PEUGEOT XPS User Manual
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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
50 cc ENGINE
MULTI-SPEED
CONTENTS
CONTENTS
CONTENTS..........................................................................................................................................2
CHARACTERISTICS.........................................................................................................................4
Characteristics.................................................................................................................................................4
Capacities........................................................................................................................................................4
Engine markings.............................................................................................................................................4
SPECIAL IMPORTANT POINTS.....................................................................................................5
Oil and fuel.....................................................................................................................................................5
TIGHTENING TORQUES.................................................................................................................6
Tightening torques..........................................................................................................................................6
SPECIAL TOOLS................................................................................................................................7
DISASSEMBLY ...................................................................................................................................9
Putting the engine on the stand.......................................................................................................................9
To remove the magneto flywheel...................................................................................................................9
To remove the stator.....................................................................................................................................10
To remove the starter motor (depending on model).....................................................................................10
To remove the gearbox output pinion...........................................................................................................10
To remove the clutch cover ..........................................................................................................................11
To remove the clutch....................................................................................................................................12
To remove the crank assembly and balance shaft pinions............................................................................14
To remove the inlet manifold and valve.......................................................................................................14
To remove the cylinder head/cylinder assembly..........................................................................................15
To remove the piston....................................................................................................................................15
Removal of the thermostat............................................................................................................................16
Removal of the temperature sensor ..............................................................................................................16
To open the engine casings...........................................................................................................................17
To remove the gearbox and the selector system...........................................................................................18
To remove a primary or secondary shaft pinion...........................................................................................20
To remove the balance shaft.........................................................................................................................21
To remove the crank assembly.....................................................................................................................21
Checking the crank assembly .......................................................................................................................22
REFITTING SPECIFIC COMPONENTS......................................................................................23
To fit the crank assembly bearings...............................................................................................................23
To fit the box output seal..............................................................................................................................24
To fit the selector shaft seal..........................................................................................................................24
To fit the clutch lever seal ............................................................................................................................24
To fit the balance shaft .................................................................................................................................25
To fit the crank assembly..............................................................................................................................25
To fit the gearbox..........................................................................................................................................25
To fit the left side casing ..............................................................................................................................27
To check the piston.......................................................................................................................................29
To check the piston rings..............................................................................................................................29
To fit the piston.............................................................................................................................................29
To fit the cylinder .........................................................................................................................................30
To fit the cylinder head.................................................................................................................................30
To fit the right side O-ring............................................................................................................................31
To fit the crank assembly and balance shaft pinions....................................................................................31
To fit the clutch.............................................................................................................................................33
To adjust the clutch control lever .................................................................................................................35
Page 2
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
CONTENTS
To fit the starter system (depending on model) and the clutch cover...........................................................35
To fit the magneto flywheel..........................................................................................................................36
MISCELLANEOUS OPERATIONS ...............................................................................................37
To remove the water pump...........................................................................................................................37
To fit the water pump ...................................................................................................................................37
To remove the oil pump and its drive pinions..............................................................................................38
To fit the oil pump........................................................................................................................................38
Page : 3
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
CHARACTERISTICS
Characteristics
Engine
Single cylinder 2-stroke with
balance shaft
Cooling Liquid
Bore x stroke 40.3 x 39 mm
Cubic capacity 49.7 cc
Max. power
output
1.82 kW at 5250 rpm
Max. torque at 5250 rpm
Gearbox 6-speed
Clutch Oil bath multi-disc with
manual control
Oil pump Mikuni ESOP-03
Spark plug NGK BR9ES
Magneto flywheel Ducati 85 W
Starter motor Ducati
Carburettor Dell'orto PHBN 12
CHARACTERISTICS
Capacities
Gearbox 0.75 L.
Engine markings
Engine type AM6
SAE 10W30
Page 4
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
SPECIAL IMPORTANT POINTS
Oil and fuel
This engine is designed to run on 95 or 98 unleaded
fuel only
The separate lubrication system oil to use is Esso 2T Spécial recommended by the manufacturer.
Note:
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.
Page : 5
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
TIGHTENING TORQUES
TIGHTENING TORQUES
Tightening torques
Cylinder head 1.8 m.daN
Cylinder casings 1.1 m.daN
Transmission cover 1.1 m.daN
Water pump 1.1 m.daN
Inlet manifold 1.1 m.daN
Crank assembly pinion 7.5 m.daN
Balance shaft pinion 6 m.daN
Clutch cover 7.5 m.daN
Clutch pressure plate 0.5 m.daN
Clutch thrust bearing locknut 2.7 m.daN
Starter motor 1.1 m.daN
Rotor 5.2 m.daN
Stator 0.3 m.daN
Magneto flywheel cover 0.4 m.daN
Gearbox drain plug 1.8 m.daN
Spark plug 2.5 m.daN
Page 6
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
SPECIAL TOOLS
. Tool N° Description Used with
SPECIAL TOOLS
752000 Piston circlip pliers
64706 Casing extractor
and opening tool
64710 Shoulder locator 64706
64765 Engine support
68994 Torque wrench 8
Nm to 54 Nm
69098 Protective cap
large model
69104 Wing nut
69117 Exterior circlip
pliers
750069 +
Casing
opening
plate + pin
Engine
support
adapter
Extension
752235
adapter
752236
754003
64711 +
64712 +
64754
752235 1/2 extension
752236 1/2-3/8 adapter
752237 Adjustable pin
wrench
753411 Magneto flywheel
extractor
753708 Casing opening
plate
753709 Engine mount
adapter
69802 or
753977
69802 or
753978
68007
64706
750069 Stud Ø10 pitch
125
69104
753726 Crank assy lip seal
fitting tool for
primary
transmission side
753728 Selector shaft lip
seal fitting tool
750539 Tie-wrap pliers
Page : 7
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
TOOLS
753729 Water pump lip seal
fitting tool
753730 Clutch lever lip seal
fitting tool
753731 Clutch locking tool
753977 Torque wrench 30
Nm to 150 Nm
Extension
752235
adapter
752237
755585 Bearing extractor
tool
755813 Valve unit safety
Allen key
Page 8
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
DISASSEMBLY
DISASSEMBLY
Putting the engine on the stand
- Fit the engine to adapter P/N 753709
- Lock the engine to the adapter using the 2 spring
pins
- Put the assembly on stand P/N 64765 clamped in
the jaws of a vice
To remove the magneto flywheel
- Remove the magneto flywheel cover
- Remove the paper gasket
- Hold the rotor (1) with the pin wrench
P/N 752237
- Remove the nut
Depending on the model, the rotor acts as the
starter ring
- Tighten flywheel extractor P/N 753411 on the
rotor
- Lock the flywheel extractor and turn the thrust
bolt until the rotor is released
Page : 9
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
DISASSEMBLY
To remove the stator
- Remove the three fixing bolts (1) from the stator
plate and stator
- Remove the stator plate and stator assembly
Note:
We recommend tapping the bolts with a
hammer and drift to facilitate slackening
The 3 bolts must be renewed once removed
To remove the starter motor (depending on model)
- Remove the starter motor (2) three fixing
bolts (1)
- Remove the 2 spring pins
which lock the engine to the adapter
- Move the engine along the adapter guides to
remove the starter motor
- Re-fit the 2 spring pins
To remove the gearbox output pinion
- Remove the circlip (1) using pliers P/N
69117
- Remove the pinion (2)
- Remove the second circlip
Page 10
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
DISASSEMBLY
To remove the clutch cover
- Remove the kickstart pedal securing bolt
(depending on model)
- Lightly operate the kickstart pedal and hold it in
position
- Slacken off the kickstart shaft thrust bearing (1)
and release the kickstart pedal to relax the spring
- Remove the kickstart pedal
Note:
Use a recipient to recover the box oil
- Remove the bolt (2) in order to drain off the
gearbox
- Remove the cover 8 fixing bolts
- Remove the cover
- Remove the two centring pillars and the paper
gasket
Page : 11
Reproduction or translation, even partial, is forbidden without prior written consent of Peugeot Motocycles
DISASSEMBLY
To remove the clutch
- Remove the four bolts and spring (1) from the
pressure plate (2)
- Remove the pressure plate
- Remove the assembly (3) of 4 lined discs and 3
smooth discs
- Withdraw the primary shaft:
- the piston (4)
- the ball (5)
- the thrust rod (6)
- Remove the clutch operating lever (7) with its
spring (8) and its washer (9)
Page 12
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