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WORKSHOP MANUAL
-

125/151 CC 4-STROKE ENGINE

2 VALVES
SYM

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 TABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTS..................................................................................................................................... 1

PRODUCTS DANGER SYMBOLS USED......................................................................................................... 3

CHARACTERISTICS......................................................................................................................................... 5
Capacities ..................................................................................................................................................5

SPECIAL IMPORTANT POINTS....................................................................................................................... 6

Oil and fuel.................................................................................................................................................6

TIGHTENING TORQUES .................................................................................................................................. 7

SPECIAL TOOLS .............................................................................................................................................. 8

Standard tools............................................................................................................................................9

OPERATION.................................................................................................................................................... 10
Putting the engine on the stand ...............................................................................................................10
Changing the engine oil ...........................................................................................................................10

PRIMARY TRANSMISSION ............................................................................................................................ 11

Removal of the primary transmission cover .............................................................................................11
Removal of the drive pulley ......................................................................................................................11
Removal of the driven pulley ....................................................................................................................12
Changing the drive pulley bearings..........................................................................................................12
Checking the drive belt.............................................................................................................................12
Removal of the clutch lining assembly .....................................................................................................13
Refitting the clutch lining assembly ..........................................................................................................14
Removal of the starter system .................................................................................................................15
Fitting the starter system..........................................................................................................................16

SECONDARY TRANSMISSION...................................................................................................................... 17
Removal of the secondary transmission ..................................................................................................17
Replacing the bearings of the relay box...................................................................................................18
Crankcase ......................................................................................................................................................... 18
Relay box cover ................................................................................................................................................. 18

CARBURETTOR ............................................................................................................................................. 19
Removal of the carburettor.......................................................................................................................19
Removal of the choke ..............................................................................................................................19
Removal of the throttle valve....................................................................................................................20
Removal of the float, needle valve and jets..............................................................................................20
Removal of the mixture screw ..................................................................................................................22
Removal of the deceleration enrichment device ......................................................................................22

1
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 TABLE OF CONTENTS

MAGNETO FLYWHEEL/FREEWHEEL........................................................................................................... 24
To remove the magneto flywheel .............................................................................................................24
Removal of the overrunning clutch...........................................................................................................26
Checking the overrunning clutch..............................................................................................................27
Replacing the lip seal...............................................................................................................................27
Oil pump...................................................................................................................................................27

CYLINDER HEAD/CYLINDER/PISTON.......................................................................................................... 29
Removal of the pulsair reed valve ............................................................................................................29
Removal of the cylinder head...................................................................................................................29
Removal of the camshaft and/or rockers..................................................................................................32
Removal of the valves or valve stem seals ..............................................................................................33
Removal of the cylinder / piston ...............................................................................................................35
Checking the cylinder...............................................................................................................................36
Checking the piston..................................................................................................................................36
Checking the piston rings.........................................................................................................................36
Installing the piston rings on the piston....................................................................................................37
Fitting the piston.......................................................................................................................................37
Fitting the cylinder....................................................................................................................................38
Setting the timing .....................................................................................................................................39
Checking the timing..................................................................................................................................40
Installing the valve clearance ...................................................................................................................40
Checking the valve clearance ..................................................................................................................41

CRANKCASE .................................................................................................................................................. 42
Removal of the crankshaft .......................................................................................................................42
Checking the crankshaft and conrod assembly .......................................................................................43
Replacing the lip seal...............................................................................................................................43
Fitting the conrod and crankshaft assembly.............................................................................................44

2
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 PRODUCTS DANGER SYMBOLS USED

PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.

Means that the product or the package
can be recycled. However, this does not
Möbius band Recyclable.
guarantee that the product will be
recycled.

Avoid contact with skin and clothes. Wear

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

Keep it away from flames or any heat

Flammable The product is flammable. source (barbecue, radiator, heating, etc.).
Do not leave the product in the sun.

Avoid contact with skin and clothes. Wear

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

The product can explode under

Explosive certain circumstances (flame, Avoid impacts, friction, sparks and heat.
heat, impact, friction).

The product affects fauna and

The ideal solution is to bring this product
Hazardous to flora. Do not dump it in
to your nearest household waste recycling
the environment dustbins, sinks or in the
centre.
environment.

The product can seriously Avoid direct contact with the body, even by
Toxic affect health if it is inhaled, inhalation. If you feel unwell, seek medical
ingested or in contact with skin. advice immediately.

This symbol informs the consumer that the

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

People's safety can be seriously affected if

Compulsory Operation that can be
the recommendations are not fully
gloves dangerous for people.
respected.

3
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 PRODUCTS DANGER SYMBOLS USED

People's safety can be seriously affected if

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

Indicate the specific procedures that shall

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

Serious damage to the vehicle and in

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

Indicate a note which gives key

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

Indicate the specific procedures that shall

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

Indicate the specific procedures that shall

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

Indicate the specific procedures that shall

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

N
Indicate the specific procedures that shall
New part Use a new part. be followed in order not to damage the
vehicle.

4
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 CHARACTERISTICS

CHARACTERISTICS

125 cc 151 cc
Marking XS1P52QMI-4 XS1P57QMJ-2
4-stroke single-cylinder
Type
2 valves per cylinder with chain driven overhead camshaft
Cooling By a circulation of forced air by means of a turbine on the flywheel magneto
Bore x stroke 52.4 x 57.8 mm 57.4 x 58.2 mm
Cubic capacity 124.6 cc 150.6 cc
Max. power output 6.5 kW at 7500 rpm 7.7 kW at 7500 rpm
Max. torque rating 9 Nm at 6000 rpm 10.6 Nm at 6000 rpm
11.8 bars at 380 rpm
Compression
7 bars. Minimum
Lubrication Trochoid pump driven by a gear set from the crankshaft
Transmission By 2 variable pulleys and V-type belt
Clutch Centrifugal automatic
Exhaust Catalytic
Spark plug NGK CR7HSA
Magneto flywheel 80 W
Fuel supply Carburettor Deni DPD24J
Standards Euro3

„ Capacities
0.95 l (0.7 I at oil change)
Crankcase SAE 5W40 Synthetic
Minimum grade: API SJ
0.18 l (0.17 I at oil change)
Relay box SAE 80W90
Minimum grade: API GL4

5
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 SPECIAL IMPORTANT POINTS

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.

Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc.
The clips are specific, they must always be changed each time they are removed and replaced
with new genuine parts clips.

Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or
sparks.

6
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 TIGHTENING TORQUES

TIGHTENING TORQUES

125/151 cc
Spark plug 12 Nm
Engine drain plug 20 Nm
Screen 15 Nm
Cylinder head
• Nut Ø8 mm 20 Nm
• Screw Ø6 mm 12 Nm
Cylinder head cover 10 Nm
Camshaft gear 12 Nm
Valve clearance covers 10 Nm
Automatic tensioner 10 Nm
Automatic tensioner plug 8 Nm
Chain tensioner 10 Nm
Inlet manifold 10 Nm
Cylinder casings 12 Nm
RH casing cover 12 Nm
Freewheel 90 Nm
Oil pump 10 Nm
Transmission cover 10 Nm
Relay box cover 22 Nm
Relay box drain plug 10 Nm
Starter motor 10 Nm
Rotor 45 Nm
Turbine 10 Nm
Stator 10 Nm
Engine speed sensor 6 Nm
Drive pulley 55 Nm
Driven pulley 45 Nm
Clutch plate and shoes 55 Nm

7
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 SPECIAL TOOLS

SPECIAL TOOLS

Used Used
Tool N° Designation Tool N° Designation
with with

Engine Lip seal push

64765 802349 756668
mount tool

Flywheel pul- Lip seal push

750016 757990
ler tool

Adjustable Clutch com- 752361

752237 758008
pin wrench pression tool 801682

39 mm pipe Valve stem

752361 758008 758596
wrench seal drift

Lip seal push

754035 Valve lifter 759788
tool

Bearing Spacer
755585 801682 758008
extractor tool adaptor

Engine
Piston loc-
756575 802349 mount adap- 64765
king fork
ter*

(*) New or modified tool

8
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 STANDARD TOOLS

STANDARD TOOLS

Wrenches with inter-

changeable end fittings
for valve clearance
Set of shims
adjustment
Type : Marolotest P/N.
500140

DC 10A
200 m
20 m

Slide calipers Multimeter

Ω
VAC
VDC
OFF

VΩ COM
mA

Automatic resetting type

torque wrench
Heat gun
5 to 25 Nm
Type : Facom R.306A25

Intertia type extractor Automatic resetting type

tool for bearings from 6 torque wrench
to 18 mm 10 to 50 Nm
Type : Facom U.49PJ3 Type : Facom J.208A50

Automatic resetting type

torque wrench
40 à 200 Nm
Type : Facom S.208A200

9
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 OPERATION

OPERATION

„ Putting the engine on the stand

- Fit the engine to adapter P/N 802349.
- Put the assembly on stand P/N 064765 802349
clamped in the jaws of a vice.

064765

„ Changing the engine oil

To drain the engine remove the cap and

let the oil drip.

Tightening torque: 20 Nm.

N Replace the seal each time you change

the oil.

- Remove the strainer cap (1) and clean the

strainer (2).

Tightening torque: 15 Nm.

2
N
Every time oil is changed, the filter (2)
must be cleaned and the O-ring
changed (3).

1
3

10
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 PRIMARY TRANSMISSION

PRIMARY TRANSMISSION

„ Removal of the primary transmission

cover
- Remove the transmission cover (8 screws).
- Remove the paper gasket and the two 2
centering pins.

Tightening torque: 10 Nm.

„ Removal of the drive pulley

- Hold the fixed flange with tool P/N 752237.
- Remove the nut (1) and washer (2) from the 1
fixed flange.
- Remove the fixed flange.
752237
Tightening torque: 55 Nm.
2

- Pull the belt aside (3).

- Remove the drive pulley (4) with the guide
hub (5). 3

5
4

11
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 PRIMARY TRANSMISSION

„ Removal of the driven pulley

- Lock the clutch drum (1) with the pin wrench 752237
P/N 752237. 1
- Remove the nut (2).
- Remove the clutch drum and the clutch and
drive pulley assembly.

Tightening torque: 45 Nm. 2

„ Changing the drive pulley bearings

- Remove the holder (1) and its 3 plastic 2
guides (2).
- Remove the moving flange (4) 6 bearings (3). 4
The bearings must be changed if they
show major signs of wear.
The guides shall be replaced if they
show signs of wear.

3 1

„ Checking the drive belt

- Measure the width of the belt (A).
A
Minimum width: 17.5 mm.

- Make sure the belt is not cracked.

12
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 PRIMARY TRANSMISSION

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).

„ Removal of the clutch lining assembly

- Using the depth calliper, measure the
thickness of the clutch linings.

Mini. thickness: 2 mm.

- Compress the clutch and driven pulley

assembly using tool 758008 equipped with 758008 752361
the protection spacer P/N 801682.
- Remove the nut using spanner P/N 752361.
- Slacken tool P/N 758008.

801682

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 PRIMARY TRANSMISSION

- Remove the clutch linings (2), the upper

centring sleeve (3), the spring (4), and the 1 2 3 4 5
lower centring sleeve (5).
- Remove the 3 pins (6) from the variable
speed drive seat.
- Separate the fixed (7) and rotating (8) flanges.
- Make sure surface of the plates in contact with
the belt does not show any cracks or signs of 7
abnormal wear.

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 9
condition, grease the governor seat 3 pins (6)
(high temperature grease) and assemble the
parts in reverse order to removal.
- Compress the clutch and driven pulley
assembly using tool 758008 equipped with
the protection spacer P/N 801682.
- Tighten the nut (1).
Tightening torque: 55 Nm.

Before fitting the clutch drive pulley and

driven pulley to the input shaft, fit the
10 8
belt into the pulley bottom by opening
the flanges by hand.

- Fit the clutch drive pulley and driven pulley

assembly.
- Fit the clutch cover.
- Fit and tighten the nut.
Tightening torque: 45 Nm.
- Fit the 2 locating pins and a new paper gasket.
- Fit the drive pulley with its guide hub onto the
connecting rod.
- Fit and tighten the nut.
Tightening torque: 55 Nm.
- Install the transmission cover (8 screws).
Tightening torque: 10 Nm.

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 PRIMARY TRANSMISSION

„ Removal of the starter system

- Remove the plate (7 screws).

- Actuate the kick starter gear sector (1) by

hand and remove the kick starter drive
piece (2) and washer. 1

2
4

- Remove the lock ring (3), using circlip pliers.

- Remove the washer.
- Remove the elastic washer.
- Remove the starter gear sector (1) and the
washer (4) from the drive train cover.

15
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 PRIMARY TRANSMISSION

„ Fitting the starter system

- Fit the return spring (4), hook the longest 1
buckle on the cover's pin (A).
- Fit the starter gear sector (1) into the
lubricated bearing sleeve.
- Hook the second buckle (B) of the spring onto C
the starter gear sector.
- Wind the spring so as to position the kick
starter sector on the stop (C) of the cover.
A
B
4

- Turn over the cover, fit the washer and the

circlip on the the gear sector spindle.
- Fit the washer (5) on the housing of the kick
starter drive piece. D
- Wind approximately 1/8th of a turn the gear
sector so as to place the kick starter drive 6
piece (2).
- Position the pin (6) on the kick starter drive
piece in the cover housing (D).
5

16
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 SECONDARY TRANSMISSION

SECONDARY TRANSMISSION

„ Removal of the secondary transmission

Remove the screw (A) in order to drain
the relay box.

Tightening torque: 10 Nm.

Use a drip pan to catch the transfer box

oil when the cover is removed.

- Remove the secondary transmission cover

(7 screws).

Tightening torque: 22 Nm.

A
- Remove the paper gasket (1) and the
2 locating pins (2). 1
- Remove the countershaft (3). 2
- Remove the secondary shaft (4).
2
Make a note of the way the secondary
shaft pinion is installed.
4

- The primary shaft can be drifted out of the

casing using a mallet (5).

17
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 SECONDARY TRANSMISSION

„ Replacing the bearings of the relay box

Crankcase

Wear gloves in order not to get burnt.

- Remove the seal.

- Using a heat gun, heat the crankcase to a
temperature between 80 and 90°C.
- Use an inertia type extractor tool to remove
the bearings.
- While the casing is expanded fit the new
bearing fully home in its housing.
- Using fitting tool P/N 757990, fit a new lightly
greased gasket (1).
757990

Relay box cover

- Remove the seal.

- Place the cover on its gasket seat surface, 759788
heat it (80 to 90°C) until the bearing falls out
by itself.
- While the casing is expanded fit the new
bearing fully home in its housing.
- Using fitting tool P/N 759788, fit a new lightly
greased gasket (2).

18
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 CARBURETTOR

CARBURETTOR

„ Removal of the carburettor

- Disconnect the vacuum hose.
- Loosen the collar.
- Remove the carburettor.

„ Removal of the choke

- Remove the choke cap.
- Locate the position of the choke (1) and then 1
remove it (2 screws).
- Remove the choke holder (2) (2 screws).

- Remove the O-ring (3).

19
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 CARBURETTOR

„ Removal of the throttle valve

- Remove the chamber cap (2 screws).
- Remove the spring.
- Remove the needle, valve and membrane
assembly.

- Remove the needle stop (2) and its spring (3)

by pulling it out. 2
- Remove the needle and its washer (4).
The height oif the needle is factory set
and cannot be modified.
Check that the membrane is in good
condition. 3

„ Removal of the float, needle valve and

jets
- Remove the float chamber and its O-ring
(4 screws).

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 CARBURETTOR

- Remove the float (6) pin (5).

- Remove the float and the needle valve.

- Remove the idle jet (7).

- Remove the main jet (8).
- Remove the needle well (9).
8
7

Check the condition of the needle valve

and the needle valve seat (A).
Check the condition of the float
chamber O-ring. A

21
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 CARBURETTOR

„ Removal of the mixture screw

- Turn clockwise the mixture control screw (1)
while counting the number of turns until it is
screwed home.
When re-fitting, this operation allows
you to put it back to its initial
adjustment position.

- Remove the mixture screw and its spring.

- Remove the washer and the O-ring (2).

„ Removal of the deceleration

enrichment device
- Remove the cover (2 screws).

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 CARBURETTOR

- Remove the spring (1).

- Remove the membrane (2).

Check that the membrane is in good

condition.
1
2

- Clean the carburettor body with Biosane

cleanser ref. 754748 or use an ultrasonic
cleaning tank.
- Blow into every jet and duct of the carburettor
body with compressed air.

Do not use any metal tool which can

damage the ducts of these items.

- Re-install all the other components and, if

necessary, when starting the engine, readjust
according to the values indicated on the
technical data card.

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 MAGNETO FLYWHEEL/FREEWHEEL

MAGNETO FLYWHEEL/FREEWHEEL

„ To remove the magneto flywheel

- Remove the carburettor.
- Remove the inlet coupling (2 nuts).

Tightening torque: 10 Nm.

- Remove the plastic spacer.

The paper gasket must be changed

each time it is removed.

- Remove the pneumatic valve (1).

- Remove the volute (2) (6 screws).
- Remove the cylinder cover. Right-hand
3
side (3) (4 screws).

2 1
- Remove the turbine (4 screws).

Tightening torque: 10 Nm.

24
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 MAGNETO FLYWHEEL/FREEWHEEL

- Lock the rotor with the adjustable pin wrench

P/N 752237.
- Remove the nut and the washer. 752237
Tightening torque: 45 Nm.

- Tighten flywheel extractor P/N 750016 on the

rotor.
- Lock the flywheel extractor and turn the thrust
bolt until the rotor is released.
750016

- Remove the sheath holder (4).

- Remove the stator and sensor assembly (3)
(2 screws each).
4
• Stator:

Tightening torque: 10 Nm.

• Sensor:

Tightening torque: 6 Nm.

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 MAGNETO FLYWHEEL/FREEWHEEL

„ Removal of the overrunning clutch .

- Remove the flywheel magneto. B
A C
- Remove the 10 bolts that secure the RH
cover.
A. Screw Length: 30 mm. A
B. Screw Length: 95 mm.
C. Screw Length: 100 mm. B

- Remove the RH cover.

Tightening torque: 12 Nm. C

B
- Remove the paper gasket (1) and the
2 locating pins (2).
- Remove the starter ring (3). 4 2
- Remove the starter dog (4).

1 3

- Using pin spanner ref. 752237, immobilise the

overrunning clutch (5).
5
The notched nut of the overrunning 752237
clutch has a left-hand thread.

- Using tool P/N 800673, remove the notched 800673

nut and the washer of the overruning clutch.

Tightening torque: 90 Nm.

- Remove the overrunning clutch.

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 MAGNETO FLYWHEEL/FREEWHEEL

„ Checking the overrunning clutch

- Rotate the overrunning clutch by hand:
• It must rotate in direction (A).
• It must be block in direction (B).
- If it doesn't, replace the overrunning clutch. A

„ Replacing the lip seal

- Remove the lip seal.
- Using fitting tool P/N 756668, fit a new lightly
greased gasket (1).
756668

„ Oil pump
- Remove the plate (2 screws).

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 MAGNETO FLYWHEEL/FREEWHEEL

- Remove the circlip (1).

- Remove the oil pump gear (2).
- Remove the pin.
- Remove the oil pump (2 screws).

2
1

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 CYLINDER HEAD/CYLINDER/PISTON

CYLINDER HEAD/CYLINDER/PISTON

„ Removal of the pulsair reed valve

- Remove the cover (1) (3 screws).
- Remove the pulsair reed valve (2).

The paper gasket must be changed

each time it is removed.
1

„ Removal of the cylinder head

- Remove the pneumatic valve (1). 3
- Remove the volute (2) (6 screws).
- Remove the cylinder cover. Right side. (3)
(4 screws).
- Disconnect the pipe from the pulsair reed
valve (2 nuts).
- Remove the rocker cover (4 screws).

Tightening torque: 10 Nm.

2 1
- Using a wrench, turn the crankshaft in the
direction of operation to as to line up the
marks on the camshaft gear (A) with the
cylinder head gasket face.

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 CYLINDER HEAD/CYLINDER/PISTON

- Removal of the chain tensioner plug (4).

- Remove the O ring.

- Using a screwdriver, slacken the chain

tensioner (5).
- Removal of the chain tensioner.

- Remove the camshaft gear (6) (2 screws).

- Tie a wire to the timing chain in order to
prevent it from falling into the crankcase.
6

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 CYLINDER HEAD/CYLINDER/PISTON

- Remove the 2 bolts (7).

- Gradually loosen in a crosswise order the 4 9
nuts which secure the cylinder head (8).
- Remove the 4 nuts.
- Remove the plate (9).

8
7

- Remove the cylinder head.

- Removal of the metal gasket (10) and the
2 centring pillars (11). 10

11

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 CYLINDER HEAD/CYLINDER/PISTON

„ Removal of the camshaft and/or rockers

- Remove the cylinder head.
- Remove the stopper plate (1).

Tightening torque: 10 Nm.

- Remove the pins from the rockers using a

5 mm screw (2).
- Remove the inlet (3) and exhaust (4) rockers. 4 5
- Remove the springs (5). 3
5

- Remove the camshaft (6).

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 CYLINDER HEAD/CYLINDER/PISTON

„ Removal of the valves or valve stem

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

- Remove:
• The upper cup (2). 1
• The spring (3). 2
• The valve (4).
• The valve stem seal (5). 3
- Remove the 2nd valve in the same way.
5

When removing a valve, always change 758596

the valve stem seal.

- Using tool P/N 758596, fit a new valve stem

seal.

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 CYLINDER HEAD/CYLINDER/PISTON

- When re-installing, fit the valve springs, the

closest coils against the cylinder head.
- When re-installing, lubricate the 2 half
cones (1) so as to hold them in the groove of
the valve's stem.
- Do not place the 2 half cones into the cup
forcefully with the tool when decompressing
the spring.

- When re-installing the rocker pins, position the

indentation of the axles towards the outside of
the cylinder head to fit the cylinder studs.
- To assemble the holder plate, position the
rocker pins with the screwdriver slits vertical.

When re-installing, the camshaft bearings, the rocker shafts and the contact between the rockers
and the valves shall well lubricated in order to avoid any risk of seizure when starting the engine
(Use lithium soap grease). Seals and valve stems must be lubricated.

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 CYLINDER HEAD/CYLINDER/PISTON

„ Removal of the cylinder / piston

- Remove the cylinder head.
- Remove the chain guide pad (1).

1
- Remove the cylinder.
- Remove the base gasket (2) and the
2 centring pillars (3).

3 2

- Remove one of the circlips (4) with pliers.

- Remove the gudgeon pin.
- Remove the piston.

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 CYLINDER HEAD/CYLINDER/PISTON

„ Checking the cylinder

- The cylinder should show no traces of scoring
or seizure.

125 cc 151 cc

Cylinder diameter

52.395 to 52.415 mm 57.395 to 57.415 mm

Utilisation limit

52.5 mm 57.5 mm

„ Checking the piston

- The piston should show no traces of scoring or 9 mm
seizure.
- The rings must be free in their grooves.
- Measure the piston diameter at 9 mm from the
piston skirt.

125 cc 151 cc

Piston diameter

52.385 to 52.405 mm 57.385 to 57.405 mm

Utilisation limit

52.29 mm 57.29 mm

„ Checking the piston rings

- Carefully remove the piston rings.
- Place a ring in the bore parallel to it and
measure the gap using a feeler gauge.
Piston ring gap:
• Top compression ring gap: 0.2 to 0.4 mm.
• Compression ring gap: 0.25 to 0.4 mm.
• Oil control ring gap: 0.2 to 0.7 mm.

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 CYLINDER HEAD/CYLINDER/PISTON

„ Installing the piston rings on the piston

- Proceed in the following order in order to
install the oil control rings. 4
• Fit the spring (1) (no special direction).
• Fit the 2 piston rings (2) on each side of the 3
spring offsetting the gap of each ring (no
special direction).
2 1
- Install the compression ring (3) by placing
the 2R mark upwards.
- Install the top compression ring (4) by placing
the 1R mark upwards.

„ Fitting the piston

- Install the piston so that the mark IN is on the
inlet side.
- Fit the gudgeon pin and circlips.

- The circlip gaps (1) must face upwards or

downwards, but under no circumstances to
the side. 1

N Use new rings.

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 CYLINDER HEAD/CYLINDER/PISTON

„ Fitting the cylinder

- Position the piston ring gap as follows: A
A. Top compression ring gap. 0°
12
B. Compression ring gap.
C. Upper oil control ring gap.

90°
D. Lower oil control ring gap.
B

°
90
D

C
- Install the cylinder base gasket and the
2 guiding pillars on the crankcase.
756575
- When refitting the cylinder, we recommend
locking the piston using the fork part
number 756575 in order to facilitate
assembly.
- Fit the cylinder over the piston by
compressing the piston rings by hand.

Lubricate the cylinder.

- Fit the chain and the chain guide tensioner

into the timing chain tunnel.

- Fit the chain pad (1).

- Fit the 2 guiding pillars (2) and the metal
gasket on the cylinder (3).
3

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 CYLINDER HEAD/CYLINDER/PISTON

- Install the cylinder head.

- Fit the plate (4). 4
- Tighten the cylinder head securing 4 nuts
working diagonally in 2 or 3 steps (5).

Tightening torque: 20 Nm.

- Fit and tighten the 2 fixing bolts (6). 5

6
Tightening torque: 12 Nm.

„ Setting the timing

- Turn the magnetic wheel to line up the "T"
mark with the the crankcase boss (A).

- Fit the timing chain on the camshaft gear.

- Make sure the camshaft marks (B) are parallel
with the gasket seat surface (C).
- If necessary, dislodge the gear from the
camshaft without removing it and move the
chain around the gear on the required side.
- Fit the 2 screws. B
Tightening torque: 12 Nm.
C

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 CYLINDER HEAD/CYLINDER/PISTON

- Fit the chain tensioner gasket.

- Install the chain tensioner and the
2 attachment screws (1).

Tightening torque: 10 Nm.

- Using a flat blade screwdriver, unlock the

chain tensioner screw.
- Fit the O-ring.
- Install the tensioner cap.

Tightening torque: 8 Nm.

1

„ Checking the timing

- Rotate the engine twice: 2 revolutions in the
engine's operating direction.
- Turn the magnetic wheel to line up the "T"
mark with the the crankcase boss (A).
- Make sure the camshaft marks (B) are parallel
with the gasket seat surface.
- If the marks are not alined, reset the valve
timing.
A

„ Installing the valve clearance .

- Remove the rocker cover.

Tightening torque: 8 Nm.

- Using a wrench, turn the crankshaft in the

direction of operation to as to line up the B
marks on the camshaft gear (B) with the
cylinder head gasket face.

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 CYLINDER HEAD/CYLINDER/PISTON

- Using the set of feeler gauges, measure the

clearance of each valve.
Clearances:
• 0.12 ± 0.02 mm at the intake.
• 0.12 ± 0.02 mm at the exhaust.
- If the clearance is not correct, adjust by means
of the cam follower screw.

„ Checking the valve clearance

• At the intake a 0.15 mm feeler gauge
shouldn't go.
• At the exhaust a 0.15 mm feeler gauge
shouldn't go.
- On the contrary, if the fealer gauge goes, reset
the clearances.

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 CRANKCASE

CRANKCASE

„ Removal of the crankshaft

- Remove the primary drive.
- Remove the overrunning clutch.
- Remove the cylinder and the piston.
- Remove the starter motor (2 screws).

Tightening torque: 10 Nm.

- Remove the 2 screws that secure the RH half

casing.
- Remove the RH casing.
- Remove the 2 centring pillars and the paper
gasket.

- Disengage the timing chain from the

crankshaft gear.
- Removing the the cranshaft and conrod
assembly.
- Remove the timing chain and notice its
direction of rotation.

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 CRANKCASE

„ Checking the crankshaft and conrod

assembly
- Using a set of shims, check the big end side
play.
- The maximum side play on the conrod end
must not exceed: 0.55 mm.

The out-of-round values measured on the ends

of the crank should not exceed 0.1 mm and must
be measured:
- 80 mm from the transmission side end.
- 40 mm from the flywheel magneto end.

8090mm
mm 60 mm
40 mm

„ Replacing the lip seal

- Remove the lip seal.
- Using fitting tool P/N 757990, fit a new lightly
greased gasket (1).
757990

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 CRANKCASE

„ Fitting the conrod and crankshaft

assembly
- Position the LH casing horizontally.
- Fit the timing chain (2) through the timing well. 2

- Fit the conrod and crankshaft assembly into

the LH crankcase.

- Fit the 2 guiding bushes (3) to the LH casing

and a new paper gasket (4), do not use oil or
grease.
- Place the RH casing over the LH casing
assembly.

3
4

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 CRANKCASE

- Fit and tighten the 2 clamping bolts.

Tightening torque: 12 Nm.

A
- Trim the casing gasket in (A).

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 P/N MA0020GB

In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress,
modify, or add any reference mentioned.
DC/APV 06/2010 (non contractual pictures)

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