Peugeot Motorcycles XR6, Workshop Manual

Page 1: ...WORKSHOP WORKSHOP MANUAL MANUAL SALES DIVISION NETWORK TECHNICAL INFORMATION ...

Page 2: ...moval of the headlight Operation 1 B 10 Removal of the fuel tank assembly Operation 2 A 11 Stripping down the fuel tank Operation 2 B 11 Removal of the instrument panel Operation 3A 12 Removal of the speedometer Operation 3 B 12 Removal of the side fairings Operation 4 12 Removal of the side fairings and the centre fairing Operation 5 13 Removal of the rear fairing and the number plate plinth Oper...

Page 3: ...moval of the exhaust Operation 11 30 Removal of the carburettor Operation 12 31 Removal of the valves 31 ELECTRICITY 32 Removal of the battery 32 Removal of the starter motor relay 32 Removal of the voltage regulator 32 Removal of a LH or RH control cluster 32 Removal of the ignition module 33 Removal of the horn 33 Removal of the rear wiring harness 33 Removal of the main harness 35 Refitting the...

Page 4: ...Air screw initial position 1 1 2 turns Needle A34 Main jet 60 Idle jet 36 Magneto Ducati 85 W Starter motor Ducati Frame 1 Manufacturer s plate 2 VIN number Capacities Gearbox 0 75 litres Fuel tank 11 75 litres Oil tank 1 1 litres Showa fork 0 175 litres per tube Dimensions Length 1 865 mm Width 675mm Height without rear view mirror 1 100 mm Wheelbase 1265 mm Weight Weight 115 kg Tyres 1 person 2 ...

Page 5: ...X Coolant piping X X X Fuel heating piping X X X Tyre pressures X Tyre condition pressure and wear X X Front and rear brake fluid level X X X Coolant level X X X Battery electrolyte level X X X Tightness of nuts and bolts X X X Battery charge X X Change Inlet silence filter element X X Front and rear brake pad X X Gearbox oil X X Chain front sprocket rear sprocket X X Clutch discs X Check and remo...

Page 6: ...sary after a complete charge using distilled water only Top up checks Check the gear box oil level Check the coolant level Check the brake fluid levels Filling the fuel and oil circuits Put 1 litre of 95 or 98 unleaded fuel mixed with 3 semi syntehtic 2 stroke oil Top up the oil with Esso semi synthetic 2 stroke oil Start the engine disconnect the oil feed hose to the carburettor and check that th...

Page 7: ...tarter 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...

Page 8: ...t 6 5 m daN Front mount to chassis 4 5 m daN Engine to front mount 4 5 m daN Engine to chassis 2 8 m daN Shock absorber upper mount 4 3 m daN Shock absorber lower mount 4 3 m daN Fork Tees 1 5 m daN Upper Tee centre bolt 5 m daN Front mudguard bracket 2 5 m daN Front brake caliper 2 5 m daN Rear brake caliper 2 5 m daN Front brake disc 1 m daN Rear brake disc 1 m daN Frame mounted stand 1 9 m daN ...

Page 9: ...r 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 n...

Page 10: ...irrors 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 ...

Page 11: ...ver 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 c...

Page 12: ...nnect 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 ...

Page 13: ...he 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 s...

Page 14: ...stop 6 on the RH tube and tighten the lock nut 2 before tightening the wheel spindle nut Slacken the lock nut 2 and compress the 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 roun...

Page 15: ...ard 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 calip...

Page 16: ...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 t...

Page 17: ...per 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 headlig...

Page 18: ...linth 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 s...

Page 19: ...ge 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 bo...

Page 20: ...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...

Page 21: ...ove 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...

Page 22: ...eration 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 ...

Page 23: ...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 grease mounted sealing cups D Refitti...

Page 24: ...dle 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 ...

Page 25: ...ion 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 Do 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 Fi...

Page 26: ...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 n...

Page 27: ...move 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 secur...

Page 28: ...ck 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 wh...

Page 29: ...airing 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 unio...

Page 30: ...ear 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 o...

Page 31: ...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 coup...

Page 32: ...ltage 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 ...

Page 33: ...crews 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 ...

Page 34: ...older 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...

Page 35: ...ve 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 A s 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 ...

Page 36: ...f 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 ...

Page 37: ...ion 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 ...

Page 38: ...ation even partial forbidden without the written consent of Peugeot Motocycles Removal of the oil pump Remove the RH fairing see operation 5 10 screws Remove the cover 1 2 bolts Release the cable 2 Disconnect the oil supply hose 3 Remove the 2 fixing bolts 4 Remove the oil pump 5 ...

Page 39: ...tten consent of Peugeot Motocycles 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 ...

Page 40: ...h 1 bolt Remove the chain cover 1 2 bolts Remove the clip and the sprocket 2 Note 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 gear...

Page 41: ... the written consent of Peugeot Motocycles Removal of the starter motor Remove the LH fairing 10 screws Remove the LH cover 1 5 bolts Disconnect the neutral switch 2 Remove the starter motor 3 securing bolts 3 2 on the inside and 1 on the outside Disconnect the starter motor power lead 4 Remove the starter motor 5 ...

Page 42: ...e 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 wa...

Page 43: ...cycles 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 ...

Page 44: ...elector 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 Di...

Page 45: ...ut 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 ...

Page 46: ...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 ...

Page 47: ...oir 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 th...

Page 48: ...ght 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 ...

Page 49: ...nsent of Peugeot Motocycles Stripping the frame Remove the controls and cables Remove the RH plate Remove the stand Remove the main harness Remove the electrical components Remove the steering bearings Remove the captive nuts Fit the new frame by proceeding in reverse order to disassembly ...

Page 50: ...n without the written consent of Peugeot Motocycles RECOMMENDS REF 755809 For reasons of continuous improvement Peugeot Motocycles reserves the right to modify delete or add any part number quoted DC PS ATR printed in EU 12 2000 photos non contractual ...