PEUGEOT TSDI User Manual

WORKSHOP
MANUAL
50 cc INJECTION
ENGINE
SALES DIVISION
NETWORK TECHNICAL INFORMATION

PEUGEOT TSDI Specifications

General

Brand	PEUGEOT
Model	TSDI
Category	Engine
Language	English

Summary

Engine Characteristics

Engine Specifications

Details engine specifications including bore, stroke, cubic capacity, power, and torque.

Capacities

Specifies fluid capacities for the engine and transfer box.

Engine Markings

Identifies different engine types based on their markings.

Special Important Points

Oil and Fuel Requirements

Guidance on appropriate oil and fuel types for the engine.

Starting Procedures

Instructions and considerations for starting the engine.

Electrical System Requirements

Information on the engine's 12V DC electrical system and battery requirements.

Special Features and Notes

Details on ECU control, sensors, throttle unit, and general operating notes.

Tightening Torques

Torque Specifications

List of critical torque values for various engine components.

Special Tools

Required Special Tools

List of specialized tools needed for maintenance and repair procedures.

Disassembly

To Remove the Engine from the Machine

Step-by-step instructions for removing the engine from the motorcycle.

Putting the Engine on the Stand

Procedure for mounting the engine onto a service stand for maintenance.

To Remove the Cooling System

Detailed steps for removing the engine's cooling system components.

To Remove the Magneto Flywheel

Instructions for safely removing the magneto flywheel assembly.

To Remove the Stator and Sensor Assembly

Guide to removing the stator and associated engine speed sensors.

To Remove the Primary Transmission Cover

Steps for detaching the primary transmission cover.

To Remove the Drive Pulley

Procedure for removing the drive pulley from the transmission.

To Remove the Driven Pulley

Instructions for removing the driven pulley assembly.

To Remove the Secondary Transmission Cover

Steps to remove the secondary transmission cover.

To Remove the Secondary Transmission

Guide for removing the secondary transmission gears and shafts.

To Remove the Starter Motor

Procedure for removing the starter motor from the engine.

To Remove the Cylinder Head/Cylinder Assembly

Detailed steps for removing the cylinder head and cylinder unit.

To Remove the Air Injector

Instructions for safely removing the air injector from the cylinder head.

To Remove the Piston

Steps for removing the piston using specific tools.

To Remove the Inlet Manifold and Valve

Guide to removing the inlet manifold and associated valve assembly.

Opening the Casings

Procedure for safely opening the engine casings.

To Remove the Crankshaft

Detailed steps for removing the crankshaft using specialized tools.

Checking the Crank

Procedures for checking crankshaft condition and tolerances.

Refitting Specific Components

To Fit Bearings

Instructions for fitting new bearings into the engine casings.

Assembling the Casings

Steps for correctly assembling the engine casings around the crankshaft.

To Fit the Piston

Procedure for fitting the piston and gudgeon pin into the cylinder.

To Fit the Cylinder

Steps for installing the cylinder onto the crankcase with new gasket.

To Fit the Cylinder Head

Instructions for fitting the cylinder head with a new gasket.

To Fit the Magneto Flywheel

Procedure for installing the magneto flywheel onto the crankshaft.

To Remove the Cooling System

Steps for removing the cooling system components.

To Fit the Injection Manifold and Compressor

Procedure for refitting the injection manifold and compressor.

To Fit the Drive Pulley Assembly

Instructions for installing the drive pulley assembly onto the crank.

Miscellaneous Operations

To Remove the Starter System

Steps for removing the engine's kick start and electric starter system.

To Fit Starter System

Procedure for installing the engine's kick start and electric starter system.

To Remove/Refit the Drive Pulley Rollers

Instructions for removing and refitting drive pulley rollers and associated parts.

To Remove the Clutch Lining Assembly

Steps for disassembling the clutch lining assembly.

To Refit the Clutch Lining Assembly

Procedure for reassembling the clutch lining assembly.

Special Work and Procedures

To Remove the Fuel Tank

Instructions for removing the fuel tank from the motorcycle.

Procedure to Lower Fuel System Pressure

Method for safely reducing fuel system pressure before maintenance.

Fuel Circuit Bleeding Procedure

Procedure for bleeding the fuel circuit after maintenance or component replacement.

To Remove the Injection Rail

Steps for removing the fuel injection rail assembly.

To Remove the Air Injector

Instructions for removing the air injector from the cylinder head.

To Remove the Air Compressor

Procedure for removing the air compressor unit from the engine.

To Remove the Throttle Unit

Steps for detaching the throttle unit from the air intake system.

To Remove the Fuel Pump

Instructions for removing the fuel pump assembly.

To Remove the Strainer

Procedure for removing the fuel strainer located in the tank.

To Remove the ECU

Steps for removing the Electronic Control Unit (ECU).

To Remove the Temperature Sensor

Instructions for removing the engine temperature sensor.

To Remove the HT Coil

Procedure for removing the high-tension ignition coil.

Setting the Spark Plug Electrode Gap

Guide for correctly setting the spark plug electrode gap.

To Remove the Oil Pump

Steps for removing the engine oil pump assembly.