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Related Manuals for Peugeot Motorcycles XR6
Summary of Contents for Peugeot Motorcycles XR6
- Page 1 SALES DIVISION NETWORK TECHNICAL INFORMATION WORKSHOP WORKSHOP MANUAL MANUAL...
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Page 2: Table Of Contents
CONTENTS CHARACTERIS TICS...........................4 Machine markings................................. 4 Characteristics..................................4 Frame..................................... 4 Capacities ....................................4 Dimensions.................................... 4 We ight ....................................4 Tyres ...................................... 4 Engine markings ................................... 4 SERVICE AND COMMISSIONING INS TRUCTIONS................5 Check:....................................5 Change ....................................5 Check and remove carbon ..............................5 Check and lubricate ................................ - Page 3 CONTENTS Removal of the rear caliper and the brake pads........................ 21 Removal of the shock absorber............................22 Removal of the shock absorber pivot ..........................23 Removal of the suspension arm............................24 Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted) ..........25 MISCELLANEOUS OPERATIONS......................26 Removal of the rear mudflap..............................
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Page 4: Characteris Tics
CHARACTERIS TICS CHARACTERIS TICS Machine markings Capacities Model code DR01A Gearbox 0,75 litres Characteristics Fuel tank 11.75 litres Oil tank 1.1 litres Engine 2 stroke water cooled Showa fork 0.175 litres per tube Dimensions Marque Minarelli 50 cc Length 1.865 mm Bore x stroke 40.3 x 39 Width... -
Page 5: Service And Commissioning Ins Tructions
SERVICE AND COMMISSIONING INS TRUCTIONS SERVICE AND COMMISSIONING INS TRUCTIONS Heavy duty servicing is for machines used under “harsh” conditions, driver temperament, short journeys with engine cold, dusty regions, ambient temperature over 30°C. Servicing operations 500 Kms Every 3000 Kms Every 6000 Kms or 3 months Check:... -
Page 6: Battery Preparation (Except For Maintenance- Free Battery)
SERVICE AND COMMISSIONING INS TRUCTIONS Battery preparation (except for maintenance- free battery) Remove the battery Remove the 6 filler caps and the vent plug Fill with electrolyte up to the UPPER LEVEL mark Electrolyte: (35% sulphuric acid = 1.28g/cc) per litre P/N: 752740, per 5 litres P/N: 752741 Let the battery stand for about half an hour Top up if necessary Charge the battery for at least 2 hours with a current of 400 mA (0.4 A) -
Page 7: Special Im Portant Points
SPECIAL IM PORTANT POINTS SPECIAL IM PORTANT POINTS Oil and fuel This machine is designed to run on super 95 or 98 unleaded fuel The oil to use for the separate lubrication system is Esso 2T special semi-synthetic 2-stroke oil Starting With the ignition on, the engine is cranked by the starter motor merely by pressing the starter button The manual choke is operated by the choke lever on the left grip... -
Page 8: Tightening Torques And Special Tools
TIGHTENING TORQUES AND SPECIAL TOOLS TIGHTENING TORQUES AND SPECIAL TOOLS Tightening torques Body panels: Headlight fairing 0,1 m.daN Speedo fairing 0,1 m.daN Side covers 0,1 m.daN Side and central fairings 0,1 m.daN Rear fairing 0,1 m.daN Front mudguard 0,1 m.daN Rear mudguard * 0.8/0.1 m.daN Mudflap *... -
Page 9: Body
BODY BODY Body panel bolt fitting Important: there are different stacking orders depending on the assembly. When refitting, assemble the fittings in the same order In the instructions below the stacking order is given in brackets after the operation. E.g.: Remove the 2 rear view mirrors (stacking order N°1) 1- part being fixed + fairing + spacer + rubber washer + support + wide flat washer + nut... -
Page 10: Removal Of The Headlight Fairing Operation 1 A
BODY Removal of the headlight fairing Operation 1 A - Remove the 2 rear view mirrors (1) (stack N° 1) - Remove the 2 bolts (2) on the windshield (stack N° - Remove the 4 bolts (3) from the side fairings (stack N°... -
Page 11: Removal Of The Fuel Tank Assembly Operation 2 A
BODY Removal of the fuel tank assembly Operation 2 A - Remove the passenger saddle (1) unlock the saddle with the ignition key and pull it rearwards) - Remove the cap (3) from the inside of the rear mudguard - Through the cap hole (3), and through the rear mudguard, remove the nut (4) and bracket (5) from the driver’s saddle and pull the driver’s saddle (2) rearwards to release it from the frame... -
Page 12: Removal Of The Instrument Panel Operation 3A
BODY Removal of the instrument panel Operation 3A - disconnect the speedometer control cable at the wheel end - Remove the instrument panel 2 screws (1) - Move the instrument panel clear - Disconnect the instrument panel connector - Remove the instrument panel (2) with the speedometer cable Removal of the speedometer Operation 3 B - Remove the headlight fairing (see operation 1A) -
Page 13: Removal Of The Side Fairings And The Centre Fairing Operation 5
BODY Removal of the side fairings and the centre fairing Operation 5 - Remove the hatches (1) of the side fairing 1 screw on each (stack N°5) - Remove the 4 screws (2) from the frame ((2A) stack N° 5, (2B) stack N° 6) - Remove the 2 screws (3) securing the RH and LH fairings (stack N°9) - Remove the 2 screws (5) securing the LH side... -
Page 14: Frame
FRAME FRAME Front part Removal of the front wheel Operation7 - Unscrew the speedometer cable (1) - Slacken the wheel spindle nut and the clamping nut (2) on the front of the fork tube - Remove the wheel spindle nut, and pull the wheel spindle clear (3) - Remove the wheel (4) D o not operate the brake lever or as a precaution fit... -
Page 15: Removal Of The Front Mudguards And The Front Mudguard Stay Operation 8
FRAME Removal of the front mudguards and the front mudguard stay Operation 8 - Remove the 4 screws (1) securing the mudguard to the stay - Remove the mudguard (2) - Remove the 4 screws (3) securing the stay to the fork tubes - Remove the stay (4) T he stay screws have an effect on the mudguard... -
Page 16: Removal Of The Fork
FRAME Removal of the fork - Remove the headlight (see operation 1B) - Remove the fork upper Tee (1) 2 bolts (2) securing it to the fork tubes and 1 centre bolt (3) using a 10 mm Allen key - Remove the 2 brake caliper bolts, and move it clear without disconnecting it - Remove the front mudguard and the front mudguard stay (see operation 8) -
Page 17: Removal Of The Fork Tubes
FRAME Removal of the fork tubes - Remove the headlight fairing (see operation 1A) - Remove the brake caliper without disconnecting it - Remove the front mudguard and the front mudguard stay (see operation 8) - Remove the front wheel (see operation 7) - Remove the 4 bolts (1) from the lower and upper Tees Removal of the headlight mount... -
Page 18: Removal Of The Rear Frame Assembly
FRAME Rear part Removal of the rear frame assembly - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 4) - Remove the rear fairing and the number plate plinth (see operation 6) - Remove the oil tank (1) (2 bolts) - Disconnect the rear wiring harness (2), the oil level switch and the brake light - Remove the air filter casing 2 screws (leave it in... -
Page 19: Removal Of The Rear Wheel
FRAME Removal of the rear wheel - Remove the wheel nut (1) and its washer - Suspend the machine - Remove the chain quick-link - Remove the wheel spindle - Release the caliper bracket assembly (2) - Recover the spacers (3) and (4) - Remove the rear wheel D o not operate the brake lever or as a precaution fit a wedge between the brake pads... -
Page 20: Removal Of The Chain Operation 9
FRAME Removal of the chain Operation 9 Note the running direction of the chain if it is to be refitted T he chain must be changed if the gearbox drive sprocket and rear sprocket are changed Chain tension adjustment Operation 10 - Slacken the wheel spindle nut (1) - Adjust each of the tensioners (2) equally so that the wheel is centred in the suspension arm. -
Page 21: Removal Of The Rear Mudguard
FRAME Removal of the rear mudguard - Remove the upper bolt (1) from each of the footrest brackets - Slacken without removing the lower bolt (2) of each of the footrest brackets - Pivot the brackets (3) - Remove the mudguard 4 securing bolts (4) - Remove the mudguard (5) Removal of the rear caliper and the brake pads - Remove the caliper bracket 2 bolts (1) -
Page 22: Removal Of The Shock Absorber
FRAME Removal of the shock absorber - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 4) - Remove the battery with the cover and the locker - Remove the air filter housing (2 bolts and 1 clip) - Remove the nut, the washer and the lower fixing pin - Remove the nut, the washer and the upper fixing pin - Remove the shock absorber (3) from the top... -
Page 23: Removal Of The Shock Absorber Pivot
FRAME Removal of the shock absorber pivot Note the fitting position of the pivot for refitting - Remove the 3 securing pins: from the suspension arm (1) from the frame (2) from the shock absorber (3) - Remove the pivot (4) The pivot assembly is composed of 2 pivots (A), 2 linkrods (B) mounted on four pivot points. -
Page 24: Removal Of The Suspension Arm
FRAME Removal of the suspension arm - Remove the chain (1) (note running direction) - Remove the rear brake caliper 2 bolts - Remove the suspension arm (2) caps and spindle nut - Remove the wheel spindle (3) with its nuts and washers, the brake caliper bracket (4) and the 2 spacers (5) - Remove the wheel... -
Page 25: Suspension Arm Pre- Assembled (Mudguard, Chain Guard, Guide And Tensioners Fitted)
FRAME - Essential points for refitting the suspension arm Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted) - Fit the rear brake caliper (1) through the suspension arm behind the spacer (2) - Position the suspension arm - Locate the fixing spindle in the frame - Tilt the pivot (3) forwards to locate the shock absorber lower mount (4) -
Page 26: Miscellaneous Operations
MISCELLANEOUS OPERATIONS MISCELLANEOUS OPERATIONS Removal of the rear mudflap - Remove the passenger saddle - Remove the 2 front screws (1) then the 2 rear screws (2) (stack N°5) -Pull the rear mudflap (3) downwards Removal of the rear light assembly - Remove the passenger saddle (1) - Remove the small rear upper fairing (2) (4 screws) - Disconnect the rear light... -
Page 27: Removal Of The Instrument Panel
MISCELLANEOUS OPERATIONS Removal of the instrument panel - Remove the headlight fairing (see operation 1A) - Remove the instrument panel 2 screws (1) - Disconnect the instrument panel 12-pin connector - Remove the instrument panel (2) Removal of the windshield - Remove the 4 screws (1) (stack N°10) - Remove the 3 screws (2) (stack N°3) - Remove the windshield (3) -
Page 28: Removal Of The Steering Lock
MISCELLANEOUS OPERATIONS Removal of the steering lock - Remove the fuel tank assembly fairing (see operation 2A) - Disconnect the steering lock from the wiring harness (5-pin connector (1) inside the frame; green, black and red wire) - Disconnect the connector (2) with 1 red and white wire Follow the removal order in order not to damage the fork Tee... -
Page 29: Removal Of The Throttle Grip And Oil Pump
MISCELLANEOUS OPERATIONS Removal of the throttle grip and oil pump - Remove the fuel tank assembly (see operation 2A) - Remove the RH fairing (10 screws) - Remove the RH grip 2 bolts (1) - Remove the cover (2) - Release the cable (3) - Remove the carburettor chamber cover (4) (1 bolt) - Remove the oil pump cover - Release the cable (3) -
Page 30: Removal Of The Air Filter Foam
MISCELLANEOUS OPERATIONS Removal of the air filter foam - Remove the fuel tank assembly (see operation 2A) - Remove the air filter cover (1) (1 bolt) - Remove the foam Removal of the air filter box - Remove the fuel tank assembly (see operation 2A) - Remove the battery and its support - Pull back the rear fairing (6 screws) to access the box 2 bolts... -
Page 31: Removal Of The Carburettor Operation 12
MISCELLANEOUS OPERATIONS Removal of the carburettor Operation 12 - Remove the fuel tank assembly (see operation 2A) - Remove the battery and its support - Disconnect the carburettor heater hose (1) plug the hose to prevent spillage of the coolant - Remove the valve (2) - Disconnect the oil hose (3) - Release the clip from the inlet coupling (4) using a 3... -
Page 32: Electricity
ELECTRICITY ELECTRICITY Removal of the battery - Remove the fuel tank assembly (see operation 2A) - Remove the battery cover (1) (1 screw) - Remove the battery Removal of the starter motor relay - Remove the fuel tank assembly (see operation 2A) - Remove the securing screw (1) - Remove the starter motor relay (2) Removal of the voltage regulator... -
Page 33: Removal Of The Ignition Module
ELECTRICITY Removal of the ignition module Note: this acts as the ignition module and the HT coil - Remove the LH fairing (10 screws) - Remove the 3 screws (1), the nuts and the washers - Remove the ignition module (2) Removal of the horn - Remove the RH fairing (10 screws) - Remove the securing screw (1) - Page 34 ELECTRICITY 1. battery leads (2 clips per pole) 12. flywheel outlet yellow wire 2. connection with the rear harness 13. LH cluster connector 3. voltage regulator/flasher unit connector 14. RH cluster connector 4. horn connection 15. brake light switch connector 5.
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Page 35: Removal Of The Main Harness
ELECTRICITY Removal of the main harness - Remove the fuel tank assembly (see operation 2A) Without pulling untowardly, gradually - Remove the side fairings (see operation 4) pull out the harness through the frame LH side - Remove the side fairings and the centre fairing (see opening in the following order: operation 5) - Disconnect the battery (1) -
Page 36: Refitting The Main Harness
ELECTRICITY Refitting the main harness Check the positioning of the different connections Proceed in reverse order to removal. If the harness is and control cables. being changed, we recommend it is prepared in the From frame RH side: same way as the one removed before fitting - throttle and clutch cables - brake light switch harness In particular:... -
Page 37: Work On The Engine W Ithout Removing The Engine
WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE Removal of the cylinder head/ cylinder/ piston - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 5) - Remove the exhaust (see operation 11) - Drain the cooling circuit (see cooling chapter) - Remove the radiator/cylinder hose (1) -
Page 38: Removal Of The Oil Pump
WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE Removal of the oil pump - Remove the RH fairing (see operation 5) (10 screws) - Remove the cover (1) (2 bolts) - Release the cable (2) - Disconnect the oil supply hose (3) - Remove the 2 fixing bolts (4) - Remove the oil pump (5) Page 38... -
Page 39: Removal Of The Rotor And The Magneto Flywheel Armature
WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE Removal of the rotor and the magneto flywheel armature - Remove the LH fairing (10 screws) - Remove the LH cover 5 bolts (1) - Remove the rotor (2) (For other operations on the magneto flywheel, see the method in the XP6 workshop manual, page 6) Note: The rotor (2) also acts and the starter motor ring gear... -
Page 40: Removal Of The Gearbox Output Sprocket
WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE Removal of the gearbox output sprocket - Remove the LH fairing hatch (1 bolt) - Remove the chain cover (1) (2 bolts) - Remove the clip and the sprocket (2) No t e which way round the output sprocket is fitted if it is to be re-used T he gearbox output sprocket must be changed if the rear sprocket and chain are changed... -
Page 41: Removal Of The Starter Motor
WORK ON THE ENGINE W ITHOUT REMOVING THE ENGINE Removal of the starter motor - Remove the LH fairing (10 screws) - Remove the LH cover (1) (5 bolts) - Disconnect the neutral switch (2) - Remove the starter motor 3 securing bolts (3) (2 on the inside and 1 on the outside) - Disconnect the starter motor power lead (4) - Remove the starter motor (5) -
Page 42: Cooling
COOLING COOLING Wh e n working on the cooling circuit, the engine must be cold Removal of the cylinder head/ radiator hose - Remove the RH fairing (see operation 5) (10 screws) - Drain the cooling circuit (drain screw (1) on the water pump) - Remove the hose clips (2) - Remove the hose (3) -
Page 43: Removal Of The Engine Temperature Sensor
COOLING Removal of the engine temperature sensor - Remove the RH and centre fairing (see operation 5) (10 screws) - Remove the radiator securing bolt - Extract the radiator from the mounts in order to facilitate access to the sensor (without disconnecting the hose) - Remove the spark plug (1) - Disconnect and unscrew the sensor (2) -
Page 44: Motor
MOTOR MOTOR Removal of the engine - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 5) - Disconnect the battery - Drain the cooling circuit (drain screw (1) on the water pump) - Remove the chain cover (2) (2 bolts) - Remove the chain (see operation 9) noting which way round it is fitted - Make a mark (A) on the selector link to line it up... - Page 45 MOTOR - Slacken the front engine mount 2 side fixing bolts (5) (without removing the nuts) - Slacken and remove the front engine mount 2 securing bolts (6) in the frame front compartment - Remove the front mount fixing shaft (7) and push the mount forwards - Remove the engine to frame lower mount shaft and the fairing support fixed to the shaft...
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Page 46: Refitting The Engine To The Frame
MOTOR - Release the engine from the rear upper lugs on the frame (8) W ith the engine removed, take the XP6 workshop manual for details of work on the engine Refitting the engine to the frame - Fit the engine rear upper mount shaft, washers and nuts - Suspend the engine from the rear upper mount (4A) - Position in the rear lower mount (4B) -
Page 47: Frame
FRAME FRAME Removal of the frame This method is used for replacement of the frame only. If replacing a frame following an accident, the method must be completed by the repair or replacement of the damage parts At the rear: - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 4) - Remove the side and centre fairings (see operation... - Page 48 FRAME At the front/ headlight: - Remove the headlight fairing (see operation 1A) - Disconnect: - the headlight - the instrument panel connection - the control cluster connections - the brake light switch - the throttle, choke, clutch and speedometer cables - Remove the headlight bracket to steering tube 2 securing bolts - Remove the headlight bracket, instrument panel and...
- Page 49 FRAME Stripping the frame: - Remove the controls and cables - Remove the RH plate - Remove the stand - Remove the main harness - Remove the electrical components - Remove the steering bearings - Remove the captive nuts Fit the new frame by proceeding in reverse order to disassembly Page 49 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
- Page 50 RECOMMENDS REF: 755809 For reasons of continuous improvement, Peugeot Motocycles reserves the right to modify, delete or add any part number quoted DC/PS/ATR printed in EU 12/2000 (photos non-contractual) Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles...
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