Cheetahchrome pull start kit for Peugeot 103 (all cases)

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This tutorial is to help you install the cheetahchrome pull start kit for the 103 bikes. This kit will fit on all stock
U.S., Euro as well as all the Polini race and 4 petal reed cases that have a large taper crank installed.
If your not sure if your crank is large taper or small look here.Peugeot crank tapers
This kit is designed for use with the Le Partie CDI flywheel only. It will not work for stock flywheel.

The kit will not work unless you use the provided machined Le Partie flywheel.
The new Le Partie flywheel provided in the kit has been machine modified to allow the starting pawl to sit flush
onto the face of the flywheel. Doing this also allows the overall height of the pull start to be shorter for pedal clearance.
The center of the new flywheel has also been bore cut deeper to allow the crank nut to reach more of the crank threads
This modification allows you to twist the nut tighter when securing your flywheel without fear of tearing off the end threads of the crank.
These before and after pics show how much further the nut can reach onto the crank.

Before mill::: After mill


You will only need basic hand tools and a power drill for this install. You will also be required to make a trip to your local
Auto parts store to buy a M6x1.00 thread tap and the corresponding drill bit 13/64. These two tools together will be about 12.00.

thread tap


This is all the components that come in the boxed kit.

parts in kit


This bike will be the victim of todays molestations.

bike


I remove the stock flywheel and stator plate then remove the stock exhaust to give me room to wrench. I plan to
go with a simo pipe for this build.

pipe off


I now remove the two nuts from the pictured case bolts. You may turn out to be unlucky and you will find that your
bolts run the other direction. In that case you will have to remove your clutch and variator and flip the bolts around so
that the threads are pointing towards you. Boo Hoo for that.
You will want to remove your clutch anyhow to shake out those heavy ass starter shoes that keep you from getting off
the line and going straight to heaven.

remove nuts


Bring up the steel mounting plate from the kit and you will see that it says "case" on one side. Place that side flat
against the two case bosses and finger start the two case bolts into the threaded holes of the plate.

case side


When you are sure you have the bolts started nice you can take over with your wrench. I made this steel mounting plate
really thick and wide so that in the future I have a firm platform to mount other accessories such as a launch lever.

wrench tight


With the mounting plate secured to the case you can now mount your La Partie stator plate and adapter ring in you usual
manner.

stator plate


Next with your timing set with your magic tools or using the poor mans method You can install the provided starter pawl
with special nut and washer. Use a 11/16 socket on the special nut.

flywheel nut and pawl


NICE!!!

nice look


Now bring over the pull start housing for a mock-up. The seam in the housing goes on the bottom. Use a small screwdriver to line up the bottom tab with the mounting
plate. When you think It is centered push the housing onto the stator plate. It will stay as it is designed to fit perfect.

line up


You can then test fit the bottom bolt and spacer.

test fit bolt


Now lets move to the top where we will create a threaded hole in the motor mount to accept the top bolt and spacer. Use
a small phillips screwdriver or anything strait and pointed and while looking straight through the top mounting tab, hammer
a nice dimple in the motor mount, This is where we will drill and tap.

dimple mark


Remove the housing and use your drill and 13/46 bit to drill through the dimple. Cover the flywheel with a rag to catch
the drill cuttings

drill drill drill


This last step can be kind of intimidating and it is the tapping threads into the hole you drilled. I was lucky to have a "T"
handle to support my tapping tool but I have done this using a small set of vice grips to grip the tap.

"T" handle


No matter what you use it is just important that you keep the tap cutting straight and square with the world.
Just go slow and keep looking at different angles so that you can correct the tap if it gets too wonky to one side.

keeping straight


Last you can mock up your kit and put in both bolts and spacers and try the pull. WOW!! this thing looks really great
and with no starter shoes in the clutch the bike just rips off the line straight up to the power band of the pipe.
The little rope spooling component included in this kit seems pretty robust but I recommend that you not pull
the rope all the way to the end of the spool as the spool is plastic and if you live in cold climate I imagine it might
snap the rope or the plastic spool. I have found that short quick snapping jerks work best and really get the motor
Spinning for a smooth start. If your rope should break, here is a link to easily repairing the spooling unit. [rope broke]

done YEAH DID IT!!!


People have been asking about pedal clearance and I can say that stock pedal arms just barely clear the starter housing
Here is the pedals on a custom build.

pedals clear

Peugeot pull pedal clear 002.JPG


I am now finished with this Wiki page. If you have any questions about the tips I suggested, or are having trouble with the process or can suggest how I can correct a mistake or to make the page better, contact Cheetahchrome