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WORKSHOP
MANUAL
CONTENTS
CHARACTERIS TICS...................................................................................................................................4
Machine markings................................................................................................................................................................. 4
Characteristics....................................................................................................................................................................... 4
Frame..................................................................................................................................................................................... 4
Capacities .............................................................................................................................................................................. 4
Dimensions............................................................................................................................................................................ 4
We ight ................................................................................................................................................................................... 4
Tyres ...................................................................................................................................................................................... 4
Engine markings ................................................................................................................................................................... 4
SERVICE AND COMMISSIONING INS TRUCTIONS..............................................................................5
Check:.................................................................................................................................................................................... 5
Change ................................................................................................................................................................................... 5
Check and remove carbon .................................................................................................................................................... 5
Check and lubricate .............................................................................................................................................................. 5
Check and adjust................................................................................................................................................................... 5
Clean and adjust.................................................................................................................................................................... 5
Test machine ......................................................................................................................................................................... 5
Battery preparation (except for maintenance- free battery) ................................................................................................ 6
Top- up checks....................................................................................................................................................................... 6
Filling the fuel and oil circuits ............................................................................................................................................. 6
Checks before handing over to the customer ...................................................................................................................... 6
SPECIAL IMPORTANT POINTS...............................................................................................................7
Oil and fuel............................................................................................................................................................................ 7
Starting................................................................................................................................................................................... 7
Special features ..................................................................................................................................................................... 7
Electricity.............................................................................................................................................................................. 7
TIGHTENING TORQUES AND SPECIAL TOOLS ..................................................................................8
Tightening torques................................................................................................................................................................ 8
Special tools: ......................................................................................................................................................................... 8
BODY.............................................................................................................................................................9
Body panel bolt fitting.......................................................................................................................................................... 9
Removal of the headlight fairing Operation 1 A............................................................................................................. 10
Removal 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 3 A.............................................................................................................. 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 Operation 6........................................................................... 13
FRAME........................................................................................................................................................14
Removal of the front wheel Operation7 .......................................................................................................................... 14
Work possible with the front wheel removed ................................................................................................................... 14
Removal of the front mudguards and the front mudguard stay Operation 8................................................................. 15
Removal of the speedometer cable .................................................................................................................................... 15
Removal of the front caliper and the brake pads .............................................................................................................. 15
Removal of the fork............................................................................................................................................................ 16
Removal of the fork tubes.................................................................................................................................................. 17
Removal of the headlight mount........................................................................................................................................ 17
Removal of the rear frame assembly................................................................................................................................. 18
Removal of the rear wheel.................................................................................................................................................. 19
Work possible with the rear wheel removed..................................................................................................................... 19
Removal of the chain Operation 9................................................................................................................................... 20
Chain tension adjustment Operation 10........................................................................................................................... 20
Removal of the chain guide................................................................................................................................................ 20
Removal of the rear mudguard........................................................................................................................................... 21
Page 2
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
CONTENTS
Removal of the rear caliper and the brake pads................................................................................................................ 21
Removal of the shock absorber.......................................................................................................................................... 22
Removal of the shock absorber pivot ................................................................................................................................ 23
Removal of the suspension arm......................................................................................................................................... 24
Suspension arm pre- assembled (mudguard, chain guard, guide and tensioners fitted) ................................................. 25
MISCELLANEOUS OPERATIONS..........................................................................................................26
Removal of the rear mudflap.............................................................................................................................................. 26
Removal of the rear light assembly................................................................................................................................... 26
Removal of the number plate plinth .................................................................................................................................. 26
Removal of the instrument panel ....................................................................................................................................... 27
Removal of the windshield................................................................................................................................................. 27
Removal of a front direction indicator .............................................................................................................................. 27
Removal of a rear direction indicator................................................................................................................................ 27
Removal of the steering lock.............................................................................................................................................. 28
Removal of the throttle grip and oil pump ........................................................................................................................ 29
Removal of the oil tank ...................................................................................................................................................... 29
Removal of the air filter foam............................................................................................................................................ 30
Removal of the air filter box .............................................................................................................................................. 30
Removal 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 main harness.................................................................................................................................................. 36
WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE......................................................37
Removal of the cylinder head/ cylinder/ piston .................................................................................................................. 37
Removal of the oil pump.................................................................................................................................................... 38
Removal of the rotor and the magneto flywheel armature............................................................................................... 39
Removal of the gearbox output sprocket........................................................................................................................... 40
Removal of the neutral s witch............................................................................................................................................ 40
Removal of the starter motor.............................................................................................................................................. 41
COOLING....................................................................................................................................................42
Removal of the cylinder head/ radiator hose...................................................................................................................... 42
Removal of the expansion tank and the expansion tank/ radiator hose............................................................................ 42
Removal of the radiator...................................................................................................................................................... 42
Removal of the engine temperature sensor ....................................................................................................................... 43
MOTOR.......................................................................................................................................................44
Removal of the engine........................................................................................................................................................ 44
Refitting the engine to the frame ....................................................................................................................................... 46
FRAME........................................................................................................................................................47
Removal of the frame ......................................................................................................................................................... 47
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Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
CHARACTERIS TICS
CHARACTERIS TICS
Machine markings
Capacities
Model code
DR01A
Characteristics
Engine
Marque
Minarelli 50 cc
Bore x stroke
Cubic capacity
Max. power
output
Maximum torque
Gross
compression ratio
Ignition
Spark plug
Carburettor
Idle speed
40.3 x 39
49.7 cc
1.32 kw
1 1/2 turns
Magneto
Starter motor
2.66 Nm
12
CDI
NGK BR9 ES
Dell'Orto PHBN 12 HS
930 200 rpm
A34
60
36
Ducati 85 W
Ducati
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
1.865 mm
675mm
1.100 mm
1265 mm
Weight
Weight
115 kg
Tyres
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 markings
Frame
Engine type
1
2
AM6
Manufacturers plate
VIN number
Page 4
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
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
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
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Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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
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BODY
BODY
Body panel bolt fitting
Important: there are different stacking orders
depending on the assembly. When refitting, assemble
the fittings 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
N1)
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
Page 9
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles
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)
Page 10
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BODY
BODY
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BODY
Removal of the side fairings and the centre fairing
Operation 5
- Remove the hatches (1) of the side fairing 1 screw
on each (stack N5)
- 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 N9)
- Remove the 2 screws (5) securing the LH side
fairing and the headlight fairing (stack N3)
- 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
Page 13
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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)
Page 14
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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
Page 15
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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
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FRAME
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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)
Page 18
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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
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FRAME
Removal of the chain Operation 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
Page 20
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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)
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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)
Page 22
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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)
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)
Page 23
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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
Page 24
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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
Page 25
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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 N5)
-Pull the rear mudflap (3) downwards
Page 26
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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)
Page 27
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MISCELLANEOUS OPERATIONS
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
Page 28
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MISCELLANEOUS OPERATIONS
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)
Page 29
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MISCELLANEOUS OPERATIONS
Page 30
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MISCELLANEOUS OPERATIONS
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
Page 31
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ELECTRICITY
ELECTRICITY
Removal of the battery
- Remove the fuel tank assembly (see operation 2A)
- Remove the battery cover (1) (1 screw)
- Remove the battery
Page 32
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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)
Page 33
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ELECTRICITY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page 34
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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)
Page 35
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ELECTRICITY
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Note: The rotor (2) also acts and the starter motor ring
gear
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COOLING
COOLING
Wh e 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)
Page 42
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COOLING
Page 43
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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)
Page 44
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MOTOR
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MOTOR
Page 46
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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
Page 47
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FRAME
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
Page 48
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FRAME
Page 49
Reproduction or translation, even partial, forbidden 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)
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles