verkstadshandbok am6 motor

7/29/2019 Verkstadshandbok Am6 Motor

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Sales divisionTechnical network leadership

WORKSHOP MANUAL

-

50CC ENGINE MULTI-SPEED

MINARELLI


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Workshopmanual

Technical network leadership

Reproductionor translation,even partial,is forbidden without thewrittenconsentof PeugeotMotocycles


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TABLE OF CONTENTS

1Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS

TABLE OF CONTENTS..................................................................................................................................... 1

PRODUCTS DANGER SYMBOLS USED......................................................................................................... 3

CHARACTERISTICS......................................................................................................................................... 5

Capacities .................................................................................................................................................. 5

SPECIAL IMPORTANT POINTS....................................................................................................................... 6

Oil and fuel.................................................................................................................................................6

TIGHTENING TORQUE..................................................................................................................................... 7

SPECIAL TOOLS .............................................................................................................................................. 8

DISASSEMBLY ............................................................................................................................................... 11

Putting the engine on the stand. ..............................................................................................................11

To remove the magneto flywheel. ............................................................................................................11Removal of the starter motor....................................................................................................................12

Removal of the starter motor (Depending on model)...............................................................................12

Removal of the gearbox output pinion. ....................................................................................................12

Removal of the clutch cover. ....................................................................................................................13

Removal of the clutch...............................................................................................................................14

Removal of the crank assembly and balance shaft pinions. .................................................................... 16

To remove the inlet manifold and valve. ...................................................................................................16

To remove the cylinder head/cylinder assembly.......................................................................................17

Removal of the piston. .............................................................................................................................17

Removal of the thermostat.......................................................................................................................18

Opening the engine casings. ...................................................................................................................19

Removal of the gearbox and the gear-change system. ........................................................................... 20

Removal of the transmission input shaft. .................................................................................................23

Removal of the balance shaft...................................................................................................................24

Removal of the crankshaft. ......................................................................................................................24

Checking the crankshaft and conrod assembly........................................................................................25

REFITTING SPECIFIC COMPONENTS.......................................................................................................... 26

Fitting the crank assembly bearings.........................................................................................................26

Replacing the RH engine casing bearings...............................................................................................27

Replacing the LH engine casing bearings. ..............................................................................................27

Replacing the RH engine casing caged needle bearings (depending on the model). .............................28

Replacing the LH engine casing caged needle bearings (depending on the model)...............................29

Fitting the box output seal........................................................................................................................30

Fitting the gear-change shaft seal............................................................................................................30

Fitting the clutch lever seal.......................................................................................................................30


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TABLE OF CONTENTS


To fit the balance shaft. ............................................................................................................................31

Fitting the conrod and crankshaft assembly.............................................................................................31

Fitting the gearbox. ..................................................................................................................................31

Fitting the left side casing. .......................................................................................................................34

Checking the piston. ................................................................................................................................36

Checking the piston rings.........................................................................................................................36

Fitting the piston.......................................................................................................................................36

Fitting the cylinder....................................................................................................................................37

Fitting the cylinder head...........................................................................................................................37

Fitting the right side O-ring. .....................................................................................................................38

Fitting the crank assembly and balance shaft pinions..............................................................................38

Fitting the clutch.......................................................................................................................................40

Adjusting the clutch control lever..............................................................................................................42

Fitting the starter system (depending on model) and the clutch cover.....................................................42

To fit the magneto flywheel. .....................................................................................................................43

MISCELLANEOUS OPERATIONS ................................................................................................................. 44

Removal of the water pump. ....................................................................................................................44

Fitting the water pump..............................................................................................................................44

Removing the oil pump and its drive pinions............................................................................................45

Fitting the oil pump...................................................................................................................................45


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PRODUCTS DANGER SYMBOLS USED



Protection of individuals and of the environment.

Mbius band Recyclable.

Means that the product or the packagecan be recycled. However, this does notguarantee that the product will be

recycled.

IrritantThe product can irritate theskin, eyes and repiratoryorgans.

Avoid contact with the skin and clothes.Wear gloves, safety glasses andappropriate clothes such as a cottonoverall. Do not breath fumes. If in contact,wash thoroughly with water.

Flammable The product is flammable.

Keep it away from any flame or heatsource (barbecue, radiator, heatingdevice, etc.). Do not leave the product inthe sun.

CorrosiveThe product can damage livingtissues or other surfaces.

Avoid contact with the skin and clothes.Wear gloves, safety glasses andappropriate clothes such as a cottonoverall. Do not breath fumes.

ExplosiveThe product can explode undercertain circumstances (flame,heat, impact, friction).

Avoid impacts, friction, sparks and heat.

Hazardous tothe environment

The product affects fauna andflora.Do not dump it ingarbage cans, sinks or nature.

The ideal solution is to bring this productto your nearest household waste recyclingcentre.

ToxicThe product can seriouslyaffect health if it is inhaled,ingested or in contact with skin.

Avoid direct contact with the body even byinhalation. If you feel unwell, seek medicaladvice immediately.

Do not throwaway into agarbage can

One of the product's

component is toxic and can behazardous to environment.Forexample:Used batteries.

Do not throw the used product in thedustbin. Take it back to the trader or to aspecific waste disposal site.

Compulsorygloves

Operation that can bedangerous for people.

People's safety can be seriously affected ifthe recommendations are not fullyrespected.

People's safety.Operation that can bedangerous for people.

People's safety can be seriously affected ifthe recommendations are not fully

respected.


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ImportantOperation that can bedangerous for people.

Indicate the specific procedures that shallbe followed in order not to damage thevehicle.

Good operating

condition of thevehicle

The operation must be carried

out in strict compliance with thedocuments.

Serious damage to the vehicle and incertain cases a cancellation of the

warranty can be involved if therecommendations are not fully respected.

Note Operation that can be difficult.Indicate a note which gives keyinformation to make the procedure easier.

LubricateLubricate the parts to beassembled.


GreaseGrease the parts to beassembled.


GlueGlue the parts to beassembled.


New part Use a new part.Indicate the specific procedures that shallbe followed in order not to damage thevehicle.

GLUE

N


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CHARACTERISTICS


CHARACTERISTICS

Capacities

50 cc 50 cc Power-Up

Marking AM6

Type Single cylinder 2 stroke with balance shaft

Cooling Liquid

Bore x stroke 40.3 x 39 mm

Cubic capacity 49.7 cc

Max. power output 1.82 kW at 5250 rpm

Max. torque rating 5250 rpm

Gearbox 6 speed mechanical gearbox

Clutch multi-disc, oil bath, and manually controlled

Lubrication circuit Separate lubrication by piston pump, synchronized with the throttle grip

Exhaust Catalytic With catalytic system and pulsair valve

Starter motor Ducati 85 W

Spark plug NGK BR9ES

Magneto flywheel Ducati 85 W Motori Minarelli 85W

Fuel supply Dellorto carburettorDellorto carburettor

ECU-controlled carburetion systemMoric

Gearbox 0.75 l: SAE 10W30


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SPECIAL IMPORTANT POINTS


SPECIAL IMPORTANT POINTS

Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc.

The clips are specific, they must always be changed each time they are removed and replacedwith new genuine parts clips.

Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames orsparks.

Before carrying out any work, leave the engine to cool for at least 2 hours.


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TIGHTENING TORQUE


TIGHTENING TORQUE

Cylinder head 18 Nm

Cylinder casings 11 Nm

Transmission cover 11 Nm

Water pump 11 Nm

Inlet manifold 11 NmConrod and crankshaft assembly gear 75 Nm

Balance shaft pinion 60 Nm

Clutch housing 75 Nm

Clutch pressure plate 5 Nm

Clutch thrust bearing locknut 27 Nm

Starter motor 11 Nm

Rotor 52 Nm

Stator 3 Nm

Flywheel magneto cover 4 Nm

Gearbox drain plug 18 NmSpark plug 25 Nm


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SPECIAL TOOLS


SPECIAL TOOLS

Tool N Designation Usedwith Tool N DesignationUsedwith

064706 Casingextractor andopening tool

750539 Tie-wrappliers

064710Shoulderedcentering

tool64706 752237 Adjustablepin wrench

064765 Enginemount 753411Flywheel

puller

068007Protectiveend-piece

small model753708

Casingopening

plate64706

069098Protectiveend-piece

large model64706 753709

Enginemount

adapter64765

069104 Pin nut 64706 753726

Crank assylip seal fitting

tool forprimarytransmission

side

750069 Pin 10pitch 125 64706 753728Selector

shaft lip sealfitting tool


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SPECIAL TOOLS


Tool N DesignationUsedwith

Tool N DesignationUsedwith

753730Clutch leverlip seal fitting

tool753729

Water pumplip seal fitting

tool

753731Clutch

locking tool756039

Fork sealpush tool

754041Timing

casing sealdrift

755585Bearing

extractor tool

757990

Crankcaseseal

installation

buffer


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SPECIAL TOOLS


Standard tools

Heat gun

Automatic resetting typetorque wrench10 to 50 Nm

Type: Facom J.208A50

Intertia type extractortool for bearings from 6

to 18 mmType: Facom U.49PJ3

Automatic resetting typetorque wrench40 to 200 NmType: FacomS.208A200

Automatic resetting typetorque wrench

5 to 25 NmType: Facom R.306A25


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DISASSEMBLY


DISASSEMBLY

Putting the engine on the stand.

- Fit the engine to adapter P/N 753709.

- Lock the engine to the adapter using the2 spring pins.

- Put the assembly on stand P/N 64765clamped in the jaws of a vice.

To remove the magneto flywheel.- Remove the flywheel magneto cover.

- Remove the paper gasket.

- Hold the rotor (1) with the pin wrenchP/N 752237.

- Remove the nut.

Depending on the model, the rotor acts as the starter ring.

- Fit protective cap P/N 068007 to the end ofthe crank assembly.

- Tighten flywheel extractor P/N 753411 onthe rotor.

- Lock the flywheel extractor and turn thethrust bolt until the rotor is released.

.


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DISASSEMBLY


Removal of the starter motor.

- Remove the 3 fixing bolts (1) from the statorplate and stator.

- Remove the stator plate and statorassembly.

We recommend tapping the bolts with a hammer and drift to facilitate slackening. The 3 boltsmust be renewed once removed.

Removal of the starter motor(Depending on model).

- Remove the 3 screws (1) that secure thestarter motor (2).

- Remove the 2 spring pins which lock theengine to the adapter.

- Move the engine along the adapter guides toremove the starter motor.

- Re-fit the 2 spring pins.

Removal of the gearbox output pinion.

- Remove the circlip (1).

- Remove the pinion (2).

- Remove the second circlip.


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DISASSEMBLY


Removal of the clutch cover.

- Remove the kickstart pedal securing bolt(depending on the model).

- Lightly operate the kickstart pedal and holdit in position.

- Slacken off the kickstart shaft thrustbearing (1) and release the kickstart pedalto relax the spring.

- Remove the kickstart pedal.

Use a recipient to recover the box oil.

- Remove the bolt (2) in order to drain off thegearbox.

- Remove the 8 bolts that secure the cover.

- Remove the cover.

- Remove the 2 centring pillars and the papergasket.


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DISASSEMBLY


Removal of the clutch.

- Remove the 4 bolts and spring (1) from thepressure plate (2).

- Remove the pressure plate.

- Remove the assembly (3) of 4 lined discsand 3 smooth discs.

- Remove the primary shaft: The pusher (4)

The ball (5)

The push rod (6)

- Remove the clutch operating lever (7) withits spring (8) and its washer (9).

7

8

9


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DISASSEMBLY


- Fold down the clutch nut (10) lockwashertab (11).

- Lock the clutch main shaft (12) with toolP/N 753731.

- Remove the nut and the washer.

- Remove the clutch main shaft (12), thesplined bush (13), the cover (14), the plain

washer (15) and the tapered washer (16).


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DISASSEMBLY


Removal of the crank assembly andbalance shaft pinions.

- Lock the balance shaft using a bolt (A)inserted into one of the threaded holes.

- Turn the balance shaft pinion (1) to bring thebolt into contact with a ribbing in the case.

- Remove the crankshaft nut (2).

- Remove the balance shaft nut (3).

- Remove the 2 pinions (20 and 34 teeth) andthe key (4) from the crank assembly.

- Remove the 34 tooth pinion and the key (5)from the balance shaft.

To remove the inlet manifold and valve.

- Remove the 4 inlet coupling bolts, 2 ofwhich (1) using the safety Allen key.

- Remove the coupling and the inlet valve.


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DISASSEMBLY


-

- Check that the valve assembly blades andsupport are in perfect condition.

The position of the limiter must be 7 mm from the valve support.

To remove the cylinder head/cylinderassembly.

- Remove the spark plug.

- Slacken off the cylinder head/cylinder4 mounting nuts in the order shown, in 2 or3 stages.

- Remove the 4 nuts and washers.

- Remove the cylinder head and the 2 O-rings.

- Remove the cylinder and its bottom seal.

Removal of the piston.

- Remove one of the circlips (1) with pliers.

- Remove the gudgeon pin.

- Remove the piston.

- Remove the needle bearing race from theconnecting rod end.


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DISASSEMBLY


Removal of the thermostat.

- Remove the thermostat (2) 2 bolts (1).

- Remove the thermostat.

When refitting, ensure that the degassing hole (A) is at the highest point.

Removal of the temperature sensor.

- Remove the sensor 1 and its seal

When re-installing, use a new gasket.


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DISASSEMBLY


Opening the engine casings.

- Remove the left casing 13 securing bolts.

- Fit the protective cap P/N 68007 to thecrank.

- Fit to casing with tool P/N 64706 fitted withplate P/N 753708.

- Fix the assembly to the casing using4 bolts (1).

- Remove the engine mount adapter 2 springpins.

- Tighten the tool centre screw until thecasings separate.

When opening the 2 casings, so that they open evenly, use a plastic mallet to tap alternativelyon the ends of the secondary shaft and the speed selector.


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DISASSEMBLY


- To remove the left casing.

- Remove the 2 centring pins (2).

- Refit the engine mount adapter 2 springpins.

Recover the friction washers which may have been retained by the oil in the left casing.

Removal of the gearbox and the gear-change system.

- Position the selector so that the mecaninduspin is positioned opposite the secondaryshaft fork shaft.

- Remove the selector shaft (1) fitted with its2 friction washers.


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DISASSEMBLY


- Remove the circlips (6).

- When refitting, ensure each part is fitted inthe right position and the right way round.

2. Plain washer

3. Gear change plate

4. Gear change shaft

5. Return spring

6. Circlip

7. Bush

8. Spring

9. Backed-up washer

The circlips must be renewed each time they are removed.

- Remove the fork shaft (10) from thesecondary shaft.

- Remove the upper fork (11) from thesecondary shaft.

- Turn the selector cylinder (12) to lower theprimary shaft fork (13) into the cylinder lowergroove.

- Remove the selector cylinder.

- Remove the secondary shaft 2nd fork (14).

2

2

43 5

6 7 8

69

10

11

13 12

14


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DISASSEMBLY


- At the same time, remove the secondaryshaft and primary shaft assembly fitted withits fork.

Model before 2008 Model 2008

- Remove the friction washer (15) from thesecondary shaft which due to the oil mayhave remained stuck in the right casing.

- Remove the locking ball (16) and its thrustspring.

- Remove the locking ball (16) and its thrustspring.

Plain bearing (A) Caged needle bearings (A)

16

15

A

16

A


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DISASSEMBLY


Removal of the transmission input shaft.

- Remove the circlips and pinions usingcirclips pliers.


1. Primary shaft with 1st gear pinion.

2. 3rd and 4th gear pinion.

3. 5th gear pinion.

4. 2nd gear pinion.

5. 6th gear pinion.

6. Circlip.

Removal of a pinion from the secondary shaft.


- Remove the circlips and pinions usingcirclips pliers.


7. Secondary shaft.

8. 1st gear pinion.

9. 3rd gear pinion.

10.4th gear pinion.

11.6th gear pinion.

12.2nd gear pinion.

13.5th gear pinion.14.Circlip.

15. Friction washer.

When changing a pinion, we recommend changing the opposite one on the other shaft.

The circlips must be renewed each time they are removed.

9 13 8 151112 10

14157 14


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DISASSEMBLY


Removal of the balance shaft.

- Remove the balance shaft (1) with the helpof a plastic mallet if necessary.

Removal of the crankshaft.

- Remove the crank assembly (2) with its

bush (3) and its O-ring (4) by tapping itlightly on the end with a plastic mallet ifnecessary.

The crank assembly is a free fit in the right-hand casing bearing.

2


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DISASSEMBLY


Checking the crankshaft and conrodassembly.

- Using a set of shims, check the big end sideplay.

- The maximum side play on the conrod endmust not exceed: 0.4 mm.

The runout at the crankshaft ends shall notexceed 0.04 mm and shall be measured at:

- 50 mm from the transmission side end.

- 50 mm from the flywheel magneto end.


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REFITTING SPECIFIC COMPONENTS



Fitting the crank assembly bearings.

- When the casings are opened, if thebearings stay on the crank, use toolP/N 755585 to remove them.

- If the bearings stay in the casings, thecasings should be heated with a heat gun toremove them.

The bearings and crank seals must be changed each time the engine casings are opened.

- Remove the seal.

- Place one of the crankcases on its gasketseat surface and heat it ( 80 to 90C) untilthe bearing falls out by itself.

- While the casing is expanded fit the newbearing fully home in its housing.

- Fit a new seal in the left casing using tool

P/N 753726.

The right hand side seal should be fitted after closing the casings, fitting the O-ring and thebush, in order to prevent the seal lips from being damaged or from turning inside out.


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Replacing the RH engine casingbearings.

- Place the crankcase on its gasket seatsurface, heat it (80 to 90 C) until thebearings fall out by themselves.

- While the casing is expanded fit the newbearings (1) fully home in their housings,using bearing drift P/N 757990.

Replacing the LH engine casingbearings.

- Remove the seals (1).

- Place the crankcase on its gasket seatsurface, heat it (80 to 90 C) until thebearings fall out by themselves.

- While the crakcase is expanded:

Fit the new bearing (2) fully home in itshousing, using bearing drift P/N 755039.

Fit the new bearing (3) fully home in its

housing, using bearing drift P/N 757990.

1

1

3

2


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Replacing the RH engine casing cagedneedle bearings (depending on the model).

- Using a heat gun, heat the crankcase to atemperature between 80 and 90C.

- Use an inertia type extractor FacomP/N U49PJ3 to remove the caged needlebearings.

1. Use Facom type pliers P/N U49P3 toremove 10 mm diameter caged needlebearings.

2. Use Facom type pliers P/N U49P4 toremove 14.5 mm diameter caged needlebearings.

- Position the clamp of the inertia typeextractor tool under the needle cage beforepulling it out.


Install a new caged needle bearings (3)flush with the casing using push toolP/N 754041.

Install a new caged needle bearings (4)flush with the casing using push toolP/N 753730. Finish to fit the caged needlebearing (4) fully home in its housing, usingpush tool P/N 753729

1

2

3

4


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Replacing the LH engine casing cagedneedle bearings (depending on the model).

- Using a heat gun, heat the crankcase to atemperature between 80 and 90C.

- Use an inertia type extractor FacomP/N U49PJ3 to remove the caged needlebearings.




Install a new caged needle bearings (3)flush with the casing using push toolP/N 754041.

Install a new caged needle bearings (4)flush with the casing using push toolP/N 753730. Finish to fit the caged needlebearing (4) fully home in its housing, usingpush tool P/N 755039.

1

2

43


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Fitting the box output seal.

- Using tool P/N 753726, fit the box outputseal.

Fitting the gear-change shaft seal.

- Using tool P/N 753728, fit the selector shaftseal.

Fitting the clutch lever seal.

- Using tool P/N 753730, fit the clutch leverseal.


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To fit the balance shaft.

- Fit the balance shaft (1) into the right sidecasing using a plastic mallet if necessary.

Fitting the conrod and crankshaftassembly.

- Fit the crank assembly (2) in the right sidecasing.

The crank assembly is a free fit in the right-hand casing bearing.

Fitting the gearbox.


- Fit the slightly greased thrust spring and thelocking ball (1) into their housing.

- Fit the slightly greased friction washer (2)onto the needle bearing sleeve on thesecondary shaft in the right side casing.

- Fit the slightly greased thrust spring and thelocking ball (1) into their housing.

1

2

1


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- At the same time fit the secondary shaft andprimary shaft assembly with its selectorfork (3) into the right side casing.

- Fit the elbow fork (4) and the 5th gear idlerpinion to the secondary shaft.


- Fit the selector cylinder and its 2 washers.

- Position the fork guide (3) in the selectorcylinder intermediate groove.

- Fit the selector cylinder and its top washer.

- Position the fork guide (3) in the selectorcylinder intermediate groove.


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- Fit the fork (5) to the 6th gear idler pinion.

- Position the fork guide (4) in the selectorcylinder lower groove.

- Position the fork guide (5) in the selectorcylinder upper groove.

- Fit the fork shaft (6).

- Position the selector cylinder in 4th gear,with the mcanindus pin opposite the forkshaft.

- Fit the selector shaft (7) fitted with its2 friction washers.


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Fitting the left side casing.


- Check the friction washers are fitted to:

The secondary shaft (1). The selector drum (2).

The gear-change shaft (3).

- Fit the 2 centring pins (4).

- Check the right side casing mating surfaceis absolutely clean.

- Coat the right side casing mating surfacewith gasket compound.

- Lightly grease the ends of the shafts.

- Check the friction washers are fitted to:

The selector drum (2). The gear-change shaft (3).

- Fit the 2 centring pins (4).

- Check the right side casing mating surfaceis absolutely clean.

- Coat the right side casing mating surfacewith gasket compound.

- Lightly grease the ends of the shafts.

- Fit the left side casing.

- Tighten pin P/N 750069 at the end of thecrank assembly.

3 2

4 4


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- Fit tool P/N 64706 fitted with plateP/N 753708 to the pin.

- Centre the assembly to the casing using4 bolts (5).

- Fit centring tool P/N 64710 to toolP/N 64706.

- Tighten pin nut P/N 69104 until the casingsare fully closed.


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- Fit and tighten the 13 clamping bolts.

Tightening torque: 11 Nm.

- Fit the gear selector without tightening it.

- Turn the primary shaft manually and checkthe gears change correctly.

- Lightly grease the crank assembly andbearings with 2 stroke oil.

Check the crank assembly turns freely in the casings.

Checking the piston.

- The piston should show no traces of scoringor seizure.

- The rings must be free in their grooves.

Checking the piston rings.

- Carefully remove the piston rings.

- Place a ring in the bore parallel to it andmeasure the gap using a feeler gauge.

- Piston ring gap: 0.15 to 0.30 mm.

- Utilisation limit: 1 mm.

Fitting the piston.

- Fit the needle bearing race (1) into theconnecting rod little end after lubricating itwith 2 stroke oil.

- Fit the piston to the connecting rod, thepositioning spigots on the piston rings facingthe inlet side.

- Fit the gudgeon pin and circlips.


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The circlips must be changed everytime they are removed.

The circlip gaps must face upwards or

downwards (2), but under nocircumstances to the side.

Fitting the cylinder.

- Fit a new base gasket (1) do not use oil orgrease.

- Ensure that the piston ring gaps areopposite the piston positioning spigots.

- Fit the cylinder (2) and insert it whilecompressing the piston rings by hand.

- Fit the cylinder over the piston bycompressing the piston rings by hand.

Fitting the cylinder head.

- Check the O-ring housings are absolutelyclean.

- Fit the new O-rings (1) to the cylinder head.

- Fit the cylinder head to the cylinder.

- Tighten the cylinder head securing 4 nutsworking diagonally in 2 or 3 steps.


- Fit the spark plug.


N


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Fitting the right side O-ring.

- Fit a new O-ring (1) and spacer (2) to thecrank assembly.

- Using tool P/N 753726, fit a new seal (3)

with its lip facing the outside.

Fitting the crank assembly and balanceshaft pinions.

- Fit key (1) into the crank assembly housing.

- Fit the key (2) into the balance shafthousing.


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- Fit the crank assembly pinion (3), with themarked tooth to the outside.

- Fit the balance shaft pinion (4) by lining upthe tooth gap marked with 2 spots ((A)) withthe mark of on spot ((A)) on the crank

assembly pinion.- Fit the nut but do not tighten it.

- Lock the balance shaft using a bolt (B)inserted into one of the threaded holes.

- Turn the balance shaft pinion to bring thebolt into contact with a ribbing on the casing.

- Tight the balance shaft nut (5).


- Fit the pinion (6), with the spotfacing

towards the outside, and fit nut (7).- Tighten the crank assembly pinion.



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Fitting the clutch.

- Fit to the primary shaft:

The tapered washer (1) with the round endtowards the bearing.

The plain washer (2). The clutch housing (2).

The splined bush (4).

The clutch main shaft (5).

The tab washer (6) and the nut (7).

- Lock the clutch main shaft with toolP/N 753731

- Tighten the nut.


- Fold over the clutch nut washer locking tab.

- Fit the clutch control lever with its spring andwasher.

- To the primary shaft, fit the piston (8), theball (9) and thrust rod (10).

- Fit the clutch discs starting with a lineddisc (11) and then alternate smooth andlined discs (12).


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- When re-assembling, ensure that themarks (A) on the smooth discs are offsetby 120 from the others.

- Fit the pressure plate (13) lining up the

arrow (B) on the plate with the roundimprint (C) on the clutch main shaft.

- Fit the pressure plate springs (14) and the4 bolts and washers (15).



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Adjusting the clutch control lever.

- Slacken the pressure plate locknut (1).

- Bring the lever into contact with the controlrod.

- Turn the centre bolt (2) on the pressureplate in order to set the control lever at 30to the magneto flywheel cover matingsurface.

- Tighten the locknut without altering theadjustment.


Fitting the starter system (depending onmodel) and the clutch cover.

- Fit the spring (1) to the starter shaft.

- Fit the starter dog (2), the starter releasemechanisms (A) lining up with the returnspring arm (B).

- Fit the starter motor dog (3).

- Fit the 2 locating pins and a new papergasket.

- Fit the clutch cover.

- Turn the crank assembly by hand, ifnecessary, to mesh the water pump pinionwith the crank assembly pinion.

- Fit the cover 8 fixing bolts.


- Fit and gently operate the kickstart pedaland hold it in position.

- Fit the kickstart shaft bump stop.


- Release the kickstart pedal.


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To fit the magneto flywheel.

- Fit the stator assembly.

Fit and tighten the stator assembly 3 fixingbolts (1) (2).


- Fit the rotor to the crank ensuring it is

positioned on the key.- Lock the rotor with the adjustable pin wrench

P/N 752237.

- Fit and tighten the rotor nut.


- Fit the gasket and the flywheel magnetocover.



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MISCELLANEOUS OPERATIONS



Removal of the water pump.

- Remove the clutch cover 8 fixing bolts.

- Remove the clutch cover.

- Remove the water pump cover (1) 2 fixing

bolts.- Remove the cover.

- Remove the 2 centring pillars and the papergasket (2).

- Remove:

The circlip (3).

The washer (4).

The 30 tooth nylon pinion (5).

The drive pin (6).

The washer (7).

The impeller with its shaft (8). The seal (9).

- Check the condition of the impeller shaft. If itis shows signs of wear, change the impeller.

Fitting the water pump.

- Using fitting tool P/N 753729, fit a new lightlygreased gasket (9).

- Re-assemble in the reverse order todisassembly.

A new circlip and paper gasket must be used each time they are removed.


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Removing the oil pump and its drivepinions.

- Remove the clutch cover 8 fixing bolts.

- Remove the clutch cover.

- Remove the oil pump cover.- Remove the oil pump 2 fixing bolts.

- Remove the pump (1) with its O-ring.

- Remove: The (2) circlips.

The pinion (3).

The drive pin (4).

The washer (5).

The pump shaft and its washer (6).

The pinion with its 2 washers(7).

- Check the condition of the oil pump shaft. Ifit shows signs of wear, change the shaft.

Fitting the oil pump.

- Lubricate the 2 shafts.

- Re-assemble in the reverse order todisassembly.

New circlips and O-ring must be used each time they are removed.

1


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P/N:757067

In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress,modify, or add any reference mentioned

DC/PS/APV Printed in the E.U. 06/2008 (non contractual pictures)

verkstadshandbok am6 motor

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