PEUGEOT XP6 50 Manual
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PEUGEOT XP6 50 Manual

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PEUGEOT XP6 50
Manuel d'atelier (EN ANGLAIS)

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Summary of Contents for PEUGEOT XP6 50

  • Page 1 PEUGEOT XP6 50 Manuel d'atelier (EN ANGLAIS)
  • Page 2 G.H.E. MOTORHISPANIA, S.L GARAGE HANDBOOK...
  • Page 3 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.

  • Page 4: Table Of Contents

    CONTENTS TECHNICAL FEATURES REPLACEMENT Engine part ..........Water pump ..........Cycle part ............ Oil pump ..........Capacities and types ........Tightening motor and cycle......Special tools ..........IGNITION AND ELECTRICAL CIRCUIT Maintenance....………………….. Electronic ignition ........DISASSEMBLY Principle and regulator ......Lights ............

  • Page 5: Technical Features

    Assembly of exhaust pinion ....... Filling of gearbox ........TECHNICAL FEATURES ENGINE PART -Gearing down relation: 3.55 (20x71) CLUTCH: Multidisc in oil coating with manual Name of the manufacturer: ..Furia6V control. Type: ........FU01 GEARBOX: 6 gears Engine marking: only engine type is inscribed, not -Lubrication by means of chain and pinions numbered.

  • Page 6: Capacities And Types

    FRONT BRAKE: Contents for each bar:... 175 cc -AJP brake pin -disc O220 mm with manual hydraulic control PARES APRIETE MOTOR -thickness: 4 mm Cylinder head nut 1,8 mdaN Crankshaft pinion nut 7,5 mdaN REAR BRAKE: Camshaft pinion nut 6 mdaN -AJP brake pin Magneto nut 5,2 mdaN...

  • Page 7: Maintenance

    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...

  • Page 8: Disassembly Of Engine

    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...

  • Page 9: Disassembly Of Magneto

    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).

  • Page 10: Disassembly Of Clutch Cover

    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).

  • Page 11: Disassembly Of Crankshaft Pinions

    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.

  • Page 12: Disassembly Cylinder Head

    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.

  • Page 13: Opening Of Cases

    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).

  • Page 14: Disassembly Of Stick And Gearbox

    DISASSEMBLY OF THE SELECTOR AND THE GEARBOX DISASSEMBLY SELECTOR SHAFT: Put the selector drum in 4 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).

  • Page 15: Replacement Of Bearings/Joints

    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;...

  • Page 16: Assembly Of Gearbox

    ASSEMBLY OF THE GEARBOX AND OF THE SELECTOR Pinion gear 3-4 Pinion gear 6 (25z) Pinion gear 5 Pinion gear 2 (16z) Pinion gear 1 Primary gear shaft Gear selector fork+ pin 5-6 Gear selector fork+ pin 2-3 Gear selector fork+ pin 1-3 Secundary gear shaft Pinion gear 1 Pinion gear 2...

  • Page 17: Assembly Of Selector Shaft

    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).

  • Page 18: Assembly Of Camshaft

    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.

  • Page 19: Closing Of Left Case

    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.

  • Page 20: Assembly Of The Piston

    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.

  • Page 21: Assembly Of The Cylinder Head

    ASSEMBLY OF THE CYLINDER HEAD: Replace the thermostatic valve: The thermostatic valve is fixed by two star head screws. Its replacement does not give any specific problems. Features of the thermostatic valve: Beginning of the opening: 70º +/- 2ºC Opening >=3.5 mm at 82º +/- 2ºC Place the central torical joint in the cylinder and also the 4 torical joints of the push sticks.

  • Page 22: Assembly Of Plate Valve And Inlet Pipe

    ASSEMBLY OF THE PLATE VALVE AND OF THE INLET PIPE CHECKING THE PLATE VALVE: Make sure the plates and their seats are in good conditions. The limit of the plate openings must be 7 mm. ASSEMBLY: Place the plate valve in the housing case. Put the inlet pipe on its place.

  • Page 23: Assembly Of Crankshaft Right Joint

    ASSEMBLY OF THE CRANKSHAFT PINIONS AND OF THE CAMSHAFT PINIONS ASSEMBLY OF THE TIGHT JOINT (RETAIN) OF THE RIGHT SIDE. Place the torical joint (A) and the modified separator (B) on the crankshaft. Assemble the tight joint in its seat (the edges of the joint towards the cover side), after lubricating it, with the push rod.

  • Page 24: Shaft

    Place the pin (A) in its seat of the cam shaft. Assemble the pinion that has 34 cogs between the marked cogs of the camshaft pinion, in the same position as the marked pinion cog of the crankshaft. Place the washer (12.3x22x0.8) and the nut. Put a screw (M6x1.00-20) (B) into one of thread holes of the cam shaft pinion so that it leans on the ribbing of the housing case.

  • Page 25: Assembly Of The Clutch

    ASSEMBLY OF THE CLUTCH CHECKING THE CLUTCH 4 upholstery discs: thickness new 3 mm (thickness of maximum use 2.4 mm). 3 plain discs: thickness new 1.35 mm; deformation (warp): 0.06 mm max. 4 springs: min. length 29.5 mm at rest. Replace the 4 springs if this were necessary.
  • Page 26 Place the clutch discs (4 upholstery discs, 3 plain discs), starting with an upholstery disc and alternate upholstery discs and plain discs. CAUTION: The plain discs have an assembly mark: During the assembly you must make sure that the marks are 120º one from another. NOTE: The new upholstery discs must be (before the assembly) wet with the gearbox oil (SAE 10W30 type SE).

  • Page 27: Clutch Lever Regulation

    ADJUSTMENT OF THE ENGINE CLUTCH LEVER Loosen (on the pressure plate) the counter nut (A) (wrench 19). Place the stick(B) leaning the stick on the control. Act on the central screw of the pressure plate with a screwdriver in order to take the clutch lever to its correct position, that is, parallelly to the magneto gasket plan.

  • Page 28: Starting Shaft/Clutch Cover

    REPLACEMENT OF THE OIL PUMP Disassemble both fixing screws (CHC M5x0.80-16) and remove the defective pump. Place a new pump equipped with a new torical gasket putting the transmission blade at the same level as the axle groove foreseen for this situation.

  • Page 29: Assemblyof Magneto

    ASSEMBLY OF THE MAGNETO Place the stator base according to the corresponding mark that was made during the disassembly and tighten the 3 fixing screws (BHC M4x0.70-10) with a pair of 0.30 mdaN. Slide the rubber thread passer of the electrical installation in its seat.

  • Page 30: Oil Level Of Gearbox

    ASSEMBLY OF THE MAGNETO COVER Place the cover on the housing case. Place the 5 fixing screws (CHC M5x0.80-20) and make sure that they are tightened properly with a pair of 0.4 mdaN. ASSEMBLY OF THE EXHAUST PINION Place the corresponding clip with pin ref.69117 in the hole that is near to the housing case.

  • Page 31: Ignition And Electrical Circuit

    IGNITION AND ELECTRICALS CIRCUITS IGNITION NEUTRAL GAUGE The Furia 6V is equipped with an electronical Fueled by regulated alternating current (yellow ignition type CDI, that is, condensator discharge conductor), the closing of the circuit (earth electronic lighting by means of tyristor. setting of the neutral ignitionl by the boltr of the gearing mechanism) allows the lighting of the Its distinguishing feature: the CDI opening and...

  • Page 32: Indicators

    INDICATORS The indicator stationl and the voltage regulator are assembled in the same case and situated under the petrol tank. The indicators are fueled by regulated alternating current. PRINCIPLE The central indicator fueling is activated by a yellow conductor (mark C). Out of this conductor two conductors emerge, a brown one, mark L1, which fuels the lamps of the right side directly, and another one which is violet, mark L2, and which fuels the lamps on the left side.

  • Page 33: Principle Scheme

    Página 32 de 34...

  • Page 34: Scheme Legend

    A Dashboard lighting B Headlamp gauge C Minimum oil level gauge D Indicator gauge I Neutral gauge K Temperature gauge 1 Magneto A lights B receiver C alternating current 2 Key switch 3 CDI Ignition 4 High voltage coil 5 Antiparasital 5Kohm 7ª...

  • Page 35: Cable Plan

    PRINCIPLE SCHEME Página 34 de 34...

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