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34

 

CONTENTS 

TECHNICAL FEATURES

 

REPLACEMENT 

Engine part .................................................. 

2 

Water pump .............................................. 

24 

Cycle part .................................................... 

2 

Oil pump .................................................. 

25 

Capacities and types ................................... 

3 

Tightening motor and cycle......................... 

3 

Special tools ................................................ 

3 

IGNITION AND ELECTRICAL CIRCUIT 

Maintenance...................………………….. 4 

Electronic ignition .................................... 

28 

DISASSEMBLY 

Principle and regulator ............................. 

28 

 

Lights 

.......................................................

28

Disassembly of engine ................................ 

5 

Neutral gauge........................................… 

28 

Disassembly of magneto ............................. 

6 

Cooling system temperature gauge.......... 

28 

Disassembly of clutch cover ....................... 

7 

Min. oil level gauge...............................… 

28 

Disassembly clutch ..................................... 

7 

Horn ......................................................... 

28 

Disassembly of crankshaft pinions  

Socket ....................................................... 

28 

and camshaft ..............................…………. 

8 

Indicators .................................................. 

29 

Disassembly of inlet pipe and 

Principle scheme....................................... 

30 

plate valve ...................................………… 

8 

Scheme legend.......................................... 

31 

Disassembly cylinder head ......................... 

9 

Cable plan ................................................ 

32 

Disassembly of cylinder ............................. 

9 

Disassembly of piston ................................ 

9 

Disassembly of exhaust pinion ................... 

9 

CONTROL

Opening of cases .................................... 

10 

Disassembly of  stick and gearbox ............. 

11 

Elements of the gearbox ........................... 

13 

Disassembly of camshaft ........................... 

11 

Connecting rod/crankshaft set................... 

15 

Disassembly of crankshaft .......................... 

11 

Piston ........................................................ 

17 

 

Cylinder 

....................................................

17

 

 

Segments 

..................................................

17

ASSEMBLY 

Thermostat valve ..................................... 

18 

Plate valve .......................................... 

19 

Replacement of bearings/joints ............…... 

12 

Clutch ....................................................... 

22 

Assembly of gearbox .................................. 

13 

Ignition advance ....................................... 

26 

Assembly of selector shaft  ......................... 

14 

Oil level of gearbox ................................. 

27 

Assembly of camshaft.... .................……… 

15 

Assembly of connecting rod/crankshaft   
in right case ................................................. 

15 

Closing of left case ..................................... 

16 

ADJUSTMENTS

Assembly of the piston ............................... 

17 

Assembly of the cylinder ............................ 

17 

Engine clutch lever...................………… 

24 

Oil pump .................................................. 

25 

Assembly of the cylinder head ................... 

18 

Ignition advance ....................................... 

26 

Assembly of plate valve and inlet  
pipe ............................................................. 

19 

Assembly of crankshaft right joint ............. 

20 

Assembly pinions crankshaft and cam 
shaft ............................................................ 

20 

Assembly of the clutch ............................... 

22 

Clutch lever regulation ............................... 

24 

Starting shaft/clutch cover .......................... 

25 

Assemblyof magneto .........................……. 

26 

Summary of Contents for XP6 50

Page 1: ...PEUGEOT XP6 50 Manuel d atelier EN ANGLAIS ...

Page 2: ...G H E MOTORHISPANIA S L GARAGE HANDBOOK ...

Page 3: ...lowing 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: ...n 9 Disassembly of exhaust pinion 9 CONTROL Opening of cases 10 Disassembly of stick and gearbox 11 Elements of the gearbox 13 Disassembly of camshaft 11 Connecting rod crankshaft set 15 Disassembly of crankshaft 11 Piston 17 Cylinder 17 Segments 17 ASSEMBLY Thermostat valve 18 Plate valve 19 Replacement of bearings joints 12 Clutch 22 Assembly of gearbox 13 Ignition advance 26 Assembly of selecto...

Page 5: ...ULATOR FACOMSA with integrated central integrator Regulation tension 13 4VAC 0 5 STARTING Starting pedal SEPARATE GREASING DELL ORTO oil pump Variable flow 6 cc H approx control between 0 and 10º 9 cc h approx control at 15º 25 cc h approx control at 45º 38 cc h approx control at 71º Gearing down relation 2 03 20x24 and 13x22 PRIMARY TRANSMISSION helical gears Gearing down relation 3 55 20x71 CLUT...

Page 6: ...PRIETE MOTOR Cylinder head nut 1 8 mdaN Crankshaft pinion nut 7 5 mdaN Camshaft pinion nut 6 mdaN Magneto nut 5 2 mdaN Clutch nut 7 5 mdaN Pressure plate screw 0 5 mdaN Clutch counter nut 2 7 mdaN Engine housing case screw 1 1 mdaN Transmission cover screw 1 1 mdaN Magneto cover screw 0 4 mdaN Inlet pipe screw 1 1 mdaN Starting pedal screw 3 mdaN Gearbox casting screw 1 8 mdaN TIGHTENING OF THE CY...

Page 7: ... A 500 Kms or 3 months PLAN B 2 500 Kms or 5 000 Kms PLAN C 5 000 Kms or 10 000 Kms Verify Adjustment of the idling X X X Gas control X X X Clutch control X X X Front and rear brake control X X X Functioning the electrical equipment X X X State and pressure tyres X X X Petrol tube X X X Oil tube X X X Brake fluid tube X X X Antifreeze fluid tube X X X Brake fluid level X X X Antifreeze fluid tube ...

Page 8: ...trical installation of the neutral Disassemble the transmission chain fast union loosen nut of the swing fork loosen and remove screw sup fastening of the engine and make it pivot upwards the other two screws of the engine Remove the engine and put it on the bracket adaptor this bracket has to be screwed to a bench Take the oil out of the gearbox screw a Remove the draining screw from the water pu...

Page 9: ...ntral part of it to take out the rotor assembled on conical axle with pin Remove the three screws with star head M4x0 70 19 and their washers IMPORTANT Before removing the stator base leave a small mark on the housing case and on the plaque so you can find back the initial position during the assembly Loosen the three screws with allen head BHC M4x0 70 10 and remove the stator plaque Allen wrench ...

Page 10: ...ing pedal on the spindle to put it back during the assembly see page 25 DISASSEMBLY OF THE CLUTCH Loosen and remove the 4 screws CB M5x0 80 20 the washers and the springs from the pressure plate Disassemble the upholstery discs and the plain ones Take out the primary driving shaft the ball and the driving stick see page 23 A B C Straighten the nut brake Immobilize the rotor clutch with tool Loosen...

Page 11: ...ft nut wrench 19 and remove them Disassembly of the crankshaft The two pinions 20 cogs and 34 cogs the in note the direction of the pinion 20 z mark towards the nut The smooth washer 812 3x22x0 8 the pinion 34 cogs and the pin DISASSEMBLY OF THE INLET PIPE AND PLATE VALVE Loosen and remove the 4 fixing screws CHC M6x1 00 20 from the inlet pipe Disassemble the pipe and the plate sheet overhaul of v...

Page 12: ...e cylinder and its base joint DISASSEMBLY OF THE PISTON Incline the engine towards the left or right side In order to avoid dropping the fixer accidentally into the engine Remove the bolt fixer by means of some tongs Push the bolt and remove the piston the bolt is adjusted to the piston with oil Remove the needle case from the stem of the connecting rod DISASSEMBLY OF THE EXHAUST PINION Remove the...

Page 13: ...que on the housing case with four screws M5x0 80 20 Remove the two safety pins from the engine bracket Act on the screw of tool the housing cases have been opened completely Be careful with both centring bubbles of both cases CAUTION while opening make sure that both cases open in parallel If necessary use a plastic hammer hitting both ends of the secondary shaft and gear shaft Put the two safety ...

Page 14: ...he friction washer from the selector drum 10x16x0 6 Remove and disassemble the fork shaft from the secondary shaft Take out the whole Main shaft Secondary shaft Selector drum Forks Remove the anchorage ball and its driver spring Remove the 2nd friction washer 14 5x27x0 6 from the secondary shaft DISASSEMBLY OF THE CAMSHAFT The camshaft is fixed on its bearing Hit its end with a plastic hammer to d...

Page 15: ...l the edges towards the wheel chamber IMPORTANT Before heating the left case we recommend that you should remove the neutral socket of the selector shaft NOTE The right tight shaft will be installed after closing the housing cases placing the torical and the separator to avoid causing any damage to its edges again when it touches that same separator Replacement of the tight joints of the secondary...

Page 16: ...ssary then we recommend replacing the entire train the pinion of the main shaft and the one that belongs to the secondary shaft ASSEMBLY OF THE GEARBOX Place the washer 14 5x27x0 6 on the needle case of the secondary shaft of the right case Put the spring and the anchorage ball in their seats and lubricate them with grease Pinion gear 3 4 th 19 22z Pinion gear 5 th 24z Pinion gear 1 th Pinion gear...

Page 17: ...t in its seat Verify the good change of the gears activating the selector drum with one hand turning the main shaft with the other hand ASSEMBLY OF THE SELECTOR SHAFT Place the selector drum in the fourth position the bolt of the aligned mechanism virtually with the fork shaft of the secondary shaft Place the selector shaft equipped with its washers with a thickness of 0 6 mm in each end 12x17x0 6...

Page 18: ... ASSEMBLY OF THE WHOLE JOINT CRANKSHAFT IN THE RIGHT CASE CHECKING THE CRANKSHAFT The side set of the head of the joint must be between 0 14 and 0 41 mm Check the ligning up of the crankshaft The values at the end must never be higher than 0 04 mm ASSEMBLY Place the crankshaft in its correct position in the right semicase Do this by hand ...

Page 19: ...uipped with plaque and settle the whole on the case by means of 4 screws M5x0 80 15 the opening of the place on the cylinder shaft Place the centrer on tool Screw tool on the one that has holding the connecting rod Continue screwing the tool on it until the crankshaft reaches the bearing During this operation make sure that the left semicase descends in parallel on the right one Help reaching this...

Page 20: ...is measure the diameter of the piston and compare it with the cylinder The max set that is allowed is 0 07 mm ASSEMBLY OF THE PISTON Verify the parity of the whole cylinder piston letter indicated on the piston and cylinder Oil and place the needle case at the stem of the connecting rod Present the piston with the arrow directed towards the exhaust pipe Push the bolt into its seat Incline the engi...

Page 21: ... 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 Place the torical joint in the cylinder head and place it in the cylinder Place the 4 washers and the 4 nuts and make sure they are tightened well with a pair of 1 8 mdaN tighten in the shape of a cross wrench 10 ...

Page 22: ... 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 Make sure that the whole is tightened correctly with 4 screws CHC M6x1 00 20 which will be tightened with a pair of 1 1 mdaN The right rear screw has the clutch thread bracket assembled on it ...

Page 23: ...parator 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 ASSEMBLY OF THE PINIONS Place the parallepipid pin A on the crankshaft axle seat Place the pinion that has 34 cogs cogs visibly marked Place the main transmission pinion that has 20 cogs visible mark and place the nut afterwards ...

Page 24: ...ace 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 With the pinion immobilized like this make sure that the camshaft pinion is tightened properly with a pair of 6 mdaN wrench 19 After this tighten the crankshaft pinions with a pair of 7 5 mdaN wrench 17 IMPORTANT Do not forget to remov...

Page 25: ... grooves change the hood if this were necessary Clutch rotor verify the state of the grooves on which the discs hit the grooves change it if necessary ASSEMBLY OF THE CLUTCH Place on the main shaft The conical washer with interior cogging A with the end of its cogs leaning on the interior bearing track The smooth washer 17 2x30x0 8 B The clutch hood after having lubricated its brass fitting The 4 ...

Page 26: ... discs must be before the assembly wet with the gearbox oil SAE 10W30 type SE Place the control lever of the clutch in its seat equipped with its spring and washer after lubricating it Introduce in the main shaft The push stick O5 length 116 6 mm A The ball O4 8 B The push rod of the clutch C Assemble the pressure plate making the mark arrow 2 meet with the mark of the clutch rotor round mark 1 Pl...

Page 27: ...top circlip A The washer B The nylon pinion with 30 cogs C The bolt D The second washer E Take out the turbine Disassemble the tight joint retain with a screwdriver for example ASSEMBLY Place the clutch cover on a plain surface be careful with the oil pump pinions if the axles have not been removed already Place a previously lubricated tight joint previously lubricated to enable placing it with a ...

Page 28: ...system has risen Loosen and remove the anchorage screw of the starting shaft of the upper part of the housing case A photograph below Introduce the starting shaft set in the transmission cover equipped with the friction washer 16x25x0 6 making sure you place the extreme of the spring in its seat B Place the spring and the ratchet launcher facing the ramp C at the end of the spring Assemble the sta...

Page 29: ...crankshaft Assemble the rotor and immobilize it with tool Make sure that the nut is tightened properly Do this with a pair of 5 2 mdaN wrench 15 NOTE the circuit advance is of 1 4 mm before the PMS of the piston distance It has an angular value of 20º before the PMS CHECKING THE ADVANCE POINT Place a comparer in the spark plug position Make the rotor turn in order to take the piston to the PMS and...

Page 30: ... the hole that is near to the housing case Place the exhaust pinion of the engine on the secondary shaft Place the second circlip in the second hole FILLING OF THE GEARBOX Loosen the nivel screw A Remove the filling cap B Fill the engine case with 0 75 litres of oil SAE 10W30 type SE With the vehicle on a horizontal surfaceand placed vertically the oil must start to pour out through the opening of...

Page 31: ...for its good functioning LIGHTS In the lighting position the yellow conductor that supplies the alternating current of the magneto already regulated by the regulator reaches the switch through the light position switchr in the ignition key Activating the switches you can change from road headlights to dipped headlights and with the lights off it allows you to produce flashes NEUTRAL GAUGE Fueled b...

Page 32: ...he right side lamps blue thread white of the main installation and of the left side lamps red thread white of the main installation go to the indicator switch Its manipulation connects the blue white thread well or the red white thread to the orange conductor of the indicator station with the earth mark The good earth setting of the indicator station by means of its fixing to the chassis and its c...

Page 33: ...Página 32 de 34 ...

Page 34: ...r C alternating current 2 Key switch 3 CDI Ignition 4 High voltage coil 5 Antiparasital 5Kohm 7ª Regulator AC 12 Lamp control 13 Headlamp 14 Rear light and stop lamp 17 Horn 18 Horn button 19 Indicator station 20 Indicator control 21 Indicator lámparas 22 Sockets 28 Minimum oil level control 29 Temperature probe 34 Rear bracket socket 35 Stop 36 Neutral ignition ...

Page 35: ...Página 34 de 34 PRINCIPLE SCHEME ...

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