SALES DIVISION
NETWORK TECHNICAL TRAINING
WORKSHOP
MANUAL
CONTENTS |
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CHARACTERISTICS......................................................................................................................... |
3 |
PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI) ........................................ |
4 |
Synoptics ................................................................................................................................................. |
4 |
DIAGNOSTIC TOOL ......................................................................................................................... |
5 |
Presentation ............................................................................................................................................. |
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Connection of the diagnostic tool............................................................................................................ |
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SPECIAL IMPORTANT POINTS .................................................................................................... |
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Fuel system.............................................................................................................................................. |
7 |
TIGHTENING TORQUES................................................................................................................. |
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50 cc Engine ............................................................................................................................................ |
8 |
125-150 cc Engine................................................................................................................................... |
8 |
SPECIAL TOOLS ............................................................................................................................... |
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INSTRUMENT PANEL.................................................................................................................... |
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Warning lights description and meanings ............................................................................................. |
10 |
Changing the speedo units..................................................................................................................... |
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Service function..................................................................................................................................... |
11 |
TRANSPONDER IMMOBILISER.................................................................................................. |
12 |
System programming ............................................................................................................................ |
12 |
Reminder of the key memory procedure............................................................................................... |
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Key memory check................................................................................................................................ |
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Diagnostic LED readings ...................................................................................................................... |
12 |
Additional information .......................................................................................................................... |
13 |
Troubleshooting chart............................................................................................................................ |
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Ignition principle schematic .................................................................................................................. |
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SPECIAL FEATURES OF THE 2nd GENERATION SYNCHRO BRAKING CONCEPT...... |
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WORKING ON 4-STROKE INJECTION SYSTEMS .................................................................. |
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To remove the fuel pump ...................................................................................................................... |
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To remove the air injector ..................................................................................................................... |
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To remove the throttle housing and idle valve ...................................................................................... |
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WORKING ON THE ABS/PBS SYSTEM...................................................................................... |
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ABS/PBS diagnostic.............................................................................................................................. |
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Troubleshooting chart............................................................................................................................ |
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Incidents which cannot be detected by the ECU................................................................................... |
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ABS/PBS principle diagram.................................................................................................................. |
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Parameter reading.................................................................................................................................. |
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To remove the control unit .................................................................................................................... |
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To refit the control unit ......................................................................................................................... |
32 |
ABS/PBS SYSTEM BLEED METHOD .......................................................................................... |
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Bleeding the front and rear circuits after changing the control unit...................................................... |
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Bleeding the circuit after removing a front or rear caliper, a front or rear lower hydraulic hose ......... |
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Bleeding the circuit after removing the front master cylinder or the upper front hydraulic hose (right |
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side) ....................................................................................................................................................... |
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Bleeding the circuit after removing the rear master cylinder or the upper front hydraulic hose (left side |
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integral braking) .................................................................................................................................... |
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Bleeding the power braking circuit ....................................................................................................... |
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HAZARD WARNING LIGHTS....................................................................................................... |
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Functioning principle diagram .............................................................................................................. |
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Operation............................................................................................................................................... |
46 |
LOCATION OF COMPONENTS.................................................................................................... |
47 |
Elystar 50 cc .......................................................................................................................................... |
47 |
Elystar 125-150 cc................................................................................................................................. |
48 |
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Page : 2 |
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS |
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FC5 Engine |
FD3 Engine |
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FD4 Engine |
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50 cc |
125 cc |
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150 cc |
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Type |
Air-cooled, single-cylinder |
Single-cylinder 4-stroke coolant cooled |
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2-stroke injection |
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Bore x stroke |
40.3 x 39.1 |
57 x 48.9 |
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57 x 58.9 |
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Cubic capacity |
49.1 cc |
124.8 cc |
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150.3 cc |
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Max. power |
3.4 kW at 6900 rpm |
9 kW at 8700 rpm |
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10.5 kW at 8200 rpm |
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output |
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Maximum torque |
4.7 Nm at 6800 rpm |
10.5 Nm at 7500 rpm |
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12.5 Nm at 6500 rpm |
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Gross |
11,4 |
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compression ratio |
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Timing |
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Chain driven overhead camshaft, 2-valve |
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Engine oil |
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1.25 L. |
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capacity |
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Relay box |
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0.12 L. |
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capacity |
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TSDI |
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EFI |
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Injection system |
Two Stroke Direct |
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Electronic Fuel Injection |
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Injection |
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Ignition / |
Synerject ECU |
Synerject ECU |
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Synerject ECU |
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Carburettor |
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Petrol injector |
Siemens green 37.028 |
Siemens |
black 8884 |
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Air injector |
Synerject blue 37.073 |
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Fuel pressure |
Synerject |
Synerject |
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regulator |
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Petrol pump |
Synerject |
Synerject |
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Throttle unit |
Bing 235 011 |
Bing 7229 104 |
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Temperature |
Synerject |
Synerject |
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sensor |
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Lubrication |
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Trochoidal pump with relief valve |
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Lubrication |
Oil pump |
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Mikuni ESOP-03 |
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Spark plug |
NGK CPR8E |
NGK CR7E |
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Magneto flywheel |
Mitsuba 180W |
Mitsuba 235 W |
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Starter motor |
Mitsuba 250 W |
Mitsuba 440 W |
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Page : 3
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI)
PRESENTATION OF THE 4 STROKE INJECTION SYSTEM (EFI)
Synoptics
Throttle unit
Engine position and speed sensor
Engine temperature sensor
INJECTION / IGNITION |
Petrol injector |
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ECU |
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Idle control valve |
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Software: |
Calibration: |
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Manages |
Values specific |
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system |
to machine |
Ignition coil |
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functioning |
(mapping) |
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Battery voltage |
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Fuel pump |
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Inlet air pressure |
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ECU locking |
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code |
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Engine temperature |
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and temperature |
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gauge |
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sensor. |
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Diagnostic plug |
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Diagnostic lamp |
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Immobiliser
module
Page : 4
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
DIAGNOSTIC TOOL
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
Page : 5
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
DIAGNOSTIC TOOL
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: |
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a - Interface cable (2) for EFI system diagnostic |
b - Interface cable (2) + special interface (3) ref: |
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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
Page : 6
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
SPECIAL IMPORTANT POINTS
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
Page : 7
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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TIGHTENING TORQUES |
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TIGHTENING TORQUES |
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50 cc Engine |
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Cylinder head |
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1.2 m.daN |
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Cylinder casings |
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1 m.daN |
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Covers |
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1 m.daN |
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Inlet manifold |
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1 m.daN |
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Starter motor |
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1 m.daN |
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Rotor |
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4 m.daN |
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Stator |
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1 m.daN |
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Engine speed sensor. |
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1 m.daN |
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Turbine |
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1 m.daN |
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Drive pulley |
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4 m.daN |
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Driven pulley |
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4.5 m.daN |
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Spark plug |
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1 m.daN |
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Compressor |
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0.65 m.daN |
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Injection rail |
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0.65 m.daN |
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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 |
Page : 8
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
SPECIAL TOOLS
Tool N° |
Description |
Used with |
750539 |
Tie-wrap pliers |
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755878 |
diagnostic tool |
755806 |
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(Color Gameboy) |
755807 |
755806 |
French cartridge |
755878 |
755807 |
Export cartridge |
755878 |
755990 |
Diagnostic tool |
755878 |
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update software |
755806 |
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755807 |
755996 |
Hose clamp |
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756056 |
Tank ring spanner |
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756017 Petrol injection power supply
harness TSDI
756076 Tank gauge spanner EFI
756449 ABS/PBS interface |
755878 |
cable for diagnostic |
755806 |
tool |
755807 |
Page : 9
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
INSTRUMENT PANEL
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)
Page : 10
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
INSTRUMENT PANEL
Changing the speedo units
Note: This function is available if the machine has done under 10 kms
The choice of distance unit (km/miles) is by pressing the control button (7) before turning on the ignition and holding it down until the display lights up.
Unit selection is by pressing the control button (7), the arrow (8) is positioned against the unit selected and "Engl" or "Cont" is displayed at (9)
The choice is confirmed by pressing the control button (7) for more than 2 seconds
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" appears for 10 seconds in place of the clock display
This display tells the customer that his machine is due for its first service.
After servicing the machine, the service counter is reset by pressing on the control button (7) before turning on the ignition
And so on, after every 5000 km covered, the same display is shown to remind the customer that servicing is due (5000 kms after the previous service counter reset)
Page : 11
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
TRANSPONDER IMMOBILISER
TRANSPONDER IMMOBILISER
Precautions:
Check that the diagnostic plug loop is fitted. The loop provides the link between the immobiliser module and the injection/ignition ECU, and is essential to be able to start the engine
If the loop is not fitted, the transponder LED diagnostic is always the same (no link between the immobiliser and the ECU)
Note: Fitting of a 5 kΩ resistive suppressor along with a resistive spark plug is essential for the proper functioning of the engine
System programming
The machine is supplied with a notched key (master) and a black key
The system is programmed in the factory
It is possible to program up to 7 black keys
The key memory procedure is the same as the AEC400 and ACI100 system
Reminder of the key memory procedure
1.Using the master key, set the ignition to on, and when the LED lights, turn off the ignition
2.Within a maximum of 15 seconds of cutting off the ignition with the master key, turn on the ignition with the black key, and when the LED comes on turn off the ignition (repeat the operation for each black key to be memorised (maximum of 7 black keys))
3.Within a maximum of 15 seconds of turning off the ignition with the last key memorised, turn on the ignition with the master key, and when the LED comes on, turn off the ignition
Key memory check
Using the master key, turn on the ignition, the LED on the instrument panel comes on for 0.5 seconds and flashes a number of times. The number of flashes indicates the number of keys memorised, including the master key
Diagnostic LED readings
There are three successive diagnostic LED lighting phases when the ignition is turned on with a black key Phase 1: System status
Lights for 2 seconds: Immobiliser not programmed
Lights for 0.5 seconds: Immobiliser programmed
Phase 2: Diagnostic
Does not light: No fault detected
Lights 1 to 4 times for 0.5 seconds Fault detected
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
TRANSPONDER IMMOBILISER
Additional information
Before carrying out any work on the transponder immobiliser, have the machine master key and black key to hand.
If the engine will not start, a first diagnostic may be carried out using the LED before checking the other parts of the ignition system.
Note: Do not remove the diagnostic plug loop
In case of a fault, do not use an immobiliser module or ECU from another machine to carry out tests. The keys, immobiliser module and ECU programmed on another machine form an assembly, are linked by a code and must under no circumstances be separated.
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
TRANSPONDER IMMOBILISER
Troubleshooting chart
If the engine will not start, a first diagnostic may be carried out using the LED before checking the other parts of the ignition system
TEST TO BE CARRIED OUT ONLY WITH THE BLACK KEY
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LED SIGNAL |
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DISPLAYS |
SOLUTIONS |
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PHASE 1 |
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PHASE 2 |
PHASE 3 |
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2 s |
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Blank immobiliser |
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connected to a blank |
Program the system using the keys |
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ECU |
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Disconnect the diagnostic plug loop, turn |
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Blank ECU |
start the engine |
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connected to a |
If OK, connect the diagnostic plug loop, |
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programmed |
turn on the ignition with the master key |
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immobiliser |
and start the engine or turn on the |
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ignition for 3 seconds to memorise the |
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0.5 s |
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Permanent |
Black key and |
Refit the immobiliser and the original |
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programmed |
keys or replace by a new one and |
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immobiliser module |
program the system using the original |
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0.5 s |
0.5 s |
Permanent |
No diagnostic plug |
Refit the diagnostic plug loop or check |
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immobiliser/ECU |
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immobiliser and the ECU |
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0.5 s |
0.5 s |
Permanent |
Antenna disconnected |
Check the antenna connection and |
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resistance (17 Ω) |
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transponder |
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0.5 s |
0.5 s |
Permanent |
Wrong or faulty key |
Refit the original immobiliser or replace |
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or programmed |
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by a new one and program the system |
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immobiliser from |
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using the original keys |
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another machine |
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2 s |
0.5 s |
Permanent |
Blank immobiliser |
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connected to a |
Program the system using the keys |
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programmed ECU |
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Page : 14
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
TRANSPONDER IMMOBILISER
Ignition principle schematic
1. |
Engine position sensor |
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2. |
Ignition switch |
BA |
White |
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3. |
Immobiliser module |
BA/NR |
White/Black |
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4. |
Injection ECU |
JN |
Yellow |
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5. |
HT coil |
JN/BE |
Yellow/Blue |
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6. |
Resistive suppressor |
MR/BA |
Brown/White |
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7. |
Resistive spark plug |
NR |
Black |
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8. |
Instrument panel LED |
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RG |
Red |
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9. |
Battery |
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RG/NR |
Red/Black |
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10. |
25A fuse |
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VE |
Green |
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11. |
15A fuse |
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VE/NR |
Green/Black |
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12. |
Transponder antenna |
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13. |
Diagnostic plug |
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14. |
Diagnostic plug loop |
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Page : 15
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
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