checking the thickness of the clutch

linings
- Using the depth calliper, measure the
thickness of the clutch linings.
Mini. thickness: 2 mm.
Removal of the clutch lining assembly

50 cc
125/151 cc
- Compress the clutch drive pulley and

driven pulley assembly with the tool P/N
752127.
- Remove nut (1) using spanner
P/N 752361.
- Slacken tool P/N 752127.
- Compress the clutch and driven pulley

assembly using tool 758008 equipped
with the protection spacer P/N 801682.
- Remove nut (1) using spanner
P/N 752361.
- Slacken tool P/N 758008.
758008
752361
752127
801682
30
SERVICE OPERATIONS
- Remove the clutch linings (2), the upper

centring sleeve (3), the spring (4), and the
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
signs of abnormal wear.
7
6
8
Refitting the clutch lining assembly

- 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.
10
50 cc
- Compress the clutch drive pulley and
driven pulley assembly with the tool P/N
752127.
8
125/151 cc
- Compress the clutch and driven pulley

assembly using tool 758008 equipped
with the protection spacer P/N 801682.
- Tighten the nut (1).

- Fit the clutch drive pulley and driven pulley assembly.
- Fit the clutch cover.
- Fit washer.
- Fit and tighten the nut.
- Tightening torque: 55 Nm.
Before fitting the clutch drive pulley and driven pulley to the input shaft, fit the belt into the
pulley bottom by opening the flanges by hand.
31
SERVICE OPERATIONS
Installing the valve clearance

-
Remove the storage compartment. See: Range 1. page 20.

Remove the battery access door.
Remove the RH and LH under body panel.
Remove the under-footboard fairing (4 screw).
Remove the battery.
50 cc
125/151 cc
- Remove the valve clearance adjustment

covers (1).
Tightening torque: 15 N.
When re-installing, use a new
gasket.
- Disconnect the oil vapour return hose to the

rocker cover.
- Remove the pneumatic valve (2).
- Remove the rocker cover. (4 screws and
2 nuts).
When re-installing, use a new
gasket.
1
2
- Using wrench, turn the crankshaft in the
direction of operation to as to line up the
marks on the camshaft gear (B) with the
cylinder head gasket face.
- Remove the turbine on the the flywheel

magneto side (4 screw).
- Turn the magnetic wheel to line up the "T"
mark with the the crankcase boss (A).
32
SERVICE OPERATIONS
50 cc
125/151 cc
- Using the set of feeler gauges, measure the clearance of each valve.
Clearances:
0.050.02 mm at the intake.
0.100.02 mm at the exhaust.
Clearances:
0.120.02 mm at the intake.
0.120.02 mm 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 0.10 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.
- 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.
33
SERVICE OPERATIONS
Brake pad wear
Front brake
- 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
Rear brake
- Remove the plastic cover.
- If one of the 2 brake pads is worn down to the
minimum dimensions (A), the 2 brake pads
must be changed.
A = 1.5mm
A. Mini. thickness: 1.5 mm.
Replacing the brake pads
Front brake
- Loosen the brake pad pin first (1).
- Remove the calliper (2 screw).
34
SERVICE OPERATIONS
- Remove the2 pins (1).

- Remove the brake pads (2).
When refitting the brake pads, push the
pistons all the way into their housing.
After refitting, actuate the brake levers

several times to bring the brake pads
against the brake disc.
2
Rear brake 125/151 cc
- Remove the plastic cover (1).
- Remove the brake pad stop pin (2).
1
2
- Remove the brake pads.

When refitting the brake pads, push the
pistons all the way into their housing.
After refitting, actuate the brake levers

several times to bring the brake pads
against the brake disc.
35
SERVICE OPERATIONS
Checking the brake fluid level
MAX
- Position the handlebars so that the master

cylinder will be horizontal.
- Check the brake fluid level and if necessary
top up in the master cylinder.
MIN
- Remove the rearview mirrors.

- Remove the handlebar front cover.
- Remove the cover and the diaphragm from
the master cylinder (2 screw).
Add brake fluid until it reaches the
maximum level.
Rear brake linings 50 cc

- Actuate the brake control lever and check
the position of the wear mark on the cam
tierod (A) compared to the mark (B) on the
engine housing.
- If the cam tierod mark is lined up with or
passes the wear mark on the engine
housing, the brake lining must be replaced.
Disassembly
- Disconnect the air hose from the exhaust (1)
(50cc).
- Remove the screw fastening the rear
mudguard on right (2).

- Remove the 2 screws from the exhaust (3).
36
SERVICE OPERATIONS
- Remove the 2 screws that secure the

muffler.
- Remove the complete exhaust system.
Use a new exhaust gasket.
- Remove the wheel spindle nut and washer.

- Remove the rear wheel.
When re-installing, use a new nut.
- Remove the brake linings (3).

- Remove the adjusting nut, the barrel (4) and
the brake control cable (5).
- Remove the brake arm (6), the brake
cam (7) and the spring.
7
4
5
6
Reassembly.
7
Lubricate the brake cam spindle and fit
it into the casing.
- Fit the brake arm (6) by aligning it with the

brake cam axis (7).
-
Slightly lubricate the brake cam and pin.

Install the brake linings.
Install the spring (8).
Install the brake control cable, the barrel and
the adjusting nut (4).
- Install the wheel.
6
8
37
SERVICE OPERATIONS
- Measure the free travel of the rear brake

control lever.
- Ajust the lever free travel using the adjusting
nut.
B. Brake control free travel: 10 to 20 mm.

- Refit the other items in the reverse order to
disassembly.
Removal of the fuel filter

Range 1. page 20.
- Clamp the end of the fuel inlet pipe using a clip
ref. 755996.
755996
- Disconnect the fuel supply hose.

- Remove the fuel filter (1).
When
re-installing,
respect
the
direction of installation of the filter
shown by the arrow which indicates in
which direction the fuel flows.
38
SERVICE OPERATIONS
Draining the front fork

- Remove the fork tubes. See chapter: Changing
the front fork seals, page 41.
- Immobilise the tube in a vice fitted with protection.
- Push the fork tube cap (B) to remove the retaining
spring clip (2).
- Remove the fork tube cap (1).
- Remove the spring (3).
2
3
- Turn the fork tube upside down to drain the oil into
a recipient.
- Pour 0.1 l SAE10W hydraulic oil into the fork

tube.
39
SERVICE OPERATIONS
- Install the spring (3).

- Install the cap.
- Push the fork tube cap to install the retaining
spring clip.
2
3
40
STEERING/FORK
STEERING/FORK
Changing the front fork seals

- Suspend or immobilize the machine securely.
- Remove the front brake caliper from the fork tube
(2 screw).
- Remove the wheel spindle (A).
- Remove the front wheel.
- Unscrew and remove the 2 upper screws (B)

from the fork Tee.
- Unscrew the 2 lower screws (C) from the fork
Tee.
- Remove the fork tubes.
- Drain the front fork. See chapter: Draining the

front fork page 39.
- Remove the tightening screw from the internal
tube and its seal (4).
- If necessary use a mallet to dislodge the
screws.
- Separate the fork tube from the fork
stanchion (5).
41
STEERING/FORK
- Remove the compression stop cone (6).

- Remove the calibrated hydraulic tube (7).
- Remove the expansion stop spring (8).
7
6
8
- Remove from the fork sleeve:
The dust cover (9).
The retaining clip (10).
The seal (11).
9
10
11
The fork and its components
1
1. Retaining spring clip.
2. Fork tube cap.
3. Spring.
4. Screw and copper seal.
5. Hollow shaft.
6. End of compression cone.
7. Calibrated hydraulic tube.
8. Expansion spring.
9. Dust cover.
10. Circlip.
11. Tightness seal.
12. Fork upper tube.
13. Fork triple clamp
9
2
10
3
11
7
8
13
12
6
42
STEERING/FORK
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
756057
- Fit the plain washer.

- Fit a new lightly greased lip seal using push
tool P/N 756057 (11).
- Install the retaining ring.
- Install the dust cover.
11
- Install the expansion stop spring (8).

- Install the calibrated hydraulic tube (7).
- Install the compression stop cone (6) on the
calibrated hydraulic tube.
7
6
8
- Fit the fork sleeve (5) to the slightly oiled fork
tube (12).
- Install the stanchion assembly screw (4) and
its seal.
12
4
43
STEERING/FORK
- Pour 0.1 l SAE10W hydraulic oil into the fork

tube.
disassembly. See chapter: Draining the front
fork page 39
- Install the spring (3).
- Install the cap.
- Install the retaining spring clip.
- Fit the fork tubes into the fork triple clamps.

- Fit and tighten the 4 fixing bolts (B).
- 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.
- Fit the wheel spindle and tighten.

disassembly.
44
STEERING/FORK
Removal of the fork

- Remove the rear shield panel. See: Range 5.
page 22
- Suspend or immobilize the machine securely.
- Remove the front brake caliper from the fork
tube.

- Remove the front wheel.
- Remove the handlebars from the fork tube

(1 screw and 1 nut) (1).
Remove the steering locknut (1) (2).

Remove the adjustment cone (3).
Remove the fork.
Remove the balls.
2
3
45
STEERING/FORK
Replacing the bearings of the steering

system
Steering headset cups

If the steering head cups are changed,
the cones and ball bearings must also
be changed.
- Using a drift, remove the steering head cups.

- Using push tool P/N 755039, fit a new upper
cup into the steering tube.
- Using push tool P/N 759788, fit a lower cup
into the steering tube.
759788
Fork cone
- Unscrew and remove the 2 upper screws (4)
from the fork Tee.
- Unscrew the 2 lower screws (5) from the fork
Tee.
- Remove the fork tubes.
- Remove the front mudguard (3 screw).
- Using a drift, remove the steering headset

cone.
- Remove the dust cover.
- Remove the washer.
46
STEERING/FORK
- Install the following new parts:

The washer . (6)
The dust cover (7).
The fork cone (8).
8
7
6
Installing the fork

- Grease the cup bearing races.
- Install 26 balls (9) for the upper cup and 19 balls
for the lower cup.
- Fit the fork into the steering column.
- Install the adjustment cone.
Steering system tightening method

- Screw the adjustment cone until it comes into
contact with the balls.
- Tighten the adjustment cone by 2/8 to 3/8 of a turn.
Do not tighten the adjustment cone beyond
the recommended value to avoid damaging
the steering bearings.
2/8
- Install and tighten the locknut without altering the
adjustment.
3/8
- Check that there is no play in the fork.

- Turn the fork from left to right to check that there are
no tight spots.
disassembly.
47
ELECTRICITY
ELECTRICITY
Ignition principle schematic/Starting off (50 cc)
4
9
8
L
VE L
LE VE
R
PE LE
UP ER
W
LO
12
ON
ON
OFF
OFF
RG
15A
VE
VE
NR
JN-BE
RG-NR
RG-JN
10A
JN-BE
JN-BE
11
VE-BA
JN-NR
JN-VE
VE
VE
BA JN VE
10
VE
6
b
1. Battery
2. CDI unit
3. Magneto flywheel
b.Ignition sensor
4. Ignition switch
5. HT coil
6. Resistive spark plug and suppressor
7. Emergency stop switch

8. Circuit breaker (Storage compartment)
9. Starter motor switch
10. Starter motor relay
11. Stop light switch
12. Stop/tail bulb
48
ELECTRICITY
Checking the ignition system
Disconnect the ignition unit and take the

measurements on the harness side.
Component
Condition
Connector
R=115 :20%
Red/black
To the ground
U=12V(Battery
voltage)
Red/black
To the ground
U=0V
High voltage primary coil
Battery positive power
Battery positive power
Circuit breaker:
ON position
Ignition switch
ON position
Emergency stop
switch
ON position
Ignition switch
OFF position
Emergency stop
switch
OFF position
Standard values
Green
To the ground
Yellow/black
To the ground
Yellow/blue
To the ground
Ground
Ignition sensor
Wire colours
R=0:
R=0.2 :20%
49
ELECTRICITY
Ignition principle schematic/Starting off (125/151 cc)
3
8
11
ON
ON
OFF
OFF
VE
BA-NR
VE
JN-BE
RG-NR
JN-BE
+AC
JN-NR
RG-NR
RG-JN
VE
VE
BA JN VE
10
9
5
VE
a
b
1
2
1. CDI unit
2. Magneto flywheel
a.Ignition
b.Ignition sensor
3. Ignition switch
4. HT coil
5. Resistive spark plug and suppressor
6. Emergency stop switch

7. Circuit breaker (Storage compartment)
8. Starter motor switch
9. Starter motor relay
10. Stop light switch
11. Stop/tail bulb
50
ELECTRICITY
Checking the ignition system
Disconnect the ignition unit and take the

measurements on the harness side.
Component
Condition
Connector
Ground
High voltage primary

coil
Ignition sensor
Circuit breaker: ON position
Low voltage coil
Ignition switch
Emergency stop
switch
A
B
Ignition switch
OFF position
Emergency stop switch
ON position
Ignition switch
ON position
ON position
OFF position
Ignition switch
ON position
ON position
Ignition switch
ON position
Wire colours
Green
To the ground
Yellow/black
To the ground
Yellow/blue
To the ground
Red/black
To the ground
Standard values
R=0:
R=0.2 :20%
R=145 :20%
R=600 :20
R=0:
White/black
To the ground
R=f:
R=0:
White/black
To the ground
R=f:
51
ELECTRICITY
Removal of the regulator/Starter resistor

- Remove the front lower shield panel. See:
Range 4. page 21.
- Disconnect the battery.
- Remove:
Regulator (1).
The starter resistor (2).
Removal of the starter motor relay

- Remove the rear cover assembly. See:
Range 2. page 20.
- Disconnect the battery.

- Disconnect and remove the starter motor
relay (1).
Removal of the fuel gauge

Range 1. page 20.
-
Disconnect the fuel gauge.

Unscrew the fuel gauge locking plate (1).
Remove the fuel gauge.
Remove the rubber gasket.
When re-installing, use a new gasket.
52
ELECTRICITY
Check:
A. Full fuel tank: 8 :20%.
B. Empty fuel tank: 95 :20%.
A
B
53
FUEL SYSTEM
FUEL SYSTEM
Removal of the carburettor
To overhaul the carburettor, consult the

workshop documentation:
50 cc engine. 2 valves. SYM.
125/151 cc engine. 2 valves. SYM.
1
2

Range 1. page 20.
- Disconnect:
The throttle control (1).
The fuel inlet pipe (2).
- Disconnect the electric choke.
- Loosen the collars.
- Remove the carburettor.
Reassembly: Fit the carburettor by
making sure its pin is correctly
positioned (A) in the recess (B)
provided in the intake pipe.
A
B
Vacuum-operated cock
- Drain the fuel tank.
- Disconnect the vacuum hose, taking note of
its location (1).
- Disconnect the fuel supply hose .
- Remove the vacuum-operated cock.
When re-installing, use a new gasket.
54
POWER UNIT
POWER UNIT
Removal of the power unit
Note: To remove the cylinder head, remove the power propulsion unit.
For removal of the cylinder head, cylinder and piston, see the workshop manual:
50 cc engine. 2 valves. SYM.
125/151 cc engine. 2 valves. SYM.
- Remove the rear cover assembly. See: Range 2. page 20
- Disconnect and remove the battery.
50 cc
125/151 cc
B
A
A
- Disconnect:
The magneto (A).
The choke (A).
The starter motor (A).
The suppressor.
- Disconnect:
The magneto (A).
The choke (A).
The power supply wire from the starter to the
relay (B).
The suppressor.
- Disconnect:
- The engine ground (1).
55
POWER UNIT
50 cc
125/151 cc
- Remove the air inlet (1 screw).
- Disconnect:
The throttle control (2).
The fuel inlet pipe (3).
The vacuum pressure hose (4).
- Disconnect the pipe from the pulsair reed valve (5).

- Remove the exhaust assembly (3 screws and
2 nuts).
- Remove the exhaust assembly (4 screws and

2 nuts).
56
POWER UNIT
50 cc
125/151 cc
14
6
6
- Disconnect the rear brake control cable (6).

intake (6).
- Remove the 2 air filter box fixing bolts (7).
- Remove the rear brake caliper (2 screw).
8
8
14
- Suspend the rear of the machine.

- Remove the shock absorber lower mounts (8).
57
POWER UNIT
9
9
10

intake (9).
- Remove the linkrod-to-engine connecting
pin (10).
- Remove the linkrod-to-engine connecting

pin (9).
Tightening torque; 60 Nm.
- Lift the rear of the machine.

- Remove the power propulsion unit from the frame.
- Remove the covers from the power unit.
58
P/N. MA0019GB
Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add any
reference mentioned in this manual.
DC/PS/APV Printed in the E.U. 04/2010 (non contractual pictures)

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PRODUCTS DANGER SYMBOLS USED

PRODUCTS DANGER SYMBOLS USED

Means that the product or the package

The product can irritate the

Avoid contact with skin and clothes. Wear

The product is flammable.

Keep it away from flames or any heat

Avoid contact with skin and clothes. Wear

The product can explode under

The product affects fauna and

The product can seriously

This symbol informs the consumer that the

Operation that can be

People's safety can be seriously affected if

Operation that can be

People's safety can be seriously affected if

Operation that can be

Indicate the specific procedures that shall

Serious damage to the vehicle and in

Operation that can be difficult.

Indicate a note which gives key

Lubricate the parts to be

Indicate the specific procedures that shall

Grease the parts to be

Indicate the specific procedures that shall

Glue the parts to be

Indicate the specific procedures that shall

Use a new part.

Indicate the specific procedures that shall

4-stroke single-cylinder. Horizontal cylinder

By a circulation of forced air by means of a turbine on the flywheel magneto

Max. power output

2.3 kW at 7500 rpm

6.5 kW at 7500 rpm

7.7 kW at 7500 rpm

Max. torque rating

3.1 Nm at 6500 rpm

10.6 Nm at 6000 rpm

9.5 bars at 550 rpm

11.8 bars at 380 rpm

Trochoid pump driven by a chain from the crankshaft

By 2 variable pulleys and V-type belt

Keihin NCV carburettor

DENI DPD24J carburettor

0.8 L (0.65 L at the oil

0.95 L (0.7 L at the oil change)

0.18 L (0.17 at the oil change)

0.1 l per tube. SAE 10W

Dimensions and weight

Height (without rear-view

16 inch aluminium alloy

Front tyre pressure

Rear wheel rim

16 inch aluminium alloy

Single disc type, hydraulic control

Disc diameter and