PEUGEOT XP6 50 User Manual

PEUGEOT XP6 50

Manuel d'atelier (EN ANGLAIS)

G.H.E. MOTORHISPANI

A, S.L

GARAGE HANDBOOK

INTRODUCTION

This garage manual refers to the AM6 engine, equipping the following vehicles:

- Furia 6V Cross

- Furia 6V Supermotard

MOTORHISPANIA RECOMMENDS

2 stroke engine:

• MOTUL POWERLUBE SEMI-SYNTHETIC 2T

Gearbox oil:

• TRANSOIL 10W30

Grease:

• GREASE 100

ADVICE

A good repairer acts with order and methodically

Use the appropiate tools, gaining time and a professional image.

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TECHNICAL FEATURES REPLACEMENT

Engine part .................................................. 2 Water pump .............................................. 24

Cycle part .................................................... 2 Oil pump .................................................. 25

Capacities and types ................................... 3

Tightening motor and cycle......................... 3

Special tools ................................................ 3 IGNITION AND ELECTRICAL CIRCUIT

Maintenance...................………………….. 4

Electronic ignition .................................... 28

DISASSEMBLY

Disassembly of engine ................................ 5 Neutral gauge........................................… 28

Disassembly of magneto ............................. 6 Cooling system temperature gauge.......... 28

Disassembly of clutch cover ....................... 7 Min. oil level gauge...............................… 28

Disassembly clutch ..................................... 7 Horn ......................................................... 28

Disassembly of crankshaft pinions Socket ....................................................... 28

and camshaft ..............................…………. 8 Indicators .................................................. 29

Disassembly of inlet pipe and Principle scheme....................................... 30

plate valve ...................................………… 8 Scheme legend.......................................... 31

Disassembly cylinder head ......................... 9 Cable plan ................................................ 32

Disassembly of cylinder ............................. 9

Disassembly of piston ................................ 9

Disassembly of exhaust pinion ................... 9 CONTROL

Openin

g of cases .................................... 10

Disassembly of stick and gearbox ............. 11 Elements of the gearbox ........................... 13

Disassembly of camshaft ........................... 11 Connecting rod/crankshaft set................... 15

Disassembly of crankshaft .......................... 11 Piston ........................................................ 17

ASSEMBLY

Replacement of bearings/joints ............…... 12 Clutch ....................................................... 22

Assembly of gearbox .................................. 13 Ignition advance ....................................... 26

Assembly of selector shaft ......................... 14 Oil level of gearbox ................................. 27

Assembly of camshaft.... .................……… 15

Assembly of connecting rod/crankshaft

in right case ................................................. 15

Closing of left case ..................................... 16 ADJUSTMENTS

sembly of the piston ............................... 17

Assembly of the cylinder ............................ 17 Engine clutch lever...................………… 24

Assembly of the cylinder head ................... 18 Ignition advance ....................................... 26

Assembly of plate valve and inlet

pipe ............................................................. 19

Assembly of crankshaft right joint ............. 20

Assembly pinions crankshaft and cam

shaft ............................................................ 20

Assembly of the clutch ............................... 22

Clutch lever regulation ............................... 24

Starting shaft/clutch cover .......................... 25

Assemblyof magneto .........................……. 26

Principle and regulator ............................. 28

Lights ....................................................... 28

Cylinder .................................................... 17

Segments .................................................. 17

Thermostat valve ..................................... 18

Plate valve .......................................... 19

Oil pump .................................................. 25

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Assembly of exhaust pinion ....................... 27

Filling of gearbox ....................................... 27

TECHNICAL FEATURES

ENGINE PART

Name of

Type: ........................................FU01

Engine marking: only engine type is inscribed, not num

ENGINE: MOTORI MINARELLI type AM6 2 stroke monocylindrical type, with separate greasing and liquid cooling by means of circulation pump.

Diameter and distance: ......... Ø40.3x39mm

Cylinder capacity: ................. 49.7 cc

B compression relation ......... 12:1

R compression relation ......... 6.86:1

Transmission:

Exhaust pipe: ............ 177º

Transfer: ................... 125º

Admission: ..........…. plate valve

Idling pattern: .............….. 1800 rpm +/- 200

Power: .......... 1.82Kw ISO at 5250 rpm

Max. Par.: ….. 3.23 mdaN ISO at 5250 rpm

IGNITION: Type CDI

-Electronic type by means of condensator discharg (tyristor)

-Advance .......... 1.4 mm before PMS (20º)

-Spark plug ....... Resisting 5 Kohm

Type: ..NGK BR8ES or EYQUEM R1000 L

Electrode space: .................... 0.6 mm

the manufacturer: ......Furia6V

bered.

-Gearing down relation: 3.55 (20x CH: Multidisc in oil coating with manual

CLUT control. GEARBOX: 6 gears

-Lubrication by means of chain and pinions

-Control by means of selector at right foot

GEARING DOWN 1 12X36 3 32,0 % 2 16X33 2,06 46,5 % 3 19X29 1,53 62,9 % 4 22X27 1,23 78,2 % 5 24X25 1,04 92,2 % 6 25X24 0,96 100 %

SECONDARY T chain and pinions

-Gearing down relation: (12x52):

CYCLE PART

RANSMISSION: by means of

71)

4,33

CARBURETTOR: DELL ‘ORTO SHA 14-12

-Main jet: .......………………. 63

GENERATOR: magneto DUCATI

-Number of poles: .....……….. 6

-Power: ...……………………. 85 W

-Voltage: .....…………………. 12 V

REGULATOR: FACOMSA (with integrated central integrator)

-Regulation tension: …………. 13.4VAC +/-0.5

STARTING: Starting pedal

SEPARATE GREASING: DELL ‘ORTO oil pump

-Variable flow 6 cc/H approx. (control between 0 and 10º 9 cc/h approx. (control at 15º) 25 cc/h approx. (control at 45º) 38 cc/h approx. (control at 71º)

-Gearing down relation: 2.03 (20x24 and 13x22) PRIMARY TRANSMISSION: helical gears

)

IDENTIFICATION MARK

-VIN nr. 17 characters VTVFU01A………….

CHASSIS: Double seat in rectangular steel tube Attack angle: 26º Advance: 167 mm

STEERING:

-on ball beari

FRONT SUSPENSION: SHOWA

-inverted hydraulic telescopic fork

-distance: 180 mm

-bar diameter: 32 mm

REAR SUSPENSION:

-Cantilever type with oilpneumatic mono shock

absorber with helical spring

-distance: 45 mm

ngs

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FRONT BRAKE:

-AJP brake pin

-disc O220 mm with manual hydraulic control

-thickness: 4 mm

REAR BRAKE:

-AJP brake pin

-floating disc O180 mm with hydraulic control at the stem

-thickness: 3.5 mm

TYRES: dimensions and pressures when cold

-Cross version: Front: 2.5x21 1.5 bars Rear: 110/80x18 1.7 bars

-Supermotard version: Front: 100/80x17 2.3 bars Rear: 130/70x17 2.5 bars

DIMENSIONS:

-Total length: 1995 mm

-Total width: 750 mm

-Total height: 1350 mm

WEIGHT:

-Weight when moving: 85

-Max. authorized total weight: 235 kg

CAPACITIES AND TYPES

FUEL: Super, unleaded, 98 or 95 oct. Capacity of the tank: 6 litres Reserve: 0.2 litres

SEPARATE GREASING: Semi synthetic oil, or synthetic MOTUL Powerlube semi-synthetic 2T Capacity of the oil tank: 1.1 litres.

Contents for each bar:........... 175 cc

PARES APRIETE MOTOR Cy

linder head nut 1,8 mdaN Crankshaft pinion nut 7,5 mdaN Camshaft pinion nut 6 mdaN Magneto nut 5,2 mdaN Clutch nut 7,5 mdaN Pressure plate screw 0,5 mdaN Clutch counter nut 2,7 mdaN Engine housing case screw 1,1 mdaN Transmission cover screw 1,1 mdaN Magneto cover screw 0,4 mdaN Inlet pipe screw 1,1 mdaN Starting pedal screw 3 mdaN Gearbox casting screw 1,8 mdaN

TIGHTENING OF THE CYCLE PART

t wheel nut 4,5 mdaN

Fron Rear wheel nut 6,5 mdaN Fork screw 2,5 mdaN Steering nut 6 mdaN Fork tube inf. T screw 1,5 mdaN Fork tube sup. T screw 2,8 mdaN Handlebar fixing screw 2,3 mdaN Engine fixing screw 2,8 mdaN Swing arm nut 6,5 mdaN Rear chassis fixing screw 2,8 mdaN Fixing footrest bracket screw 2,8 mdaN Upper shock absorber screw 4,5 mdaN Lower shock absorber screw 4,5 mdaN Front brake pin screw 2,8 mdaN Rear brake pin screw 2,8 mdaN Front brake disc screw 1,2 mdaN Rear brake disc screw 0,5 mdaN

SPECIAL TOOLS

GEARBOX: Transmission oil MOTUL Transoil 10W30 Capacity gearbox: 0.75 litres.

COOLING CIRCUIT: Protection until –20ºC Antifreeze fluid type Procor 3000 or equivalent, change every 2 years Capacity of the circuit: 0.7 litres

BRAKE FLUID: fluid according to the rules DOT 3 or DOT 4

HYDRAULIC FORK: Fork oil type: SAE 20

Engine bracket Adaptation Furia 6V VAR tool Opening and closing plaque Protection cap Special 10x125 nut Centrer Special nut bracket Gauge 47 set Wheel extractor Clutch immobil. tool Clutch side crankshaft driver Wheel side crankshaft driver Selector shaft driver Water pump driver Clutchstick driver Lock pin Adjustable immobilizer Outer circlip pin

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MAINTENANCE

Depend

ing on the use of the vehicles, we recommend that you should apply:

 The normal maintenance plan  The reinforced maintenance plan

The normal maintenance plan includes:

 Service after 500 km or 3 month……….…..……Plan A

 Service every 5000 km......................……………Plan B

 Service every 10000 km............…………………Plan C

The reinforced maintenance plan includes:

 Service after 500 km..........................Plan A

 Service every 2500 km......................Plan B

 Service after 5000 km........................Plan C

NOTE: The replacement of certain parts is directly related to the use of the vehicle and it is also related to “the user’s nature”.

ACTI O NS

PL AN A

500 Kms. or 3

months

PLAN B

2.500 Kms or

5.000 Kms *

PLAN C

5.000 Kms or

10.000 Kms *

Verify:

- Adjustment of the idling

- Gas control

- Clutch control

- Front and rear brake control

- Functioning the electrical equipment

- State and pressure tyres

- Petrol tube

- Oil tube

- Brake fluid tube

- Antifreeze fluid tube

- Brake fluid level

- Antifreeze fluid tube

- Regulation of tension chain and oiling

- Tightening of screws

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Replace:

- Gearbox fluid

- Spark plug

- Filtering elements of the filter box

- Brake pads ( if necessary )

- Crown, pinion, chain ( if necessary )

- Clutch disc ( if necessary )

X X

X X X X

X X

Clean:

- Pinion head

- Combustion chamber

- Exhaust pipe exit

X X X

Clean:

- Carburettor

Vehicle testing:

- On the road

X X X

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DISASSEMBLY OF THE ENGINE OF THE VEHICLE

-D

isassemble:

the petrol tube to the carburettor the oil pipe to the pump the two tubes of the cooling circuit (cylinder head and pump) gas control the spark plug cap the oil pump control the filter box

-Disconn

the electrical installation of the magneto the electrical installation of the neutral

-Disassemble the transmission chain (fast union

loosen nut of the swing fork loosen and remove: screw sup fastening of the engine and make it pivot upwards the other two screws of the engine

-Remove the engine and put it on the brack adaptor (this bracket has to be screwed to a bench)

ect:

)

-Take the oil out of the gearbox, screw (a)

-Remove the draining screw from the water pump (B) to empty it.

CAUTION: respect the environment, recover the used oil and antifreeze fluid in the appropiate containers.

Página 7 de 34

DISA

Remove the 5 screws (CHC M5x0.80-20) and remove the cover.

Immobilize the rotor and loosen the magneto nut with tool.

Screw the extractor off the wheel and act on the central part of it to take out the rotor (assembled on conical axle with pin).

SSEMBLY OF THE MAGNETO

Remove the three screws with star head (M4x0.70-19) and their washers.

IMPORTANT: Before removing the stator base, leave a small mark on the housing case and on the plaque so you can find back the initial position during the assembly.

Loosen the three screws with allen head (BHC M4x0.70-10) and remove the stator plaque (Allen wrench of 2.5 mm).

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ASSEMBLY OF THE CLUTCH COVER

Activate the starting pedal slightly and keep it in this position.

Remove the fixing screw from the pedal.

Loosen the pedal launcher screw and remove the spring.

Loosen and remove the 8 fixing screws from the cover (type CHC).

Remove the joint and the two centring bubbles from the cover with the housing case.

IMPORTANT: Write down the position of the starting pedal on the spindle to put it back during the assembly (see page 25).

DISASSEMBLY OF THE CLUTCH

Loosen and remove the 4 screws (CB M5x0.80-

20), the washers and the springs from the pressure plate.

Disassemble the upholstery discs and the plain ones.

Take out the primary driving shaft, the ball and the driving stick (see page 23 A B C).

Straighten the nut brake.

Immobilize the rotor clutch with tool.

Loosen and remove the nut (wrench 17) and the nut brake. Disassemble the rotor, grooved separator, the plain washer (17.2x30x0.8) and the interior cogged conical washer (write down its position for the assembly).

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DISASSEMBLY OF THE CRANKSHAFT PINIONS AND OF THE CAM SHAFT

Put

a screw (type CHC M6x1.00-25 for example) into one of the thread holes of the camshaft pinion, resting its end on the ribbing of the housing case.

With the immobilixed pin in rotation, loosen the crankshaft nut (wrench 17) and the cam shaft nut (wrench 19) and remove them.

Disassembly of the crankshaft:

The two pinions (20 cogs and 34 cogs), the in (note the direction of the pinion 20 z, mark towards the nut). The smooth washer (812.3x22x0.8), the pinion (34 cogs) and the pin.

DISASSEMBLY OF THE INLET PIPE AND PLATE VALVE

Loosen and remove the 4 fixing screws (CHC M6x1.00-20) from the inlet pipe.

Disassemble the pipe and the plate sheet (overhaul of valve is in the chapter dedicated to the assembly, page 19). Disassemble the clutch lever with its spring and washer.

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