Peugeot Motorcycles XR6 Instruction manual

WORKSHOPWORKSHOP
MANUALMANUAL
SALES DIVISION
NETWORK TECHNICAL INFORMATION

CONTENTS
Page 2
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS...................................................................................................................................4
Machine markings................................................................................................................................................................. 4
Characteristics....................................................................................................................................................................... 4
Frame..................................................................................................................................................................................... 4
Capacities.............................................................................................................................................................................. 4
Dimensions............................................................................................................................................................................ 4
Weight ................................................................................................................................................................................... 4
Tyres...................................................................................................................................................................................... 4
Engine markings................................................................................................................................................................... 4
SERVICE AND COMMISSIONING INSTRUCTIONS..............................................................................5
Check:.................................................................................................................................................................................... 5
Change................................................................................................................................................................................... 5
Check and remove carbon.................................................................................................................................................... 5
Check and lubricate.............................................................................................................................................................. 5
Check and adjust................................................................................................................................................................... 5
Clean and adjust.................................................................................................................................................................... 5
Test machine ......................................................................................................................................................................... 5
Battery preparation (except for maintenance-free battery) ................................................................................................ 6
Top-up checks....................................................................................................................................................................... 6
Filling the fuel and oil circuits............................................................................................................................................. 6
Checks before handing over to the customer...................................................................................................................... 6
SPECIAL IMPORTANT POINTS ...............................................................................................................7
Oil and fuel............................................................................................................................................................................ 7
Starting................................................................................................................................................................................... 7
Special features..................................................................................................................................................................... 7
Electricity.............................................................................................................................................................................. 7
TIGHTENING TORQUES AND SPECIAL TOOLS ..................................................................................8
Tightening torques................................................................................................................................................................ 8
Special tools:......................................................................................................................................................................... 8
BODY.............................................................................................................................................................9
Body panel bolt fitting.......................................................................................................................................................... 9
Removal of the headlight fairing 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 3A..............................................................................................................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

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................................................................................................................21
Removal of the shock absorber..........................................................................................................................................22
Removal of the shock absorber pivot................................................................................................................................23
Removal of the suspension arm......................................................................................................................................... 24
Suspension arm pre-assembled (mudguard, chain guard, guide and tensioners fitted) .................................................25
MISCELLANEOUS OPERATIONS..........................................................................................................26
Removal of the rear mudflap.............................................................................................................................................. 26
Removal of the rear light assembly...................................................................................................................................26
Removal of the number plate plinth .................................................................................................................................. 26
Removal of the instrument panel.......................................................................................................................................27
Removal of the windshield.................................................................................................................................................27
Removal of a front direction indicator .............................................................................................................................. 27
Removal of a rear direction indicator................................................................................................................................27
Removal of the steering lock..............................................................................................................................................28
Removal of the throttle grip and oil pump........................................................................................................................29
Removal of the oil tank ...................................................................................................................................................... 29
Removal of the air filter foam............................................................................................................................................ 30
Removal of the air filter box..............................................................................................................................................30
Removal of the exhaust 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 switch............................................................................................................................................40
Removal of the starter motor..............................................................................................................................................41
COOLING....................................................................................................................................................42
Removal of the cylinder head/radiator hose......................................................................................................................42
Removal of the expansion tank and the expansion tank/radiator hose............................................................................ 42
Removal of the radiator......................................................................................................................................................42
Removal of the engine temperature sensor.......................................................................................................................43
MOTOR .......................................................................................................................................................44
Removal of the engine........................................................................................................................................................ 44
Refitting the engine to the frame .......................................................................................................................................46
FRAME........................................................................................................................................................47
Removal of the frame.........................................................................................................................................................47

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 39
Cubic capacity 49.7 cc
Max. power
output 1.32 kw
Maximum torque 2.66 Nm
Gross
compression ratio 12
IgnitionCDI
Spark plug NGK BR9 ES
CarburettorDell'Orto PHBN 12 HS
Idle speed 930 ±200 rpm
Air screw initial
position 1 1/2 turns
Needle A34
Main jet 60
Idle jet 36
Magneto Ducati 85 W
Starter motorDucati
Frame
1Manufacturer’s plate
2VIN number
Capacities
Gearbox 0,75 litres
Fuel tank 11.75 litres
Oil tank 1.1 litres
Showa fork 0.175 litres per tube
Dimensions
Length 1.865 mm
Width 675mm
Height without rear
view mirror 1.100 mm
Wheelbase 1265 mm
Weight
Weight 115 kg
Tyres
1 person 2 persons
Front wheel 1.85"x16"
Front tyre 90/90x16"
Front tyre pressure 1,8 bar 2,2 bar
Rear wheel 2,5"x16"
Rear tyre 120/80x16"
Rear tyre pressure 2 bar 2.5 bar
Engine markings
Engine type AM6
(1) engine number: paper label stuck to rear
mudguard 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 journeys
with engine cold, dusty regions, ambient temperature over 30°C.
Servicing operations 500 Kms
or 3 months Every 3000 Kms Every 6000 Kms
Check:
Idle adjustment X X X
Throttle and oil pump X X X
Front and rear brake lever X X X
Functioning of electrical equipment X X X
Fuel piping X X X
Oil piping X X X
Front and rear brake fluid piping X X X
Coolant piping X X X
Fuel heating piping X X X
Tyre pressures X
Tyre condition, pressure and wear X X
Front and rear brake fluid level X X X
Coolant level X X X
Battery electrolyte level X X X
Tightness of nuts and bolts X X X
Battery charge X X
Change
Inlet silence filter element X X
Front and rear brake pad #X #X
Gearbox oil X X
Chain-front sprocket-rear sprocket #X #X
Clutch discs #X
Check and remove carbon
Piston (1) # Every 10000 kms
Cylinder head (1) # Every 10000 kms
Exhaust port (1) # Every 10000 kms
Check and lubricate
Chain tension and condition X X X
Check and adjust
Clutch cable X X
Oil pump cable X X
Spark plug X X
Headlight height X X
Clean and adjust
Carburettor X X
Test machine
On road X X X
(1) the need to remove carbon may be determined by checking the quantity of carbon in the cylinder exhaust port.
# if necessary

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 battery
Remove the 6 filler caps and the vent plug
Fill with electrolyte up to the UPPER LEVEL mark
Electrolyte: (35% sulphuric acid = 1.28g/cc) per litre P/N: 752740, per 5 litres P/N: 752741
Let the battery stand for about half an hour
Top up if necessary
Charge the battery for at least 2 hours with a current of 400 mA (0.4 A)
Refit the battery and connect the vapour vent pipe
Connect the terminal with the red wires to the + and the terminal with the black wire to the -
Then the battery should be topped up if necessary, after a complete charge, using distilled water only
Top-up checks
Check the gear box oil level
Check the coolant level.
Check the brake fluid levels
Filling the fuel and oil circuits
Put 1 litre of 95 or 98 unleaded fuel mixed with 3% semi-syntehtic 2-stroke oil
Top up the oil with Esso semi-synthetic 2-stroke oil
Start the engine, disconnect the oil feed hose to the carburettor, and check that the oil is fed through drop by
drop (the drop by drop speed increases with engine speed)
Complete filling of the fuel tank with pure fuel
Checks before handing over to the customer
Check the wheel nuts are tight
Front wheel: 4,5 m.daN
Rear wheel: 6,5 m.daN
Check all nuts and bolts are tight
Check brake adjustment and efficiency
Check the tyre pressures cold
Front wheel: 1.8 bar
Rear wheel: 2 bar
Check operation of the lights, flashers, horn, and brake light
Check functioning of the different warning lights
Carry out a road test

SPECIAL IMPORTANT POINTS
Page 7
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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

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 torques
Body panels:
Headlight fairing 0,1 m.daN
Speedo fairing 0,1 m.daN
Side covers 0,1 m.daN
Side and central fairings 0,1 m.daN
Rear fairing 0,1 m.daN
Front mudguard 0,1 m.daN
Rear mudguard * 0.8/0.1 m.daN
Mudflap * 0.8/0.1 m.daN
Securing strap 1,2 m.daN
Frame:
Front wheel spindle nut 4,5 m.daN
Rear wheel spindle nut 6,5 m.daN
Suspension arm nut 6,5 m.daN
Front mount to chassis 4,5 m.daN
Engine to front mount 4,5 m.daN
Engine to chassis 2,8 m.daN
Shock absorber upper mount 4,3 m.daN
Shock absorber lower mount 4,3 m.daN
Fork Tees 1,5 m.daN
Upper Tee centre bolt 5 m.daN
Front mudguard bracket 2,5 m.daN
Front brake caliper 2,5 m.daN
Rear brake caliper 2,5 m.daN
Front brake disc 1 m.daN
Rear brake disc 1 m.daN
Frame mounted stand 1,9 m.daN
Steering lock 0,6 m.daN
Standard:
Nut and bolt 5 mm diameter 0,5 m.daN
Nut and bolt 6mm diameter 1 m.daN
Nut and bolt 8mm diameter 2,2 m.daN
Nut and bolt 10mm diameter 3,5 m.daN
Nut and bolt 12mm diameter 5.5 m.daN
Special tools:
Standard Part N°
3 mm allen key (inlet manifold) 755812
4 mm allen key (valve body) 755813
* depending on size of bolt

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 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

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 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)