PEUGEOT XR6 User Manual
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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOPWORKSHOP
MANUALMANUAL
CONTENTS
CHARACTERISTICS................................................................................................................................... 4
Machine markings................................................................................................................................................................. 4
Characteristics....................................................................................................................................................................... 4
Frame..................................................................................................................................................................................... 4
Capacities..............................................................................................................................................................................4
Dimensions............................................................................................................................................................................ 4
Weight ................................................................................................................................................................................... 4
Tyres......................................................................................................................................................................................4
Engine markings ................................................................................................................................................................... 4
SERVICE AND COMMISSIONING INSTRUCTIONS.............................................................................. 5
Check:.................................................................................................................................................................................... 5
Change................................................................................................................................................................................... 5
Check and remove carbon .................................................................................................................................................... 5
Check and lubricate .............................................................................................................................................................. 5
Check and adjust................................................................................................................................................................... 5
Clean and adjust.................................................................................................................................................................... 5
Test machine ......................................................................................................................................................................... 5
Battery preparation (except for maintenance-free battery) ................................................................................................ 6
Top-up checks ....................................................................................................................................................................... 6
Filling the fuel and oil circuits............................................................................................................................................. 6
Checks before handing over to the customer ...................................................................................................................... 6
SPECIAL IMPORTANT POINTS ............................................................................................................... 7
Oil and fuel ............................................................................................................................................................................7
Starting................................................................................................................................................................................... 7
Special features..................................................................................................................................................................... 7
Electricity .............................................................................................................................................................................. 7
TIGHTENING TORQUES AND SPECIAL TOOLS ..................................................................................8
Tightening torques ................................................................................................................................................................ 8
Special tools:......................................................................................................................................................................... 8
BODY.............................................................................................................................................................9
Body panel bolt fitting ..........................................................................................................................................................9
Removal of the headlight fairing
Removal of the headlight
Operation 1 B
Removal of the fuel tank assembly
Stripping down the fuel tank
Removal of the instrument panel
Removal of the speedometer
Removal of the side fairings
Operation 1 A
.........................................................................................................................10
Operation 2 A
Operation 2 B
Operation 3A
Operation 3 B
Operation 4
Removal of the side fairings and the centre fairing
Removal of the rear fairing and the number plate plinth
.............................................................................................................10
.........................................................................................................11
....................................................................................................................11
..............................................................................................................12
....................................................................................................................12
........................................................................................................................12
Operation 5
Operation 6
...................................................................................13
...........................................................................13
FRAME........................................................................................................................................................14
Removal of the front wheel
Operation7
..........................................................................................................................14
Work possible with the front wheel removed................................................................................................................... 14
Removal of the front mudguards and the front mudguard stay
Operation 8
.................................................................15
Removal of the speedometer cable .................................................................................................................................... 15
Removal of the front caliper and the brake pads.............................................................................................................. 15
Removal of the fork............................................................................................................................................................ 16
Removal of the fork tubes.................................................................................................................................................. 17
Removal of the headlight mount........................................................................................................................................ 17
Removal of the rear frame assembly ................................................................................................................................. 18
Removal of the rear wheel.................................................................................................................................................. 19
Work possible with the rear wheel removed.....................................................................................................................19
Removal of the chain
Operation 9
Chain tension adjustment
Operation 10
...................................................................................................................................20
...........................................................................................................................20
Removal of the chain guide................................................................................................................................................ 20
Removal of the rear mudguard...........................................................................................................................................21
Page 2
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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.............................................................................................................................................. 26
Removal of the rear light assembly ................................................................................................................................... 26
Removal of the number plate plinth ..................................................................................................................................26
Removal of the instrument panel ....................................................................................................................................... 27
Removal of the windshield.................................................................................................................................................27
Removal of a front direction indicator .............................................................................................................................. 27
Removal of a rear direction indicator ................................................................................................................................27
Removal of the steering lock.............................................................................................................................................. 28
Removal of the throttle grip and oil pump ........................................................................................................................ 29
Removal of the oil tank ......................................................................................................................................................29
Removal of the air filter foam ............................................................................................................................................30
Removal of the air filter box .............................................................................................................................................. 30
Removal of the exhaust
Removal of the carburettor
Operation 11
Operation 12
Removal of the valves........................................................................................................................................................ 31
ELECTRICITY ...........................................................................................................................................32
Removal of the battery........................................................................................................................................................32
Removal of the starter motor relay ....................................................................................................................................32
Removal of the voltage regulator.......................................................................................................................................32
Removal of a LH or RH control cluster............................................................................................................................ 32
Removal of the ignition module.........................................................................................................................................33
Removal of the horn ...........................................................................................................................................................33
Removal of the rear wiring harness ...................................................................................................................................33
Removal of the main harness .............................................................................................................................................35
Refitting the main harness.................................................................................................................................................. 36
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE......................................................37
Removal of the cylinder head/cylinder/piston.................................................................................................................. 37
Removal of the oil pump ....................................................................................................................................................38
Removal of the rotor and the magneto flywheel armature...............................................................................................39
Removal of the gearbox output sprocket........................................................................................................................... 40
Removal of the neutral switch............................................................................................................................................40
Removal of the starter motor..............................................................................................................................................41
COOLING....................................................................................................................................................42
Removal of the cylinder head/radiator hose......................................................................................................................42
Removal of the expansion tank and the expansion tank/radiator hose............................................................................ 42
Removal of the radiator ......................................................................................................................................................42
Removal of the engine temperature sensor ....................................................................................................................... 43
MOTOR .......................................................................................................................................................44
Removal of the engine ........................................................................................................................................................44
Refitting the engine to the frame .......................................................................................................................................46
FRAME........................................................................................................................................................47
Removal of the frame ......................................................................................................................................................... 47
.............................................................................................................................30
........................................................................................................................31
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 3
CHARACTERISTICS
Machine markings
Model code
Characteristics
Engine
2 stroke water cooled
CHARACTERISTICS
Capacities
Gearbox 0,75 litres
Fuel tank 11.75 litres
Oil tank 1.1 litres
Showa fork 0.175 litres per tube
Marque Minarelli 50 cc
Bore x stroke 40.3 x 39
Cubic capacity 49.7 cc
Max. power
1.32 kw
output
Maximum torque 2.66 Nm
Gross
12
compression ratio
Ignition
CDI
Spark plug NGK BR9 ES
Carburettor
Idle speed 930
Air screw initial
Dell'Orto PHBN 12 HS
±200
rpm
1 1/2 turns
position
Needle A34
Main jet 60
Idle jet 36
Magneto
Starter motor
Ducati 85 W
Ducati
Dimensions
Length 1.865 mm
Width 675mm
Height without rear
1.100 mm
view mirror
Wheelbase 1265 mm
Weight
Weight 115 kg
Tyres
1 person 2 persons
Front wheel 1.85"x16"
Front tyre 90/90x16"
Front tyre pressure 1,8 bar 2,2 bar
Rear wheel 2,5"x16"
Rear tyre 120/80x16"
Rear tyre pressure 2 bar 2.5 bar
Frame
1
2
Engine markings
Engine type AM6
Manufacturer’s plate
VIN number
(1) engine number: paper label stuck to rear
mudguard under the saddle
Page 4
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
SERVICE AND COMMISSIONING INSTRUCTIONS
SERVICE AND COMMISSIONING INSTRUCTIONS
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:
Idle adjustment X X X
Throttle and oil pump X X X
Front and rear brake lever X X X
Functioning of electrical equipment X X X
Fuel piping X X X
Oil piping X X X
Front and rear brake fluid piping X X X
Coolant piping X X X
Fuel heating piping X X X
Tyre pressures X
Tyre condition, pressure and wear X X
Front and rear brake fluid level X X X
Coolant level X X X
Battery electrolyte level X X X
Tightness of nuts and bolts X X X
Battery charge X X
Change
Inlet silence filter element X X
Front and rear brake pad #X #X
Gearbox oil X X
Chain-front sprocket-rear sprocket #X #X
Clutch discs #X
Check and remove carbon
Piston (1) # Every 10000 kms
Cylinder head (1) # Every 10000 kms
Exhaust port (1) # Every 10000 kms
Check and lubricate
Chain tension and condition X X X
Check and adjust
Clutch cable X X
Oil pump cable X X
Spark plug X X
Headlight height X X
Clean and adjust
Carburettor X X
Test machine
On road X X X
(1) the need to remove carbon may be determined by checking the quantity of carbon in the cylinder exhaust port.
# if necessary
Page 5
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
SERVICE AND COMMISSIONING INSTRUCTIONS
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)
Refit the battery and connect the vapour vent pipe
Connect the terminal with the red wires to the + and the terminal with the black wire to the Then the battery should be topped up if necessary, after a complete charge, using distilled water only
Top-up checks
Check the gear box oil level
Check the coolant level.
Check the brake fluid levels
Filling the fuel and oil circuits
Put 1 litre of 95 or 98 unleaded fuel mixed with 3% semi-syntehtic 2-stroke oil
Top up the oil with Esso semi-synthetic 2-stroke oil
Start the engine, disconnect the oil feed hose to the carburettor, and check that the oil is fed through drop by
drop (the drop by drop speed increases with engine speed)
Complete filling of the fuel tank with pure fuel
Checks before handing over to the customer
Check the wheel nuts are tight
Front wheel: 4,5 m.daN
Rear wheel: 6,5 m.daN
Check all nuts and bolts are tight
Check brake adjustment and efficiency
Check the tyre pressures cold
Front wheel: 1.8 bar
Rear wheel: 2 bar
Check operation of the lights, flashers, horn, and brake light
Check functioning of the different warning lights
Carry out a road test
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 6
SPECIAL IMPORTANT POINTS
SPECIAL IMPORTANT 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
Special features
The positions of the levers (brake and clutch) on the handlebars should not be altered to avoid any risk of
contact with the instrument panel fairing
The bolts at the ends of the handlebars must be slackened off before those of the fork upper Tee to prevent
any risk of breakage at the Tee tightening points
Electricity
The ignition unit acts both as the ignition unit and the high-tension coil
The voltage rectifier/regulator also serves as the flasher control unit
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 7
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 * 0.8/0.1 m.daN
Securing strap 1,2 m.daN
Frame:
Front wheel spindle nut 4,5 m.daN
Rear wheel spindle nut 6,5 m.daN
Suspension arm nut 6,5 m.daN
Front mount to chassis 4,5 m.daN
Engine to front mount 4,5 m.daN
Engine to chassis 2,8 m.daN
Shock absorber upper mount 4,3 m.daN
Shock absorber lower mount 4,3 m.daN
Fork Tees 1,5 m.daN
Upper Tee centre bolt 5 m.daN
Front mudguard bracket 2,5 m.daN
Front brake caliper 2,5 m.daN
Rear brake caliper 2,5 m.daN
Front brake disc 1 m.daN
Rear brake disc 1 m.daN
Frame mounted stand 1,9 m.daN
Steering lock 0,6 m.daN
Standard:
Nut and bolt 5 mm diameter 0,5 m.daN
Nut and bolt 6mm diameter 1 m.daN
Nut and bolt 8mm diameter 2,2 m.daN
Nut and bolt 10mm diameter 3,5 m.daN
Nut and bolt 12mm diameter 5.5 m.daN
Special tools:
Standard Part N°
3 mm allen key (inlet manifold) 755812
4 mm allen key (valve body) 755813
* depending on size of bolt
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 8
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 (
)
N°1
part being fixed + fairing + spacer + rubber washer
1-
stacking order
+ support + wide flat washer + nut
bolt + plastic washer + fairing + spacer + rubber
2-
washer + support + wide flat washer + nut
bolt + plastic washer + fairing + captive nut fixed
3-
to support
bolt + plastic washer + fairing + spacer + rubber
4-
washer + support + wide flat washer + nut
bolt + plastic washer + fairing + rubber washer +
5-
captive nut fixed to support
bolt + plastic washer + fairing + spacer + rubber
6-
washer + support + wide flat washer + nut
bolt + plastic washer + fairing + spacer + rubber
7-
washer + support + wide flat washer + nut
bolt + fairing + spacer + rubber bush + reservoir +
8-
captive nut fixed to support
- bolt + plastic washer + fairing + captive nut fixed
9
to support
- bolt + fairing + windshield + flat washer + nut
10
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 9
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°
2)
- Remove the 4 bolts (3) from the side fairings (stack
N° 3)
Remove the 2 bolts (4) under the headlight (stack N°
4)
- Disconnect the direction indicators
- Remove the headlight fairing (5)
Removal of the headlight Operation 1 B
- Remove the headlight fairing (see operation 1A)
- Remove the headlight 4 securing bolts (6)
- Remove the headlight (7)
BODY
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 10
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
- Remove the driver’s saddle (2)
- Remove the 2 bolts (6) from the tank (stack N° 8)
- Raise the tank to disconnect the fuel level warning
light, the fuel supply pipe and the fuel tap vacuum
coupling
BODY
Stripping down the fuel tank Operation 2 B
- Remove the fuel tank assembly (see operation 2A)
- Remove the filler cap (7)
- Remove the cap trim (9) five screws (8)
- Remove the fuel tank cover (10)
- Remove the fuel tank shim (11)
- Remove the filler cap surround 6 screws (12)
- Remove the filler cap surround (13) and its gasket
(14)
- Remove the fuel tank front spacer (15)
- Remove the fuel tank rear spacer (16)
certain machines do not have fuel tank spacers
Note:
(11) and (16)
When refitting, the filler cap surround locking slots
must be lined up with the machine axis
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 11
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)
- Remove the instrument panel (see operation 3A)
Remove the 4 screws (1) and the 6 rubber washers
(stack N°5)
- Remove the speedometer fairing (2)
BODY
Removal of the side fairings Operation 4
- Remove the 2 screws (1) (stack N°5)
- Remove the side fairings (2)
warning
they interlock
under the fuel tank at (A) and under the rear fairing at
(B)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 12
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
fairing and the headlight fairing (stack N°3)
- Remove the 3 screws (4) securing the RH side
fairing to the centre fairing (stack N° 9)
- Remove the LH side and centre fairing assembly
- Remove the 2 screws (5) securing the RH side
fairing and the headlight
- Remove the RH side fairing
Removal of the rear fairing and the number plate
plinth Operation 6
- Remove the passenger saddle
- Removing the driver’s saddle (see operation 2 A)
- Disconnect the rear light and the indicator lights
- Remove the 6 screws (1) on the rear fairing; 2 at the
front (stack N°6) and 4 in the saddle housing (stack
N°5)
- Remove the rear fairing (2)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 13
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
Do not operate the brake lever or as a precaution fit
a wedge between the brake pads
Re-assembly
- Grease the wheel spindle and also the speedometer
drive before refitting the wheel
- Bring the speedometer drive (5) into contact (A)
with the stop (6) on the RH tube and tighten the locknut (2) before tightening the wheel spindle nut
- Slacken the lock-nut (2), and compress the fork
several times in order to seat the fork tubes correctly
on the wheel spindle
- Re-tighten the lock-nut (2)
Work possible with the front wheel removed
-
Tyre or valve replacement
note the direction of rotation of the tyre
Note:
before removing and refit it the same way round
-
Brake disc replacement
when refitting, fit the right way round:
Note:
marking on the outside, and fit the 6 bolts with
normal locking compound
-
Wheel bearing replacement
there is a seal (5) and the speedometer drive
Note:
(6) on the RH side
-
Speedometer drive replacement
After removing the wheel, the caliper or the pads,
before road testing, check the brake operates correctly
by operating the lever several times
Page 14
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
The stay screws have an effect on the mudguard
angle, hold the front of the mudguard in the up
position while tightening the screws
Removal of the speedometer cable
- Remove the instrument panel (see operation 3A)
without disconnecting the wiring harness
- Unscrew the speedometer cable (1) from the
instrument panel
- Remove the speedometer cable (1)
Removal of the front caliper and the brake pads
- Remove the 2 bolts (1) from the fork tube
- Remove the caliper (2)
- Remove the pins (3)
- Remove the brake pads (4)
The brake pads are identical; when removing them
and not fitting new ones, note the RH/LH side pad
positions and fit them the same way round
Page 15
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