PEUGEOT Elystar Workshop Manual
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PEUGEOT Elystar Workshop Manual

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See also: Owner's Manual
SALES DIVISION
NETWORK TECHNICAL TRAINING
WORKSHOP
MANUAL

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Summary of Contents for PEUGEOT Elystar

  • Page 1 SALES DIVISION NETWORK TECHNICAL TRAINING WORKSHOP MANUAL...

  • Page 2: Table Of Contents

    HAZARD WARNING LIGHTS....................... 45 Functioning principle diagram ......................45 Operation ............................... 46 LOCATION OF COMPONENTS....................47 Elystar 50 cc ............................47 Elystar 125-150 cc..........................48 Page : 2 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 3: Characteristics

    Mikuni ESOP-03 Spark plug NGK CPR8E NGK CR7E Magneto flywheel Mitsuba 180W Mitsuba 235 W Starter motor Mitsuba 250 W Mitsuba 440 W Page : 3 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 4: Presentation Of The 4 Stroke Injection System (Efi)

    (mapping) Battery voltage Fuel pump ECU locking Inlet air pressure code Engine temperature and temperature gauge sensor. Diagnostic plug Diagnostic lamp Immobiliser module Page : 4 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 5: Diagnostic Tool

    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 Page : 5 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 6: Connection Of The Diagnostic Tool

    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 Page : 6 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 7: Special Important Points

    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 Page : 7 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 8: Tightening Torques

    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 Page : 8 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 9: Special Tools

    755806 French cartridge 755878 755807 Export cartridge 755878 755990 Diagnostic tool 755878 update software 755806 755807 755996 Hose clamp 756056 Tank ring spanner Page : 9 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 10: Instrument Panel

    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...

  • Page 11: Changing The Speedo Units

    Service function Note: This function is only available on Elystar 125-150 cc and if the machine has covered over 10 kms As from 5000 kms and once this distance is exceeded, when the ignition is turned on, the message "change oil"...

  • Page 12: Transponder Immobiliser

    Phase 3: Starting enabled Does not light: Starting enabled (if engine does not start, see troubleshooting chart) Light stays on Starting not enabled Page : 12 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 13: Additional Information

    Important: If an ECU is changed without memorising the keys, do not turn on the ignition more than 16 times if the diagnostic loop is disconnected as beyond this number, the ECU immobiliser function is erased. Page : 13 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 14: Troubleshooting Chart

    0.5 s Permanent Blank immobiliser connected to a Program the system using the keys programmed ECU Page : 14 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 15: Ignition Principle Schematic

    9. Battery RG/NR Red/Black 10. 25A fuse Green 11. 15A fuse VE/NR Green/Black 12. Transponder antenna 13. Diagnostic plug 14. Diagnostic plug loop Page : 15 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 16: Special Features Of The 2 Nd Generation Synchro Braking Concept

    5. Front brake caliper This is a fixed two opposed piston caliper. 6. Main circuit rear brake caliper This is a fixed two opposed piston caliper. Page : 16 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 17: Working On 4-Stroke Injection Systems

    - Remove the side panel assembly (7) 6 screws (5) and the 2 plasti-rivets (6) - Release the saddle opening catch - Remove the side panel assembly Page : 17 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 18 Note: Put a rag over the fuel pipe (3) to catch any fuel splashes - Disconnect the fuel feed pipe (3) and the regulator vacuum pipe (4) Page : 18 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 19 (B) on the tank - Fit the fuel gauge with a new seal Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page : 19 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 20: To Remove The Air Injector

    - Remove the fuel injector (4) Reassembly: Re-assemble in the reverse order to dismantling Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page : 20 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 21: To Remove The Throttle Housing And Idle Valve

    (refer to the documentation "Using the Diagnostic Tool for the Injection Engine) Check: Using the diagnostic tool, check for fault codes, clear them if necessary Page : 21 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 22: Working On The Abs/Pbs System

    1. Fault codes A (1, 3, 4, 7, 8, 21, 22, 27, 28, 30): ABS/PBS ECU internal faults Change the control unit and return it to Peugeot Motocycles with the filled out parameter sheet 2. Fault codes B (5, 6, 11): Control unit power supply fault...
  • Page 23 Check the coding Note: The control unit is terminals are not the original check correctly connected machine history (19, 20, 22) Page : 23 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 24 The speed sensor harness continuity - The speed sensor condition - The condition of the pulse wheel ±0.75 - The sensor gap is 0.95 Page : 24 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 25: Incidents Which Cannot Be Detected By The Ecu

    Check the control unit electric motor, terminal 15 and terminal 18 If these checks prove OK and the fault persists, change the control unit Page : 25 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 26 (except for early production machines on which the pump functions continually). Page : 26 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 27: Abs/Pbs Principle Diagram

    8. Speed sensor and pulse wheel Brown 9. Control unit Black 10. 25A fuse Orange 11. 15A fuse 12. Brake light RG/NR Red/Black 13. Diagnostic plug Green Page : 27 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 28: Parameter Reading

    ECU PIN code Possible ECU codes xxx-xxx-xxx-xxx-xxx Photocopy and sent to Peugeot Motocycles in case of problem requiring help from our network training department Page : 28 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 29: To Remove The Control Unit

    - Remove the handlebar upper cover (2) nine fixing bolts (1) - Remove the lower panel (4) three fixing screws - Remove the bottom panel (6) four fixing bolts Page : 29 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 30 It also facilitates bleeding of the main circuit (left-hand brake) Hook diagram, full scale 1 Page : 30 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 31 - Remove the clip (15), cap (16) and filter (17) to drain off the reservoir Note: The control unit must not be opened Only the manufacturer is authorised to work on this component Page : 31 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 32: To Refit The Control Unit

    - Release the control unit from its mounts so that it is as vertical as possible - Bleed the hydraulic system using the correct method Page : 32 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 33: Abs/Pbs System Bleed Method

    Note: It is essential to avoid being under the master cylinder during bleeding to avoid brake fluid splashes Page : 33 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 34 - Re-fit the bleed screw cap - Check the brake fluid level in the master cylinder, top up if necessary and fit the cover Page : 34 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 35 The recipient must be kept higher than the control unit to facilitate checking that the air bubbles are being expelled. - Open the bleed screw half a turn Page : 35 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 36 - Check the brake fluid level in the master cylinder, top up if necessary and fit the cover Important: The brake fluid level in the master cylinders in the horizontal position must always be above the sight gauge level. Page : 36 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 37: Bleeding The Circuit After Removing A Front Or Rear Caliper, A Front Or Rear Lower Hydraulic Hose

    - Position the handlebar in order to set the master cylinder horizontal Important: It is essential to avoid being under the master cylinder during bleeding to avoid brake fluid splashes Page : 37 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 38 - Using the diagnostic tool operate the pump to assess lever firmness Note: If the lever does not feel sufficiently firm, repeat the operation as from operation 1 Page : 38 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 39: Bleeding The Circuit After Removing The Front Master Cylinder Or The Upper Front Hydraulic Hose (Right Side)

    - Open the bleed screw half a turn Page : 39 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 40 - Re-fit the bleed screw cap Note: If the lever does not feel sufficiently firm, repeat the control unit bleed operation. Page : 40 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 41: Bleeding The Circuit After Removing The Rear Master Cylinder Or The Upper Front Hydraulic Hose (Left Side Integral Braking)

    - Open the caliper bleed screw half a turn Page : 41 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 42 - Check the brake fluid level in the master cylinder, top up if necessary and fit the cover - Re-fit the bleed screw cap Page : 42 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 43: Bleeding The Power Braking Circuit

    Note: As a preventive measure, the pump should not be operated for more than 2 minutes continuously. Page : 43 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 44 - Using the diagnostic tool, operate the control unit pump and exert a high pressure on each of the levers to ensure they are operating correctly Page : 44 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 45: Hazard Warning Lights

    7. Hazard warning lights relay RG/NR Red/Black 8. Direction indicator switch Light Green 9. RH direction indicators Green 10. LH direction indicators Mauve 11. Direction indicator unit Page : 45 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 46: Operation

    Note: If the hazard warning lights switch is moved the relay (7) control circuit power supply is cut off, and the hazard warning lights function de-activated. The ignition must be turned on again to activate the hazard warning lights function. Page : 46 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 47: Location Of Components

    4. Engine temperature sensor 11. Oil pump 5. Battery 12. Diagnostic lamp 6. Petrol injector 13. Diagnostic plug 7. Air injector 14. Compressor Page : 47 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

  • Page 48: Elystar 125-150 Cc

    15. Petrol pump, ABS/PBS, direction indicators 6. Battery and hazard warning lights relays 7. Petrol injector 16. Speed sensor and pulse wheel 8. Idle valve 9. Ignition coil Page : 48 Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...
  • Page 49 RECOMMENDS REF: 756445 With a constant concern for improvement Peugeot Motocycles reserves the right to delete, modify, or add any quoted reference DC/PS/ATR printed in E.U. 06/2002 (photos non-contractual) Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles...

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