PEUGEOT XP6 50 User manual

PEUGEOT XP6 50
Manuel d'atelier (EN ANGLAIS)

G.H.E. MOTORHISPANIA, S.L.
GARAGE HANDBOOK

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INTRODUCTION
This garage manual refers to the AM6 engine, equipping the following vehicles:
- Furia 6V Cross
- Furia 6V Supermotard
MOTORHISPANIA RECOMMENDS
2 stroke engine:
•MOTUL POWERLUBE SEMI-SYNTHETIC 2T
Gearbox oil:
•TRANSOIL 10W30
Grease:
•GREASE 100
ADVICE
A good repairer acts with order and methodically
Use the appropiate tools, gaining time and a professional image.

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CONTENTS
TECHNICAL FEATURES REPLACEMENT
Engine part .................................................. 2 Water pump .............................................. 24
Cycle part .................................................... 2 Oil pump .................................................. 25
Capacities and types ................................... 3
Tightening motor and cycle......................... 3
Special tools ................................................ 3 IGNITION AND ELECTRICAL CIRCUIT
Maintenance...................………………….. 4
Electronic ignition .................................... 28
DISASSEMBLY Principle and regulator ............................. 28
Lights ....................................................... 28
Disassembly of engine ................................ 5 Neutral gauge........................................… 28
Disassembly of magneto ............................. 6 Cooling system temperature gauge.......... 28
Disassembly of clutch cover ....................... 7 Min. oil level gauge...............................… 28
Disassembly clutch ..................................... 7 Horn ......................................................... 28
Disassembly of crankshaft pinions Socket ....................................................... 28
and camshaft ..............................…………. 8 Indicators .................................................. 29
Disassembly of inlet pipe and Principle scheme....................................... 30
plate valve ...................................………… 8 Scheme legend.......................................... 31
Disassembly cylinder head ......................... 9 Cable plan ................................................ 32
Disassembly of cylinder ............................. 9
Disassembly of piston ................................ 9
Disassembly of exhaust pinion ................... 9 CONTROL
Opening of cases .................................... 10
Disassembly of stick and gearbox ............. 11 Elements of the gearbox ........................... 13
Disassembly of camshaft ........................... 11 Connecting rod/crankshaft set................... 15
Disassembly of crankshaft .......................... 11 Piston ........................................................ 17
Cylinder .................................................... 17
Segments .................................................. 17
ASSEMBLY Thermostat valve ..................................... 18
Plate valve .......................................... 19
Replacement of bearings/joints ............…... 12 Clutch ....................................................... 22
Assembly of gearbox .................................. 13 Ignition advance ....................................... 26
Assembly of selector shaft ......................... 14 Oil level of gearbox ................................. 27
Assembly of camshaft.... .................……… 15
Assembly of connecting rod/crankshaft
in right case ................................................. 15
Closing of left case ..................................... 16 ADJUSTMENTS
Assembly of the piston ............................... 17
Assembly of the cylinder ............................ 17 Engine clutch lever...................………… 24
Oil pump .................................................. 25
Assembly of the cylinder head ................... 18 Ignition advance ....................................... 26
Assembly of plate valve and inlet
pipe ............................................................. 19
Assembly of crankshaft right joint ............. 20
Assembly pinions crankshaft and cam
shaft ............................................................ 20
Assembly of the clutch ............................... 22
Clutch lever regulation ............................... 24
Starting shaft/clutch cover .......................... 25
Assemblyof magneto .........................……. 26

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Assembly of exhaust pinion ....................... 27
Filling of gearbox ....................................... 27
TECHNICAL FEATURES
ENGINE PART
Name of the manufacturer: ......Furia6V
Type: ........................................FU01
Engine marking: only engine type is inscribed, not
numbered.
ENGINE: MOTORI MINARELLI type AM6
2 stroke monocylindrical type, with separate
greasing and liquid cooling by means of circulation
pump.
Diameter and distance: ......... Ø40.3x39mm
Cylinder capacity: ................. 49.7 cc
B compression relation ......... 12:1
R compression relation ......... 6.86:1
Transmission:
Exhaust pipe: ............ 177º
Transfer: ................... 125º
Admission: ..........…. plate valve
Idling pattern: .............….. 1800 rpm +/- 200
Power: .......... 1.82Kw ISO at 5250 rpm
Max. Par.: ….. 3.23 mdaN ISO at 5250 rpm
IGNITION: Type CDI
-Electronic type by means of condensator discharge
(tyristor)
-Advance .......... 1.4 mm before PMS (20º)
-Spark plug ....... Resisting 5 Kohm
Type: ..NGK BR8ES or EYQUEM R1000 L
Electrode space: .................... 0.6 mm
CARBURETTOR: DELL ‘ORTO SHA 14-12
-Main jet: .......………………. 63
GENERATOR: magneto DUCATI
-Number of poles: .....……….. 6
-Power: ...……………………. 85 W
-Voltage: .....…………………. 12 V
REGULATOR: FACOMSA (with integrated
central integrator)
-Regulation tension: …………. 13.4VAC +/-0.5
STARTING: Starting pedal
SEPARATE GREASING: DELL ‘ORTO oil pump
-Variable flow
6 cc/H approx. (control between 0 and 10º)
9 cc/h approx. (control at 15º)
25 cc/h approx. (control at 45º)
38 cc/h approx. (control at 71º)
-Gearing down relation: 2.03 (20x24 and 13x22)
PRIMARY TRANSMISSION: helical gears
-Gearing down relation: 3.55 (20x71)
CLUTCH: Multidisc in oil coating with manual
control.
GEARBOX: 6 gears
-Lubrication by means of chain and pinions
-Control by means of selector at right foot
GEARING DOWN
1 12X36 3 32,0 %
2 16X33 2,06 46,5 %
3 19X29 1,53 62,9 %
4 22X27 1,23 78,2 %
5 24X25 1,04 92,2 %
6 25X24 0,96 100 %
SECONDARY TRANSMISSION: by means of
chain and pinions
-Gearing down relation: (12x52): 4,33
CYCLE PART
IDENTIFICATION MARK
-VIN nr. 17 characters VTVFU01A………….
CHASSIS:
Double seat in rectangular steel tube
Attack angle: 26º
Advance: 167 mm
STEERING:
-on ball bearings
FRONT SUSPENSION: SHOWA
-inverted hydraulic telescopic fork
-distance: 180 mm
-bar diameter: 32 mm
REAR SUSPENSION:
-Cantilever type with oilpneumatic mono shock
absorber with helical spring
-distance: 45 mm

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FRONT BRAKE:
-AJP brake pin
-disc O220 mm with manual hydraulic control
-thickness: 4 mm
REAR BRAKE:
-AJP brake pin
-floating disc O180 mm with hydraulic control at
the stem
-thickness: 3.5 mm
TYRES: dimensions and pressures when cold
-Cross version:
Front: 2.5x21 1.5 bars
Rear: 110/80x18 1.7 bars
-Supermotard version:
Front: 100/80x17 2.3 bars
Rear: 130/70x17 2.5 bars
DIMENSIONS:
-Total length: 1995 mm
-Total width: 750 mm
-Total height: 1350 mm
WEIGHT:
-Weight when moving: 85 kg
-Max. authorized total weight: 235 kg
CAPACITIES AND TYPES
FUEL: Super, unleaded, 98 or 95 oct.
Capacity of the tank: 6 litres
Reserve: 0.2 litres
SEPARATE GREASING: Semi synthetic oil, or
synthetic
MOTUL Powerlube semi-synthetic 2T
Capacity of the oil tank: 1.1 litres.
GEARBOX: Transmission oil
MOTUL Transoil 10W30
Capacity gearbox: 0.75 litres.
COOLING CIRCUIT: Protection until –20ºC
Antifreeze fluid type Procor 3000 or equivalent,
change every 2 years
Capacity of the circuit: 0.7 litres
BRAKE FLUID: fluid according to the rules DOT
3 or DOT 4
HYDRAULIC FORK: Fork oil type: SAE 20
Contents for each bar:........... 175 cc
PARES APRIETE MOTOR
Cylinder head nut 1,8 mdaN
Crankshaft pinion nut 7,5 mdaN
Camshaft pinion nut 6 mdaN
Magneto nut 5,2 mdaN
Clutch nut 7,5 mdaN
Pressure plate screw 0,5 mdaN
Clutch counter nut 2,7 mdaN
Engine housing case screw 1,1 mdaN
Transmission cover screw 1,1 mdaN
Magneto cover screw 0,4 mdaN
Inlet pipe screw 1,1 mdaN
Starting pedal screw 3 mdaN
Gearbox casting screw 1,8 mdaN
TIGHTENING OF THE CYCLE PART
Front wheel nut 4,5 mdaN
Rear wheel nut 6,5 mdaN
Fork screw 2,5 mdaN
Steering nut 6 mdaN
Fork tube inf. T screw 1,5 mdaN
Fork tube sup. T screw 2,8 mdaN
Handlebar fixing screw 2,3 mdaN
Engine fixing screw 2,8 mdaN
Swing arm nut 6,5 mdaN
Rear chassis fixing screw 2,8 mdaN
Fixing footrest bracket screw 2,8 mdaN
Upper shock absorber screw 4,5 mdaN
Lower shock absorber screw 4,5 mdaN
Front brake pin screw 2,8 mdaN
Rear brake pin screw 2,8 mdaN
Front brake disc screw 1,2 mdaN
Rear brake disc screw 0,5 mdaN
SPECIAL TOOLS
Engine bracket
Adaptation Furia 6V
VAR tool
Opening and closing plaque
Protection cap
Special 10x125 nut
Centrer
Special nut bracket
Gauge 47 set
Wheel extractor
Clutch immobil. tool
Clutch side crankshaft driver
Wheel side crankshaft driver
Selector shaft driver
Water pump driver
Clutchstick driver
Lock pin
Adjustable immobilizer
Outer circlip pin

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MAINTENANCE
Depending on the use of the vehicles, we recommend that you should apply:
The normal maintenance plan
The reinforced maintenance plan
The normal maintenance plan includes:
Service after 500 km or 3 month……….…..……Plan A
Service every 5000 km......................……………Plan B
Service every 10000 km............…………………Plan C
The reinforced maintenance plan includes:
Service after 500 km..........................Plan A
Service every 2500 km......................Plan B
Service after 5000 km........................Plan C
NOTE: The replacement of certain parts is directly related to the use of the vehicle and it is also related to
“the user’s nature”.
ACTIONS
PLAN A
500 Kms. or 3
months
PLAN B
2.500 Kms or
5.000 Kms *
PLAN C
5.000 Kms or
10.000 Kms *
Verify:
- Adjustment of the idling X X X
- Gas control X X X
- Clutch control X X X
- Front and rear brake control X X X
- Functioning the electrical equipment X X X
- State and pressure tyres X X X
- Petrol tube X X X
- Oil tube X X X
- Brake fluid tube X X X
- Antifreeze fluid tube X X X
- Brake fluid level X X X
- Antifreeze fluid tube X X X
- Regulation of tension chain and oiling X X X
- Tightening of screws X X X
Replace:
- Gearbox fluid X X
- Spark plug X X
- Filtering elements of the filter box X X
- Brake pads ( if necessary ) X
- Crown, pinion, chain ( if necessary ) X X
- Clutch disc ( if necessary ) X
Clean:
- Pinion head X
- Combustion chamber X
- Exhaust pipe exit X
Clean:
- Carburettor X
Vehicle testing:
- On the road X X X

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DISASSEMBLY OF THE ENGINE OF THE VEHICLE
-Disassemble:
the petrol tube to the carburettor
the oil pipe to the pump
the two tubes of the cooling circuit (cylinder
head and pump)
gas control
the spark plug cap
the oil pump control
the filter box
-Disconnect:
the electrical installation of the magneto
the electrical installation of the neutral
-Disassemble the transmission chain (fast union)
loosen nut of the swing fork
loosen and remove:
screw sup fastening of the engine and make it
pivot upwards
the other two screws of the engine
-Remove the engine and put it on the bracket
adaptor (this bracket has to be screwed to a
bench)
-Take the oil out of the gearbox, screw (a)
-Remove the draining screw from the water
pump (B)
to empty it.
CAUTION: respect the environment, recover
the used oil
and antifreeze fluid in the appropiate containers.

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DISASSEMBLY OF THE MAGNETO
Remove the 5 screws (CHC M5x0.80-20) and
remove the cover.
Immobilize the rotor and loosen the magneto
nut with tool.
Screw the extractor off the wheel and
act on the central part of it to take out the rotor
(assembled on conical axle with pin).
Remove the three screws with star head
(M4x0.70-19) and their washers.
IMPORTANT: Before removing the stator base,
leave a small mark on the housing case and on
the plaque so you can find back the initial
position during the assembly.
Loosen the three screws with allen head (BHC
M4x0.70-10) and remove the stator plaque
(Allen wrench of 2.5 mm).

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ASSEMBLY OF THE CLUTCH COVER
Activate the starting pedal slightly and keep it
in this position.
Remove the fixing screw from the pedal.
Loosen the pedal launcher screw and remove
the spring.
Loosen and remove the 8 fixing screws from the
cover (type CHC).
Remove the joint and the two centring bubbles
from the cover with the housing case.
IMPORTANT: Write down the position of the
starting pedal on the spindle to put it back
during the assembly (see page 25).
DISASSEMBLY OF THE CLUTCH
Loosen and remove the 4 screws (CB M5x0.80-
20), the washers and the springs from the
pressure plate.
Disassemble the upholstery discs and the plain
ones.
Take out the primary driving shaft, the ball and
the driving stick (see page 23 A B C).
Straighten the nut brake.
Immobilize the rotor clutch with tool.
Loosen and remove the nut (wrench 17) and the
nut brake.
Disassemble the rotor, grooved separator, the
plain washer (17.2x30x0.8) and the interior
cogged conical washer (write down its position
for the assembly).

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DISASSEMBLY OF THE CRANKSHAFT PINIONS
AND OF THE CAM SHAFT
Put a screw (type CHC M6x1.00-25 for
example) into one of the thread holes of the
camshaft pinion, resting its end on the ribbing of
the housing case.
With the immobilixed pin in rotation, loosen the
crankshaft nut (wrench 17) and the cam shaft
nut (wrench 19) and remove them.
Disassembly of the crankshaft:
The two pinions (20 cogs and 34 cogs), the
in (note the direction of the pinion 20 z, mark
towards the nut).
The smooth washer (812.3x22x0.8), the pinion
(34 cogs) and the pin.
DISASSEMBLY OF THE INLET PIPE AND PLATE VALVE
Loosen and remove the 4 fixing screws (CHC
M6x1.00-20)
from the inlet pipe.
Disassemble the pipe and the plate sheet
(overhaul of
valve is in the chapter dedicated to the
assembly, page 19).
Disassemble the clutch lever with its spring and
washer.

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DISASSEMBLY OF THE UPPER PART OF THE ENGINE
DISASSEMBLY OF THE CYLINDER HEAD:
Loosen and remove the 4 nuts (wrench 10) and
washers.
Disassemble the cylinder head equipped with its
torical joint.
DISASSEMBLY OF THE CYLINDER:
Remove the 4 torical joints from the pullsticks
and the central torical joint.
Disassemble the cylinder and its base joint.
DISASSEMBLY OF THE PISTON:
Incline the engine towards the left or right side
In order to avoid dropping the fixer accidentally
into the engine.
Remove the bolt fixer by means of some tongs.
Push the bolt and remove the piston (the bolt is
adjusted to the piston with oil).
Remove the needle case from the stem of the
connecting rod.
DISASSEMBLY OF THE EXHAUST PINION
Remove the retention circlip by means of some
tongs from the exhaust shaft.
Disassemble the exit pinion.
Remove the second retention circlip.

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OPENING OF THE ENGINE HOUSING CASES
Remove the 13 fixing screws (CHC M6x1.00-
40) from
the two cases.
Put the protection cap at the end of the
crankshaft.
Place the plaque in the left case equipped with
tool. Fix the plaque on the housing case with
four screws (M5x0.80-20).
Remove the two safety pins from the engine
bracket.
Act on the screw of tool the housing cases have
been opened completely. Be
careful with both centring bubbles of both cases.
CAUTION: while opening, make sure that both
cases
open in parallel. If necessary, use a plastic
hammer, hitting
both ends of the secondary shaft and gear shaft.
Put the two safety pins back on the engine
bracket.

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DISASSEMBLY OF THE SELECTOR AND THE GEARBOX
DISASSEMBLY OF THE SELECTOR
SHAFT:
Put the selector drum in 4th position (pin of the
mechanism looking towards the fork shaft of the
secondary shaft).
Remove the selector shaft equipped with its two
friction
washers (10x16x0.6(A) and 12x17x0.6 (B)).
DISASSEMBLY OF THE GEARBOX:
Remove the friction washer from the secondary
shaft(20.4x25x0.6).
Remove the friction washer from the selector
drum (10x16x0.6).
Remove and disassemble the fork shaft from the
secondary shaft.
Take out the whole:
Main shaft
Secondary shaft
Selector drum
Forks
Remove the anchorage ball and its driver
spring.
Remove the 2nd friction washer (14.5x27x0.6)
from the secondary shaft.
DISASSEMBLY OF THE CAMSHAFT
The camshaft is fixed on its bearing.
Hit its end with a plastic hammer to disassemble
it.
DISASSEMBLY OF THE CRANKSHAFT
Disassemble the whole connecting rod /
crankshaft, the modified separator and the
torical joint (the crankshaft is assembled on its
bearing and it is lubricated).

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REPLACEMENT OF BEARINGS AND JOINTS
The opening of the housing cases of the engine
implies, at least, the replacement of the crank-
shaft bearings and joints.
Heat the housing cases at approx. 80ºC in an
even way (with a thermal layer remover, for
example) to expand them; the bearings will fall
off by themselves. Remove the joints.
Take advantage of the expansion to place the
new bearings in their position.
Lubricate the left tight joint and put it in its
position with tool, the edges towards the wheel
chamber.
IMPORTANT: Before heating the left case, we
recommend that you should remove the neutral
socket of the selector shaft.
NOTE: The right tight shaft will be installed
after closing the housing cases, placing the
torical and the separator, to avoid causing any
damage to its edges again when it touches that
same separator.
Replacement of the tight joints of the secondary
shaft:
Use tool to put this joint in the correct place and
position.
Replacement of the tight joints of the selector
shaft:
Use tool to put this joint in the correct place and
position.
Replacement of the clutch lever joints:
Use tool to put this joint in the correct place and
position.

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ASSEMBLY OF THE GEARBOX AND OF THE SELECTOR
CHECK BEFORE THE ASSEMBLY:
Verify:
The bearings and needle cages of the housing cases.
The state of the tops (clips) and seats.
Each and every pinion to verify wearing out or deformation.
The state of the selection forks (wearing out or deformation of the fork or wearing out of its end: it must be
cylindrical).
The good condition of the drum and its holes.
The drum shafts (wearing out-breaking).
NOTE: should replacement of a pinion be necessary, then we recommend replacing the entire train (the pinion
of the main shaft and the one that belongs to the secondary shaft).
ASSEMBLY OF THE GEARBOX:
Place the washer (14.5x27x0.6) on the needle
case of the secondary shaft of the right case.
Put the spring and the anchorage ball in their
seats and lubricate them with grease.
Pinion gear 3-4
th
19-
22z
Pinion gear 5
th
24z
Pinion gear 1
th
Pinion gear 6
th
(25z)
Pinion gear 2
th
(16z)
Gear selector fork+
p
in 5-6
th
Gear selector fork+
p
in 2-3
th
Secundary gear shaft
Gear selector fork+
p
in 1-3
th
Primary gear shaft
Pinion
g
ear 2
th
33z
Pinion
g
ear 6
th
24z
Pinion
g
ear de 4
th
27z
Pinion
g
ear 1
th
36Z
Pinion
g
ear 5
th
(
25z
)
Pinion
g
ear 3
th
29z

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Place the set of the secondary shaft/main shaft
equipped with its control fork of the double
rocker pinion, in the case.
Place the bent fork (A) on the secondary shaft n
the pinion of the fifth (control of the first and
third) and the second pin (B) on the rocker
pinion of the sixth (control of the second and the
fourth). Place the selector drum, after oiling its
shaft, and place the hole guides starting with the
pin of the fifth-sixth in the intermediate drum
hole. After this, place the pin first-third in the
inferior hole and, finally, the pin of the second-
fourth in the superior hole.
Place the fork shaft of the secondary shaft in its
seat.
Verify the good change of the gears activating
the selector drum with one hand, turning the
main shaft with the other hand.
ASSEMBLY OF THE SELECTOR SHAFT:
Place the selector drum in the fourth position
(the bolt of the aligned mechanism virtually
with the fork shaft of the secondary shaft).
Place the selector shaft equipped with its
washers (with a thickness of 0.6 mm in each end
(12x17x0.6 and 10x16x0.6) taking care that you
place the ends of the spring of both sides of the
fixing shaft.
Place the friction washer (10x16x0.6) on the
selection drum.
Place the friction washer (20.45x25x0.6) on the
secondary shaft.
The side set of the secondary shaft must not be
bigger than 0.2 mm.
NOTE: the placing of the selector drum in
fourth position allows
the assembly of the selector shaft without being
bothered by
the bolt of the mechanism.

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ASSEMBLY OF THE CAMSHAFT
This shaft is assembled tightly on the bearing.
Make sure you place it well with a plastic
hammer.
ASSEMBLY OF THE WHOLE JOINT/CRANKSHAFT
IN THE RIGHT CASE
CHECKING THE CRANKSHAFT
The side set of the head of the joint must be
between 0.14 and 0.41 mm.
Check the ligning-up of the crankshaft.
The values at the end must never be higher
than 0.04 mm.
ASSEMBLY
Place the crankshaft in its correct position in the
right semicase. Do this by hand.

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CLOSING OF THE LEFT CASE
Verify the presence of the friction washers
(secondary shaft, selector drum, selector shaft).
Verify the presence of both centring bubbles in
the semicase.
Apply the joint paste.
Lubricate all the ends of the shafts and their
seats.
Place the left semicase.
Screw tool to the end of the crankshaft.
Place tool equipped with plaque and settle the
whole on the case by means of 4 screws
(M5x0.80-15, the opening of the place on the
cylinder shaft).
Place the centrer on tool.
Screw tool on the one that has, holding the
connecting rod.
Continue screwing the tool on it until the
crankshaft reaches the bearing.
During this operation, make sure that the left
semicase descends in parallel on the right one.
Help reaching this position, if necessary,
making the shafts of the gearbox and cam turn.
Place the 13 screws (CHC M6x1.00-40) and
tighten them
with a pair of mdaN 1.1.

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ASSEMBLY OF THE SUPERIOR PART OF THE ENGINE
CHECKING THE PISTON:
It must not be scratched or show traces of
breaking down.
The segments must be free in their seats.
CHECKING THE SEGMENTS: compression
segments and tight ones.
Cutting set new segment: 0.15 to 0.33 mm.
Limit of use: max. 1 mm.
Set in the hole: 0.03 to 0.06 mm.
CHECKING THE CYLINDER:
The cylinder must not have any scratches, show
traces of breaking down or show traces of
having worn out considerably.
Verify this with a comparer in two directions,
the first one perpendicular to the piston shaft,
the second one in parallel with its shaft
(measured between the head of the piston and
the exhaust hole). The allowed ovalization is
0.03 mm.
After this, measure the diameter of the piston
and compare it with the cylinder. The max. set
that is allowed is 0.07 mm.
ASSEMBLY OF THE PISTON:
Verify the parity of the whole cylinder/piston
(letter indicated on the piston and cylinder).
Oil and place the needle case at the stem of the
connecting rod.
Present the piston with the arrow directed
towards the exhaust pipe.
Push the bolt into its seat.
Incline the engine to one side to prevent the clip
from falling on the engine.
Assemble a new fixing clip (THIS IS
COMPULSARY!) with Pin.
REMEMBER: the opening of the clip must look
up or down, never to a side.
NOTE: as in all engines, we recommend
verifying the lining-up of the connecting rod in
the assembly.
ASSEMBLY OF THE CYLINDER:
Place de new base joint after oiling it.
Also oil the piston and the cylinder.
Make sure that the opening of the segments is in
position.
Introduce the cylinder compressing both
segments with your fingers.