PEUGEOT Geopolis User Manual

Sales division Technical network leadership

WORKSHOP MANUAL

Workshop manual Technical network leadership Reproduction or transla tion, even partial, is for bidden without the written consent of Peugeot Motoc ycles

TABLE OF CONTENTS.

TABLE OF CONTENTS. ...................................... ... ..........................................................................................1

PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4

CHARACTERISTICS.........................................................................................................................................6

Engine........................................................................................................................................................6

Capacities..................................................................................................................................................6

Chassis......................................................................................................................................................7

Dimensions and weight............. ... .... ... .......................................................................................................7

Tyres..........................................................................................................................................................7

SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 8

Check.........................................................................................................................................................8

Change ......................................................................................................................................................8

Check and lubricate ............... ... ... .... ...................................... .... ... ... ... .......................................................9

Reading the ECU fault codes.... ... .............................................................................. ... ... .... ... .. .................9

Test machine .............................................................................................................................................9

Time required for maintenance................................. .... ... ....................................... ... ... ... .... ......................9

Battery preparation (Except battery without maintenance)*.....................................................................10

Checks before handing over to the customer ..........................................................................................10

SPECIAL IMPORTANT POINTS..................................................................................................................... 11

Oil and fuel...............................................................................................................................................11

Starting up after overhauling the engine..................................................................................................11

Electricity..................................................................................................................................................11

Special features ..................................................... ... .... ... ... ....................................... ... ...........................11

TIGHTENING TORQUES. ....................... ... ... ... .... .......................................... .................................................12

Engine part...............................................................................................................................................12

Body panels .............................................................................................................................................13

Cycle part.................................................................................................................................................13

Standard ..................................................................................................................................................13

SPECIAL TOOLS ............................................................................................................................................ 14

ELECTRICITY..................................................................................................................................................15

4 stroke indirect injection system functional diagram...............................................................................15

ABS/MBS system schematic diagram .....................................................................................................16

Fuses and energy distribution..................................................................................................................17

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS.

LOCATION OF COMPONENTS...................................................................................................................... 18

BODY PANELS ............................. .................................................................................................................. 19

Location of body components..................................................................................................................19

Body component sequence of disassembly.............................................................................................20

Removal of the storage compartment........................................................... ...........................................21

Removal of a RH or LH side cover ..........................................................................................................21

Removal of the tank covers .......................... ... ... ... ... ....................................... ... .... ... ... ...........................22

Removal of a RH or LH footboard.... ... ... ... .... ... ........................................................................................23

Removal of the front shield panel .......................... ....................................... ... ... .... ... ..............................24

Removal of the rear shield panel ..... ... ... ... .... ... ....................................... ... ... ... ........................................25

Removal of the dirt shield ................................ ... ... ....................................... ... ... .... ... ... ... ........................25

Removal of the instrument cluster ................... ... ....................................... ... ... ... .... .................................26

Removal of the battery holder.......................................... ... ... .... ... ....................................... ... .................26

SERVICE OPERATIONS............... ... .......................................... .......................................... ........................... 27

Changing the engine oil and replacing the oil filter ..................................................................................27

Draining the relay box............................................ ... .... ...................................... .... ... ... ... ... .....................29

Replacing the air filter ..............................................................................................................................30

Removal of the transmission air filter.......................................................................................................32

Changing the drive pulley bearings..........................................................................................................32

Removal of the spark plug ........... .... ... ... ... .... ...................................... .... ... ... ...........................................33

Draining the cooling circuit........ ... .... ... ....................................... ... ... ... .... ... ... ...........................................33

Installing the valve clearance........................... ........................................................................................34

Replacing the brake pads ........................................................................................................................36

Front brake........................................................................................................................................................36

Rear brake................. ... ....................................................................................................................................36

Checking the brake fluid level.......................................... ........................................................................40

SERVICING THE ABS/MBS SYSTEM............................................................................................................41

Reminder .................................................................................................................................................41

Removal of the brake modulator.. ....................................... ... .... ... ... ....................................... ... ..............41

Re-installing the modulator ......................................................................................................................42

Bleed procedure.......................................................................................................................................43

Draining the rear brake circuit...........................................................................................................................43

Bleeding the assistance circuit..........................................................................................................................45

Draining the front brake circuit..........................................................................................................................46

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TABLE OF CONTENTS.

MISCELLANEOUS OPERATIONS ................................................................................................................. 49

Procedure for reducing the fuel circuit pr es su re ........................................ ...................................... ........49

Checking fuel pressure ............. ... .... ... ... ... ....................................... ... .... ... ... ...........................................50

Removal of the fuel pump................................................................................ ... .... ... ... ...........................51

Removal of the fuel gauge............................................................................... ... .... ... ... ...........................52

Removal of the throttle box.............................................................................. ... .... ... ... ...........................53

Removal of the lambda sensor ........ ...................................... .... ... ... ... ....................................... . .............53

Removal of the regulator. .... ...................................... .... ... ... ... ....................................... ... .... . ...................54

Removal of the radiator....... ...................................... .... ... ... ... ....................................... ... ........................55

Removal of the engine mounting assembly............................................................... ... ... .... ... ... ... ...........56

Removal of the engine........................................... ... .... ... ....................................... ... ... ... .... . ...................58

Removal of the fork................ ... ....................................... ... ... .... ... ...........................................................62

Replacing the bearings of the steering system........................................................................................62

Steering system tightening method........................... .... ...................................... .... ... ... ... ........................64

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.

Möbius band Recyclable

The product can irritate the

Irritant

Flammable The product is flammable

Corrosive

skin, eyes and repiratory organs

The product can damage living tissues or other surfaces

Means that the product or the package can be recycled. However, this does not guarantee that the product will be recycled.

Avoid contact with the skin and clothes. Wear gloves, safety glasses and appropriate clothes such as a cotton overall. Do not breath fumes. If in contact, wash thoroughly with water.

Keep it away from any flame or heat source (barbecue, radiator, heating

device, etc.). . . . Do not leave the product

in the sun. Avoid contact with the skin and clothes.

Wear gloves, safety glasses and appropriate clothes such as a cotton overall. Do not breath fumes.

Explosive

Hazardous to the environment

Toxic

Do not throw away into a garbage can

Compulsory gloves

The product can explode under certain circumstances (flame, heat, impact, friction)

The product affects fauna and flora. Do not dump it in garbage cans, sinks or nature.

The product can seriously affect health if it is inhaled, ingested or in contact with skin

One of the product's component is toxic and can be hazardous to environment. Ex.

Used batteries

Operation that can be dangerous for people

Avoid impacts, friction, sparks and heat.

The ideal solution is to bring this product to your nearest household waste recycling centre.

Avoid direct contact with body even by inhalation. If you feel unwell, seek medical advice immediately.

This symbol informs the consumer that the used product shall not be thrown away into a garbage can, but shall be brought back to the merchant or dropped at a specific collection point

People's safety can be seriously affected if the recommendations are not fully respected.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

PRODUCTS DANGER SYMBOLS USED

People's safety

Important

Good operating condition of the vehicle

Note Operation that can be difficult

Lubricate

Grease

Operation that can be dangerous for people

Operation that can be hazardous to the vehicle

The operation must be carried out in strict compliance with the documents

Lubricate the parts to be assembled

Grease the parts to be assembled

People's safety can be seriously affected if the recommendations are not fully respected.

Indicate the specific procedures that shall be followed in order not to damage the vehicle

Serious damage to the vehicle and in certain cases a cancellation of the warranty can be involved if the recommendations are not fully respected.

Indicate a note which gives key information to make the procedure easier

Indicate the specific procedures that shall be followed in order not to damage the vehicle.

GLUE

Glue Glue the parts to be assembled

New part Use a new part

Indicate the specific procedures that shall be followed in order not to damage the vehicle.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

CHARACTERISTICS

 Engine

Marking M564M

400 cc

Type

4 valves per cylinder with chain driven overhead camshaft

4-stroke single-cylinder

Cooling Liquid

Bore x stroke 85.8 x 69 mm

Cubic capacity 399 cc

Max. power output 25 kW at 7500 rpm

Max. torque rating 5500 rpm

Lubrication Trochoidal pump

Transmission By 2 variable pulleys and V-type belt

Clutch Centrifugal automatic

Exhaust Catalytic

Starter motor Mitsuba 900 W

1 spark plug

Spark plug

NGK CR7EKB

Electrode gap

0.7-0.8 mm

Magneto flywheel Mitsuba 350 W

Fuel supply

Indirect electronic injection

Magneti-Marelli

 Capacities

Engine oil

Relay box oil

Coolant 1.4 l Peugeot coolant part number 754614.

Fork oil 212 cc per tube (Esso Univis 46 or Agip HLift 46)

Fuel tank 13.2 l / Version ABS 10.5 l

1.7 l SAE 5W40.

Minimum grade: API SJ.

0.25 l SAE 80W90.

Minimum grade: API GL4.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

CHARACTERISTICS

 Chassis

Chassis Double cradle out of high-resistance steel tube

Front suspension Hydraulic telescopic fork. Ø37 mm

Travel 100 mm

Rear suspension 2 adjustable combined spring hydraulic shock absorbers

Travel 100 mm

 Dimensions and weight

Overall length

Width at handlebar

Height.(without rear-view

2180 mm

755 mm

1486 mm

mirrors)

Wheelbase 1527 mm

Ground clearance

Saddle height

Unladen weight

 Tyres

157 mm 805 mm

200 kg.

Front wheel rim 16 inch aluminium alloy

Front tyre 110/70 - 16

Front tyre pressure 2.2 bars

Rear wheel rim 14 inch aluminium alloy

Rear tyre 150/70 - 14

Rear tyre pressure 2.4 bars

Chassis markings Engine marking

M461M

xxxxxxxxxx

1. Manufacturer's plate.(Left side)

- VIN number of the RH side of the vehicle

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

2. Engine number

SERVICE SCHEDULE AND COMMISSIONING

Heavy duty servicing applies to vehicles used under rugged operating conditions: door-to-door deliveries, intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.

Service operations

Heavy duty servicing 500 kms

 Check

1000 kms or

1 months

Every

5000 kms

Every

2500 kms

Every

10000 kms

Every

5000 kms

Every

20000 kms

Every

10000 kms

Throttle cable play C C C C Steering column play C C C C Operation of electrical equipment C C C C Condition of front and rear brake

hydraulic controls

CCCC

Condition of petrol pipes C C C C Condition of oil pipes C C C C Tyre pressures C C C C Tyre condition, pressure and wear C C C Condition of the front suspension C C C C Condition of the rear suspension C C C C Brake fluid level C C C C Battery electrolyte level * C C C C Coolant level C C C C Engine oil level C Valve clearances C Transmission air filter N N Intake silencer drain N N N N Tightening the engine mounting and

linkrod

CCC

Tightness of nuts and bolts C C C C

 Change

Spark plug R R Inlet silencer/air filter N N Front brake pads C C C Rear brake pads C C C Drive pulley bearings and guides C C Transmission belt R R Belt anti-flapping roller C C Engine oil R R R Engine oil filter R R R Relay box oil R C C Brake fluid and coolant Once every 2 years

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

SERVICE SCHEDULE AND COMMISSIONING

Service operations

Heavy duty servicing 500 kms

 Check and lubricate

1000 kms or

1 months

Every

5000 kms

Every

2500 kms

Every

10000 kms

Every

5000 kms

Every

20000 kms

Every

10000 kms

Drive pulley/Movable face C C Driven pulley: Movable face C C Driven pulley caged needle bearing G G

 Reading the ECU fault codes

Injection and ABS/MBS system* C C C C

 Test machine

On road (at least 2 km) C C C C

 Time required for

maintenance

Code 9100 9300 9400 9600 Time required for maintenance 1.0 0.8 2.2 2.5

C: Check. N: Clean. R: Change. G: Check and lubricate.

* Depending on equipment. # Change if necessary.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

SERVICE SCHEDULE AND COMMISSIONING

 Battery preparation (Except battery without maintenance)*

Remove the battery. Remove the 6 filler caps and the vent plug. Fill all the battery cells with electrolyte to the upper level shown on the battery "UPPER LEVEL". Electrolyte: (35% sulfuric acid = 1.28g/cm3). 1 litre can P/N 752740. 5 litre can P/N 752741. Leave the battery to stand for around half an hour. Top up if necessary. Charge the battery for at least 2 hours with a current of 1.4 A. Refit the battery and connect the vapour vent pipe. Connect the red wire lug to the battery's + terminal, and the green wire lug to the battery's - termin al. Then, the battery level should be topped up if necessary, after fully charging, using distilled water only.

 Checks before handing over to the customer

Check the wheel nuts are tight. Check nuts and bolts are tight. Check brake adjustment and efficiency. Check the tyre pressures cold. Check operation of the lights, flashers, horn, and brake light. Check the different warning lights work. Carry out a road test.

Depending on equipment.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

SPECIAL IMPORTANT POINTS

 Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc. The clips are specific, they must always be changed each time they are removed and replaced

with new genuine parts clips.

Petrol is highly inflammable, do not smoke in the working area and a void proximity to flames or sparks.

Before carrying out any work, leave the engine to cool for at least 2 hours.

SPECIAL IMPORTANT POINTS



Starting up after overhauling the engine

When starting the engine hot or cold do not accelerate. Check the coolant level in the header tank. After road-testing the machine, check there are no fault codes left in the ECUs (using the diagnostic

tool).

 Electricity

All components of the electrical system are powered with 12 volts DC. The battery must not be disconnected while the engine is running and the voltage must be at least

7 volts for the ECU to function and enable engine starting.

 Special features

An immobiliser built in the ECU provides the antitheft function by means of a transponder. The ECU has a diagnostic function which via the instrument cluster LED or the diagnostic tool, enables

reading of the faults in the memory.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TIGHTENING TORQUES.

 Engine part

Drive pulley 17 m.daN Driven pulley 9.6 m.daN Clutch plate and shoes 7 m.daN Belt anti-flapping roller 1.8 m.daN Transmission cover;

• 6 mm diameter screw

• 8 mm diameter screw Relay box cover 2.5 m.daN Relay box drain plug 1.5 m.daN Flywheel magneto cover 1.2 m.daN Stator 1 m.daN Engine speed sensor 0.5 m.daN Rotor 12 m.daN Freewheel 1.4 m.daN Starter motor 1.2 m.daN Automatic tensioner 1.2 m.daN Automatic tensioner plug 0.5 m.daN Spark plug 1.2 m.daN Camshaft gear 3.2 m.daN Chain tensioner 1.2 m.daN Camshaft stop plat 0.5 m.daN Cylinder head. (Guide pins Procedure Cylinder head bolts and nuts 1.2 m.daN Cylinder head cover 0.8 m.daN Inlet manifold 1.2 m.daN Engine temperature sensor 1.1 m.daN Injection ECU 1.2 m.daN Injection rail 0.3 m.daN Oil pressure switch 1.2 m.daN Oil pump 0.6 m.daN Oil filter 1.4 m.daN Oil pump cover 0.9 m.daN Crankcase 1.2 m.daN Conrod and crankshaft assembly gear 1.1 m.daN Balancing shaft 2.8 m.daN Engine drain plug 2.5 m.daN Water pump cap 0.4 m.daN Water pump impeller 0.5 m.daN Cooling system bleeder screw 0.3 m.daN

1.2 m.daN

2.4 m.daN

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

TIGHTENING TORQUES.

 Body panels

Front mudguard 0.8 to 1.2 m.daN Handlebar cover 0.2 to 0.4 m.daN Front shield panels 0.2 to 0.4 m.daN Rear shield 0.2 to 0.4 m.daN Bottom panel 0.2 to 0.4 m.daN Floor panel 0.4 to 0.6 m.daN Saddle storage compartment 0.8 to 1.2 m.daN Rear panels 0.2 to 0.4 m.daN Grab handle 2 to 2.5 m.daN Rear mudguard 0.4 to 0.6 m.daN

 Cycle part

Front wheel spindle 6.5 m.daN Rear wheel bolt 2.5 m.daN Rear wheel spindle nut 13.5 m.daN Linkrod to engine pivot 8 m.daN Linkrod to frame pivot 8 m.daN Linkrod connecting pin 8 m.daN Linkage torque arms 3.8 m.daN Shock absorber top mount 4.5 m.daN Shock absorber bottom mount 4.5 m.daN Exhaust to cylinder head mounting nut 2.2 m.daN Exhaust to casing mounting bolt 2.2 m.daN Exhaust system strap 1.8 m.daN Exhaust clamp 1.8 m.daN Centre stand holder 2.2 m.daN Suspension arm 2.8 m.daN Lambda sensor 4.5 m.daN Upper cone (in 2 operations) 4/2.2 m.daN Upper cone locknut Hand tightened Steering locknut 7.5 m.daN Front brake caliper 2.5 m.daN Rear brake caliper 2.5 m.daN Front brake disc 3 m.daN Rear brake disc 3 m.daN Handle bar 4 m.daN

 Standard

Nut and bolt 5 mm diameter 0.6 m.daN Nut and bolt 6 mm diameter 1 m.daN Nut and bolt 8 mm diameter 2.2 m.daN Nut and bolt 10 mm diameter 3.5 m.daN Nut and bolt 12 mm diameter 5.5 m.daN

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

SPECIAL TOOLS

Tool N° Designation

750539

Tie-wrap

pliers

Used with

Tool N° Designation

1 0

b a r

757877

Balance

754278

support with

pins Ø15 and

Ø17 mm

TEP 2005

test

xxo

758358 TEP 2005

755996 Hose clamp 758585

Used with

Pressure

gauge

Power supply

cable tool

756017

756715

(*)

757860 Steering tool

(*) New or modified tool.

Fuel injector

power supply

harness

Tank gauge

spanner

Steeing head

758810

cup

installation

tool

432

9208197186

17516

24122311221021

BM 2005

e s t

xxo

b y

151413

758924

24 way

terminal block

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

ELECTRICITY

 4 stroke indirect injection system functional diagram

ELECTRICITY

PEUGEOT

K m M

H rs

0 2

OFF

7,5A

RG-NR

30A F1a

L E

R L

W O L

15A

12345

GR-RG

2 V

21345

VE-NR

VI-BA

1 2

- 2 5A

GR-RGMR-BA

B1A1

BA-NR

BCNR

VI-NR

82420716 5 6

100

120

8 0

140

120

9 0

160

K m

/ h

RG-BA

BA-VE

BE-NR

15 1413926 12

VE-NR

GR-VE

RG MR OR

BA-BE

VE-NR

1. Injection ECU.

2. Engine speed and position sensor.

3. Petrol injector.

4. Fuel pump.

5. Ignition coil.

6. Lambda sensor.

7. Starter motor switch.

8. Starter motor relay.

9. Cooling fan.

10. Fan relay.

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

11. Injection relay.

12. Battery.

13. Ignition switch.

14. Transponder antenna.

15. Diagnostic plug.

16. Instrument panel.

17. Kickstand switch.

18. Emergency stop switch

19. Engine temperature sensor.

ELECTRICITY

 ABS/MBS system schematic diagram

JN/VE

START

100

5 0

120

0 4

140

120

100

160

r s

K m/h

PEUGEOT

51417

2345

MR/BA

OFF

RG/NR

F1a 30A

F1b 30A

RG/NR

VEL

UPPER LE OWER LE

12345

13101

A1 B1

JN/BA

23911

1. Pressure control unit.

2. Speed sensor and pulse wheel.

3. Battery.

4. Ignition switch.

5. ABS/MBS relay.

6. Starter motor switch.

7. Starter motor relay.

8. Injection ECU.

9. Diagnostic plug.

10.Instrument panel (diagnostic lamp, machine speed).

Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

 Fuses and energy distribution

ELECTRICITY

F1a 30A

F7-10A

GR-NR

GR-RG

GR-BE

GR-RG

12V - 25A

F5-7.5A

RG-NR

UPPER LEVEL LOWER LEVEL

F4-15A

F1a-30A

F1b-30A

F2-15A

F3-15A

Geopolis 400cc

Regulator

Ignition switch

F1b 30A

15A

7.5A

ABS relay

Pressure control unit

Injection ECU.

Power supply relay

Fan relay

Instrument panel

Lighting relay

Starter motor relay control relay

Instrument panel

Dip switch (main/low headlight)

Horn

Number plate light

Sidelight

Stop light contact switch

Injection ECU

Transponder antenna

Diagnostic plug

Injection relay

Lighting relay

10A

Accessory socket

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LOCATION OF COMPONENTS

100

120

0 4

0 3

140

120

K m

100

160

H rs

K m

PEUGEOT

VEL

ER LE

UPPER LE

W O L

TEP 2005

test

xxo

1. Injection ECU.

2. Engine speed and position sensor.

3. Engine temperature sensor.

4. Battery.

5. Lambda sensor.

6. Petrol injector.

7. Ignition coil.

8. Transponder antenna.

9. Fuel pump.

10.Fuel gauge.

11.Diagnostic lights.

12.Diagnostic plug.

13.Starter motor relay.

22/02/

50395014

06 9 :

E63853

12V

- 2 5A

39 :

0101

CE 0051

e24

0064

14.Oil pressure switch.

15.10 A fuse.(Accessory socket. 12V.)

16.Fuses.

17.Motor-driven fan.

18.Lighting relay/Fan relay/Power supply relay.

19.Voltage regulator.

20.Horn.

21.Saddle lock.

22.Machine speed sensor.

23.Emergency stop switch.

24.Kickstand switch.

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BODY PANELS

 Location of body components

BODY PANELS

1. Handlebar front fairing.

2. Wind protector.

3. Counter panel.

4. Lower handlebar cover.

5. Front top cover panel.

6. Front shield panels.

7. Mudguard.

8. Bottom panel.

9. Saddle.

10.Tank streamlining.

13 8127

11.Rear shield.

12.Footboard.

13.Access door.

14.Luggage carrier.

15.Helmet compartment.

16.Mudflap.

17.Rear cover.

18.Side panels.

19.Front mudguard.

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