PEUGEOT ELYSTAR Scooter Full Service & Repair Manual

WORKSHOP MANUAL SALES DIVISION NETWORK TECHNICAL TRAINING Downloaded from www.Manualslib.com manuals search engine

CONTENTS Page : 2 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles CHARACTERISTICS......................................................................................................................... 3 PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI) ........................................ 4 Synoptics ................................................................................................................................................. 4 DIAGNOSTIC TOOL ......................................................................................................................... 5 Presentation ............................................................................................................................................. 5 Connection of the diagnostic tool ............................................................................................................ 6 SPECIAL IMPORTANT POINTS .................................................................................................... 7 Fuel system.............................................................................................................................................. 7 TIGHTENING TORQUES ................................................................................................................. 8 50 cc Engine ............................................................................................................................................ 8 125-150 cc Engine ................................................................................................................................... 8 SPECIAL TOOLS ............................................................................................................................... 9 INSTRUMENT PANEL .................................................................................................................... 10 Warning lights description and meanings ............................................................................................. 10 Changing the speedo units ..................................................................................................................... 11 Service function..................................................................................................................................... 11 TRANSPONDER IMMOBILISER.................................................................................................. 12 System programming ............................................................................................................................ 12 Reminder of the key memory procedure ............................................................................................... 12 Key memory check................................................................................................................................ 12 Diagnostic LED readings ...................................................................................................................... 12 Additional information .......................................................................................................................... 13 Troubleshooting chart............................................................................................................................ 14 Ignition principle schematic .................................................................................................................. 15 SPECIAL FEATURES OF THE 2 nd GENERATION SYNCHRO BRAKING CONCEPT ...... 16 WORKING ON 4-STROKE INJECTION SYSTEMS .................................................................. 17 To remove the fuel pump ...................................................................................................................... 17 To remove the air injector ..................................................................................................................... 20 To remove the throttle housing and idle valve ...................................................................................... 21 WORKING ON THE ABS/PBS SYSTEM...................................................................................... 22 ABS/PBS diagnostic.............................................................................................................................. 22 Troubleshooting chart............................................................................................................................ 22 Incidents which cannot be detected by the ECU ................................................................................... 25 ABS/PBS principle diagram.................................................................................................................. 27 Parameter reading .................................................................................................................................. 28 To remove the control unit .................................................................................................................... 29 To refit the control unit ......................................................................................................................... 32 ABS/PBS SYSTEM BLEED METHOD .......................................................................................... 33 Bleeding the front and rear circuits after changing the control unit ...................................................... 33 Bleeding the circuit after removing a front or rear caliper, a front or rear lower hydraulic hose ......... 37 Bleeding the circuit after removing the front master cylinder or the upper front hydraulic hose (right side) ....................................................................................................................................................... 39 Bleeding the circuit after removing the rear master cylinder or the upper front hydraulic hose (left side integral braking) .................................................................................................................................... 41 Bleeding the power braking circuit ....................................................................................................... 43 HAZARD WARNING LIGHTS....................................................................................................... 45 Functioning principle diagram .............................................................................................................. 45 Operation ............................................................................................................................................... 46 LOCATION OF COMPONENTS.................................................................................................... 47 Elystar 50 cc .......................................................................................................................................... 47 Elystar 125-150 cc ................................................................................................................................. 48 Downloaded from www.Manualslib.com manuals search engine

CHARACTERISTICS Page : 3 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles CHARACTERISTICS FC5 Engine 50 cc FD3 Engine 125 cc FD4 Engine 150 cc Type Air-cooled, single-cylinder 2-stroke injection Single-cylinder 4-stroke coolant cooled Bore x stroke 40.3 x 39.1 57 x 48.9 57 x 58.9 Cubic capacity 49.1 cc 124.8 cc 150.3 cc Max. power output 3.4 kW at 6900 rpm 9 kW at 8700 rpm 10.5 kW at 8200 rpm Maximum torque 4.7 Nm at 6800 rpm 10.5 Nm at 7500 rpm 12.5 Nm at 6500 rpm Gross compression ratio 11,4 Timing Chain driven overhead camshaft, 2-valve Engine oil capacity 1.25 L. Relay box capacity 0.12 L. Injection system TSDI Two Stroke Direct Injection EFI Electronic Fuel Injection Ignition / Carburettor Synerject ECU Synerject ECU Synerject ECU Petrol injector Siemens green 37.028 Siemens black 8884 Air injector Synerject blue 37.073 Fuel pressure regulator Synerject Synerject Petrol pump Synerject Synerject Throttle unit Bing 235 011 Bing 7229 104 Temperature sensor Synerject Synerject Lubrication Trochoidal pump with relief valve Lubrication Oil pump Mikuni ESOP-03 Spark plug NGK CPR8E NGK CR7E Magneto flywheel Mitsuba 180W Mitsuba 235 W Starter motor Mitsuba 250 W Mitsuba 440 W Downloaded from www.Manualslib.com manuals search engine

PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI) Page : 4 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI) Synoptics Throttle unit Petrol injector Engine position and speed sensor Idle control valve Engine temperature sensor Ignition coil Battery voltage Fuel pump Inlet air pressure and temperature sensor. Engine temperature gauge Diagnostic plug Diagnostic lamp Immobiliser module INJECTION / IGNITION ECU Software: Manages system functioning Calibration: Values specific to machine (mapping) ECU locking code Downloaded from www.Manualslib.com manuals search engine

DIAGNOSTIC TOOL Page : 5 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles DIAGNOSTIC TOOL Presentation 1 - A screen, a Nintendo © Game Boy ™ Color console a - on/off button b - arrows: select key c - button A: confirm button d - button B: return button e - select button: for help 2 - Cartridge, containing the software for dialog between the machine and the screen 3 - Interface cable between the machine and the tool for diagnostic of the 4-stroke injection system (EFI) 4 - Interface cable between the machine and interface cable (3) for diagnostic of the ABS/PBS system Downloaded from www.Manualslib.com manuals search engine

DIAGNOSTIC TOOL Page : 6 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles Connection of the diagnostic tool 1. Turn on the ignition (to unlock the ECU and authorise engine starting) 2. Remove the diagnostic plug loop (1) 3. Connect the diagnostic tool to the machine using: a - Interface cable (2) for EFI system diagnostic b - Interface cable (2) + special interface (3) ref: 756449 for diagnostic of the ABS/PBS system 4. Turn on the diagnostic tool. Note: Never forget to re-connect the diagnostic plug loop. The loop provides the link between the immobiliser module and the injection/ignition ECU, and is essential to be able to start the engine Downloaded from www.Manualslib.com manuals search engine

SPECIAL IMPORTANT POINTS Page : 7 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles SPECIAL IMPORTANT POINTS Fuel system Before commencing work, clean the power unit. The injection system is composed of precision components and cannot withstand impurities. Perfectly clean working conditions are therefore essential. Note: Before carrying out any work, leave the engine to cool for a minimum of 2 hours. Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Work in a clear and well-ventilated area. The fuel pipes must be changed if they show signs of wear, cracks, etc. Moreover, the hoses and clips are specific and must only be replaced by the original genuine parts Downloaded from www.Manualslib.com manuals search engine

TIGHTENING TORQUES Page : 8 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles TIGHTENING TORQUES 50 cc Engine Cylinder head 1.2 m.daN Cylinder casings 1 m.daN Covers 1 m.daN Inlet manifold 1 m.daN Starter motor 1 m.daN Rotor 4 m.daN Stator 1 m.daN Engine speed sensor. 1 m.daN Turbine 1 m.daN Drive pulley 4 m.daN Driven pulley 4.5 m.daN Spark plug 1 m.daN Compressor 0.65 m.daN Injection rail 0.65 m.daN 125-150 cc Engine Cylinder head 2.3 m.daN Cylinder casings 1 m.daN Covers 1 m.daN Starter motor 1 m.daN Rotor 7 m.daN Stator 1 m.daN Engine speed sensor. 0.65 m.daN Drive pulley 7 m.daN Driven pulley 7 m.daN Spark plug 1 m.daN Injection rail 1 m.daN Downloaded from www.Manualslib.com manuals search engine

SPECIAL TOOLS Page : 9 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles SPECIAL TOOLS Tool N° Description Used with 750539 Tie-wrap pliers 755878 diagnostic tool (Color Gameboy) 755806 755807 755806 French cartridge 755878 755807 Export cartridge 755878 755990 Diagnostic tool update software 755878 755806 755807 755996 Hose clamp 756056 Tank ring spanner 756017 Petrol injection power supply harness TSDI 756076 Tank gauge spanner EFI 756449 ABS/PBS interface cable for diagnostic tool 755878 755806 755807 Downloaded from www.Manualslib.com manuals search engine

INSTRUMENT PANEL Page : 10 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles INSTRUMENT PANEL Warning lights description and meanings Note: The above diagram shows the Elystar 125-150 cc speedo On the 50 cc Elystar, there is no the engine temperature gauge and ABS/PBS warning light When ignition is turned on: 1 - The coded immobiliser diagnostic LED comes on (1) and goes off after 0.5 seconds If there is an immobiliser fault, the LED flashes several times depending on the fault detected then stays on 2 - The EFI (Electronic Fuel Injection) or TSDI (Two Stroke Direct injection) diagnostic warning light (2) comes on then goes off when the engine is started If there is an injection system fault, the lamp flashes or stays on 3 – The ABS/PBS (Anti Blocking System/Powered Braking System) diagnostic warning light (3) comes on then goes off once the vehicle is on the move (over 5 km/h) (Elystar only) If there is an ABS/PBS fault, the lamp stays on 4 - The battery charge light (4) does not come on However, this warning light can come on at under 11.6 V or over 15.8 V to show there is a fault in the battery charging circuit 5 - The oil pressure warning light (5) comes on then goes off when the engine starts. This warning light comes on when under 0.5 bar to indicate a drop in engine oil pressure (stop the machine as quickly as possible) (on the Elystar 50 cc, this warning light is used for the separate lubrication system oil level, and comes on 3 seconds after turning on the ignition) Downloaded from www.Manualslib.com manuals search engine

PEUGEOT ELYSTAR Scooter Full Service & Repair Manual

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