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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
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CONTENTS
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CHARACTERIS TICS
CHARACTERIS TICS
Machine markings
Capacities
Model code DR01A
Gearbox 0,75 litres
Characteristics Fuel tank 11.75 litres
Oil tank 1.1 litres
Engine 2 stroke water cooled Showa fork 0.175 litres per tube
Dimensions
Marque Minarelli 50 cc
Engine markings
Frame
Engine type AM6
1 Manufacturer’s plate
2 VIN number
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SERVICE AND COMMISSIONING INS TRUCTIONS
Heavy duty servicing is for machines used under “harsh” conditions, driver temperament, short journeys
with engine cold, dusty regions, ambient temperature over 30°C.
Servicing operations 500 Kms Every 3000 Kms Every 6000 Kms
or 3 months
Check:
Idle adjustment X X X
Throttle and oil pump X X X
Front and rear brake lever X X X
Functioning of electrical equipment X X X
Fuel piping X X X
Oil piping X X X
Front and rear brake fluid piping X X 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 remove carbon
Piston (1) # Every 10000 kms
Cylinder head (1) # Every 10000 kms
Exhaust port (1) # Every 10000 kms
Check and lubricate
Chain tension and condition X X X
Check and adjust
Clutch cable X X
Oil pump cable X X
Spark plug X X
Headlight height X X
Clean and adjust
Carburettor X X
Test machine
On road 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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SERVICE AND COMMISSIONING INS TRUCTIONS
Top- up checks
Check the gear box oil level
Check the coolant level.
Check the brake fluid levels
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SPECIAL IMPORTANT POINTS
Starting
With the ignition on, the engine is cranked by the starter 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 breakage at the Tee tightening points
Electricity
The ignition unit acts both as the ignition unit and the high-tension coil
The voltage rectifier/regulator also serves as the flasher control unit
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TIGHTENING TORQUES AND SPECIAL TOOLS
Tightening torques
Body panels:
Headlight fairing 0,1 m.daN
Speedo fairing 0,1 m.daN
Side covers 0,1 m.daN
Side and central fairings 0,1 m.daN
Rear fairing 0,1 m.daN
Front mudguard 0,1 m.daN
Rear mudguard * 0.8/0.1 m.daN
Mudflap * 0.8/0.1 m.daN
Securing strap 1,2 m.daN
Frame:
Front wheel spindle nut 4,5 m.daN
Rear wheel spindle nut 6,5 m.daN
Suspension arm nut 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
Steering lock 0,6 m.daN
Standard:
Nut and bolt 5 mm diameter 0,5 m.daN
Nut and bolt 6mm diameter 1 m.daN
Nut and bolt 8mm diameter 2,2 m.daN
Nut and bolt 10mm diameter 3,5 m.daN
Nut and bolt 12mm diameter 5.5 m.daN
Special tools:
Standard Part N°
3 mm allen key (inlet manifold) 755812
4 mm allen key (valve body) 755813
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BODY
BODY
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BODY
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BODY
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BODY
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FRAME
FRAME
Front part
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 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)
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FRAME
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FRAME
- 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
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FRAME
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FRAME
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FRAME
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FRAME
- Remove the nut, the washer and the upper fixing pin
(2)
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FRAME
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)
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FRAME
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FRAME
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MISCELLANEOUS OPERATIONS
MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
Adjustment:
Idle: screw (7), remove the left-hand fairing hatch
Mixture: screw (8), directly accessible
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ELECTRICITY
ELECTRICITY
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ELECTRICITY
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ELECTRICITY
1. battery leads (2 clips per pole) 12. flywheel outlet yellow wire
2. connection with the rear harness 13. LH cluster connector
3. voltage regulator/flasher unit connector 14. RH cluster connector
4. horn connection 15. brake light switch connector
5. engine earth lead 16. instrument panel connector
6. fuse holder 17. steering lock connector
7. starter motor relay connector and earth wire 18. LH cable grommet
8. temperature sensor connector 19. RH cable grommet
9. ignition module connector 20. fuel low level warning light connector
10. starter motor connector 21. front direction indicators connector
11. neutral switch connector 22. headlight connector
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ELECTRICITY
- Remove the fuel tank assembly (see operation 2A) Without pulling untowardly, gradually
- Remove the side fairings (see operation 4) pull out the harness through the frame LH side
- Remove the side fairings and the centre fairing (see opening in the following order:
operation 5)
- Disconnect the battery (1) 1. the taped assembly (1) of the LH connections
- Disconnect the connection with the rear harness (2) (starter motor relay, etc)
- Disconnect the voltage regulator/flasher unit(3)
- Disconnect the horn (4) 2. the steering lock harness (B) section located
- Disconnect the engine earth lead (5) inside the frame
- Remove the fuse holder assembly from its support
(6) 3. the front RH connection taped assembly (C)
- Disconnect the starter motor relay and its earth wire
(7) 4. feed the rear RH connection taped assembly (D)
- Disconnect the temperature sensor (8) through the frame
- Disconnect the ignition module (9)
- Disconnect the starter motor (10) 5. complete extraction through the LH opening
- Disconnect the neutral switch (11)
- Disconnect the flywheel outlet yellow wire (12)
Preparation:
- Wrap a few turns of sticky tape around the rear left
(A), front right (C), rear right (D) and the harness
ends to facilitate its extraction from the frame front
structure
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ELECTRICITY
Refitting the main harness Check the positioning of the different connections
Proceed in reverse order to removal. If the harness is and control cables.
being changed, we recommend it is prepared in the From frame RH side:
same way as the one removed before fitting - throttle and clutch cables
- brake light switch harness
In particular: - direction indicator harness
- wrap a few turns of insulating tape over the ends - RH control cluster connector (6-pin)
- make the same curves with the plastic ties
- connect the different items from the harness changed From frame LH side:
(diodes, fuses, steering lock harness) - choke cable
- steering lock harness
- instrument panel connector (12-pin)
- LH control cluster connector (9-pin) with the
headlight connection harness
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
Note: The rotor (2) also acts and the starter motor ring
gear
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
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WORK ON THE ENGINE WITHOUT REMOVING THE ENGINE
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COOLING
COOLING
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COOLING
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MOTOR
MOTOR
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MOTOR
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MOTOR
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FRAME
FRAME
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
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
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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
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FRAME
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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)
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