PEUGEOT Kisbee Workshop Manual
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PEUGEOT Kisbee Workshop Manual

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Sales division
Technical network leadership
WORKSHOP MANUAL
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Summary of Contents for PEUGEOT Kisbee

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

  • Page 3: Table Of Contents

    Oil and fuel...............................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 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 4 Removal of the fork ..........................44 Replacing the bearings of the steering system ..................44 Steering system tightening method......................46 Changing the front fork seals ........................48 The fork and its components........................48 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 5 Removal of the valves or valve stem seals ....................67 Fitting the cylinder head...........................68 Method for tightening the cylinder head ....................68 Setting the timing .............................69 Checking the timing ..........................70 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 6: 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 7 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 8: Characteristics

    0.035 l per tube (Hydraulic oil SAE 10W) Chassis Chassis Steel tube Hydraulic telescopic fork. Ø27 mm Front suspension Travel: 68 mm Combined spring and hydraulically-damped shock absorber Rear suspension Travel: 68 mm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Dimensions And Weight

    Front tyre 110/70 - 12 Front tyre pressure 1.6 bars Rear wheel rim 12 inch aluminium alloy Rear tyre 110/70 - 12 Rear tyre pressure 1.8 bars Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Brakes

    Brake drum diameter 110 mm Brake lining thickness 4 mm Chassis markings Engine marking Manufacturer's plate (1) Engine number (2) Chassis no. (3) Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 11: Service Schedule And Commissioning

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

  • Page 12: Service Operations

    Servicing time in tenths of an hour (0.5 h = 30 min) V: Check, clean, adjust. N: Clean. R: Change. C: Inspect and change if necessary. G: Check, clean, lubricate. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 13: 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 14: 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 15: Tightening Torques

    Saddle storage compartment 8 to 10 Nm Rear body panels 6 to 8 Nm Grab handle 20 to 25 Nm Rear mudguard 2 to 4 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Cycle Part

    10 Nm Nut and bolt 8 mm diameter 22 Nm Nut and bolt 10 mm diameter 35 Nm Nut and bolt 12 mm diameter 55 Nm Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Special Tools

    Lip seal push 752127 compression 756725 756668 tool tool Adjustable pin 38 mm pipe 752237 756725 752127 wrench wrench Steeing head 753726 757860 Steering tool cup push tool Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 18: Standard Tools

    Type: Facom R.306A25 Automatic resetting type torque Automatic resetting type torque wrench wrench 10 to 50 Nm 40 to 200 Nm Type: Facom S.208A200 Type: Facom J.208A50 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 19: Location Of Components

    11. Ignition sensor 4. Starter motor relay 12. Carburetor heater 5. Fuse 13. Carburettor heater thermo-switch 6. Flasher unit 14. Drive sensor 7. Starter resistor 8. Horn Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 20: Body Panels

    12. Mudflap 5. Front lower legshields 13. Saddle and storage compartment 6. Front mudguard 14. Rear body panels 7. Front wheel 15. Central panels 8. Mudguard Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 21: Body Component Sequence Of Disassembly

    6. Front mudguard 14. Grab handle 7. Front wheel 15. Rear body panels 8. Mudguard 16. Central panels * This item may be removed on its own. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Removal Of The Rear Storage Compartment

    - Remove the splash guard (6 screw). - Remove the grab handle (3 screw). - Remove the rear cover assembly (4 screw). - Disconnect the taillight. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 23: Removal Of The Rh Or Lh Central Cover Panel

    Procedure 2. page 20. - Remove the battery access door (1 screw). - Remove the complete footrest assembly (1 screw). - Remove the 5 screws from the central fairing. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 24: Removal Of The Instrument Cluster

    - Remove the instrument cluster (4 screw). Removal of the RH or LH under body panel Procedure 5. - Remove the 2 screws from the bottom panel. - Remove the bottom panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Removal Of The Front Top Shield Panel

    - Remove the handlebar front and rear covers. See: Procedure 4. page 22. - Remove the front upper shield panel. See: Procedure 6. page 23. - Remove the ingnition switch trim. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 26: Removal Of The Front Lower Shield Pannel

    See: Procedure 5. page 22. - Remove the 4 fastening screws from the mudguard (A). - Remove the 2 screws that secure the front shield panel (B). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Removal Of The Footboard

    - Remove the RH and LH under body panel. Procedure 5. page 22. - Remove the battery. - Remove the starter relay. - Remove the fuse holder. - Remove the footboard (4 screw). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Service Operations

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.8 l. - Start the engine and let it run for a short while. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 29: Draining The Relay Box

    - Pour the required quantity of oil corresponding to the manufacturer's standards into the filler hole. Quantity: 0.12 l. - Fit the filler cap (1). Tightening torque: 12 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 30: Removal Of The Spark Plug

    (a few turns) by hand. - Tighten the spark plug. Tightening torque: 18 Nm. Replacing the air filter - Remove the 6 screws from the air filter cover. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 31: Transmission

    - Remove the transmission sensor (2 screw). - Remove the transmission cover (9 screw). Tightening torque: 10 Nm. - Remove the paper gasket and the two 2 centering pins. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 32 - Lock the clutch drum with the pin wrench P/N 752237. - Remove the clutch drum and the clutch and drive pulley assembly. Tightening torque: 50 Nm. 752237 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 33 Checking the drive belt - Measure the width of the belt (A). Minimum width: 16.3 mm. - Make sure the belt is not cracked. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 34: Checking Clutch Linings

    - 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. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 35 - Fit the clutch drive pulley and driven pulley assembly. - Fit the clutch cover. - Fit and tighten the nut. Tightening torque: 50 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 36: Installing The Valve Clearance

    - Rotate the engine by hand in the operating direction in order to align the (A) mark on the pinion with the mark on the cylinder head. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 37: Idle Setting

    - Screw or unscrew the engine speed adjuster screw (1) to alter the idle speed. - The rear wheel should not turn. Idle speed: 1600 to 2000 rpm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 38: Removal Of The Fuel Filter

    A. Mini. thickness: 1.5 mm. A = 1.5mm Replacing the brake pads - Remove the calliper (2 screw). Tightening torque: 27-32 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 39: Checking The Brake Fluid Level

    (6 screw). See: Procedure 4. page 22. - Remove the cover and the diaphragm from the master cylinder (2 screw). - Add brake fluid until it reaches the maximum level. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 40: Rear Brake Linings

    Use a new exhaust gasket. - Remove the 2 screws fastening the mudguard. - Remove the 2 screws from the exhaust. Tightening torque: 20-25 Nm. - Remove the exhaust. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 41 Lubricate the brake cam spindle and fit it into the casing. - Fit the brake arm onto the cam and align the punched marks (A). Tightening torque: 8-11 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 42 - 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 43: Draining The Front Fork

    - Unscrew the 2 lower screws (3) from the fork Tee. - Remove the fork stanchions. - Remove the fork tube cap (1). - Remove the spring (4). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 44 - Insert the fork stanchions into the fork tee. - Fit and tighten the 4 clamping bolts. Tightening torque: 30-40 Nm. - Fit the front shield panel. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 45 - Fit the wheel spindle and tighten. Tightening torque: 50-60 Nm. When re-installing, use a new nut. - 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 46: Miscellaneous Operations

    • The nut. • The rubber washer. • The nut. • The dust cover. • The upper cone. - Remove the fork. - Remove the caged ball bearings. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 47 - Using a chisel, pry the steering head cup off by pressing the tool behind the dust cover. Reassembly - Install the following new parts: • The dust cover (1). • The fork cone (2). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 48: Steering System Tightening Method

    - Install the dust cover (6). - Fit and tighten the nut (7). Tightening torque: 38-42 Nm. - Loosen and re-tighten the nut. Tightening torque: 15-19 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 49 - Fit the lock washer (6) in the notches of the 2 nuts. - Install the steering head locknut and tighten it (7). Tightening torque: 70-80 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 50: Changing The Front Fork Seals

    - Unscrew and remove the 2 upper screws (A) from the fork Tee. - Unscrew the 2 lower screws (B) from the fork Tee. - Remove the fork stanchions. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 51 - Remove the stanchion assembly screw (11) and its seal. - If necessary use a mallet to dislodge the screws. - Separate the fork's tube (8) from the cover (10). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 52 - Remove the calibrated hydraulic tube (3). - Remove the expansion stop spring (4). - Remove the dust cover (5). - Remove the retaining clip (6). - Remove the seal (7). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 53 - Fit the fork sleeve (10) to the slightly oiled fork tube (8). - Install the stanchion assembly screw and its seal (11). Tightening torque: 25-30 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 54 - Fit and tighten the (4) clamping bolts. Tightening torque: 30-40 Nm. - Re-install all the fork equipment. - Refit the fairings in reverse order to removal. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 55: Electricity

    10. Voltage regulator 4. Spark plug socket 11. Carburetor heater 5. Spark plug 12. Carburettor heater thermo-switch 6. HT coil 13. Drive sensor 7. Starter resistor Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 56: Regulator/Ignition Unit

    R = 517 HT coil: ±20% Primary Yellow/black_Green R = 0.5 Secondary High voltage wire_Green ±20% R = 3.7 K Spark plug socket R = 5 K Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 57: Removal Of The Fuel Gauge

    - Remove the rear storage compartment. See: Procedure 1. page 20. - Disconnect the suppressor (1). - Disconnect and remove the high voltage coil (2) (1 screw). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 58: Fuel System

    - Disconnect: • The throttle control (1). • The fuel supply hose (2). - Disconnect: • The choke (3). • The carburettor heater (2 Connectors) (4). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 59 - Locate the position of the choke (3) and then remove it. - Remove the choke holder and its gasket (2 screw). Check the condition of the O-ring. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 60 - Remove the needle stop (7). - Remove the spring (8). - Remove the needle (9). 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 61 - Remove the float (11), its pin (12) and the needle valve (13). - Remove the idle jet (14). - Remove the main jet (15). - Remove the needle well (16). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 62 Do not turn the screw home forcefully. - Remove the mixture screw and its spring (17). When re-fitting, this operation allows you to put it back to its initial adjustment position. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 63 - Re-install all the other components and, if necessary, when starting the engine, readjust according to the values indicated on the technical data card. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 64: The Carburettor And Its Components

    18. Idle screw 8. Float 19. Piston 9. Float pin 20. Float chamber gasket 10. Needle valve 21. Carburetor heater 11. Idle jet 22. Heater earth connection Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 65: Power Unit

    B.Starter earth wire. • The transmission sensor (6). - Disconnect: • The throttle control (7). • The fuel inlet pipe (8). • The vacuum pressure hose (9). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 66: Removal Of The Cylinder Head

    - Remove the 2 mounting screws (2) from the tensioner body. Tightening torque: 10 Nm. - Remove the chain tensioner and slacken it by pressing the ratchet tooth (A). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 67 - Rotate the engine manually in the direction of operation in order to bring the rocker pads over the cam lobes (B). - Remove the rubber plug (6). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 68: Removal Of The Camshaft And/Or Rockers

    5 mm screw. - Remove the inlet (1) and exhaust (2) rockers. - Remove the stopper plate (3). Tightening torque: 15 Nm. - Remove the camshaft (4). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 69: Removal Of The Valves Or Valve Stem Seals

    - Placing the 2 half cones (1) into the cup using the tool shall not be done forcefully when decompressing the spring (3). Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 70: Fitting The Cylinder Head

    - Tighten the 4 nuts (1) and the 2 washer screws (2) slightly. - Torque the 4 nuts in a crosswise order to 18 Nm and the 2 washer screws to 8 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 71: Setting The Timing

    - Fit the 2 screws. - Immobilise the magnetic wheel using a wrench and tighten the camshaft pinion. Tightening torque: 10 Nm. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...

  • Page 72: Checking The Timing

    - Make sure the mark (B) of the camshaft gear is aligned with the mark (C) of the cylinder head. If the marks are not alined, reset the valve timing. Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles...
  • Page 76 P/N MA0016GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/PS/APV Printed in the E.U. 07/2010 (non contractual pictures)

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