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Page 2
SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOPWORKSHOP
MANUALMANUAL
Page 3
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
Page 4
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
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Page 5
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
Page 6
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
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Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 7
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
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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
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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
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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
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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
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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
Page 13
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
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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
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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
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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
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Page 17
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
- Remove the front wheel (see operation 7)
- Drift the fork (4) out of the steering tube (5) (the
fork has a slight interference fit in the steering tube
bearings)
IMPORTANT: do not damage the pivot tube internal
thread (6) when drifting out the fork
- Recover washers (A) and (B) from the upper and
lower Tees
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Page 18
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
- Remove the headlight (see operation 1B)
- Remove the speedometer fairing (see operation 3B)
- Remove the expansion tank (1) (1 bolt)
- Remove the 2 bolts (2) from the fork tubes
- Remove the headlight mount (3)
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Page 19
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
position)
- Remove the securing strap (4) (2 screws)
- Move the brake fluid reservoir clear without
disconnecting it, 1 screw (9)
- Remove the passenger footrests (3) (2 x 2 bolts)
- Remove the rear mudflap (6) by removing the 4
screws (7) ((7A) stack N°5, (7B) stack N°3)
- Remove the rear frame assembly 4 bolts (5)
- Remove the rear frame assembly (8)
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Page 20
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
Do not operate the brake lever or as a precaution fit
a wedge between the brake pads
Work possible with the rear wheel removed
-
Tyre or valve replacement
note the direction of rotation of the tyre before
Note:
removing and refit it the same way round
-
Brake disc replacement
when refitting, fit the right way round: marking
Note:
on the outside, and fit the 6 bolts with normal locking
compound
-
Wheel bearing replacement
-
Rear sprocket replacement
: refit the 6 bolts with normal locking compound
Note
If the sprocket is to be refitted, note which way round
it is fitted before removal
The rear sprocket must be changed if the gearbox
drive sprocket and chain are changed
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FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Removal of the chain Operation 9
Note the running direction of the chain if it is to be
refitted
The 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. A properly
adjusted chain should have a slack (A) of 25 to 30
mm at 15 cm from the rear wheel spindle
Removal of the chain guide
- Remove the LH fairing hatch (1 bolt)
- Remove the chain cover (1) (2 bolts)
- Remove the guide 2 securing bolts (3)
- Remove the guide (4)
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FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
- Remove the caliper (2)
- Remove the pins (3)
- Remove the brake pads (4) and their shims (5)
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
After removing the wheel, the caliper or the pads,
before road testing, check the brake operates correctly
by operating the lever several times
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FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
(1)
- Remove the nut, the washer and the upper fixing pin
(2)
- Remove the shock absorber (3) from the top
: the shock absorber is not adjustable, only the
Note
supplier is authorised to adjust it
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FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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.
Point (3) is fitted to the shock absorber
Points (1) and (2) are fitted to the frame (E) and are
composed of: a bolt (B1), a washer (B2) a nut (B3), a
spacer (C) and two grease-mounted sealing cups (D)
Point (5) is used for the link between the pivots (A)
and the linkrods (B) and is composed of: a bolt (B1), a
washer (B2) a nut (B3), a spacer (C) and two greasemounted sealing cups (D)
- Refitting order to be complied with
1 – fit pin (1) to the suspension arm
2 – fit pin (3) to the shock absorber
3 – fit pin (2) to the frame (raise the rear wheel to
facilitate fitting)
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Page 25
FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
- Remove the pivot pin fixing point (6) from the
suspension arm
- Remove the shock absorber lower spindle fixing
point (7)
- Remove the pin from the suspension arm (2)
- Remove the suspension arm (note the routing of the
hydraulic pipe)
The suspension arm front mount bush is
interference fitting in the silentblocs (avoid removing
it if it is not necessary)
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FRAME
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
-
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)
- Locate the pivot mounting pin on the suspension
arm (taking care with the sealing cups (5))
Do not pinch the hydraulic pipe
- Position the wheel and the caliper bracket
- Locate the wheel spindle making sure the bushes are
properly fitted
- Put the caliper in position (2 bolts)
- Fit the chain and tension it (see operation 10)
- Tighten all parts to the recommended torque
- Refit the suspension arm spindle caps
Page 25
Page 27
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
- Remove the 2 rear light nuts from inside the rear
fairing (stack N° 7)
- Remove the rear light (3)
Removal of the number plate plinth
- Remove the rear fairing 4 bolts (1)
- Disconnect the rear light and the indicator lights
- Remove the number plate plinth (2)
- Remove the direction indicators (3) and the rear light
(4)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 26
Page 28
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)
Removal of a front direction indicator
- Remove 1 bolt (1) under the headlight fairing and
disconnect it
- Remove the front direction indicator (2)
Removal of a rear direction indicator
- Unlock the passenger saddle
- Disconnect the direction indicator connection
(secured by a plastic tie)
- Remove 1 bolt and 1 nut (3) in the rear mudflap
- Remove the rear direction indicator (4)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 27
Page 29
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
- Remove the handle bars (1)
- Remove the fork upper Tee 3 bolts (2 bolts (2) on
the fork tube, 1 central bolt (3) using a 10 mm Allen
key
- Pull the upper Tee clear to access the steering lock 2
bolts (1) one of which is a shear bolt
- Remove the steering lock (2)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 28
Page 30
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)
- Remove of the throttle grip and oil pump
Removal of the oil tank
- Remove the rear fairing (see operation 6)
- Drain the tank or take the necessary precautions to
prevent spillage
- Disconnect the oil level switch and the feed union
- Remove the 2 bolts (1)
- Remove the tank (2)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 29
Page 31
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
- Release the box from the carburettor sleeve
- Remove the box (1) from the top by turning it a
quarter of a turn to the left of the machine
Removal of the exhaust Operation 11
- Remove the right-hand fairing (see operation 5) with
the central (10 screws)
- Unhook the 2 springs (1) from the exhaust
- Remove the 2 securing bolts mounted on silentblocs
(1 on the frame, 1 on the passenger footrest)
- Note the position of the exhaust on its mounting
points front mounting on the inside of the machine
and rear mounting on the outside of the machine
- Remove the exhaust (2)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 30
Page 32
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
mm Allen key P/N: 755812
- Undo the air filter clip (5)
- Remove the choke connection, 1 screw (6)
- Release the carburettor from the inlet coupling
- Remove the carburettor
Adjustment:
Idle: screw (7), remove the left-hand fairing hatch
Mixture: screw (8), directly accessible
Removal of the valves
- Remove the carburettor (see operation 12)
- Remove the coupling 4 screws (1)
Screws (1A) are removed with a 4 mm Allen key,
P/N: 755813
Screw (1B) is common to the clutch cable outer stop
bracket (2)
- Remove the carburettor union (3) and the valves (4)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 31
Page 33
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
this also acts as a rectifier and direction
Note:
indicator control unit
- Remove the fuel tank assembly (see operation 2A)
- Remove the 2 screws (3), the nuts and the washers
- Remove the regulator (4)
Removal of a LH or RH control cluster
- Remove the instrument panel (see operation 3A)
- Remove the grip 2 screws (1)
- Release the throttle cable or choke cable, depending
on the side
- Disconnect the brake light (RH side)
- Disconnect the connection with the main harness
under the instrument panel
- Remove the control cluster
note the position of the cluster harness ties
Note:
before cutting them, and refit them in the same place
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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Page 34
Removal of the ignition module
ELECTRICITY
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)
- Remove the horn (2)
Removal of the rear wiring harness
- Remove the fuel tank assembly (see operation 2A)
- Remove the rear fairing (see operation 6)
- Disconnect the oil reservoir connector
- disconnect the rear brake light switch
- Disconnect the connection with the main harness
- Cut the 3 plastic ties (1)
- Remove the harness (2)
Page 33
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 35
ELECTRICITY
1. battery leads (2 clips per pole)
2. connection with the rear harness
3. voltage regulator/flasher unit connector
4. horn connection
5. engine earth lead
6. fuse holder
7. starter motor relay connector and earth wire
8. temperature sensor connector
9. ignition module connector
10. starter motor connector
11. neutral switch connector
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
12. flywheel outlet yellow wire
13. LH cluster connector
14. RH cluster connector
15. brake light switch connector
16. instrument panel connector
17. steering lock connector
18. LH cable grommet
19. RH cable grommet
20. fuel low level warning light connector
21. front direction indicators connector
22. headlight connector
Page 34
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Removal of the main harness
ELECTRICITY
- Remove the fuel tank assembly (see operation 2A)
- Remove the side fairings (see operation 4)
- Remove the side fairings and the centre fairing (see
operation 5)
- Disconnect the battery (1)
- Disconnect the connection with the rear harness (2)
- Disconnect the voltage regulator/flasher unit(3)
- Disconnect the horn (4)
- Disconnect the engine earth lead (5)
- Remove the fuse holder assembly from its support
(6)
- Disconnect the starter motor relay and its earth wire
(7)
- Disconnect the temperature sensor (8)
- Disconnect the ignition module (9)
- Disconnect the starter motor (10)
- Disconnect the neutral switch (11)
- Disconnect the flywheel outlet yellow wire (12)
- Remove the headlight (see operation 1B)
- Disconnect the control cluster connectors
LH and RH sides (13) and (14)
- Disconnect the RH cluster brake light switch
- Disconnect the instrument panel (16)
- Remove the electrical part of the steering lock (17)
Without pulling untowardly, gradually
pull out the harness through the frame LH side
opening in the following order:
1. the taped assembly (1) of the LH connections
(starter motor relay, etc)
2. the steering lock harness (B) section located
inside the frame
3. the front RH connection taped assembly (C)
4. feed the rear RH connection taped assembly (D)
through the frame
5. complete extraction through the LH opening
As the lock is connected inside the machine front
structure, it is preferable to use this method to
facilitate refitting
- Remove the RH and LH cable grommets (18 and 19)
Preparation:
- Wrap a few turns of sticky tape around the rear left
(A), front right (C), rear right (D) and the harness
ends to facilitate its extraction from the frame front
structure
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 35
Page 37
ELECTRICITY
Refitting the main harness
Proceed in reverse order to removal. If the harness is
being changed, we recommend it is prepared in the
same way as the one removed before fitting
In particular:
- wrap a few turns of insulating tape over the ends
- make the same curves with the plastic ties
- connect the different items from the harness changed
(diodes, fuses, steering lock harness)
Check the positioning of the different connections
and control cables.
From frame RH side:
- throttle and clutch cables
- brake light switch harness
- direction indicator harness
- RH control cluster connector (6-pin)
From frame LH side:
- choke cable
- steering lock harness
- instrument panel connector (12-pin)
- LH control cluster connector (9-pin) with the
headlight connection harness
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 36
Page 38
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
WORK ON THE ENGINE WITHOUT
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)
- Disconnect the carburettor heating hoses (2)
- Disconnect the water pump hose (3)
- Slacken the engine mount side fixing points (4) and
(4a) in the frame front compartment
- Slacken and remove the front mount pin (5) and
push the mount forwards
See the XP6 workshop manual pages 9 and 17 for
removal of the cylinder head, cylinder and piston
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 37
Page 39
WORK ON THE ENGINE WITHOUT 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)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 38
Page 40
WORK ON THE ENGINE WITHOUT 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)
The rotor (2) also acts and the starter motor ring
Note:
gear
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 39
Page 41
WORK ON THE ENGINE WITHOUT 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)
Note which way round the output sprocket is fitted
if it is to be re-used
The gearbox output sprocket must be changed if
the rear sprocket and chain are changed
Removal of the neutral switch
- Remove the LH fairing (10 screws)
- Disconnect the wire (1) (1 nut on the terminal)
- Remove the switch (2)
Lean the vehicle so that the gearbox oil does not
run out
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 40
Page 42
WORK ON THE ENGINE WITHOUT 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)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 41
Page 43
COOLING
COOLING
When 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)
Removal of the expansion tank and the expansion
tank/radiator hose
- Remove the LH fairing (10 screws)
- Drain the cooling circuit (drain screw (1) on the
water pump)
- Remove the expansion tank (4) hose (2)
- Remove the expansion tank fixing bolt (3)
- Remove the expansion tank (4)
Removal of the radiator
- Remove the side fairings (see operation 5)
- Drain the cooling circuit (drain screw on the water
pump)
- Disconnect the three radiator hoses
- Remove the securing bolt (1) from the radiator
bracket under the frame steering tube
- Remove the radiator (2)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 42
Page 44
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)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 43
Page 45
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
with the selection shaft (gearbox in first)
- Disconnect the link
- Remove the exhaust (see operation 11)
- Disconnect the oil feed and the oil pump control
cable
- Disconnect the clutch cable and remove the outer
covering stop fixed to the inlet coupling
- Disconnect the starter motor, neutral switch,
flywheel outlet harness (yellow wire and coil HT
lead), suppressor, temperature sensor
- Disconnect the carburettor heating hoses
- Remove the carburettor (see operation 12) and the
air filter box coupling
- Disconnect the water pump and cylinder head hoses
- Slacken the engine 3 mountings (4) (do not remove
the rear upper mounting nut (4A))
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 44
Page 46
- 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
MOTOR
- 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
in order to facilitate refitting of the fairings, this
Note:
shaft must be tightened after refitting fairings
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 45
Page 47
MOTOR
- Release the engine from the rear upper lugs on the
frame (8)
With 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)
- Position the front engine mount (4C)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 46
Page 48
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
5)
- Remove the battery and its support
- Disconnect the harness and rear brake light switch
- Remove the exhaust
- Remove the rear brake fluid reservoir without
disconnecting it
- Slacken the air filter box sleeve hose clip on the
carburettor side
- Disconnect the oil pump feed pipe
- Remove the 4 bolts securing the rear frame to the
main frame
- Remove the rear frame assembly (1)
On the engine:
- Remove the chain
- Remove the selector linkage from the engine
- Disconnect:
- the neutral switch
- the horn
- the magneto output yellow wire
- the starter motor connector
- the temperature sensor
- the ignition module engine cut-out
- the ignition module earth wires
- throttle and choke valves
- the oil pump cable
- the clutch cable
- Remove the expansion tank without disconnecting it
- Remove the radiator upper mount
- Slacken the rear upper engine mount
- Remove the rear lower mount
- Remove the 4 engine mount bolts from under the
front frame
- Remove the engine, front mount and radiator (2)
assembly
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 47
Page 49
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
headlight (3) assembly
At the front/fork:
- Remove the electrical part of the steering lock (2)
- Remove the fork upper Tee (2 side bolts, 1 centre
bolt)
- Remove the fork, front wheel and handlebar
assembly (4)
At the rear:
- Remove the RH footrest plate 2 securing bolts
- Remove the shock absorber upper fixing bolt
- Remove the S/A pivot to frame bolt
- Remove the suspension arm, S/A pivot, shock
absorber, caliper, plate and brake cylinder, mudguard
and rear wheel assembly (5)
Remove the frame
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 48
Page 50
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
FRAME
Fit the new frame by proceeding in reverse order to
disassembly
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
Page 49
Page 51
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
Page 52
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