Peugeot XR6 / MotorHispania Racing RX Service Repair Manual MANUALMADNESS.com

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CONTENTS CHARAC CHARACTER TERIS IST TICS...... ICS......................................... ....................................................................... ....................................................................... ......................................................4 ...................4 Machine markings................................................................................................................................................................. 4 Characteristics............... Characteristi cs....................................................................................................................................................................... ........................................................................................................................................................ 4 Frame..................................................................................................................................................................................... Frame ..................................................................................................................................................................................... 4 Capacities apacit ies .............................................................................................................................................................................. 4 Dimensions............................................................................................................................................................................ Dimensions.................... ........................................................................................................................................................ 4 We ight ................................................................................................................................................................................... 4 Tyres ...................................................................................................................................................................................... 4 Engine markings ................................................................................................................................................................... 4 SERVICE AND COMMI COMMISSIONING SSION ING INSTRUCTI NSTRUCTION ONS.......... S................. ............... ............... .............. .............. ............... ............... .............. .............. .......... ... 5 Check: .................................................................................................................................................................................... 5 Change................................................................................................................................................................................... Change ................................................................................................................................................................................... 5 Check he ck and remove remove carbo carbon n .................................................................................................................................................... 5 Check he ck and lubricate lubricate .............................................................................................................................................................. 5 Check he ck and adjust................................................................................................................................................................... adjust ................................................................................................................................................................... 5 Clean and adjust.................................................................................................................................................................... adjust............ ........................................................................................................................................................ 5 Test machine ......................................................................................................................................................................... 5 Batte at tery ry preparation (except for for maintenance maintenance-- free battery) battery) ................................................................................................ 6 Topop- up checks....................................................................................................................................................................... checks....................................................................................................................................................................... 6 Filling the fuel fuel and oil circuits ............................................................................................................................................. 6 Checks he cks before handin handing g over to the custom customer er...................................................................................................................... ...................................................................................................................... 6 SPECIAL SPECIAL IMPORTANT IMPORTANT POINTS POINTS .................................................................... ........................................................................................................ ...........................................7 .......7 Oil and fuel............................................................................................................................................................................ fuel............................................................................................................................................................................ 7 Starting................................................................................................................................................................................... 7 Special features ..................................................................................................................................................................... 7 Electricit y .............................................................................................................................................................................. 7 TIGHTENING TO TORQ RQUE UES S AND AND SPECIAL SPECIAL TOOLS ..................................................................... ..................................................................................8 .............8 Tightening torques ................................................................................................................................................................ 8 Special tools: ......................................................................................................................................................................... 8 BODY................................ BODY................................................................... ....................................................................... ....................................................................... ......................................................9 ...................9 Body od y panel panel bolt bolt fitting............................................................................................... fitting............................................................................................... ........................................................... 9 Removal of the headlight fairing Op Opee ratio rat ion n 1 A............................................................................................................. 10 Removal of the headlight Opera pe rati tion on 1 B ......................................................................................................................... 10 Removal of the fuel tank assembly Operat pe ration ion 2 A......................................................................................................... 11 Stripping down the fuel tank Ope ratio ra tion n 2 B.................................................................................................................... 11 Removal of the instrument panel Oper peration ation 3A.............................................................................................................. 12 Removal of the speedometer Opera pe rati tion on 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................. FRAME..................................................... ....................................................................... ...................................................................... ................................................................14 .............................14 Removal of the front wheel Operation7 .......................................................................................................................... 14 Wo r k possible wit wit h the the front wheel wheel removed removed ................................................................................................................... 14 Removal of the front mudguards and the front mudguard stay Operation 8................................................................. 15 Removal emo val of the speedo speedomete meterr cable cable .................................................................................................................................... 15 Removal emo val of the front front caliper caliper and the the brake pads pads .............................................................................................................. 15 Removal emo val of the the fork...... fork............................................................................................................................................................ ...................................................................................................................................................... 16 Removal emo val of the the fork fork tubes.................................................................................................................................................. 17 Removal emo val of the headligh headlightt mount........................................................................................................................................ 17 Removal emo val of the rear rear frame frame assembly................................................................................................................................. assembly................................................................................................................................. 18 Removal emo val of the rear rear wheel.................................................................................................................................................. wheel.................................................................................................................................................. 19 Wo r k poss poss ible wit wit h the the rear rear wheel removed..................................................................................................................... 19 Removal of the chain Operation 9 ................................................................................................................................... 20 Chain tension adjustment Operation 10........................................................................................................................... 20 Removal emo val of the chain chain guide................................................................................................................................................ guide................................................................................................................................................ 20 Removal emo val of the rear mudgua mudguard........................................................................................................................................... rd........................................................................................................................................... 21

Page 2 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

CONTENTS Removal emo val of the rear calipe caliperr and the brake pads pads................................................................................................................ ................................................................................................................ 21 Removal emo val of the shoc shock k absorber................................................................................. ......................................................... 22 Removal emo val of the the shock shock absorber pivot ................................................................................................................................ 23 Removal emo val of the the suspe suspension nsion arm................................................................................ ......................................................... 24 Suspension arm pre pre- assembled assembled (mudguard, (mudguard, chain guard, guide and and tensioners fitted) fitted) ................................................. 25 MISCELLANEOUS OPERATIONS..........................................................................................................26 Removal emo val of the rear mudfla mudflap.............................................................................................................................................. p.............................................................................................................................................. 26 Removal emo val of the rear rear light light assembly................................................................................................................................... assembly................................................................................................................................... 26 Removal emo val of the numb number er plate plate plinth plinth .................................................................................................................................. 26 Removal emo val of the instr instrume ument nt panel panel....................................................................................................................................... ....................................................................................................................................... 27 Removal emo val of the the wind windsh shield................................................................................................................................................. ield................................................................................................................................................. 27 Removal emo val of a front front dire direction ction indicator .............................................................................................................................. 27 Removal emo val of a rear rear dire direction ction indicator indicator................................................................................................................................ ................................................................................................................................ 27 Removal emo val of the steeri steering ng lock.............................................................................................................................................. lock.............................................................................................................................................. 28 Removal emo val of the throttl throttlee grip and and oil pump pump ........................................................................................................................ 29 Removal emo val of the oil tank tank ...................................................................................................................................................... 29 Removal emo val of the the air filter filter foam................................................................................... foam................................................................................... ......................................................... 30 Removal emo val of the the air filter filter box box .............................................................................................................................................. 30 Removal of the exhaust Operation 11 ............................................................................................................................. 30 Removal of the carburettor Operation 12 ........................................................................................................................ 31 Removal emo val of of the the valves ........................................................................................................................................................ 31 ELECTRIC ELECTRICITY ITY.................................. ..................................................................... ...................................................................... ......................................................................32 ...................................32 Removal emo val of the battery battery........................................................................................................................................................ ........................................................................................................................................................ 32 Removal emo val of the starter starter motor motor relay relay.................................................................................................................................... .................................................................................................................................... 32 Removal emo val of the voltage regula regulator....................................................................................................................................... tor....................................................................................................................................... 32 Removal emo val of a LH or RH control cluster ............................................................................................................................ 32 Removal emo val of the ign ignition ition module......................................................................................................................................... module......................................................................................................................................... 33 Removal emo val of of the the horn horn ........................................................................................................................................................... 33 Removal emo val of the rea rearr wiring wiring harness.......................................................................... ......................................................... 33 Removal emo val of the the main main harness.................................................................................... harness.................................................................................... ......................................................... 35 Refitting ef itting the main harness.................................................................................................................................................. harness.................................................................................................................................................. 36 WORK ON THE ENGINE WITHOUT ITHO UT REMOVIN REMOVING G TH THE E ENGI ENGINE NE........ .... ....... ....... ....... ....... ........ ....... ....... ....... ....... ........ ....... ....... ....... ... 37 Removal emo val of the cylinde cylinderr head head/ cylinder/ cylinder/ piston piston .................................................................................................................. 37 Removal emo val of the the oil oil pump........................................................................................... pump........................................................................................... ......................................................... 38 Removal emo val of the rotor rotor and the magneto magneto flywhee flywheell armature............................................................................................... 39 Removal emo val of the gearbox gearbox output sprocket........................................................................................................................... 40 Removal emo val of the neutral neutral switc switch............................................................................................................................................ h............................................................................................................................................ 40 Removal emo val of the starter starter motor.............................................................................................................................................. motor.............................................................................................................................................. 41 COOLING COOLING.................................................................. ..................................................................................................... ....................................................................... ............................................... ........... 42 Removal emo val of the cylinder cylinder head head/ radiator radiator hose...................................................................................................................... 42 Removal emo val of the expan expanss ion tank and the expansion expansion tank/ radiator radiator hose............................................................................ 42 Removal emo val of the the radi radiato atorr ...................................................................................................................................................... 42 Removal emo val of the engine engine temperat temperature ure sensor sensor ....................................................................................................................... 43 MOTOR MOTOR.................................. ..................................................................... ...................................................................... ....................................................................... ............................................... ........... 44 Removal emo val of the the engin engine............................................................................................... e............................................................................................... ......................................................... 44 Refitting ef itting the engine to to the frame frame ....................................................................................................................................... 46 FRAME................. FRAME..................................................... ....................................................................... ...................................................................... ................................................................47 .............................47 Removal emo val of the frame frame......................................................................................................................................................... ......................................................................................................................................................... 47


CHARACTERIS TICS TICS CHARACTERIS TICS TICS

Machine M achine markings Capacities Model code

DR01A

Characteristics Engine

2 stroke water cooled

Marque

Minarelli 50 cc

Bore x stroke Cubic capacity Max. power output Max Maximum imum torq torqu ue Gross compression ratio Ignition Spark plug Carburettor Idle speed

40.3 x 39 49.7 cc 1.32 kw

Air screw initial position Needle Main jet Idle jet Ma g neto

Starter motor

2.66 .66 Nm Nm 12 CDI NGK BR9 ES Dell'Orto PHBN 12 HS ±200 930 rpm

Gearbox Fuel tank Oil tank Showa fork

0,75 litres 11.75 litres 1.1 litres 0.175 litres per tube

Dimensions Length Width Height without rear view mirror Wheelbase

1265 mm

Weight Weight

115 kg

Tyres

1 1/2 turns A34 60 36 Ducati 85 W Ducati

1.865 mm 675mm 1.100 mm

Front wheel Front tyre Front tyre pressure Rear wheel Rear tyre Rear tyre pressure

1 person 2 persons 1.85"x16" 90/90x16" 1,8 bar 2,2 bar 2,5"x16" 120/80x16" 2 bar 2.5 bar

Engine Engine markings markings Frame Engine type 1 2

AM6

Manufacturer’s plate VIN number

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


SERVICE SERV ICE AND COMMIS COMMISSI SIONING ONING INS INS TRUCTIONS TRUCTIONS SERVICE SERV ICE AND COMMIS COMMISSI SIONIN ONING G INS INS TRUCTIONS TRUCTIONS

Heavy duty servicing is for machines used under “harsh” har sh” conditions, conditions, driver temperament, short journeys with engine cold, dusty regions, ambient temperature over 30°C. Servicing operations

Check: Idle adjustment Throttle and oil pump Front and rear brake lever Functioning of electrical equipment Fuel piping Oil piping Front and rear brake fluid piping Coolant piping Fuel heating piping Tyre pressures Tyre condition, pressure and wear Front and rear brake fluid level Coolant level Battery electrolyte level Tightness of nuts and bolts Battery charge Change Inlet silence filter element Front and rear brake pad Gearbox oil Chain-front sprocket-rear sprocket Clutch discs Check and remove carbon Piston (1) Cylinder head (1) Exhaust port (1) Check and lubricate Chain tension and condition Check and adjust Clutch cable Oil pump cable Spark plug Headlight height Clean and adjust Carburettor Test machine On road

500 Kms or 3 months

X X X X X X X X X X X X X X

Every 3000 Kms

Every 6000 Kms

X X X X X X X X X

X X X X X X X X X

X X X X X X

X X X X X X

X #X

X #X X #X #X

X #X

# Every 10000 kms # Every 10000 kms # Every 10000 kms X

X

X X X X

X

X X X X X

X

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 Page 5 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

SERVICE AND COMMISSIONING INS TRUCTIONS

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 li tre 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% s emi-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 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 TIGHTENING TORQUES AND SPECIAL TOOLS

Tightening torques Body panels: Headlight fairing Speedo fairing Side covers Side and central fairings Rear fairing Front mudguard Rear mudguard * Mudflap * Securing strap Frame: Front wheel spindle nut Rear wheel spindle nut Suspension arm nut Front mount to chassis Engine to front mount Engine to chassis Shock absorber upper mount Shock absorber lower mount Fork Tees Upper Tee centre bolt Front mudguard bracket Front brake caliper Rear brake caliper Front brake disc Rear brake disc Frame mounted stand Steering lock Standard: Nut and bolt 5 mm diameter Nut and bolt 6mm diameter Nut and bolt 8mm diameter Nut and bolt 10mm diameter Nut and bolt 12mm diameter Special tools: Standard 3 mm allen key (inlet manifold) 4 mm allen key (valve body)

0,1 m.daN 0,1 m.daN 0,1 m.daN 0,1 m.daN 0,1 m.daN 0,1 m.daN 0.8/0.1 m.daN 0.8/0.1 m.daN 1,2 m.daN 4,5 m.daN 6,5 m.daN 6,5 m.daN 4,5 m.daN 4,5 m.daN 2,8 m.daN 4,3 m.daN 4,3 m.daN 1,5 m.daN 5 m.daN 2,5 m.daN 2,5 m.daN 2,5 m.daN 1 m.daN 1 m.daN 1,9 m.daN 0,6 m.daN 0,5 m.daN 1 m.daN 2,2 m.daN 3,5 m.daN 5.5 m.daN

Part N° 755812 755813

* depending on size of bolt


BODY BODY

Body panel bolt fitting I mpor tant: th er e are dif ferent stackin g orders dependi ng on the assembl y. When r ef itti ng, assemble the fi ttin gs 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

Removal of the headlight fairing Operation 1 A - Remove the 2 rear view mirrors (1) (stack N° 1) - Remove the 2 bolts (2) on the windshield (stack N° 2) - Remove the 4 bolts (3) from the side fairings (stack N° 3) Remove the 2 bolts (4) under the headlight (stack N° 4) - Disconnect the direction indicators - Remove the headlight fairing (5)

Removal of the headlight Operation 1 B - Remove the headlight fairing (see operation 1A) - Remove the headlight 4 securing bolts (6) - Remove the headlight (7)


BODY

Removal of the fuel tank assembly Operation 2 A - Remove the passenger saddle (1) unlock the saddle with the ignition key and pull it rearwards) - Remove the cap (3) from the inside of the rear mudguard - Through the cap hole (3), and through the rear mudguard, remove the nut (4) and bracket (5) from the driver’s saddle and pull the driver’s saddle (2) rearwards to release it from the frame - Remove the driver’s saddle (2) - Remove the 2 bolts (6) from the tank (stack N° 8) - Raise the tank to disconnect the fuel level warning light, the fuel supply pipe and the fuel tap vacuum coupling

Stripping down the fuel tank Operation 2 B - Remove the fuel tank assembly (see operation 2A) - Remove the filler cap (7) - Remove the cap trim (9) five screws (8) - Remove the fuel tank cover (10) - Remove the fuel tank shim (11) - Remove the filler cap surround 6 screws (12) - Remove the filler cap surround (13) and its gasket (14) - Remove the fuel tank front spacer (15) - Remove the fuel tank rear spacer (16) Note: certain machines do not have fuel tank spacers (11) and (16) When refitting, the filler cap surround locking slots must be lined up with the machine axis Page 11 Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

BODY

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

Removal of the speedometer Operation 3 B - Remove the headlight fairing (see operation 1A) - Remove the instrument panel (see operation 3A) Remove the 4 screws (1) and the 6 rubber washers (stack N°5) - Remove the speedometer fairing (2)

Removal of the side fairings Operation 4 - Remove the 2 screws (1) (stack N°5) - Remove the side fairings (2) warning they interlock under the fuel tank at (A) and under the rear fairing at (B)


BODY

Removal of the side fairings and the centre fairing Oper ation 5

- Remove the hatches (1) of the side fairing 1 screw on each (stack N°5) - Remove the 4 screws (2) from the frame ((2A) stack N° 5, (2B) stack N° 6) - Remove the 2 screws (3) securing the RH and LH fairings (stack N°9) - Remove the 2 screws (5) securing the LH side fairing and the headlight fairing (stack N°3) - Remove the 3 screws (4) securing the RH side fairing to the centre fairing (stack N° 9) - Remove the LH side and centre fairing assembly

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

Removal of the rear fairing and the number plate plinth Operation 6 - Remove the passenger saddle - Removing the driver’s saddle (see operation 2 A) - Disconnect the rear light and the indicator lights - Remove the 6 screws (1) on the rear fairing; 2 at the front (stack N°6) and 4 in the saddle housing (stack N°5) - Remove the rear fairing (2)


FRAME FRAME Front part

Removal of the front wheel Operation7 - Unscrew the speedometer cable (1) - Slacken the wheel spindle nut and the clamping nut (2) on the front of the fork tube - Remove the wheel spindle nut, and pull the wheel spindle clear (3) - Remove the wheel (4) D o not operate the brake lever or as a precaution fit a wedge between the brake pads

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

Work possible with the front wheel removed - Tyre or valve replacement Note: note the direction of rotation of the tyre before removing and refit it the same way round - Brake disc replacement Note: when refitting, fit the right way round: marking on the outside, and fit the 6 bolts with normal locking compound - Wheel bearing replacement Note: there is a seal (5) and the speedometer drive (6) on the RH side - Speedometer drive replacement  A fter removing the wheel, the caliper or the pads, before road testing, check the brake operates correctly by operating the lever several times

Page 14 Re roduction or translation even artial forbidden without the written consent of Peu eot Moto c cles

FRAME

Removal of the front mudguards and the front mudguard stay Operation 8 - Remove the 4 screws (1) securing the mudguard to the stay - Remove the mudguard (2) - Remove the 4 screws (3) securing the stay to the fork tubes - Remove the stay (4) T he stay screws have an effect on the mudguard angle, hold the front of the mudguard in the up position while tightening the screws

Removal of the speedometer cable - Remove the instrument panel (see operation 3A) without disconnecting the wiring harness - Unscrew the speedometer cable (1) from the instrument panel - Remove the speedometer cable (1)

Removal of the front caliper and the brake pads - Remove the 2 bolts (1) from the fork tube - Remove the caliper (2) - Remove the pins (3) - Remove the brake pads (4)

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


FRAME

Removal of the fork - Remove the headlight (see operation 1B) - Remove the fork upper Tee (1) 2 bolts (2) securing it to the fork tubes and 1 centre bolt (3) using a 10 mm Allen key - Remove the 2 brake caliper bolts, and move it clear without disconnecting it - Remove the front mudguard and the front mudguard stay (see operation 8) - Remove the front wheel (see operation 7)

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

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


FRAME

Removal of the fork tubes - Remove the headlight fairing (see operation 1A) - Remove the brake caliper without disconnecting it - Remove the front mudguard and the front mudguard stay (see operation 8) - Remove the front wheel (see operation 7) - Remove the 4 bolts (1) from the lower and upper Tees

Removal of the headlight mount - Remove the headlight (see operation 1B) - Remove the speedometer fairing (see operation 3B) - Remove the expansion tank (1) (1 bolt) - Remove the 2 bolts (2) from the fork tubes - Remove the headlight mount (3)


FRAME Rear part

Removal of the rear frame assembly - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 4) - Remove the rear fairing and the number plate plinth (see operation 6) - Remove the oil tank (1) (2 bolts) - Disconnect the rear wiring harness (2), the oil level switch and the brake light - Remove the air filter casing 2 screws (leave it in position) - Remove the securing strap (4) (2 screws)

- Move the brake fluid reservoir clear without disconnecting it, 1 screw (9) - Remove the passenger footrests (3) (2 x 2 bolts) - Remove the rear mudflap (6) by removing the 4 screws (7) ((7A) stack N°5, (7B) stack N°3) - Remove the rear frame assembly 4 bolts (5)

- Remove the rear frame assembly (8)


FRAME

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

D o not operate the brake lever or as a precaution fit a wedge between the brake pads

Work possible with the rear wheel removed - Tyre or valve replacement Note: note the direction of rotation of the tyre before removing and refit it the same way round - Brake disc replacement Note: when refitting, fit the right way round: marking on the outside, and fit the 6 bolts with normal locking compound - Wheel bearing replacement - Rear sprocket replacement Note : refit the 6 bolts with normal locking compound If the sprocket is to be refitted, note which way round it is fitted before removal T he rear sprocket must be changed if the gearbox drive sprocket and chain are changed


FRAME

Removal of the chain Operati on 9  Note the running direction of the chain if it is to be refitted T he chain must be changed if the gearbox drive sprocket and rear sprocket are changed Chain tension adjustment Operation 10 - Slacken the wheel spindle nut (1) - Adjust each of the tensioners (2) equally so that the wheel is centred in the suspension arm. A properly adjusted chain should have a slack (A) of 25 to 30 mm at 15 cm from the rear wheel spindle

Removal of the chain guide - Remove the LH fairing hatch (1 bolt) - Remove the chain cover (1) (2 bolts)

- Remove the guide 2 securing bolts (3) - Remove the guide (4)


FRAME

Removal of the rear mudguard - Remove the upper bolt (1) from each of the footrest brackets - Slacken without removing the lower bolt (2) of each of the footrest brackets - Pivot the brackets (3) - Remove the mudguard 4 securing bolts (4) - Remove the mudguard (5)

Removal of the rear caliper and the brake pads - Remove the caliper bracket 2 bolts (1) - Remove the caliper (2) - Remove the pins (3) - Remove the brake pads (4) and their shims (5) T he brake pads are identical; when removing them and not fitting new ones, note the RH/LH side pad positions and fit them the same way round  A fter removing the wheel, the caliper or the pads, before road testing, check the brake operates correctly by operating the lever several times


FRAME

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 the supplier is authorised to adjust it


FRAME

Removal of the shock absorber pivot  Note the fitting position of the pivot for refitting - Remove the 3 securing pins:  from the suspension arm (1)  from the frame (2)  from the shock absorber (3) - Remove the pivot (4)

The pivot assembly is composed of 2 pivots (A), 2 linkrods (B) mounted on four pivot points. Point (3) is fitted to the shock absorber Points (1) and (2) are fitted to the frame (E) and are composed of: a bolt (B1), a washer (B2) a nut (B3), a spacer (C) and two grease-mounted sealing cups (D)

Point (5) is used for the link between the pivots (A) and the linkrods (B) and is composed of: a bolt (B1), a washer (B2) a nut (B3), a spacer (C) and two greasemounted sealing cups (D)

- Refitting order to be complied with 1 –fit pin (1) to the suspension arm 2 –fit pin (3) to the shock absorber 3 –fit pin (2) to the frame (raise the rear wheel to facilitate fitting)


FRAME

Removal of the suspension arm - Remove the chain (1) (note running direction) - Remove the rear brake caliper 2 bolts - Remove the suspension arm (2) caps and spindle nut

- Remove the wheel spindle (3) with its nuts and washers, the brake caliper bracket (4) and the 2 spacers (5) - Remove the wheel

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

T he suspension arm front mount bush is interference fitting in the silentblocs (avoid removing it if it is not necessary)


FRAME

- Essential points for refitting the suspension arm Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted) - Fit the rear brake caliper (1) through the suspension arm behind the spacer (2) - Position the suspension arm - Locate the fixing spindle in the frame

- Tilt the pivot (3) forwards to locate the shock absorber lower mount (4) - Locate the pivot mounting pin on the suspension arm (taking care with the sealing cups (5))

D o not pinch the hydraulic pipe

- Position the wheel and the caliper bracket - Locate the wheel spindle making sure the bushes are properly fitted - Put the caliper in position (2 bolts) - Fit the chain and tension it (see operation 10) - Tighten all parts to the recommended torque - Refit the suspension arm spindle caps


MISCELLANEOUS OPERATIONS MISCELLANEOUS OPERATIONS

Removal of the rear mudflap - Remove the passenger saddle - Remove the 2 front screws (1) then the 2 rear screws (2) (stack N°5) -Pull the rear mudflap (3) downwards

Removal of the rear light assembly - Remove the passenger saddle (1) - Remove the small rear upper fairing (2) (4 screws) - Disconnect the rear light - Remove the 2 rear light nuts from inside the rear fairing (stack N° 7) - Remove the rear light (3)

Removal of the number plate plinth - Remove the rear fairing 4 bolts (1) - Disconnect the rear light and the indicator lights - Remove the number plate plinth (2) - Remove the direction indicators (3) and the rear light (4)


MISCELLANEOUS OPERATIONS

Removal of the instrument panel - Remove the headlight fairing (see operation 1A) - Remove the instrument panel 2 screws (1) - Disconnect the instrument panel 12-pin connector - Remove the instrument panel (2)

Removal of the windshield - Remove the 4 screws (1) (stack N°10) - Remove the 3 screws (2) (stack N°3) - Remove the windshield (3)

Removal of a front direction indicator - Remove 1 bolt (1) under the headlight fairing and disconnect it - Remove the front direction indicator (2)

Removal of a rear direction indicator - Unlock the passenger saddle - Disconnect the direction indicator connection (secured by a plastic tie) - Remove 1 bolt and 1 nut (3) in the rear mudflap - Remove the rear direction indicator (4)



Removal of the steering lock - Remove the fuel tank assembly fairing (see operation 2A) - Disconnect the steering lock from the wiring harness (5-pin connector (1) inside the frame; green, black and red wire) - Disconnect the connector (2) with 1 red and white wire

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

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



Removal of the throttle grip and oil pump - Remove the fuel tank assembly (see operation 2A) - Remove the RH fairing (10 screws) - Remove the RH grip 2 bolts (1) - Remove the cover (2) - Release the cable (3)

- Remove the carburettor chamber cover (4) (1 bolt) - Remove the oil pump cover - Release the cable (3) - Remove of the throttle grip and oil pump

Removal of the oil tank - Remove the rear fairing (see operation 6) - Drain the tank or take the necessary precautions to prevent spillage - Disconnect the oil level switch and the feed union - Remove the 2 bolts (1) - Remove the tank (2)



Removal of the air filter foam

- Remove the fuel tank assembly (see operation 2A) - Remove the air filter cover (1) (1 bolt) - Remove the foam

Removal of the air filter box - Remove the fuel tank assembly (see operation 2A) - Remove the battery and its support - Pull back the rear fairing (6 screws) to access the box 2 bolts - Release the box from the carburettor sleeve - Remove the box (1) from the top by turning it a quarter of a turn to the left of the machine

Removal of the exhaust Operation 11 - Remove the right-hand fairing (see operation 5) with the central (10 screws) - Unhook the 2 springs (1) from the exhaust - Remove the 2 securing bolts mounted on silentblocs (1 on the frame, 1 on the passenger footrest) - No te the position of the exhaust on its mounting points front mounting on the inside of the machine and rear mounting on the outside of the machine - Remove the exhaust (2)



Removal of the carburettor Operation 12 - Remove the fuel tank assembly (see operation 2A) - Remove the battery and its support - Disconnect the carburettor heater hose (1) plug the hose to prevent spillage of the coolant - Remove the valve (2) - Disconnect the oil hose (3) - Release the clip from the inlet coupling (4) using a 3 mm Allen key P/N: 755812 - Undo the air filter clip (5) - Remove the choke connection, 1 screw (6) - Release the carburettor from the inlet coupling - Remove the carburettor

 Adjustment: Idle: screw (7), remove the left-hand fairing hatch Mixture: screw (8), directly accessible

Removal of the valves - Remove the carburettor (see operation 12) - Remove the coupling 4 screws (1) Screws (1A) are removed with a 4 mm Allen key, P/N: 755813 Screw (1B) is common to the clutch cable outer stop bracket (2) - Remove the carburettor union (3) and the valves (4)


ELECTRICITY

ELECTRICITY

Removal of the battery - Remove the fuel tank assembly (see operation 2A) - Remove the battery cover (1) (1 screw) - Remove the battery

Removal of the starter motor relay - Remove the fuel tank assembly (see operation 2A) - Remove the securing screw (1) - Remove the starter motor relay (2)

Removal of the voltage regulator Note: this also acts as a rectifier and direction indicator control unit - Remove the fuel tank assembly (see operation 2A) - Remove the 2 screws (3), the nuts and the washers - Remove the regulator (4)

Removal of a LH or RH control cluster - Remove the instrument panel (see operation 3A) - Remove the grip 2 screws (1) - Release the throttle cable or choke cable, depending on the side - Disconnect the brake light (RH side) - Disconnect the connection with the main harness under the instrument panel - Remove the control cluster Note: note the position of the cluster harness ties before cutting them, and refit them in the same place


ELECTRICITY

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

1. battery leads (2 clips per pole) 2. connection with the rear harness 3. voltage regulator/flasher unit connector 4. horn connection 5. engine earth lead 6. fuse holder 7. starter motor relay connector and earth wire 8. temperature sensor connector 9. ignition module connector 10. starter motor connector 11. neutral switch connector

12. flywheel outlet yellow wire 13. LH cluster connector 14. RH cluster connector 15. brake light switch connector 16. instrument panel connector 17. steering lock connector 18. LH cable grommet 19. RH cable grommet 20. fuel low level warning light connector 21. front direction indicators connector 22. headlight connector


ELECTRICITY

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 (see operation 5) - Disconnect the battery (1) - Disconnect the connection with the rear harness (2) - Disconnect the voltage regulator/flasher unit(3) - Disconnect the horn (4) - Disconnect the engine earth lead (5) - Remove the fuse holder assembly from its support (6) - Disconnect the starter motor relay and its earth wire (7) - Disconnect the temperature sensor (8) - Disconnect the ignition module (9) - Disconnect the starter motor (10) - Disconnect the neutral switch (11) - Disconnect the flywheel outlet yellow wire (12)

Without pulling untowardly, gradually pull out the harness through the frame LH side opening in the following order:

1. the taped assembly (1) of the LH connections (starter motor relay, etc) 2. the steering lock harness (B) section located inside the frame 3. the front RH connection taped assembly (C) 4. feed the rear RH connection taped assembly (D) through the frame 5. complete extraction through the LH opening

- Remove the headlight (see operation 1B) - Disconnect the control cluster connectors LH and RH sides (13) and (14) - Disconnect the RH cluster brake light switch - Disconnect the instrument panel (16) - Remove the electrical part of the steering lock (17) As the lock is connected inside the machine front structure, it is preferable to use this method to facilitate refitting

- Remove the RH and LH cable grommets (18 and 19) Preparation: - Wrap a few turns of sticky tape around the rear left (A), front right (C), rear right (D) and the harness ends to facilitate its extraction from the frame front structure


ELECTRICITY

Refitting the main harness Proceed in reverse order to removal. If the harness is being changed, we recommend it is prepared in the same way as the one removed before fitting In particular: - wrap a few turns of insulating tape over the ends - make the same curves with the plastic ties - connect the different items from the harness changed (diodes, fuses, steering lock harness)

Check the positioning of the different connections and control cables. From frame RH side: - throttle and clutch cables - brake light switch harness - direction indicator harness - RH control cluster connector (6-pin) From frame LH side: - choke cable - steering lock harness - instrument panel connector (12-pin) - LH control cluster connector (9-pin) with the headlight connection harness


WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Removal of the cylinder head/ cylinder/ piston - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 5) - Remove the exhaust (see operation 11) - Drain the cooling circuit (see cooling chapter) - Remove the radiator/cylinder hose (1) - Disconnect the carburettor heating hoses (2)

- Disconnect the water pump hose (3) - Slacken the engine mount side fixing points (4) and (4a) in the frame front compartment - Slacken and remove the front mount pin (5) and push the mount forwards

S ee the XP6 workshop manual pages 9 and 17 for removal of the cylinder head, cylinder and piston


WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE

Removal of the oil pump - Remove the RH fairing (see operation 5) (10 screws) - Remove the cover (1) (2 bolts)

- Release the cable (2) - Disconnect the oil supply hose (3) - Remove the 2 fixing bolts (4) - Remove the oil pump (5)



Removal of the rotor and the magneto flywheel armature - Remove the LH fairing (10 screws) - Remove the LH cover 5 bolts (1)

- Remove the rotor (2)

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

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



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)

 N o t e

which way round the output sprocket is fitted if it is to be re-used T he gearbox output sprocket must be changed if the rear sprocket and chain are changed

Removal of the neutral switch - Remove the LH fairing (10 screws) - Disconnect the wire (1) (1 nut on the terminal) - Remove the switch (2) L e an the vehicle so that the gearbox oil does not run out



Removal of the starter motor - Remove the LH fairing (10 screws) - Remove the LH cover (1) (5 bolts)

- Disconnect the neutral switch (2) - Remove the starter motor 3 securing bolts (3) (2 on the inside and 1 on the outside) - Disconnect the starter motor power lead (4)

- Remove the starter motor (5)


COOLING COOLING

 Whe n working on the cooling circuit, the engine must be cold Removal of the cylinder head/ radiator hose - Remove the RH fairing (see operation 5) (10 screws) - Drain the cooling circuit (drain screw (1) on the water pump) - Remove the hose clips (2) - Remove the hose (3)

Removal of the expansion tank and the expansion tank/ radiator hose - Remove the LH fairing (10 screws) - Drain the cooling circuit (drain screw (1) on the water pump) - Remove the expansion tank (4) hose (2) - Remove the expansion tank fixing bolt (3) - Remove the expansion tank (4)

Removal of the radiator - Remove the side fairings (see operation 5) - Drain the cooling circuit (drain screw on the water pump) - Disconnect the three radiator hoses - Remove the securing bolt (1) from the radiator bracket under the frame steering tube - Remove the radiator (2)


COOLING

Removal of the engine temperature sensor - Remove the RH and centre fairing (see operation 5) (10 screws) - Remove the radiator securing bolt - Extract the radiator from the mounts in order to facilitate access to the sensor (without disconnecting the hose) - Remove the spark plug (1) - Disconnect and unscrew the sensor (2)


MOTOR MOTOR

Removal of the engine - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 5) - Disconnect the battery - Drain the cooling circuit (drain screw (1) on the water pump)

- Remove the chain cover (2) (2 bolts) - Remove the chain (see operation 9) noting which way round it is fitted - Make a mark (A) on the selector link to line it up with the selection shaft (gearbox in first) - Disconnect the link - Remove the exhaust (see operation 11) - Disconnect the oil feed and the oil pump control cable - Disconnect the clutch cable and remove the outer covering stop fixed to the inlet coupling - Disconnect the starter motor, neutral switch, flywheel outlet harness (yellow wire and coil HT lead), suppressor, temperature sensor - Disconnect the carburettor heating hoses - Remove the carburettor (see operation 12) and the air filter box coupling - Disconnect the water pump and cylinder head hoses

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


MOTOR

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

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

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

- Remove the engine to frame lower mount shaft and the fairing support fixed to the shaft Note: in order to facilitate refitting of the fairings, this shaft must be tightened after refitting fairings


MOTOR

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

 W ith the engine removed, take the XP6 workshop manual for details of work on the engine

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

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


FRAME FRAME

Removal of the frame This method is used for replacement of the frame only. If replacing a frame following an accident, the method must be completed by the repair or replacement of the damage parts At the rear: - Remove the fuel tank assembly (see operation 2A) - Remove the side fairings (see operation 4) - Remove the side and centre fairings (see operation 5) - Remove the battery and its support - Disconnect the harness and rear brake light switch - Remove the exhaust - Remove the rear brake fluid reservoir without disconnecting it - Slacken the air filter box sleeve hose clip on the carburettor side - Disconnect the oil pump feed pipe - Remove the 4 bolts securing the rear frame to the main frame

- Remove the rear frame assembly (1) On the engine: - Remove the chain - Remove the selector linkage from the engine - Disconnect: - the neutral switch - the horn - the magneto output yellow wire - the starter motor connector - the temperature sensor - the ignition module engine cut-out - the ignition module earth wires - throttle and choke valves - the oil pump cable - the clutch cable - Remove the expansion tank without disconnecting it - Remove the radiator upper mount - Slacken the rear upper engine mount - Remove the rear lower mount - Remove the 4 engine mount bolts from under the front frame

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


FRAME

At the front/ headlight: - Remove the headlight fairing (see operation 1A) - Disconnect: - the headlight - the instrument panel connection - the control cluster connections - the brake light switch - the throttle, choke, clutch and speedometer cables - Remove the headlight bracket to steering tube 2 securing bolts

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

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

- Remove the fork, front wheel and handlebar assembly (4)

At the rear: - Remove the RH footrest plate 2 securing bolts - Remove the shock absorber upper fixing bolt - Remove the S/A pivot to frame bolt

- Remove the suspension arm, S/A pivot, shock absorber, caliper, plate and brake cylinder, mudguard and rear wheel assembly (5) Remove the frame


FRAME

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 to disassembly


Peugeot XR6 / MotorHispania Racing RX Service Repair Manual MANUALMADNESS.com

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