WORKSHOPWORKSHOPMANUALMANUAL

SALES DIVISIONNETWORK TECHNICAL INFORMATION

CONTENTS

Page 2

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

CHARACTERISTICS ...................................................................................................................................4Machine markings.................................................................................................................................................................4Characteristics.......................................................................................................................................................................4Frame.....................................................................................................................................................................................4Capacities..............................................................................................................................................................................4Dimensions............................................................................................................................................................................4Weight...................................................................................................................................................................................4Tyres......................................................................................................................................................................................4Engine markings...................................................................................................................................................................4SERVICE AND COMMISSIONING INSTRUCTIONS ..............................................................................5

Check:....................................................................................................................................................................................5Change...................................................................................................................................................................................5Check and remove carbon....................................................................................................................................................5Check and lubricate..............................................................................................................................................................5Check and adjust...................................................................................................................................................................5Clean and adjust....................................................................................................................................................................5Test machine.........................................................................................................................................................................5Battery preparation (except for maintenance- free battery)................................................................................................6Top- up checks.......................................................................................................................................................................6Filling the fuel and oil circuits.............................................................................................................................................6Checks before handing over to the customer......................................................................................................................6SPECIAL IMPORTANT POINTS ...............................................................................................................7

Oil and fuel............................................................................................................................................................................7Starting...................................................................................................................................................................................7Special features.....................................................................................................................................................................7Electricity..............................................................................................................................................................................7TIGHTENING TORQUES AND SPECIAL TOOLS ..................................................................................8

Tightening torques................................................................................................................................................................8Special tools:.........................................................................................................................................................................8BODY.............................................................................................................................................................9

Body panel bolt fitting..........................................................................................................................................................9Removal of the headlight fairing Operation 1 A.............................................................................................................10Removal of the headlight Operation 1 B.........................................................................................................................10Removal of the fuel tank assembly Operation 2 A.........................................................................................................11Stripping down the fuel tank Operation 2 B....................................................................................................................11Removal of the instrument panel Operation 3A..............................................................................................................12Removal of the speedometer Operation 3 B....................................................................................................................12Removal of the side fairings Operation 4........................................................................................................................12Removal of the side fairings and the centre fairing Operation 5...................................................................................13Removal of the rear fairing and the number plate plinth Operation 6...........................................................................13FRAME ........................................................................................................................................................14

Removal of the front wheel Operation7..........................................................................................................................14Work possible with the front wheel removed...................................................................................................................14Removal of the front mudguards and the front mudguard stay Operation 8.................................................................15Removal of the speedometer cable....................................................................................................................................15Removal of the front caliper and the brake pads..............................................................................................................15Removal of the fork............................................................................................................................................................16Removal of the fork tubes..................................................................................................................................................17Removal of the headlight mount........................................................................................................................................17Removal of the rear frame assembly.................................................................................................................................18Removal of the rear wheel..................................................................................................................................................19Work possible with the rear wheel removed.....................................................................................................................19Removal of the chain Operation 9...................................................................................................................................20Chain tension adjustment Operation 10...........................................................................................................................20Removal of the chain guide................................................................................................................................................20Removal of the rear mudguard...........................................................................................................................................21

CONTENTS

Page 3

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the rear caliper and the brake pads................................................................................................................21Removal of the shock absorber..........................................................................................................................................22Removal of the shock absorber pivot................................................................................................................................23Removal of the suspension arm.........................................................................................................................................24Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted).................................................25MISCELLANEOUS OPERATIONS ..........................................................................................................26

Removal of the rear mudflap..............................................................................................................................................26Removal of the rear light assembly...................................................................................................................................26Removal of the number plate plinth..................................................................................................................................26Removal of the instrument panel.......................................................................................................................................27Removal of the windshield.................................................................................................................................................27Removal of a front direction indicator..............................................................................................................................27Removal of a rear direction indicator................................................................................................................................27Removal of the steering lock..............................................................................................................................................28Removal of the throttle grip and oil pump........................................................................................................................29Removal of the oil tank......................................................................................................................................................29Removal of the air filter foam............................................................................................................................................30Removal of the air filter box..............................................................................................................................................30Removal of the exhaust Operation 11.............................................................................................................................30Removal of the carburettor Operation 12........................................................................................................................31Removal of the valves........................................................................................................................................................31ELECTRICITY ...........................................................................................................................................32

Removal of the battery........................................................................................................................................................32Removal of the starter motor relay....................................................................................................................................32Removal of the voltage regulator.......................................................................................................................................32Removal of a LH or RH control cluster............................................................................................................................32Removal of the ignition module.........................................................................................................................................33Removal of the horn...........................................................................................................................................................33Removal of the rear wiring harness...................................................................................................................................33Removal of the main harness.............................................................................................................................................35Refitting the main harness..................................................................................................................................................36WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE ......................................................37

Removal of the cylinder head/ cylinder/ piston..................................................................................................................37Removal of the oil pump....................................................................................................................................................38Removal of the rotor and the magneto flywheel armature...............................................................................................39Removal of the gearbox output sprocket...........................................................................................................................40Removal of the neutral switch............................................................................................................................................40Removal of the starter motor..............................................................................................................................................41COOLING....................................................................................................................................................42

Removal of the cylinder head/ radiator hose......................................................................................................................42Removal of the expansion tank and the expansion tank/ radiator hose............................................................................42Removal of the radiator......................................................................................................................................................42Removal of the engine temperature sensor.......................................................................................................................43MOTOR.......................................................................................................................................................44

Removal of the engine........................................................................................................................................................44Refitting the engine to the frame.......................................................................................................................................46FRAME ........................................................................................................................................................47

Removal of the frame.........................................................................................................................................................47

CHARACTERISTICS

Page 4

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

CHARACTERISTICS

Machine markings

Model code DR01A

Characteristics

Engine 2 stroke water cooled

Marque Minarelli 50 cc

Bore x stroke 40.3 x 39Cubic capacity 49.7 ccMax. poweroutput

1.32 kw

Maximum torque2.66 NmGrosscompression ratio

12

Ignition CDISpark plug NGK BR9 ESCarburettor Dell'Orto PHBN 12 HSIdle speed 930 200 rpm

Air screw initialposition

1 1/2 turns

Needle A34Main jet 60Idle jet 36

Magneto Ducati 85 WStarter motor Ducati

Frame

1 Manufacturers plate2 VIN number

Capacities

Gearbox 0,75 litresFuel tank 11.75 litresOil tank 1.1 litresShowa fork 0.175 litres per tube

Dimensions

Length 1.865 mmWidth 675mmHeight without rearview mirror

1.100 mm

Wheelbase 1265 mm

Weight

Weight 115 kg

Tyres

1 person 2 personsFront wheel 1.85"x16"Front tyre 90/90x16"Front tyre pressure 1,8 bar 2,2 barRear wheel 2,5"x16"Rear tyre 120/80x16"Rear tyre pressure 2 bar 2.5 bar

Engine markings

Engine type AM6

(1) engine number: paper label stuck to rearmudguard under the saddle

SERVICE AND COMMISSIONING INSTRUCTIONS

Page 5

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

SERVICE AND COMMISSIONING INSTRUCTIONS

Heavy duty servicing is for machines used under harsh conditions, driver temperament, short journeyswith engine cold, dusty regions, ambient temperature over 30C.

Servicing operations 500 Kmsor 3 months

Every 3000 Kms Every 6000 Kms

Check:Idle adjustment X X XThrottle and oil pump X X XFront and rear brake lever X X XFunctioning of electrical equipment X X XFuel piping X X XOil piping X X XFront and rear brake fluid piping X X XCoolant piping X X XFuel heating piping X X XTyre pressures XTyre condition, pressure and wear X XFront and rear brake fluid level X X XCoolant level X X XBattery electrolyte level X X XTightness of nuts and bolts X X XBattery charge X X

ChangeInlet silence filter element X XFront and rear brake pad #X #XGearbox oil X XChain-front sprocket-rear sprocket #X #XClutch discs #X

Check and remove carbonPiston (1) # Every 10000 kmsCylinder head (1) # Every 10000 kmsExhaust port (1) # Every 10000 kms

Check and lubricateChain tension and condition X X X

Check and adjustClutch cable X XOil pump cable X XSpark plug X XHeadlight height X X

Clean and adjustCarburettor X X

Test machineOn 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

SERVICE AND COMMISSIONING INSTRUCTIONS

Page 6

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Battery preparation (except for maintenance- free battery)Remove the batteryRemove the 6 filler caps and the vent plugFill with electrolyte up to the UPPER LEVEL markElectrolyte: (35% sulphuric acid = 1.28g/cc) per litre P/N: 752740, per 5 litres P/N: 752741Let the battery stand for about half an hourTop up if necessaryCharge the battery for at least 2 hours with a current of 400 mA (0.4 A)Refit the battery and connect the vapour vent pipeConnect 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 checksCheck the gear box oil levelCheck the coolant level.Check the brake fluid levels

Filling the fuel and oil circuitsPut 1 litre of 95 or 98 unleaded fuel mixed with 3% semi-syntehtic 2-stroke oilTop up the oil with Esso semi-synthetic 2-stroke oilStart the engine, disconnect the oil feed hose to the carburettor, and check that the oil is fed through drop bydrop (the drop by drop speed increases with engine speed)Complete filling of the fuel tank with pure fuel

Checks before handing over to the customerCheck the wheel nuts are tight

Front wheel:4,5 m.daNRear wheel:6,5 m.daN

Check all nuts and bolts are tightCheck brake adjustment and efficiencyCheck the tyre pressures cold

Front wheel:1.8 barRear wheel:2 bar

Check operation of the lights, flashers, horn, and brake lightCheck functioning of the different warning lightsCarry out a road test

SPECIAL IMPORTANT POINTS

Page 7

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

SPECIAL IMPORTANT POINTS

Oil and fuelThis machine is designed to run on super 95 or 98 unleaded fuelThe oil to use for the separate lubrication system is Esso 2T special semi-synthetic 2-stroke oil

StartingWith the ignition on, the engine is cranked by the starter motor merely by pressing the starter buttonThe manual choke is operated by the choke lever on the left grip

Special featuresThe positions of the levers (brake and clutch) on the handlebars should not be altered to avoid any risk ofcontact with the instrument panel fairingThe bolts at the ends of the handlebars must be slackened off before those of the fork upper Tee to preventany risk of breakage at the Tee tightening points

ElectricityThe ignition unit acts both as the ignition unit and the high-tension coilThe voltage rectifier/regulator also serves as the flasher control unit

TIGHTENING TORQUES AND SPECIAL TOOLS

Page 8

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

TIGHTENING TORQUES AND SPECIAL TOOLS

Tightening torquesBody panels:Headlight fairing 0,1 m.daNSpeedo fairing 0,1 m.daNSide covers 0,1 m.daNSide and central fairings 0,1 m.daNRear fairing 0,1 m.daNFront mudguard 0,1 m.daNRear mudguard * 0.8/0.1 m.daNMudflap * 0.8/0.1 m.daNSecuring strap 1,2 m.daNFrame:Front wheel spindle nut 4,5 m.daNRear wheel spindle nut 6,5 m.daNSuspension arm nut 6,5 m.daNFront mount to chassis 4,5 m.daNEngine to front mount 4,5 m.daNEngine to chassis 2,8 m.daNShock absorber upper mount 4,3 m.daNShock absorber lower mount 4,3 m.daNFork Tees 1,5 m.daNUpper Tee centre bolt 5 m.daNFront mudguard bracket 2,5 m.daNFront brake caliper 2,5 m.daNRear brake caliper 2,5 m.daNFront brake disc 1 m.daNRear brake disc 1 m.daNFrame mounted stand 1,9 m.daNSteering lock 0,6 m.daNStandard:Nut and bolt 5 mm diameter 0,5 m.daNNut and bolt 6mm diameter 1 m.daNNut and bolt 8mm diameter 2,2 m.daNNut and bolt 10mm diameter 3,5 m.daNNut and bolt 12mm diameter 5.5 m.daN

Special tools:Standard Part N3 mm allen key (inlet manifold) 7558124 mm allen key (valve body) 755813

* depending on size of bolt

BODY

Page 9

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

BODY

Body panel bolt fitting

Important: there are different stacking ordersdepending on the assembly. When refitting, assemblethe fittings in the same order

In the instructions below the stacking order is given inbrackets after the operation.E.g.: Remove the 2 rear view mirrors (stacking orderN1)

1- part being fixed + fairing + spacer + rubber washer+ support + wide flat washer + nut

2- bolt + plastic washer + fairing + spacer + rubberwasher + support + wide flat washer + nut

3- bolt + plastic washer + fairing + captive nut fixedto support

4- bolt + plastic washer + fairing + spacer + rubberwasher + support + wide flat washer + nut

5- bolt + plastic washer + fairing + rubber washer +captive nut fixed to support

6- bolt + plastic washer + fairing + spacer + rubberwasher + support + wide flat washer + nut

7- bolt + plastic washer + fairing + spacer + rubberwasher + support + wide flat washer + nut

8- bolt + fairing + spacer + rubber bush + reservoir +captive nut fixed to support

9- bolt + plastic washer + fairing + captive nut fixedto support

10- bolt + fairing + windshield + flat washer + nut

BODY

Page 10

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 N2)- Remove the 4 bolts (3) from the side fairings (stackN 3)Remove the 2 bolts (4) under the headlight (stack N4)- 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

Page 11

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the fuel tank assembly Operation 2 A- Remove the passenger saddle (1) unlock the saddlewith the ignition key and pull it rearwards)- Remove the cap (3) from the inside of the rearmudguard

- Through the cap hole (3), and through the rearmudguard, remove the nut (4) and bracket (5) fromthe drivers saddle and pull the drivers saddle (2)rearwards to release it from the frame- Remove the drivers saddle (2)

- Remove the 2 bolts (6) from the tank (stack N 8)- Raise the tank to disconnect the fuel level warninglight, the fuel supply pipe and the fuel tap vacuumcoupling

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 slotsmust be lined up with the machine axis

BODY

Page 12

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the instrument panel Operation 3A- disconnect the speedometer control cable at thewheel end- Remove the instrument panel 2 screws (1)- Move the instrument panel clear- Disconnect the instrument panel connector- Remove the instrument panel (2) with thespeedometer 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 N5)- Remove the speedometer fairing (2)

Removal of the side fairings Operation 4- Remove the 2 screws (1) (stack N5)- Remove the side fairings (2) warning they interlockunder the fuel tank at (A) and under the rear fairing at(B)

BODY

Page 13

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the side fairings and the centre fairingOperation 5

- Remove the hatches (1) of the side fairing 1 screwon each (stack N5)- Remove the 4 screws (2) from the frame ((2A) stackN 5, (2B) stack N 6)- Remove the 2 screws (3) securing the RH and LHfairings (stack N9)- Remove the 2 screws (5) securing the LH sidefairing and the headlight fairing (stack N3)- Remove the 3 screws (4) securing the RH sidefairing to the centre fairing (stack N 9)- Remove the LH side and centre fairing assembly

- Remove the 2 screws (5) securing the RH sidefairing and the headlight- Remove the RH side fairing

Removal of the rear fairing and the number plateplinth Operation 6

- Remove the passenger saddle- Removing the drivers saddle (see operation 2 A)- Disconnect the rear light and the indicator lights- Remove the 6 screws (1) on the rear fairing; 2 at thefront (stack N6) and 4 in the saddle housing (stackN5)- Remove the rear fairing (2)

FRAME

Page 14

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 wheelspindle clear (3)- Remove the wheel (4)

Do not operate the brake lever or as a precaution fita wedge between the brake pads

Re- assembly- Grease the wheel spindle and also the speedometerdrive before refitting the wheel- Bring the speedometer drive (5) into contact (A)with the stop (6) on the RH tube and tighten the lock-nut (2) before tightening the wheel spindle nut- Slacken the lock-nut (2), and compress the forkseveral times in order to seat the fork tubes correctlyon the wheel spindle- Re-tighten the lock-nut (2)

Work possible with the front wheel removed- Tyre or valve replacementNote: note the direction of rotation of the tyrebefore removing and refit it the same way round- Brake disc replacementNote: when refitting, fit the right way round:marking on the outside, and fit the 6 bolts withnormal locking compound- Wheel bearing replacementNote: 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 correctlyby operating the lever several times

FRAME

Page 15

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the front mudguards and the frontmudguard stay Operation 8

- Remove the 4 screws (1) securing the mudguard tothe stay- Remove the mudguard (2)- Remove the 4 screws (3) securing the stay to thefork tubes- Remove the stay (4)

T he stay screws have an effect on the mudguardangle, hold the front of the mudguard in the upposition 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 theinstrument 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 themand not fitting new ones, note the RH/LH side padpositions and fit them the same way round

FRAME

Page 16

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 itto the fork tubes and 1 centre bolt (3) using a 10 mmAllen key- Remove the 2 brake caliper bolts, and move it clearwithout disconnecting it- Remove the front mudguard and the front mudguardstay (see operation 8)- Remove the front wheel (see operation 7)

- Drift the fork (4) out of the steering tube (5) (thefork has a slight interference fit in the steering tubebearings)IMPORTANT: do not damage the pivot tube internalthread (6) when drifting out the fork

- Recover washers (A) and (B) from the upper andlower Tees

FRAME

Page 17

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 mudguardstay (see operation 8)- Remove the front wheel (see operation 7)- Remove the 4 bolts (1) from the lower and upperTees

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)

FRAME

Page 18

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 levelswitch and the brake light- Remove the air filter casing 2 screws (leave it inposition)- Remove the securing strap (4) (2 screws)

- Move the brake fluid reservoir clear withoutdisconnecting it, 1 screw (9)- Remove the passenger footrests (3) (2 x 2 bolts)- Remove the rear mudflap (6) by removing the 4screws (7) ((7A) stack N5, (7B) stack N3)- Remove the rear frame assembly 4 bolts (5)

- Remove the rear frame assembly (8)

FRAME

Page 19

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 fita wedge between the brake pads

Work possible with the rear wheel removed- Tyre or valve replacement

Note: note the direction of rotation of the tyre beforeremoving and refit it the same way round- Brake disc replacement

Note: when refitting, fit the right way round: markingon the outside, and fit the 6 bolts with normal lockingcompound- Wheel bearing replacement- Rear sprocket replacement

Note: refit the 6 bolts with normal locking compoundIf the sprocket is to be refitted, note which way roundit is fitted before removal

T he rear sprocket must be changed if the gearboxdrive sprocket and chain are changed

FRAME

Page 20

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the chain Operation 9Note the running direction of the chain if it is to berefitted

T he chain must be changed if the gearbox drivesprocket 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 thewheel is centred in the suspension arm. A properlyadjusted chain should have a slack (A) of 25 to 30mm 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)

FRAME

Page 21

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 footrestbrackets- Slacken without removing the lower bolt (2) of eachof 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)

T he brake pads are identical; when removing themand not fitting new ones, note the RH/LH side padpositions and fit them the same way round

A fter removing the wheel, the caliper or the pads,before road testing, check the brake operates correctlyby operating the lever several times

FRAME

Page 22

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

Note: the shock absorber is not adjustable, only thesupplier is authorised to adjust it

FRAME

Page 23

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), 2linkrods (B) mounted on four pivot points.Point (3) is fitted to the shock absorberPoints (1) and (2) are fitted to the frame (E) and arecomposed of: a bolt (B1), a washer (B2) a nut (B3), aspacer (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), awasher (B2) a nut (B3), a spacer (C) and two grease-mounted sealing cups (D)

- Refitting order to be complied with1 fit pin (1) to the suspension arm2 fit pin (3) to the shock absorber3 fit pin (2) to the frame (raise the rear wheel tofacilitate fitting)

FRAME

Page 24

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 andwashers, the brake caliper bracket (4) and the 2spacers (5)- Remove the wheel

- Remove the pivot pin fixing point (6) from thesuspension arm- Remove the shock absorber lower spindle fixingpoint (7)- Remove the pin from the suspension arm (2)- Remove the suspension arm (note the routing of thehydraulic pipe)

T he suspension arm front mount bush isinterference fitting in the silentblocs (avoid removingit if it is not necessary)

FRAME

Page 25

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, chainguard, guide and tensioners fitted)

- Fit the rear brake caliper (1) through the suspensionarm behind the spacer (2)- Position the suspension arm- Locate the fixing spindle in the frame

- Tilt the pivot (3) forwards to locate the shockabsorber lower mount (4)- Locate the pivot mounting pin on the suspensionarm (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 areproperly 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

MISCELLANEOUS OPERATIONS

Page 26

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

MISCELLANEOUS OPERATIONS

Removal of the rear mudflap- Remove the passenger saddle- Remove the 2 front screws (1) then the 2 rear screws(2) (stack N5)-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 rearfairing (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)

MISCELLANEOUS OPERATIONS

Page 27

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 N10)- Remove the 3 screws (2) (stack N3)- Remove the windshield (3)

Removal of a front direction indicator- Remove 1 bolt (1) under the headlight fairing anddisconnect 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)

MISCELLANEOUS OPERATIONS

Page 28

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the steering lock

- Remove the fuel tank assembly fairing (seeoperation 2A)- Disconnect the steering lock from the wiring harness(5-pin connector (1) inside the frame; green, black andred wire)- Disconnect the connector (2) with 1 red and whitewire

Follow the removal order in order not to damage thefork Tee- Remove the handle bars (1)- Remove the fork upper Tee 3 bolts (2 bolts (2) onthe fork tube, 1 central bolt (3) using a 10 mm Allenkey

- Pull the upper Tee clear to access the steering lock 2bolts (1) one of which is a shear bolt- Remove the steering lock (2)

MISCELLANEOUS OPERATIONS

Page 29

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 toprevent spillage- Disconnect the oil level switch and the feed union- Remove the 2 bolts (1)- Remove the tank (2)

MISCELLANEOUS OPERATIONS

Page 30

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 thebox 2 bolts- Release the box from the carburettor sleeve- Remove the box (1) from the top by turning it aquarter of a turn to the left of the machine

Removal of the exhaust Operation 11- Remove the right-hand fairing (see operation 5) withthe 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 mountingpoints front mounting on the inside of the machineand rear mounting on the outside of the machine- Remove the exhaust (2)

MISCELLANEOUS OPERATIONS

Page 31

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 thehose 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 hatchMixture: 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: 755813Screw (1B) is common to the clutch cable outer stopbracket (2)- Remove the carburettor union (3) and the valves (4)

ELECTRICITY

Page 32

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 regulatorNote: this also acts as a rectifier and directionindicator 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, dependingon the side- Disconnect the brake light (RH side)- Disconnect the connection with the main harnessunder the instrument panel- Remove the control cluster

Note: note the position of the cluster harness tiesbefore cutting them, and refit them in the same place

ELECTRICITY

Page 33

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the ignition module

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)

ELECTRICITY

Page 34

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

1. battery leads (2 clips per pole)2. connection with the rear harness3. voltage regulator/flasher unit connector4. horn connection5. engine earth lead6. fuse holder7. starter motor relay connector and earth wire8. temperature sensor connector9. ignition module connector10. starter motor connector11. neutral switch connector

12. flywheel outlet yellow wire13. LH cluster connector14. RH cluster connector15. brake light switch connector16. instrument panel connector17. steering lock connector18. LH cable grommet19. RH cable grommet20. fuel low level warning light connector21. front direction indicators connector22. headlight connector

ELECTRICITY

Page 35

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the main harness

- Remove the fuel tank assembly (see operation 2A)- Remove the side fairings (see operation 4)- Remove the side fairings and the centre fairing (seeoperation 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 connectorsLH 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)

As the lock is connected inside the machine frontstructure, it is preferable to use this method tofacilitate 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 harnessends to facilitate its extraction from the frame frontstructure

Without pulling untowardly, graduallypull out the harness through the frame LH sideopening in the following order:

1. the taped assembly (1) of the LH connections(starter motor relay, etc)

2. the steering lock harness (B) section locatedinside 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

ELECTRICITY

Page 36

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Refitting the main harnessProceed in reverse order to removal. If the harness isbeing changed, we recommend it is prepared in thesame 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 connectionsand 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 theheadlight connection harness

WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Page 37

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

WORK ON THE ENGINE WITHOUTREMOVING 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) andpush the mount forwards

S ee the XP6 workshop manual pages 9 and 17 forremoval of the cylinder head, cylinder and piston

WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Page 38

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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)

WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Page 39

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

Removal of the rotor and the magneto flywheelarmature

- Remove the LH fairing (10 screws)- Remove the LH cover 5 bolts (1)

- Remove the rotor (2)

(For other operations on the magneto flywheel, seethe method in the XP6 workshop manual, page 6)

Note: The rotor (2) also acts and the starter motor ringgear

WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Page 40

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 fittedif it is to be re-used

T he gearbox output sprocket must be changed ifthe 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 notrun out

WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Page 41

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 onthe inside and 1 on the outside)- Disconnect the starter motor power lead (4)

- Remove the starter motor (5)

COOLING

Page 42

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

COOLING

When working on the cooling circuit, the enginemust 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 thewater pump)- Remove the hose clips (2)- Remove the hose (3)

Removal of the expansion tank and the expansiontank/ radiator hose

- Remove the LH fairing (10 screws)- Drain the cooling circuit (drain screw (1) on thewater 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 waterpump)- Disconnect the three radiator hoses- Remove the securing bolt (1) from the radiatorbracket under the frame steering tube- Remove the radiator (2)

COOLING

Page 43

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 tofacilitate access to the sensor (without disconnectingthe hose)- Remove the spark plug (1)- Disconnect and unscrew the sensor (2)

MOTOR

Page 44

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 thewater pump)

- Remove the chain cover (2) (2 bolts)- Remove the chain (see operation 9) noting whichway round it is fitted- Make a mark (A) on the selector link to line it upwith the selection shaft (gearbox in first)- Disconnect the link

- Remove the exhaust (see operation 11)- Disconnect the oil feed and the oil pump controlcable- Disconnect the clutch cable and remove the outercovering stop fixed to the inlet coupling- Disconnect the starter motor, neutral switch,flywheel outlet harness (yellow wire and coil HTlead), suppressor, temperature sensor- Disconnect the carburettor heating hoses- Remove the carburettor (see operation 12) and theair filter box coupling- Disconnect the water pump and cylinder head hoses

- Slacken the engine 3 mountings (4) (do not removethe rear upper mounting nut (4A))

MOTOR

Page 45

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

- Slacken the front engine mount 2 side fixing bolts(5) (without removing the nuts)

- Slacken and remove the front engine mount 2securing bolts (6) in the frame front compartment

- Remove the front mount fixing shaft (7) and pushthe mount forwards

- Remove the engine to frame lower mount shaft andthe fairing support fixed to the shaft

Note: in order to facilitate refitting of the fairings, thisshaft must be tightened after refitting fairings

MOTOR

Page 46

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

- Release the engine from the rear upper lugs on theframe (8)

W ith the engine removed, take the XP6 workshopmanual for details of work on the engine

Refitting the engine to the frame- Fit the engine rear upper mount shaft, washers andnuts

- Suspend the engine from the rear upper mount (4A)- Position in the rear lower mount (4B)- Position the front engine mount (4C)

FRAME

Page 47

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

FRAME

Removal of the frameThis method is used for replacement of the frameonly. If replacing a frame following an accident, themethod must be completed by the repair orreplacement 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 operation5)- Remove the battery and its support- Disconnect the harness and rear brake light switch- Remove the exhaust- Remove the rear brake fluid reservoir withoutdisconnecting it- Slacken the air filter box sleeve hose clip on thecarburettor side- Disconnect the oil pump feed pipe- Remove the 4 bolts securing the rear frame to themain 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 thefront frame

- Remove the engine, front mount and radiator (2)assembly

FRAME

Page 48

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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 2securing bolts

- Remove the headlight bracket, instrument panel andheadlight (3) assembly

At the front/ fork:- Remove the electrical part of the steering lock (2)- Remove the fork upper Tee (2 side bolts, 1 centrebolt)

- Remove the fork, front wheel and handlebarassembly (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, shockabsorber, caliper, plate and brake cylinder, mudguardand rear wheel assembly (5)

Remove the frame

FRAME

Page 49

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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

Fit the new frame by proceeding in reverse order todisassembly

Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

RECOMMENDS

REF: 755809

For reasons of continuous improvement, Peugeot Motocycles reserves the right to modify, delete or add any part number quotedDC/PS/ATR printed in EU 12/2000 (photos non-contractual)