PEUGEOT Ludix 4T Workshop Manual
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PEUGEOT Ludix 4T Workshop Manual

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Sales division
Technical network leadership
WORKSHOP MANUAL
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Summary of Contents for PEUGEOT Ludix 4T

  • Page 1 Sales division Technical network leadership WORKSHOP MANUAL...

  • Page 3: Table Of Contents

    Removal of the rear shield panel ......................16 Removal of the footboard.........................17 Removal of the under body panel ......................17 Removal of the fuel tank ..........................18 Removal of handlebar fairing ........................19 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 4 Checking the high tension coil .........................41 Vacuum-operated cock ..........................42 FUEL SYSTEM ..............................43 Removal of the carburettor........................43 The carburettor and its components ......................49 POWER UNIT ..............................50 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 5: Products Danger Symbols Used

    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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 6 Indicate the specific procedures that shall New part Use a new part. be followed in order not to damage the vehicle. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 7: Characteristics

    5.3 l Chassis Chassis Tubular chassis Upside down telescopic front fork Front suspension Travel: 73 mm Combined spring and hydraulically-damped shock absorber Rear suspension Travel: 65 mm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 8: Dimensions And Weight

    Single-cam drum type, controlled by cable Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking (1) number and manufacturer's plate Engine number (2) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Service Schedule And Commissioning

    Overall operation. Road test V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Service Operations

    (0.5 h = 30 mn) V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. * Depending on equipment. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 11: Battery Preparation (Except Battery Without Maintenance)

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

  • Page 12: Special Important Points

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

  • Page 13: Tightening Torques

    50 Nm Turbine 10 Nm Stator 10 Nm Engine speed sensor 10 Nm Drive pulley 55 Nm Driven pulley 55 Nm Clutch plate and shoes 55 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 14: Body Panels

    6 Nm Nut and bolt 6 mm diameter 10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Special Tools

    Adjustable pin 752237 757860 Steering tool wrench 39 mm pipe Steeing head 752361 759788 wrench cup push tool Spark plug 755996 766062 spanner Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Standard Tools

    Type: Facom R.306A25 Type: Facom S.208A200 Automatic resetting type torque wrench Inertia extraction tool and 10 to 50 Nm sockets with internal grip Type: Facom J.208A50 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Location Of Components

    8. Switch "Reserve" 3. Magneto flywheel 9. Horn 4. Fuse 10. Starter resistor 5. HT coil 11. Resistor warming carburator 6. Regulator 12. Temperature control unit Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Body Panels

    - Remove the 3 screws (B) that secure the rear shield panel. - Unclip the rear shield panel from the footboard (C). - Remove the rear shield panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Removal Of The Footboard

    - Remove the footboard (2 screws) (F). Removal of the under body panel - Remove the footboard. See: Procedure 3 page 17. - Unclip the under body panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Removal Of The Fuel Tank

    - Lift the fuel tank (1 nuts) (C). - Disconnect the fuel gauge (D). - Disconnect the vacuum hose (E). - Disconnect the fuel supply hose (F). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 21: Removal Of Handlebar Fairing

    BODY PANELS Removal of handlebar fairing Procedure 5. - Remove the handlebar front cover (4 screw) (A). - Remove the rear handlebar fairing (3 screw) (B). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Service Operations

    • Filler cap: 20 Nm. • Screen: 15 Nm. - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.65 l. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 23: Draining The Relay Box

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.09 l. - Fit the filler cap (1). Tightening torque: 10 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Replacing The Air Filter

    Check the condition of the seals and make sure they are properly positioned. - Remove the inlet silencer drain plug to let humidity and oil drip out (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Removal Of The Spark Plug

    - Hold the fixed flange with tool P/N 752237. - Remove the fixed flange nut and washer. - Remove the fixed flange. Tightening torque: 55 Nm. 752237 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 26 6 bearings (4). - The bearings must be changed if they show major signs of wear. - The guides shall be replaced if they show signs of wear. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 27 Mini. thickness: 2 mm. - Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 28 Tightening torque: 55 Nm. 752127 - Slacken tool P/N 752127. - Remove the clutch lining assembly (2). - When re-installing the driven pulley, lubricate the needle bearing (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 29: Installing 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Idle Setting

    - 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Replacing The Brake Pads

    B. Minimum level. - Remove the cover and the diaphragm from the master cylinder (2 screws). - Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 32: Rear Brake Linings

    Tightening torque: 20 Nm. - Remove the 2 screws that secure the muffler. Tightening torque: 15 Nm. - Remove the exhaust assembly. Use a new exhaust gasket. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 33 - Install the spring (7). - Install the brake control cable, the barrel and the adjusting nut (4). - Refit the other items in the reverse order to disassembly. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 34 - 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 35: Miscellaneous Operations

    757860 • The brake washer. • The nut. • The rubber washer. • the adjustable cone. - Remove the fork. - Remove the caged ball bearings. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 36 - Using a drift, remove the steering head cups. - Using a drift, remove the steering headset cone. Reassembly • Fit a new steering head cone (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 37: Steering System Tightening Method

    Steering system tightening method - Install the adjustable cone and tighten it (5). Tightening torque: 40 Nm. - Loosen and then retighten the adjustable cone. Tightening torque: 23 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 38: Wheel Bearing Replacement

    - Use a drift driver to fit the second bearing. Use new bearings when refitting. Fit the bearings, pressing against the outer cage. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 39: Electricity

    2. Battery 8. Temperature control unit 3. CDI unit 9. Choke 4. Spark plug socket 10. Magneto flywheel 5. Spark plug 11. Regulator 6. HT coil Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 40: Checking The Ignition System

    Ignition off: U=0V HT coil: R=0.2 Ω ±20% Primary Yellow/black and Green Secondary High tension wire and Gren ±20% R=3 KΩ ±20% Spark plug socket R=5 KΩ Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 41: Checking The Carburettor Heating Circuit

    Resistor warming carburator To the ground Black Ignition on: U=12V Battery positive power To the ground Ignition off: U=0V The engine is running: Regulated alternating current Yellow U=13.5V Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 42: Regulator/Starter Motor Relay/Ignition Unit/Starter Resistor/Ht Coil

    Apply a voltage of 12 V to the A motor relay. R=0 Ω terminls on the relay. Between terminals B The relay must trip. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 43: Checking The Starter Resistance

    Standard values Between terminals R=0.2 Ω ±20% Disconnect the high voltage A and B coil. Between terminals Disconnect the suppressor. ±20% R=3 kΩ B and C Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 44: Vacuum-Operated Cock

    A. Full fuel tank: ∞ Ω. B. Empty fuel tank: 0 Ω. Ω When refitting, position the vacuum- operated cock as shown Check the condition of the O-ring. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 45: Fuel System

    Removal of the choke - Remove the choke cap. - Remove the screw and the holder plate. - Locate the position of the choke (1) and then remove it. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 46 - Remove the needle stop (1). - Remove the spring (2). - Remove the needle (3). The height oif the needle is factory set and cannot be modified. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 47 - Remove the float (3), its pin (4) and the needle valve (5). - Remove the idle jet (6). - Remove the main jet (7). - Remove the needle well (8). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 48 - Remove the bushing (1) and the protective rubber (2). Check the condition of the bushing and the rubber protection. - Remove the piston (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 49 Check the condition of the O-ring. Removal of the carburetor heater - Remove the carburator warming resistor (1). - Remove the heater earthing connection (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 50 - When refitting the carburettor, adjust the throttle tensioner to obtain a clearance on the handlebar of: A. 4 to 6 mm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 51: The Carburettor And Its Components

    4. Float. 12. Pick-up pump suction valve. 5. Idle jet. 13. Deceleration enrichment device. 6. Main jet. 14. Carburetor heater. 7. Needle well. 8. Needle valve. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 52: Power Unit

    • The throttle control (5). • The fuel inlet pipe (6). • The vacuum pressure hose (7) (Pulsair). • The vacuum pressure hose (8) (Petrol tap). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 53 Tightening torque: 45 Nm. - Lift the rear of the machine. - Remove the power propulsion unit from the frame. - Remove the covers from the power unit. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 56 P/N MA0027GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/APV Printed in the E.U. 11/2010 (non contractual pictures)

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