i TABLE OF CONTENTS SIFICATIONS AND METRIC ADJUSTHENTS, PLATE CLUTCH......... 'Y : VARIALE TRANSMISSION KITH OSCILLATING BLOCKS... AND REPLACENENT OF THE ENGINE... LY, RE-ASSENBLY, AND ADJUSTMENT OF FLYWHEEL MAGNETO. ... -ING-ADJUSTMENT-REASSEMBLY OF CLUTCH. ....cececsseeeseeees LING AND REASSEMBLY OF CLUTCH WITH E TRANSMISSION... INTLING AND REASSEMBLY ON THE VEHICULE OF THE ING GASKET ON THE CLUTCH SIDE......- ee WNTLING AND REASSEMBLY OF THE CYLINDER HEAD AND CYLINDER. ING AND REASSEMBLY OF THE PISTON.. NISHANTLING AND REASSEMBLY OF THE FLAP VALVE SYSTEM. . [DISASSEMBLY OF THE CRANKCASE. REMOVAL OF THE CRANKSHAFT ASSENBLY. REMOVAL AND REFITTING OF CRANKSHAFT BEARING. FITTING OF THE CRANKSHAFT INTO THE LEFT HAND CRANKCASE..... FITTING OF THE RIGHT HAND CRANKCASE ONTO THE CRANKSHAFT AND THE LEFT HAND CRANKCASE ASSEMBLY... ‘CARBURETOR, INSTRUCTIONS FOR USING FUEL TANK SEALANT (REF. 69155) TO PLUG SMALL LEAKS IN THE FUEL TANK. ar a a 32 2 3 6 39 Er 42MAIN TECHNICAL DATA ~ 2 stroke engine with flap valve and Bore and stroke Cubic capacity Compression ratio Ignition advance Prinary transmission Fuel consumption Tank capacity Driving pulley Spark pug 40 x 39 pm 49 cc 8,4 to 1OLS REQUIRED DESCRIPTION Deconpressor pin rivetting tool 1,5. mm feeler gauge Test light for setting contact points and continuity of wires (PEUSEOTEST) Clutch drum holding strap Toal for mounting and renaving wrist. pin 10 mm socket 16 mn socket 17 wm socket 21 mm socket Shap. ring pliers Crankshaft extractor Crankshaft end protector (for the crankshaft extractor 69097) Torque handle for extended nut (installing crankshaft} Extended nut attachsent for installation of crankshaft 10m4100 Extended nut attachment for installation of crankshaft 1imm¥100 LH. crankcase guide Lo crankcase drift LH! crankcase seal ring guide sleeve RH. crankcase base crankcase guide for the oi] seal crankcase guide sleeve crankease drift crankcase guide for the bearing Lever spacer for #R and R the crankshaft at the proper angle Cutaway clutch drum for testing lining clearance Clutch assenbling stand for testing lining clearance Knurled nut for holding clutch assembly in place while removing the pulley assenbly Tapered sleeve for resetting the crankshaft into the clutch side of the crankcase without damaging the seal Special grease for clutch balls Base for halding oi] seal sleove - 69110 in place while replacing ofl seal on clutch side from outside of crankcase 32 mm socket : Gas tank sealant (to repair smal] leaks - 103) Flywheel magneto extractor Bench mounted engine support Wrist pin centering tocl for installation of pin Ignition advance timing tool Driving pulley holding tool for *R and R the variator holding nut Engine support spring compressor rod Rotor holding wrench for*R and R flywheel magneto Torque wrench with reducer and lengthener *R and R means renove and replaceDRQUE SPECIFICATIONS & METRIC ADJUSTMENTS: Nuts which must. be tightened to a specific ‘orque are outlined in black.) IGNITION ADVANCE leoeee,AUTOMATIC CLUTCH Large Diameter Belt Position [Small Diometer Belt Position {High Gear) | (low Gear)m system has the following two wain pares + ting clutch + ing of 2 cranking shoos primary (A) which attach to the driving y (B). Duc to the contrifugal force, these shoes transmit motion to juteh drum (C) vhich ia rigidly locked with the crankshaft. omatic plate-eluteh + ing of a drum (D) which bears 6 valle, a pressure plate (®), and {ning (F). The lining (F) ia notched #0 it is rigidly locked with the 4g bulley (B). f starting eluteh and automatic plate eturen sets pedaling action first transfers motion to the cear wheel through ide erankgear chain. Av the rear vheel turns, the attached drive frankTers motion to the large, intermediate pulley and finally to the elutch by a ¥ belt to the drive pulley. ys the apeed reaches B km per hour (about 5 mph), the starting cluteh ‘and turns the engine ever to produce ignition amd engine start. engine se running, it apeed can be controled and increased vith ottle. When engine Speed and centrifugal foree increase, the steel An the automatic plate clutch are forced outwards from the conter. Bo- S the pall drum (D) i a fixed support, the oulward movonent of tha stool forcexpreasure plate (E) against the lining (FJ, which contacts and is by drua (C). The lining (F), which is thus rigidly locked with both escure plate (£) and the drua (C), transfers motion to the pulley by bf its notches. Engine pover is thereatter transmitted to the rear over the palley belt and drive chaine PULLEY VARTADLE TRANSHISSTON WITH OSCILLATING BLCCKS ‘ive pulley is basically composed of 2 oneiilating blocks (V) which ful- the following two functions + Displacement of the movable plate (W) by contrifugal force. “Rotary drive of the movable plate, without frictions tomatic tension on the pulley belt ix obtained by @ compression spring Pushes the engine towards the frant of the vehicle. The displacement she movable plate (W) forces the belt to mave up the drive pulley fran the ff the groove to the outside. ton S begin with, when endine ape isfactory acceleration. dis lew, the drive ratte is high and allows Ghett ie at the bottom of the oroove in the variable drive pulley. leh engine speed increases, centrifugal force acts on the blocks (¥) and Rakes thes pivot around their axes (i). The blocks push the movable plato (¥) nward, thus foreing the belt ta rice towards the edge ef the drive pulley © a position of balance between engine power (RPM) and the resistance of theREMOVAL AND REPLACEMENT OF TH ENGINE. Tools required = One B me ocket wrench = One engine support spring compressor rod 69260 = One pin #945 = One torque wrench 69802 = One 17 mm socket 69084 = One 11 ma socket vreneh = Sereviriver = One 37 mm socket wrench Removal of the engine Proceed as follows for removal of the engine 4.= Resove engine fairinas. 2 = Hemove belt protector and the decompressor cable, by unscrewing the cabin orip. 3 = Undo the locking bolt of the earburator collar rings 4 = Remove carhurater fron coupling, drawing it towards the rear of the vehicles 5 - Unhook the magneto wires and remove apark plug lead fron ita clan 6 = Konove flywheel cover and turh eight Pedal crank towards the rear of the vehicl 7- Insert tool 69260 between the rator ‘the crank sprocket wheel (woe Hust 8 - Push down on the right pedal evank so the rear of the vehicle, then remove | 9 = Perform the opposite movement ta 1p” front, so as to slacken the engine support 10 ~ Remove tho earing compressing Fad, 69260, 41 Unserow alternately the support plate fish 1y slacken off the compressing springs 12 - Remove spring 13 = Undo and resove engine connecting bolt by pushing {t eut with a 9,5 red to prevont the suspension arm fron drempings ; 44 = Now pull the pin back out slowly to release the engine, When the engine is loose thon push the pin back through to hold arm im plaee again. (See itustracion) « Remounting engine on frame Reverse the instructions qiven far removal. = Tighten the engine mounting shaft belt with the torque wrench 69802 fittoa Nith the reaucer and the 17 an secket no. 69004 (torque load 2,3 m/kg — 18 ft/Tbs.) We advise you paint the end of the bolt after torquing so you know It has been done and not tapered with. Placing the engine on support unit 69255 ‘The figure shows an engine support unit which is very handy and can be used for all our moped engines. ‘The engine is mounted on a rotating shaft and can he tecked in any of four Positions. All parts bocoms ensily accessible this way. This engine support is supplied by our apare parts departaent under part no. 69255. To place engine on the support, use a threaded rod, § 8 ma, length 110 am ‘front bicycle wheel axle) and’2 no. 45465 shouldered washers to protect the support race.oa > RE-ASSEMBLING, AND ADJUSTMENT OF THE FLYWHEEL WAGNETO pe wrench = One ignition edvance timing too) 69253 holding lever 69546 ~ One 245 mm feeler gauge Spanner = One torque wrench 69902 spanner = Gne 16 am socket 69083 f magneto extractor 69254 One PEUGEOTEST 68457 of the rotor : off the magneto flywheel cover the nut at the end of the crankshaft using a 16 mm socket wrench while jlizing the rotor with the holding lever 69648 (see i1lustration) the flywheel magneto extractor body into the rotor ‘the thrust bolt of the extractor 69254 into the body until it bottoms lof the stator : jcren the two cylindrical head Screws off the stator ly of the stator : ‘the ststor in position on the crankcase, making sure the spark plug lead is inted in the area of the carburator in the two fixing screws with a lock-washer under the head of each screw.a fae Timing of the ignition advance = Screw the tenttion advance tinting tool 69258 inta the spark plug hole. (see fig.) = Screw in the locking screw of the upper sliding rod, but do not tighten it: ~ Find the top dead center of the piston by rotating the clutch drum (C) in ‘the direction of normal engine operation (see the arrow on the rotor). = Tighten the screw firmly in order to lock the upper highest point. = Rotate the clutch drum {C) slightly in the oppos: engine operation in order to Tet the Tower 1f Insert a 1,5 mn feeler gauge between the tinue to rotate the drum (C) slowly in the d ‘operation until there is no gap ‘gauge. Without moving the crankshaft, mork *2" matches the timing mark Set the rotor in place and tighten the rotor holding lever 69646 and the torque 16 mm socket No 69083 (the applied torque (see fig.) echeck the timing to make sure the rotor was Adjustment. of the breaker ~ hoe tug grocers ro corilased vite nork "1" so that they face each other. Loosen the = Insert a screwdriver between the adjusting notches and actuate them untfl the breaker points just stert to open in that position (use the device 68457 to check this operation). The 14 will go off as fig.) then tighten the breaker points holding- Screw : Very important When the timing adjustment fs accurate, the maxinun gap between the breaker points is about 4/10 mm {0.4 mm). Nevertheless, that gap can vary from 3/10 te 5/10 fn without any problen. bo not adjust ihe gap between the breaker points to a definite width. The efficiency of the flywheel magneto does not Gepend on the gap width itself, but upon the precision of the breaker points opening &t the very monent the rotor and stator marks face each ather.ath NTLING ~ ADJUSTMENT - REASSEMBLING OF CLUTCH oo1s required ‘Dne 17 rm socket, wrench ‘One torque wrench 69802 ‘One 17 mm socket 69084 Plate strap 68460 Knurled holding nut 69142 ‘She 8 mm spanner One clutch assenbling shaft 69141 A set of feeler gauges One support disc 69140 Special grease 69145 itling of the clutch without variable speed transmission unit ‘Loosen the nut at the end of the shaft (clockwise thread) using a 17 mm Socket wrench or torque wrench S9@02 with the reducer and the 17 mn socket 89084, while holding the crun (C) with the drum holding strap 69860 (see fig.) in dismantling the clutch on the complete moped, place the tube of drum p 68460 50 that it leans on the front fender stay. + torque wrench 69802 may be used for the tightening and loosening ‘operations. Remove the nut (6) and the washers (P) and (H) rew on to the end of the shaft the knurled holding nut 69142. ove the drive pulley (B). ve as a single unit the pressure plate (E), the ball drum (D) end balls (see fig.) went the balls from stIpping away, proceed as follows : Hold the untt with one hand and with the other, umscrew the knurled holding 69142, remove the spacer (I), the washer (K), and take the assembly (see Fig.) in the following order lining (F) spring (L) adjusting washer (M) drum (C) washer (N) (Mark the plate on the drum side so that you do not reverse it when re-assenbling the unit.) of the clutch shoes placing the driving pulley assembly on a bench : and unscrew the nuts attaching the locking ring (0), remove the ck-Nashers, and remove the locking ring. ook the retracting springs fron the studs of the shoes. Oo not forget mark the way they were hooked on (1st or 2nd stud). the shoes off (see fig.) of the clutch shoes the Terge hook of the retracting spring inside the articulation ‘Ning on one of the shoes, Then position this assembly on the anchor the retracting spring onto the Ist shoe stud for Mopeds without variable d unit, or onto the 2nd stud for Mopeds with variable speed unit. When ‘springs are in the right position, the apen sida of thety hooks must ‘turned towards the center of the plate. it the locking ring (0). ‘two 5 mm nuts have to be tightened in such a nner as to bring one of Fr flanks parallel to the outer edge of the 1i ing locking stops (F).245 = Clutch adjustment In case the clutch works badly, either by stioping or arabbing too sharply. sake sure thet the pulley slides freely on the crankshaft (axial clesrance about 4/10 to 6/10 mm), then check the clearance between the lining (F) and the pressure plate (E). This check should be made as follows + Place the clutch assembling shaft 69141 vertically in the jaws of a vise and as- semble in the following order = = the washer (N) ~ the adjusting plate 69140 = the adjusting washer (M) = the spring (L) = the Hinting (F) = the pressure plate (E) = the balls = the drum (D) = the washor (K) = the spacer (1) = the nut (6) Firmly tighten the assenbly using the torque wrench 69802 with the reducer and the 17 mm socket 69884, the applied torque being 4.0 m/kg or 30 ft/Ibs. Use 2 feeler gauge set to check the operating clearance between the lining (F) and the pressure plate (E). That clearance should measure between 6/10 and 8/10 mei (see fig.) If you find that the clearance fs greater or less than the amount permitted. replac ‘the adjusting washer (M) with another one whose thickness, when properly chosen, wi give the correct clearance. That adjus 1g washer can be supplied with the following thickness measures : 0,4 - 0,6 - 0,8 and tam, the part nunbers being respectively 45818, 45819, 45820 « 4521.-19- iting of the clutch to the shaft it the adjusting washer () fn ts position on the shaft, beveled edge facing crankcase. jsemble in the following order - The drum (C) and, immediately after, place the belt cover holders con- centric to the drum and tighten the two holding bolts. The adjusting washer (M) ‘The Spring (L) with the fingers up Then assemble on your bench : The drum (D) 6D 12 mm balls, slightly greased with special grease 69145 The pressure plate (E) with 2 indentations tn line with the oblong hole Turn this assenbly upside down on the lining (F) and, while holding the assembly, fit 1¢ on the shaft. placing the plates of the drum (0) correc- tly. Continue the assemoly as follows : For clutch without variable speed unit. washer (U) spacer (1) washer (J) yr clutch with variable speed unit washer (U) 2 spacers (1) on the end of the shaft the knurled holding nut 69142, put fixed plate ) Fitted with the shoes in position (see Fig.) ‘ion : Don't use excessive force when pulley reaches the bottom of the drum. Instead, rotate it in one direction or the other to allow the lugs of the lining (F) to drop into the notches of the coupling disc (0). Renave knurled holding aut 69142 st in place washers (P) and (H), screw up nut (6) and tighten 1t using the yrque wrench 69802 with the reducer and the sprocket 69084 (the applied que being 4,0 m/kg 30 ft/Lbs) (see fig.) while immobilizing the drum (C) jth holding strap 68460, n asserbling the clutch on the complete Moped, place the handle of the holding strap so that it rests under the front fender stay.2 soe DISMANTLING AND REASSEMBLY OF CLUTCH WITH VARIABLE TRANSMISSION Tools required : ~ Screwdriver One holding strap 68460 One knurled holding nut 69412 Driving pulley hud fixing tool 69259 = Torgue wrench 69802 = One 32 mm socket 69153 = One 32 mm socket wrench Dismantling of clutch and variable transmission = Undo and remove the 3 fixing screws (S) of the cap. = Unclamp the nut (8), using tool 68460 to hold the clutch drum (see Tig.) ~ Lift off nut (6), and screw knurled holding nut 68460 to the end of the crankshaft. = Remove the variable crive pulley (see fig.) = In order to dismantle the clutch and prevent the balls from escaping, support everything in one hand and unscrew the knurled holding nut 69142 with the other hand, and then remove the two spacers (I) (see fig.) Renove in this order : = The washer (U) ~ The support plate (0) = The plate (E) = The spring (L) = The washer (M) = The dise (F) = The drun (C) = The thrust washer (N) ae, OUD e F LM-2- “nylon spacers found at each end of the variable tronsmission iving pulley fixing tool 69259 into the barrel and position | the corresponding countersunk grooves. (see fig.) lat end of the tool in the vise. ining the washer locking tabs, unscrew the nut with a 32 am 1 (see fig.) Fixed pulley plate (8). movable plate (W). ary, remove the nylon drive piece with a levering movement, using iver. (see fig.) block (V), renove the shaft-clips and the shafts (R). we OR Xx OW Be? eee LM abila Ghis eassenbly of the variable transmission = Put drive ptece (X) into position in the movable plate (KH). ~ put blocks (V) into position on variable transmission plate (V)- = Insert shafts (R)s these being in opposite directions to hold the centrifuga? wetahts. = Set the clips on the shafts. = place the following parts on the variable transmission plate (¥), in this order + Movable plate (W) Fixed plate (8) The ted-washer (Z1) Locking nut (2) = Slide the driving pulley hub fixing tool 69259 into the barre? the side where the nut (Z) 4s to be found. = position the lugs of the tool in the corresponding countersunk grooves. = Grip the flat end of the tool in the vise. = Tighten the 32 em nut (Z) right-hand thread with the tongue, wrench 68502+ fitted Tanta Se wm socket 69153 (toraue Toad 5.0 to 6.0 m/kg, about 36 to 45 ft/Ibs) = Lock the 32 mm nut in place by resetting the tabs of the locking washer. = continue veassenbly in the correct order, placing on the barre] on the same side as the nut : = the nylon washer and on opposite side + = the external nylon washer (H). Remounting the drive pulley on the crankshaft with the clutch mounted on the crankshaft and tha knurled holding nut 69142 fittes Th place, remount the pulley (see fig.) caution : Do not use force when the pulley reaches the bottom of the drum. Tnsted oe ree the pulley in one direction or the other fo allow the Tugs of th, Tining (F) £0 drop into the notches of the coupling (0) = Withdraw holding nut 69142. « Serew up nut (6) to the correct tightness by using the toraue wrench, 69802 With Sere a ot sca) the Zl mm socket 68085, with 2 torque load of 4,0 m/kg - 30 ¢t/ {te Teducer tines inmobilize the drum (c) with holding strap 68460 (see fi9-)-— tes ING AND REASSEMBLY ON THE VEHICLE OF THE SEALING GASKET ON THE CLUTCH required river ring t001 69151 red Sleeve for setting seal on crankshaft 69143 i, crankcase guide sleeve 69110 J. crankcase drift 69109 1 of the sealing gasket ve drive pulley the 2 fixing screws of the sealing gasket stop plate (see fig.) we the defective gasket with a screwdriver (see fig.) jon of sealing gasket ‘the following items on the housing in the following order = Gentering tool 69151, the B 35 centering tool directed against the housing Tapered Sleeve 69143 with large part of sleeve first LH. crankease guide sleeve 69110, with the greased sealing gasket: inside, Tips towards the engine L.H. crankcase drift 69109 ih the sen ing gasket home into its seating place the sealing gasket stop plate (see fig.) ING AND REASSEMBLY OF THE CYLINDER HEAD AND CYLINDER required ine support spring yressor rod 69260 10 mm socket wrench Het (plostic or rubber) Wooden wedge One 19 am Wrench Torque wrench 69602 One 10 mm socket 69079 {you perform this operation on the vehicle t spring compressor rod 69260 between the rotor locking nut and the teeth ‘the crank sprocket-wheel (see Fig.) the right pedal-crank in order to tip the engine towards the rear of the ete. the 4 bolts holding the cylinder head, taking then in a crosswise pattern to any distortion. (Use the 10 mm socket wrench). Remave the washers. Lift off linder head and its gasket. the silencer. Off the cylinder. 1f it 1s stuck, put the piston to the bottor neutral posi- and tap gently on the exhaust outlet with a rubber mallet (do not touch the s, these are extremely fragile). the gasket. sl of the decompressor valve ten the cylinder head using two bolts in a vise ip off the end of the deconpressor pivat pin, then compress the spring end re~ the pin ut the valye fert 2 screwdriver into the hairpin spring and open it unt] it can be slipped yr the head of the deccmpressor body screw the body of the deconpressor with a 19 mm Socket wrench.28 - Reassenbly of the decompressor CAUTION : the tightness of the valve has a vital effect on engine ope~ ration, Check the valve seat and the valve thoroughly before refitting the valve If the valve face shows any kind of defect, do not hesitate to replace the complete decompressor unit. Nake sure that the copper gasket fs fitted in place. Mount the cylinder head in a vise by means of two bolts. = Tighten the decompressor bady tightly on the cylinder head using @ 19 wn socket wrench. = Insert the valve stem into the deconpressor body. = Put the valve spring in place. = Put in the pivot pin and secure it by flattening its end. If this pin cones 00se, the valve will fall into the cylinder and damage it, pos- Sibly causing an accident. if the engine seizes (use the decompressor pin riveting tool n® 68045). Fitting of the cylinder. In order to make this operation easy, we recommend that you use the wooden shim (see fig.) = Clean the mounting surface and cut the projecting part of the gasket. - Make sure that the gasket and its seal are completely dry. = Set the piston down to rest on the wooden shim, IMPORTANT : Make sure that the gaps of the piston ring are accurately fa~ cing the stops which are located in the grooves of the piston. Push the cylinder, well down aver the piston dy hand only. Do not use any hammer. Renove the wooden tool and push the cylin- der down until it is completely bottomed. CAUTION : Make sure the rings are compressing as the cylinder slides ‘over the piston, Fitting of the cylinder heed. = Replace the head gasket. Make sure you put it in its correct position. The hole provided in the top of the cylinder to let out the decompressor gases must match the hole in the gasket. = Install the cylinder head, positioning it with the same care a5 the gas~ ket. ~ Place the washers with the serrations up, and the nuts which mist be screed in and securely tightened crosswise, using the torque wrench 69802 with the reducer and the 10 mm socket 69079 (torque Toad 1,1m/kg or 8 ft/Ibs). (See fig.)Pe too] for mounting and removing wrist pin 68467. ‘Dne centering pin for replacing wrist pin 69256 ‘Snap ring pliers 69092. a1 of the piston ERanove the two wrist pin circlips using the sap ring pliers 69002 {see 113.) Altgn the piston rings with the stops in the grooves to keep from breaking then. You should not remove the piston rings. Drive out the wrist pin using the wrist pin too] 68467 but don't drive it out completely (see fig.) Remove the neadle bearing race with care. Check the piston ring gap. It should not exceed a maximum of 3/10 mm. Position the piston rings in the cylinder bore and check the gap with a fooler gauge. If necessary, clean out the wrist pin circlip grooves. Place in the piston inside the wrist pin too) 68467 (raking sure rings are in line with the stops). insert the wrist pin in its bore unti1 it fs flush with the inner bossing.. Dip the needle bearing race in light oil. Then, fit it into the connec- ting rod bore. Position the wrist pin tool 68467 with the piston over the connecting tod, the reference letter being directed towards the exhaust port. Insert the wrist pin centering tool 69256 through the needle bearing race into the wrist pin hole for positioning in the center af the needle bearing (see fig.) = Push the pin in 3/4 of its length. Then. remove the wrist pin centering tool 69256. = Push the wrist pin close to the groove of the circlip. = Renove the wrist pin tool 68467 and put on the clips (pliers 69092), Nake sure the clips are well inside the grooves. = Nount the rings on the piston if this is a new piston.-3- DISHANTLING AND REASSEMBLY OF THE VALVE SYSTEN Tool required : = Gne 8 wm socket wrench Dismantling of the flap valve system, = Undo the 4 nuts holding the carburetor intake manifold (8 mm socket wrench) = Remove in this order + I= the Tockwashers, 2 the intake manifold 3- the first gasket 4- the flap val! S= the second gasket Precaution to be taken for the flap valve assembly : do not bend the 2 ‘thrust prongs on the flap valve (see fig.) sembly Reassenbly of valve syste = Before replacing the flap valve, check the thrust prongs to make sure they have not been bent or buckled. If necessary, correct their opening, which should be 5,5 am, This measurement must never be altered. = Assenble, in this order : (see flg.) 1 the first gasket 2 the flap valve assembly 3 the second gasket a the intake manifold 5 the @ lockwashers and 4 nuts DISASSEMBLY OF THE CRANKCASES REMOVAL OF THE CRANKSHAFT ASSEMBLY AND BEARINGS REASSEMBLY Tools required + = One 10 mm spanner = One L.ll. crankcase drift 69109 > One Teveler ring for setting + One RIA. crankease guide 69112 tthe crankshaft 69137 = One crankshart extractor 69097 ~ One RH. crankease guide base = One crankease end pratector 69121 69098 (for crankshaft extracto) = One RH. seal ring guide sleeve = One L.A. crankcase guide 69108 6a110 = Gne UA. crankcase of] seal = One RH, crankcase drift 69114 guide sieeve 69110 he #2H- crankcase bearing gue 59115 Disassembly of the crankcase + = Unscrew the nuts holding the crankeases.using a 10 nm wrench. = Take out the bolts. = Pull the crankeases out from the engine support bracket which wiTT renain fixed to the engine support stand 69225 (see fig.) ao Flywheel tiagneto side or the right hand crankcase : see fig. 1+ the filler ring 69137, using the 48 mn @ part of the ring. (nake sure it sits solid against the crankcase). a. {hereranshaft extractor 69097, tightened well by means of 2 bolts (9 5m, | = 35 mn) set in the two stator fixing holes. 3- the crankshaft end protector 69098, = Take the motor unit in your left hand by gripping the cylinder head studs. Tighten down the puller bolt until the crankcase comes off the crankshaft completely.moval of the crankshaft assenb, gasket. f the Fil}er ring 69137 into position against ‘the crankshaft extractor 69097 in place and ts correctly. (see fig.) 6mm, L = 70mm) into 2 of the crankcase holes with ‘Ttonards the crankcase surface and tighten softly. sft end protector 69098 and tighten the extractor he crankcase is completely off the crankshaft. ‘ing of bearing ase down on its mounting surface. se until the bearing falls out by itself and continue jt 15 seconds so the refitting of the new bearing may ished with only 1 heating process. ring and oi] seal into the left hand crankcase. case is not already hot fron the renovel of bearing, then it the crankcase-half to bring it to a temperature of 80 5 C (176 to 196 degrees F). crankcase on the L.H. crankcase guide 69108 with the crank= ber pointed upwards (see fig.) ‘ofl Seal L.H. crankcase guide sleeve 69110 into the bearing knurled part must project out of the crankcase). previously greased ef] sea1 onto the L.H. crankcase guide while the spring is turned upward, then drive the seal in with ‘Of the LH. crankshaft drift 69109 (using the small dianeter ‘the of] seal quide sleeve 69110 and the driver. washer into position. ‘the bearing onto the L.i. crankcase quide 69108, then drive it 'with the aid of the L.H. crankcase drift 69109 (using the large ter end). (see fig.)36 - Fitting the bearing and oi1 seal into the right hand eranica: = Heat the R.R. erankease to bring it toa temperature of 80 to 90 degrees © (176 to 194 degrees F). guide 69112 (9 = 16 mm) into the ouide i = Place the Rell crankoas 69111 (see Tig.) = Pot the erankease on the tool with the crankshaft chamber turned upwards. = Put the felt weal inte the crankcase. = Pit the oil seal guide sleeve 69113 into the bearing bore (tne knur— led part projecting out of the crankcase). = Slide the previously greased oil seal onto the Rill crankcase guide 69112 (while the spring is turned upwards). = Drive the seal in with the aid of the Rel. crankease drift 69114, using the small diameter end. = Remove the drift 69414 and the oil seal guide 69113. = Without taking the crankcase off the Rul. erankease guide 69111, pull the gaide piece 69112 (# 16 mm) upwards, and replace it by the LH. crankcase guide 69115 (f = 17 by 16 mm), aliding the latter through the oil seal (see fig.) = Put the bearing thrust washer inte poxition in the erankea = Slide the bearing onto the guide piece 69115 and drive it in with the aid of the R.H. crankcase drift 69114, using the large diameter end.45636 . 6 FT/LBs.0,.9 Mkg-39- CRANKSHAFT INTO THE LEFT HAND CRANKCASE jing the seal, place the tapered sleeve 69143, what making = solid cone (see figs) ‘the shaft onto the bearing. fe 9 ring of the £) Asolid fit. ler ring 69137 on the cranke Bxtandeds nut 69106 onto the snaft. Set in place the crank- ctor 69097. on the torque handle 69104 until the érankshaft bottoms in fe (make aure the face of the crankcase is half way acrose ‘ting red). THE RIGHT HAND CRANKCASE ONTO CRANKSHAFT AND THE LEFT HAND b ASSEMBLY crankcase gasket in position. the shaft onto the pearina. Alitate the asscabling, tomporarily place-the rectified volt 636 as voll as the teo other volts (A) in position. {see figs) be 48 um f ring of tho filler ring 69137 on the crankease,making Ht is a solid rit. the extended nut 69105 onto the crankshaft end. Position the iat extractor 69097 and werev down the torque handle 69104 un- ‘the crankshaft bottoms in the crankease. oubling bolts starting with rectified bolt 45636. De not get the two belt-protector fixing brackets and position the lock FB on the fixing bolts of the engine suppert bracket only. Tigh- up at! bolts except the two bolts holding the belt protectar Mot forget to turn the crankshaft to be sure its motion is quite If necessary, put the crankshaft in position by tapping light= Fwith a hasmer on one end of the shaft or ihe others torque loads are in be kets + For bolt heads marked "68" torque ead 1 0,9 m/ky - 6 ft/tbe For belt heads warked "BB" torque lead t 1,2 m/kg - 9 £t/Tbe=40- CARBURATOR Description : see your spare parts catalogue The Gurtner carburator is set before it leaves the factory, and only the adjustrent of its "idle" can be modified. However, this adjustment is imortant because maintaining the correct idle speed allows the engine to Hun while the vehicle is stationery and insures smooth acceleration from a simple movement of the throttle control. Make this carburator ad~ ustnent when the engine is warm by tteans of the “silver screw to be found on the right-hand side of the carburator. ‘Adjustment. = = Remove the engine fairings. = Start the engine (vehicle on stand). = Put the throttle control to a “closed” position. = Completely close the adjusting screw. = lthen the engine is warm, slowly loosen the adjusting screw to reduce the engine speed as much as possible so that the rear wheel does not turn. = linen the running speed is slow enough, put the vehicle on its wheels and sit on the seat, The engine should not stall when the rear wheel 4s grounded in this manner.~ ke = INSTRUCTIONS FOR USING FUEL TANK SEALANT (REF. 69458) ‘TO PLUG SMALL LEAKS IN THE FUEL TANK 1) Find the leak and mark the exact spot on the frame or tank where it is visible with chalk. 2) Disconnect the fuel line leading from the fuel valve to the carburator. 3) In order to drain the tank completely, tip the Moped over on its fuel valve side (ert). 4) Use comprensed air to blew tha interior of tha fuel tank completely ary.) 5) In order to remove all excess grease and oil from the inside walls of the fuel tank, close the fuel valve, pour 1 liter (one quart) of trichlerethylene into the tank, replace the fuel tank cap, chake the Moped vigorously for one te two minut 4) After degreasing, pour the trichlorethyleae solution inte a sterable container. You will be able to reuse this solution in other cleaning operations. 7) Remove the fuel valve. Biles occas Nc Gyfin 20K Om oh tank cinta atin Tatts. one 9) Position the Moped so that the leak point is lover than any other part of the fuel tank. This position will allow the sealant to accumulate at the point of the losk. Then pour the contents of the wall bottle of sealant (rét, 69158 + 30 oc) inte tho tank. (Tf the Moped is posi- tioned correctly, all of the sealant will settle at the leak point). 10) Leave the Moped in the same position and allow the 48 hours. ant to dry for 14) After drying, reattach the fuel valve and fill the tank with your fuel mixture. 12) After the tank has beon filled with fuel, let the Meped sit for a cou- ple of hours, then examine the tank carefully to make sure that the loak has been completely gual NOTE : The sealant should be stored in a cool place. If you find the 1i~ quid partially evaporated upon opening the bottls, the sealant ia no longer effective and should be discarded. The shelf life of «bottle of sealant is about 6 months.