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S ALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
CONTENTS
CHARACTERIS TICS................................................................................................................................... |
4 |
Machine markings................................................................................................................................................................. |
4 |
Characteristics....................................................................................................................................................................... |
4 |
Frame ..................................................................................................................................................................................... |
4 |
Capacities .............................................................................................................................................................................. |
4 |
Dimensions............................................................................................................................................................................ |
4 |
We ight ................................................................................................................................................................................... |
4 |
Tyres ...................................................................................................................................................................................... |
4 |
Engine markings ................................................................................................................................................................... |
4 |
SERVICE AND COMMISSIONING INS TRUCTIONS.............................................................................. |
5 |
Check: .................................................................................................................................................................................... |
5 |
Change ................................................................................................................................................................................... |
5 |
Check and remove carbon .................................................................................................................................................... |
5 |
Check and lubricate .............................................................................................................................................................. |
5 |
Check and adjust................................................................................................................................................................... |
5 |
Clean and adjust.................................................................................................................................................................... |
5 |
Test machine ......................................................................................................................................................................... |
5 |
Battery preparation (except for maintenancefree battery) ................................................................................................ |
6 |
Topup 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 Operation 1 A............................................................................................................. |
10 |
Removal of the headlight Operation 1 B......................................................................................................................... |
10 |
Removal of the fuel tank assembly Operation 2 A......................................................................................................... |
11 |
Stripping down the fuel tank Operation 2 B.................................................................................................................... |
11 |
Removal of the instrument panel Operation 3 A.............................................................................................................. |
12 |
Removal of the speedometer Operation 3 B.................................................................................................................... |
12 |
Removal of the side fairings Operation 4........................................................................................................................ |
12 |
Removal of the side fairings and the centre fairing Operation 5................................................................................... |
13 |
Removal of the rear fairing and the number plate plinth Operation 6........................................................................... |
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................................................................................................................................... |
20 |
Chain tension adjustment Operation 10........................................................................................................................... |
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 preassembled (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 Operation 11 ............................................................................................................................. |
30 |
Removal of the carburettor Operation 12........................................................................................................................ |
31 |
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 s witch............................................................................................................................................ |
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 |
Page 3
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
CHARACTERIS TICS
CHARACTERIS TICS
Machine markings
Model code |
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DR01A |
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Characteristics |
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Engine |
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2 stroke water cooled |
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Marque |
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Minarelli 50 cc |
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Bore x stroke |
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40.3 x 39 |
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Cubic capacity |
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49.7 cc |
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Max. power |
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1.32 kw |
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output |
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Maximum torque |
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2.66 Nm |
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Gross |
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12 |
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compression ratio |
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Ignition |
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CDI |
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Spark plug |
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NGK BR9 ES |
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Carburettor |
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Dell'Orto PHBN 12 HS |
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Idle speed |
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930 ±200 rpm |
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Air screw initial |
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1 1/2 turns |
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position |
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Needle |
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A34 |
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Main jet |
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60 |
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Idle jet |
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36 |
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Magneto |
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Ducati 85 W |
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Starter motor |
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Ducati |
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Frame
1Manufacturer’s plate
2VIN number
Capacities
Gearbox |
0,75 litres |
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Fuel tank |
11.75 litres |
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Oil tank |
1.1 litres |
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Showa fork |
0.175 litres per tube |
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Dimensions |
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Length |
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1.865 mm |
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Width |
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675mm |
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Height without rear |
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1.100 mm |
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view mirror |
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Wheelbase |
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1265 mm |
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Weight |
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Weight |
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115 kg |
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Tyres |
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1 person |
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2 persons |
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Front wheel |
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1.85"x16" |
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Front tyre |
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90/90x16" |
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Front tyre pressure |
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1,8 bar |
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2,2 bar |
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Rear wheel |
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2,5"x16" |
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Rear tyre |
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120/80x16" |
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Rear tyre pressure |
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2 bar |
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2.5 bar |
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Engine markings |
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Engine type |
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AM6 |
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(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 INS TRUCTIONS
SERVICE AND COMMISSIONING INS TRUCTIONS
Heavy duty servicing is for machines used under “harsh” conditions, driver temperament, short journeys with engine cold, dusty regions, ambient temperature over 30°C.
Servicing operations |
500 Kms |
Every 3000 Kms |
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Every 6000 Kms |
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or 3 months |
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Check: |
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Idle adjustment |
X |
X |
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X |
||||||||
Throttle and oil pump |
X |
X |
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X |
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Front and rear brake lever |
X |
X |
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X |
||||||||
Functioning of electrical equipment |
X |
X |
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X |
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Fuel piping |
X |
X |
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X |
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Oil piping |
X |
X |
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X |
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Front and rear brake fluid piping |
X |
X |
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X |
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Coolant piping |
X |
X |
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X |
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Fuel heating piping |
X |
X |
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X |
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Tyre pressures |
X |
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Tyre condition, pressure and wear |
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X |
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X |
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Front and rear brake fluid level |
X |
X |
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X |
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Coolant level |
X |
X |
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X |
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Battery electrolyte level |
X |
X |
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X |
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Tightness of nuts and bolts |
X |
X |
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X |
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Battery charge |
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X |
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X |
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Change |
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Inlet silence filter element |
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X |
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X |
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Front and rear brake pad |
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#X |
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#X |
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Gearbox oil |
X |
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X |
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Chain-front sprocket-rear sprocket |
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#X |
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#X |
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Clutch discs |
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#X |
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Check and remove carbon |
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Piston (1) |
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# Every 10000 kms |
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Cylinder head (1) |
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# Every 10000 kms |
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Exhaust port (1) |
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# Every 10000 kms |
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Check and lubricate |
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Chain tension and condition |
X |
X |
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X |
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Check and adjust |
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Clutch cable |
X |
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X |
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Oil pump cable |
X |
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X |
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Spark plug |
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X |
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X |
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Headlight height |
X |
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X |
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Clean and adjust |
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Carburettor |
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X |
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X |
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Test machine |
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On road |
X |
X |
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X |
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(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 INS TRUCTIONS
Battery preparation (except for maintenancefree 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
Topup 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
Page 6
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
Page 7
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
|
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|
TIGHTENING TORQUES AND SPECIAL TOOLS |
|||
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TIGHTENING TORQUES AND SPECIAL TOOLS |
|
|
|||
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|
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Tightening torques |
|
|
|
|
|
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Body panels: |
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|
|||
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Headlight fairing |
0,1 m.daN |
|
|||
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Speedo fairing |
0,1 m.daN |
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|||
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Side covers |
0,1 m.daN |
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|||
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Side and central fairings |
0,1 m.daN |
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|||
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Rear fairing |
0,1 m.daN |
|
|||
|
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Front mudguard |
0,1 m.daN |
|
|||
|
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Rear mudguard * |
0.8/0.1 m.daN |
|
|||
|
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Mudflap * |
0.8/0.1 m.daN |
|
|||
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Securing strap |
1,2 m.daN |
|
|||
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Frame: |
|
|
|||
|
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Front wheel spindle nut |
4,5 m.daN |
|
|||
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Rear wheel spindle nut |
6,5 m.daN |
|
|||
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Suspension arm nut |
6,5 m.daN |
|
|||
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Front mount to chassis |
4,5 m.daN |
|
|||
|
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Engine to front mount |
4,5 m.daN |
|
|||
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Engine to chassis |
2,8 m.daN |
|
|||
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Shock absorber upper mount |
4,3 m.daN |
|
|||
|
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Shock absorber lower mount |
4,3 m.daN |
|
|||
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Fork Tees |
1,5 m.daN |
|
|||
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Upper Tee centre bolt |
5 m.daN |
|
|||
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Front mudguard bracket |
2,5 m.daN |
|
|||
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Front brake caliper |
2,5 m.daN |
|
|||
|
|
Rear brake caliper |
2,5 m.daN |
|
|||
|
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Front brake disc |
1 m.daN |
|
|||
|
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Rear brake disc |
1 m.daN |
|
|||
|
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Frame mounted stand |
1,9 m.daN |
|
|||
|
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Steering lock |
0,6 m.daN |
|
|||
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|
Standard: |
|
|
|||
|
|
Nut and bolt 5 mm diameter |
0,5 m.daN |
|
|||
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Nut and bolt 6mm diameter |
1 m.daN |
|
|||
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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
Page 8
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
BODY
BODY
Body panel bolt fitting
Important: there are different stacking orders depending on the assembly. When refitting, assemble the fittings in the same order
In the instructions below the stacking order is given in brackets after the operation.
E.g.: Remove the 2 rear view mirrors (stacking order N°1)
1- part being fixed + fairing + spacer + rubber washer + support + wide flat washer + nut
2- bolt + plastic washer + fairing + spacer + rubber washer + support + wide flat washer + nut
3- bolt + plastic washer + fairing + captive nut fixed to support
4- bolt + plastic washer + fairing + spacer + rubber washer + support + wide flat washer + nut
5- bolt + plastic washer + fairing + rubber washer + captive nut fixed to support
6- bolt + plastic washer + fairing + spacer + rubber washer + support + wide flat washer + nut
7- bolt + plastic washer + fairing + spacer + rubber washer + support + wide flat washer + nut
8- bolt + fairing + spacer + rubber bush + reservoir + captive nut fixed to support
9- bolt + plastic washer + fairing + captive nut fixed to support
10- bolt + fairing + windshield + flat washer + nut
Page 9
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
BODY
Removal of the headlight fairing Operation 1 A
-Remove the 2 rear view mirrors (1) (stack N° 1)
-Remove the 2 bolts (2) on the windshield (stack N° 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)
Page 10
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
BODY
Removal of the fuel tank assembly Operation 2 A
-Remove the passenger saddle (1) unlock the saddle with the ignition key and pull it rearwards)
-Remove the cap (3) from the inside of the rear mudguard
-Through the cap hole (3), and through the rear mudguard, remove the nut (4) and bracket (5) from the driver’s saddle and pull the driver’s saddle (2) rearwards to release it from the frame
-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
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)
Note: certain machines do not have fuel tank spacers (11) and (16)
When refitting, the filler cap surround locking slots must be lined up with the machine axis
Page 11
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
BODY
Removal of the instrument panel Operation 3A
-disconnect the speedometer control cable at the wheel end
-Remove the instrument panel 2 screws (1)
-Move the instrument panel clear
-Disconnect the instrument panel connector
-Remove the instrument panel (2) with the speedometer cable
Removal of the speedometer Operation 3 B
-Remove the headlight fairing (see operation 1A)
-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)
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)
Page 12
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
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FRAME
FRAME
Front part
Removal of the front wheel Operation7
-Unscrew the speedometer cable (1)
-Slacken the wheel spindle nut and the clamping nut
(2) on the front of the fork tube
-Remove the wheel spindle nut, and pull the wheel spindle clear (3)
-Remove the wheel (4)
D o not operate the brake lever or as a precaution fit a wedge between the brake pads
Reassembly
-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: note the direction of rotation of the tyre before removing and refit it the same way round - Brake disc replacement
Note: when refitting, fit the right way round: marking on the outside, and fit the 6 bolts with normal locking compound
- Wheel bearing replacement
Note: there is a seal (5) and the speedometer drive
(6) on the RH side
-Speedometer drive replacement
A fter 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
Removal of the front mudguards and the front mudguard stay Operation 8
-Remove the 4 screws (1) securing the mudguard to the stay
-Remove the mudguard (2)
-Remove the 4 screws (3) securing the stay to the fork tubes
-Remove the stay (4)
T he stay screws have an effect on the mudguard 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)
T he 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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Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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