PEUGEOT BLASTER, Workshop Manual

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

Page 2: ...Sales division Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Page 3: ... 6 Battery preparation Except battery without maintenance 7 Checks before handing over to the customer 7 SPECIAL IMPORTANT POINTS 8 Oil and fuel 8 Starting up after overhauling the engine 8 TIGHTENING TORQUES 9 Body panels 9 Cycle part 9 Standard 9 SPECIAL TOOLS 10 LOCATION OF COMPONENTS 11 BODY PANELS 12 Removal of the front top shield panel 12 Removal of the radiator covers 12 Removal of the fro...

Page 4: ...ard 15 Installing the front lower shield panel 16 MISCELLANEOUS OPERATIONS 18 Removal of the radiator top connecting pipe 18 Removal of the header tank 18 Removal of the radiator lower connecting pipe 18 Removal of the RH and LH radiators 19 Removal of the cylinder piston 19 Removal of the engine temperature sensor 20 Removal of the regulator 20 ...

Page 5: ...49 9 cc Max power output 3 6 kW at 7300 rpm Max torque rating 7000 rpm Fuel supply Carburettor Gurtner PY15 Lubrication Electric oil pump Transmission By 2 variable pulleys and V type belt Clutch Centrifugal automatic Spark plug NGK CR7EB Exhaust Catalytic Fuel tank 5 5 l 95 or 98 lead free Oil tank 1 2 l Semi synthetic for 2 stroke engines with separate oiling Relay box 0 12 l SAE 80W90 life lubr...

Page 6: ... shock absorber Travel 65 mm Overall length 1720 mm Width at handlebar 705 mm Height without rear view mirrors 110 mm Wheelbase 1210 mm Ground clearance 135 mm Unladen weight 81 5 kg Front wheel rim 10 inch aluminium alloy Front tyre 120 90 10 Front tyre pressure 1 7 bars Rear wheel rim 10 inch aluminium alloy Rear tyre 130 90 10 Rear tyre pressure 2 bars Chassis markings Engine marking 1 VIN numb...

Page 7: ...12 months Every 10000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Check Idle setting X X X Throttle cable play X X X Steering column play X X X Operation of electrical equipment X X X Condition of front and rear brake hydraulic controls X X X Condition of petrol pipes X X X Condition of oil pipes X X X Tyre pressures X Tyre condition pressure and wear X X Brake fluid level X X X...

Page 8: ...uipment Change if necessary Service operations 500 kms or 1 months Every 5000 kms or 12 months Every 10000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Check and lubricate Driven pulley Moving flange and needle bush X Kick lever boss Kick starter control shaft X X Rear brake cam X Clean and adjust Carburettor X Test machine On road X X X ...

Page 9: ...ecessary Charge the battery for at least 2 hours with a current of 0 4A Refit the battery and connect the vapour vent pipe Connect the red wire lug to the battery s terminal and the green wire lug to the battery s terminal Then the battery level should be topped up if necessary after fully charging using distilled water only Checks before handing over to the customer Check the wheel nuts are tight...

Page 10: ...operties Should it be changed replace it with a genuine pipe Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Work in a clear and well ventilated area Before carrying out any work leave the engine to cool for at least 2 hours Starting up after overhauling the engine The oil pump must be drained in accordance with the recommended procedures When ...

Page 11: ... spindle nut 10 m daN Linkrod to engine pivot 5 2 m daN Linkrod to frame pivot 5 2 m daN Shock absorber top mount 4 31 m daN Shock absorber bottom mount 2 m daN Exhaust to cylinder mounting nut 1 5 m daN Exhaust to casing mounting bolt 2 m daN Upper cone in 2 operations 4 2 3 m daN Upper cone locknut Hand tightened Steering locknut 7 m daN Front brake caliper 2 5 m daN Front brake disc 1 m daN Han...

Page 12: ...cles SPECIAL TOOLS Tool N Designation Used with Tool N Designation Used with 068994 Torque wrench 8 N m to 54 N m 752235 752236 753977 Torque wrench 30 N m to 150 N m 752235 752236 750539 Tie wrap pliers 755996 Hose clamp 752235 1 2 extension 68994 or 753977 757860 Steering tool 752236 1 2 3 8 adapter 68994 or 753977 ...

Page 13: ...ONENTS 1 Oil pump control unit 2 Battery 3 Ignition sensor 4 CDI unit 5 Oil level indicator 6 Oil pump 7 HT coil 8 Low oil level warning light 9 STOP light 10 Regulator 11 Starter motor relay 12 Horn 13 Engine temperature sensor 14 7 5 A fuse 15 Air pump 5 10 14 1 15 2 9 8 6 13 3 7 4 11 12 UP PE R LE VE L LO W ER LE VE L 12V 25A STOP STOP N C N C ...

Page 14: ... speedometer driver control cable Unclip the control cable from the front mudguard Remove the 4 screws that secure the shield panel 1 Unclip the rubber protector 2 Disconnact the headlight Disconnect the instrument cluster Remove the front upper shield panel Removal of the radiator covers Procedure 2 Remove the 3 retaining screws 1 from the radiator covers Remove the radiator covers 1 1 1 2 1 1 ...

Page 15: ...eld panel as shown in A and the tabs B of the dirt shield Remove the front shield panel Removal of the dirt shield Procedure 4 Remove the front lower shield panel see procedure 3 Remove the dirt shield 1 by unclipping it from the upper bracket and by swivelling it to the right or to the left Removal of the rear shield panel Procedure 5 Remove the front lower shield panel see procedure 3 Remove the...

Page 16: ...ove the rear shield panel see procedure 5 Remove the shock absorber trim 1 1 screw Remove the side fairings 2 screw Remove the 2 clips 2 in order to avoid scratching the frame Remove the complete footrest ass y 3 Remove the 2 screws 4 that secure the footboard Remove the footboard ass y Removal of the under body panel Unclip the under body panel 1 2 1 2 3 2 4 ...

Page 17: ...ten consent of Peugeot Motocycles Installing the under body panel Cip on the under body panel Make sure the pipe of the cooling system is properly positioned in the locations moulded in the under body panel Installing the footboard Install the footboard by starting to fit the front part ...

Page 18: ...locating pin 1 into the holes provided in the under body panel Follow the procedure to install the footboard carefully in order to avoid it from contacting the radiators Installing the front lower shield panel Install the shield panel by fitting the footboard locating pins 1 into the holes provided in the under shield panel 1 1 ...

Page 19: ... even partial is forbidden without the written consent of Peugeot Motocycles Push the front shield panel against the rear shield panel by clipping in the following order A Side tabs B The screw tightening locations C The dirt guard clips B A C ...

Page 20: ... from the header tank Remove the header tank Disconnect the upper pipes 2 from the RH and LH radiator Remove the 2 screws 3 that secure the connecting pipe 4 Remove the connecting pipe Removal of the radiator lower connecting pipe Remove the footboard see procedure 6 Disconnect the lower pump from the coolant pump to drain the cooling system Remove the lower pipes 1 from the radiators Disconnect t...

Page 21: ...m Disconnect the pipes 1 from the RH and LH radiator Remove the RH or LH radiator All the collar opening tabs are to be oriented upwards Removal of the cylinder piston Remove the footboard see procedure 6 Remove the exhaust Disconnect the lower pump from the coolant pump to drain the cooling system Disconnect the coolant pipes from the cylinder head and cylinder Disconnect the temperature sensor F...

Page 22: ... Motocycles Removal of the engine temperature sensor Remove the battery access door Remove the battery Disconnect the temperature sensor Remove the engine temperature sensor Refit a sensor quickly to prevent loss of coolant Removal of the regulator Remove the footboard see procedure 6 Disconnect and remove the regulator ...

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Page 24: ... N 758078 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 04 2005 non contractual pictures ...