PEUGEOT Satelis 500, Satelis 400 Workshop Manual

Sales division
Technical network leadership

WORKSHOP MANUAL

-

Workshop manual
Technical network leadership
Reproduction or translat ion, even partial, is forbi dden without the written co nsent of Peugeot Motocyc les

TABLE OF CONTENTS

1

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

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

Standard tools..........................................................................................................................................15

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE ...........................................................................16

Functions of the instrument pane l.......... ... .............................................................................. .................16

Initializing the system............................. ... .... ...........................................................................................16

Analog functions (hands) .........................................................................................................................17

Speedometer. ..................................................................................................................................17

Revolution counter............................................................................................................................................ 17

TABLE OF CONTENTS

2

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

Numeric functions (multifunctional display)..............................................................................................17

Tripmeter........................................................................................................................................................... 18

Daily odometer.. ................................................................................................................................................18

Fuel gauge........................................................................................................................................................18

Digital clock.......................................................................................................................................................19

Outside temperature gauge.............................................................................................................................. 19

Engine temperature gauge. .............................................................................................................................. 19

Battery voltage fault.......................................................................................................................................... 19

Maintenance indicator..................................................... ... ... .................................... ... ..................................... 19

Additional functions..................................................................................................................................20

Flasher unit............. ... ..................................... .. ..................................... ... ........................................................20

Instrument panel indicator lamps......................................................................................................................20

Lighting control.................................... ..................................... ... .. ....................................................................20

ABS/MBS system control..................................................................................................................................20

Incident. ............................................................................................................................................................20

ELECTRICITY..................................................................................................................................................22

4 stroke indirect injection system functional diagram...............................................................................22

Schematic diagram of the instrument panel and of the lighting ...............................................................23

ABS/MBS system schematic diagram .....................................................................................................24

Fuses and energy distribution..................................................................................................................25

LOCATION OF COMPONENTS...................................................................................................................... 27

BODY PANELS ............................................................................................................................................... 28

Location of body components..................................................................................................................28

Body component sequence of disassembly.............................................................................................29

Removal of the rider's saddle...................................................................................................................30

Removal of the passenger's saddle.........................................................................................................30

Removal of a RH or LH grab handle........................................................................................................31

Removal of a RH or LH taillight................................................................................................................31

Removal of a taillight bulb........................................................................................................................31

Removal of a RH or LH side cover...........................................................................................................32

Removal of the storage compartment......................................................................................................33

Removal of the tank covers......................................................................................................................34

Removal of a RH or LH footboard............................................................................................................34

Removal of the front top cover panel .......................................................................................................35

Removal of the headlight and sidelight assemblies .................................................................................36

Removal of the headlight bulbs................................................................................................................36

Removal of the front shield panel.............................................................................................................36

Removal of the rear shield panel .............................................................................................................37

Removal of the instrument cluster ...........................................................................................................39

Removal of the dirt shield ........................................................................................................................40

Removal of the battery holder..................................................................................................................40

TABLE OF CONTENTS

3

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

SERVICE OPERATIONS................................................................................................................................. 41

Changing the engine oil and replacing the oil filter ....... ... ... ... .... ... ... .......................................... ..............41

Draining the relay box..............................................................................................................................42

Replacing the air filter ..............................................................................................................................43

Removal of the transmission air filter.......................................................................................................45

Replacing the rollers and the drive belt....................................................................................................45

Removal of the spark plug .......................................................................................................................46

Draining the cooling circuit.......................................................................................................................46

Installing the valve clearance........................ ... ... .......................................... ... ... .... ... ..............................48

Replacing the brake pads ........................................................................................................................50

Front brake..................................... ... .... ... ........................................................................................50

Rear brake.......................................................................................................................................50

Checking the brake fluid level..................................................................................................................54

SERVICING THE ABS/MBS SYSTEM............................................................................................................55

Reminder .................................................................................................................................................55

Removal of the brake modulator..............................................................................................................55

Re-installing the modulator ......................................................................................................................57

Bleed procedure.......................................................................................................................................58

Draining the rear brake circuit...........................................................................................................................58

Bleeding the assistance circuit..........................................................................................................................60

Draining the front brake circuit..........................................................................................................................61

MISCELLANEOUS OPERATIONS ................................................................................................................. 64

Procedure for reducing the fuel circuit pressure. ............................................. ... .... ... ..............................64

Checking fuel pressure ............................................................................................................................65

Removal of the fuel pump........................................................................................................................66

Removal of the fuel gauge.......................................................................................................................66

Removal of the throttle box......................................................................................................................67

Removal of the lambda sensor ................................................................................................................68

Removal of the regulator..........................................................................................................................68

Removal of the radiator............................................................................................................................69

Removal of the engine mounting assembly .............................................................................................70

Removal of the engine.............................................................................................................................72

Removal of the fork..................................................................................................................................76

Replacing the steering head cups............................................................................................................76

Removal of the fork..................................................................................................................................76

Replacing the steering head cups............................................................................................................76

Steering system tightening method..........................................................................................................79

PRODUCTS DANGER SYMBOLS USED

4

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

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

Irritant

The product can irritate the
skin, eyes and repiratory
organs

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

Flammable The product is flammable

Keep it away from any flame or heat
source (barbecue, radiator, heating
device, etc.). Do not leave the product in
the sun

Corrosive

The product can damage living
tissues or other surfaces

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

Explosive

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

Avoid impacts, friction, sparks and heat

Hazardous to
the environment

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

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

Toxic

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

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

Do not throw
away into a
garbage can

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

example: Used batteries

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

Compulsory
gloves

Operation that can be
dangerous for people

People's saf ety can be seriously aff ected if
the recommendations are not fully
respected

PRODUCTS DANGER SYMBOLS USED

5

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

People's safety

Operation that can be
dangerous for people

People's saf ety can be seriously aff ected if
the recommendations are not fully
respected

Important

Operation that can be
hazardous to the vehicle

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

Good operating
condition of the
vehicle

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

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

Note Operation that can be difficult

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

Lubricate

Lubricate the parts to be
assembled

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

Grease

Grease the parts to be
assembled

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

Glue Glue the parts to be assembled

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

New part Use a new part

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

GLUE

N

CHARACTERISTICS

6

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

CHARACTERISTICS

 Engine

 Capacities

400 cc 500 cc

Marking M564M M563M

Type

4-stroke single-cylinder

4 valves per cylinder with chain driven overhead camshaft

Cooling Liquid

Bore x stroke 85.8 x 69 mm 94 x 71 mm

Cubic capacity 398.9 cc 492.7 cc
Max. power output 24 kW at 7250 rpm 29 kW at 7500 rpm
Max. torque rating 5250 rpm

Compression ratio 10.6 bars

Lubrication Trochoidal pump

Transmission By 2 variable pulleys and V-type belt

Clutch Centrifugal automatic

Exhaust Catalytic

Starter motor Mitsuba 900 W

Spark plug

1 spark plug 2 spark plugs

NGK CR7EKB

Electrode gap

0.7-0.8 mm

Magneto flywheel Mitsuba 350 W

Fuel supply

Indirect electronic injection

Magneti-Marelli

Engine oil

1.7 l SAE 5W40.

Minimum grade: API SJ.

Relay box oil

0.25 l SAE 80W90.

Minimum grade: API GL4.

Coolant 1.4 LPeugeot coolant part number 754614
Fork oil 200 cc per tube (Esso Univis 46 or Agip HLift 46)

Fuel tank 13.2 L

CHARACTERISTICS

7

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

 Chassis

 Dimensions and weight

 Tyres

Chassis Double cradle out of high-resistance steel tube

Front suspension Hydraulic telescopic fork. Ø40 mm

Travel 110 mm

Rear suspension 2 adjustable combined spring hydraulic shock absorbers

Travel 90 mm

Overall length

2168 mm

Width at handlebar

769 mm

Height. (without rear-view

mirrors)

1140 mm

Wheelbase 1534 mm

Ground clearance

174 mm

Saddle height

784 mm

Unladen weight

218 kg.

Front wheel rim 14 inch aluminium alloy

Front tyre 120/70 - 14

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

1. Manufacturer's plate. (Left side).

- VIN number of the RH side of the vehicle

2. Engine number

1

xxxxxxxxxx

M461M

2

SERVICE SCHEDULE AND COMMISSIONING

8

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

SERVICE SCHEDULE AND COMMISSIONING

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

Service operations

1000 kms or

1 months

Every

5000 kms

Every

10000 kms

Every

20000 kms

Heavy duty servicing 500 kms

Every

2500 kms

Every

5000 kms

Every

10000 kms

 Check

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 R R
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 (+ clean strainer) R R R
Engine oil filter R R R
Relay box oil R C C
Brake fluid and coolant Once every 2 years

SERVICE SCHEDULE AND COMMISSIONING

9

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

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

* Depending on equipment.
# Change if necessary.

Service operations

1000 kms or

1 months

Every

5000 kms

Every

10000 kms

Every

20000 kms

Heavy duty servicing 500 kms

Every

2500 kms

Every

5000 kms

Every

10000 kms

 Check and lubricate

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 2.4 3.5

SERVICE SCHEDULE AND COMMISSIONING

10

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

 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/cm

3

).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 - terminal.
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.

SPECIAL IMPORTANT POINTS

11

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 avoid pr oximity to flames or
sparks.

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



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.

TIGHTENING TORQUES

12

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

1.2 m.daN

2.4 m.daN

Relay box cover 2.5 m.daN
Relay box drain plug 1.5 m.daN
Flywheel magneto cover 1.2 m.daN
Stator 1m.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
Decompressor valve balance weight 0.8 m.daN
Decompressor valve housing 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

TIGHTENING TORQUES

13

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

 Body panels

 Cycle part.

 Standard

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

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

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

SPECIAL TOOLS

14

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

SPECIAL TOOLS

(*) New or modified tool

Tool N° Designation

Used
with

Tool N° Designation

Used
with

750539

Tie-wrap

pliers

757860 Steering tool

754278

Balance

support with

pins Ø15 and

Ø17 mm

757877

Pressure

gauge

754306

Bleed

syringe

758358 TEP 2005

755996 Hose clamp 758585

Power supply

cable tool

756017

Fuel injector

power supply

harness

758810

Steeing head

cup

installation

tool

756715

(*)

Tank gauge

spanner

758924

24 way

terminal block

0

6

8

1
0

2

4

b
a
r

OK

TEP 2005

by

xxo

test

1

24122311221021

9208197186

17516

151413

26

25

432

BM 2005

b
y

xxo

t

e
s

t

SPECIAL TOOLS

15

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

 Standard tools

Oil filter notched cap

wrench.

Type: Facom D155

Automatic resetting type

torque wrench.

10 to 50 Nm

Type: Facom J.208A50

Automatic resetting type

torque wrench.

5 to 25 Nm

Type: Facom R.306A25

Automatic resetting type

torque wrench.

40 to 200 Nm

Type: Facom S.208A200

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

16

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

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

 Functions of the instrument panel

 Initializing the system

The instrument panel initializes itself every time the ignition is switched on:

- All warning lights are switched on.

- All elements of the multifunctional display are activated.

- The two hands (speedometer and revolution counter) move simultaneously from the minimum to
the maximum and back.

If this is not the case, switch the ignition off, disconnect and re-connect the battery.
After initializing, the low oil, stoplight or ABS, injection diagnosis indicator lights remain on.

- Speedometer.

- Revolution counter.

- Tripmeter.

- Daily odometer.

-Digital clock.

- Fuel gauge.

- Outside temperature gauge.

- Engine temperature gauge.

- Battery voltage fault.

- Maintenance indicator.

- Flasher unit.

Instrument panel indicator lamps:

• Oil pressure.

• ABS/MBS or STOP

• Left direction indicator.

• High beam.

• Immobiliser state.

• Diagnosis of the ignition system.

• Opening the storage compartment.

• Right direction indicator.

(A) Control button.
Two versions are available:

1. Basic version featuring
a STOP indicator light (B).

2. ABS/MBS version

featuring an ABS indicator
light (B)

When preparing the vehicle, switch off the ignition and connect the battery. The system
initializes itself when connecting the battery.

The battery must never be connected or disconnected when the ignition is switched on.

ABS

km

°C

C

F

E

H

Trip

EFI

km/h

mph

70

10

20

30

40

50

60

80

90

100

110

10

0

30

50

70

90

110

130

150

170

X1000 r/min

0

1

2

3

4

5

6

7

8

9

10

11

12

B

A

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

17

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

 Analog functions (hands)

Speedometer.

Double-scale indication, kilometres/miles.
Vehicle without ABS/MBS: The signal is supplied by the speed sensor mounted on the front wheel.
Vehicle with ABS/MBS: The signal is sent by the ABS/MBS ECU.

Revolution counter.

Vehicle with Magneti Marelli ECU: 2 pulses per engine revolution.

 Numeric functions (multifunctional display)

1. The tripmeter.

2. Daily odometer.

3. Fuel gauge.

4. Digital clock.

5. Outside temperature gauge.

6. Engine temperature gauge.

7. Battery voltage fault.

8. Maintenance indicator.

9. Empty tank indicator light.

km

Miles

°C

°F

C

F

E

H

Trip

1

2

6

3

89

7

4

5

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

18

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

Tripmeter.

The tripmeter displays and stores the number of kilometres travelled by the vehicle.

Changing the distance unit (km or miles) is as follows

- The ignition is switched off, press the control button while switching on the ignition, the distance unit
will flash.

- Select the unit by briefly pressing the control button, the distance unit changes from "km" to "miles"
or inversely.

- Switch off ignition to confirm.

Daily odometer.

The tripmeter displays and stores the number of kilometers travelled during a given period.
The daily odometer uses the same unit of measurement as the tripmeter.
Resetting the daily odometer:

- Press the control button (several times briefly) until the figures of the daily odometer flash.

- Pressing the control button for more than 3 s allows you to reset the daily odometer.

Fuel gauge.

In the fuel reserve position, the two last segments are lit and flash.
When the fuel tank is empty, all segments are off and the pump flashes.
Fuel gauge self-diagnostic
All segments flash if the fuel gauge or its wiring is faulty. Open circuit (wire cut).

The machine total kilometres remains in the memory when the battery is disconnected.

If the distance unit is kilometres, the outside temperature is displayed in °C.
If the distance unit is miles, the outside temperature is displayed in °F.

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

19

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

Digital clock.

Time setting:
Press the control button (several times briefly) until the figures of the clock flash.
Pressing the control button for more than 3 s make the the time characters flash.
Set the time by successive pushes on the control button.
Pressing the control button for more than 3 s will make the first character of the minutes flash.
Set the time by successive pushes on the control button.
Pressing the control button for more than 3 s will make the second characters of the minutes flash.
Set the time by successive pushes on the control button.
Pressing the control button for more than 3 s will allow you to confirm the time.

Outside temperature gauge.

Engine temperature gauge.

Vehicle with Magneti Marelli ECU: the engine temperature sensor controls the temperature gauge.

When the engine temperature is too high, all segments are switched on and the last flashes.
Temperature alarm. On the basic instrument panel, the stop warning light is on.

If the temperature information does not reach the instrument panel, all segments flash. Open circuit
(wire cut).

Battery voltage fault.

The battery charge warning light flashes if the battery voltage goes below 11.2 volts and it stops
flashing when the voltage passes again above 11.7 volts.

The battery charge warning light flashes and the stop warning light comes on (only basic instrument
panel version) when the battery voltage is below 16 volts.

Maintenance indicator.

Maintenance function:
The maintenance indicator goes on 5000 kms after the last reset.
Maintenance reset:

Outside temperature sensor.

If the distance unit is kilometres, the outside temperature is displayed in °C.
If the distance unit is miles, the outside temperature is displayed in °F.

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

20

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

- The ignition is switched off, press the control button while switching on the ignition, the distance unit
will flash.

- Pressing the control button for more than 5s allows you to reset the maintenance indicator, and the
"key" icon will go off.

 Additional functions

Flasher unit.

The instrument panel is equipped with one flasher unit per side.
A buzzer reminds the driver of the direction indicators.
For the hazard warning lights, both flasher units operate.
The flasher unit is protected against accidental short-circuits.
The ignition must be turned on again to activate the hazard warning lights function.
The hazard warning lights can only operate with the ignition off if they were turned on before switching

off the ignition.
The hazard warning lights are switched off automatically 1 hour after the ignition was switched off, to

perserve the battery.

Instrument panel indicator lamps.

Basic version:
To allow a better warning of the driver, the stop warning light will come on besides the spe cific alarm

warning light in the following cases:

- Oil pressure fault.

- Engine temperature fault.

- Battery overvoltage faulr.

Lighting control.

The instrument panel controls the lighting of the vehicle. When the ignition is switched on, the parking
lights go on. The headlight goes on when the engine is started (Depending on the position of the dip
beam/high beam switch).

The headlight remains on as long as the vehicle runs, even if the engine stalled, and remains on 7 s
after the vehicle stopped running.

The headlight remains on for 3 s after the ignition was switched off, when the wehicle is stopped.

ABS/MBS system control.

The ABS/MBS ECU remains powered as long as the vehicle runs, even if the engine stalled.

Incident.

Revolution counter and speedometer hands are not synchronized when switching the ignition on.

When a flasher bulb has failed the repeater light an d the other f lasher light f lash more quickly t o
alert the rider of a failure.

In the high beam position, both dip beam and high beam are on simultaneously.

ELECTRONIC INSTRUMENT FUNCTIONING PRINCIPLE

21

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

- Turn off the ignition.

- Disconnect and re-connect the battery.

The engine speed displayed is the double of the actual speed. Faulty detection of the measuring
system.

Vehicle with Magneti Marelli system. Temperature sensor circuit not detected.

- Check the engine temperature sensor circuit.

- Turn off the ignition.

- Disconnect and re-connect the battery.

ELECTRICITY

22

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

ELECTRICITY

 4 stroke indirect injection system functional diagram

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.

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.

1

2
V

­2

5
A

21345

1

2
V

­2

5
A

12345

2

1

3

4

5

1

2

6

3

OFF

ON

8

14

2

1

-

U

P

P

E

R

L

E

V

E

L

L

O

W

E

R

L

E

V

E

L

VE

B1A1

A3

VE

6

5

4

3

2

19

16

15

14

13

12

11

10

9

8

7

2

1

21

22

11

4

15 1413926 12

2

1

17

18

82420716 5 6

1

1

2

1

2

3

2

1

x

x

1

2

30A

F1

7,5A

F6

15 A

F2

15A

F4

VE

VE

JN

BCNR

NR

NR

RG

RG

VI

VE-NR

RG-BA

BA-BE

VE-NR

BE-NR

BA-VE

VI-BA

BE-NR

GR-RG

RG-NR

VI-NR

VE-NR

GR-RGMR-BA

BA-NR

12

+

VC

BE

BA

VE

VE

RG MR OR

VI

NR

ABS

k

m

°C

C

F

E

H

T

r

i

p

EFI

km/h

mph

7

0

10

2

0

3

0

4

0

5

0

60

8
0

90

100

110

1

0

0

30

50

7

0

90

110

1
3
0

1
50

17

0

X1000 r/min

0

1

2

3

4

5

6

7

8

9

10

11

12

GR-VE

GR-VE

GR-VE

GR-VE

R

R

R

400cc

500cc

17

18

0

1

0

1

1

2
V

-
2
5A

ELECTRICITY

23

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

 Schematic diagram of the instrument panel and of the lighting

1. Instrument panel.

2. Battery.

3. Ignition switch.

4. Immobilizer.

5. Injection ECU.

6. Fuel gauge.

7. Speed sensor.

8. Outside temperature sensor.

9. Oil pressure switch.

10.Saddle opening contact switch.

11.Lighting relay.

12.Dip beam.

13.High beam.

14.Dip switch (main/low headlight).

15."Side light" bulbs.

16.Number plate light.

17.Direction indicator switch.

18.Hazard warning lights switch.

19.RH direction indicators.

20.LH direction indicators.

-

U

P

P

E

R

LE

V

E

L

L

O

W

E

R

LE

V

E

L

3

6

OFF

ON

11 20122223

15

24

17

10

0

1

2

3

4

5

6

7

8

9

1
0

11

12

12
V

­ 2

5

A

21543

30A

F1

15A

F4

15A

F5

4 514218

172 1

3

1

2

EFI

16

19

6

7

9

26

21

18

H7 12V-55W

H7 12V-55W

12V-5W

12V-5W

12V-5W

12V-10W12V-10W

VE

VE

JN

MFVC

BE BA

GR

RS

RS

BCOR

RG

RG

VE

VE

VE

BA

MR

GR-NR

GR-BE

OR-BA

GR-NR

RG-NR

BA-BE

GR-NR

GR-BE

VE-NR

MR-BA

RS-BA

VE-BE

JN-BE

JN-BA

JN-BE

ABS

km

°

C

C

F

E

H

Tri

p

EFI

km/h

mph

7

0

1

0

20

3

0

4

0

5

0

6
0

80

90

1
0
0

110

10

0

3

0

50

7

0

90

110

1
3

0

1
5
0

1
70

X1000 r/min

0

1

2

3

4

5

6

7

8

9

1
0

1
1

1
2

RG-BA

9

5

7

64

15

17

8

10

11

13

18

1920

14

3

16

2

1

12

ELECTRICITY

24

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

 ABS/MBS system schematic diagram

1. Pressure control unit.

2. Speed sensor and pulse wheel.

3. Battery.

4. Ignition switch.

5. Power supply relay.

6. ABS/MBS relay.

7. ABS diode.

8. Starter motor switch.

9. Starter motor relay.

10.Injection ECU.

11.Diagnostic plug.

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

7,5A

30A

START

PIN

VI

VI

VI

VE

BE/NR

BE/NR

BE/NR

GR/NR

RG/NR

MR/BA

JN/BA

JN/VE

VE

GR

BA

OR

JN

RG

VE

RG

RG

RG

BE

RG

VE

VE

A3

A2

A1 B1

B3

23911

3

14

5

17

19

21

25

20

13101

-

U

P

P

E

R

L

E

V

E

L

L

O

W

E

R

L

E

V

E

L

1

2

V

-

2

5

A

12345

1

2

V

­ 2

5

A

12345

1

2

V

- 25
A

12345

6

3

OFF

ON

24

ABS

km

°

C

C

F

E

H

Tri

p

EFI

km/h

mph

70

10

20

30

40

5

0

60

80

9

0

1
0
0

1
1

0

10

0

30

50

70

90

1

10

130

150

1
7
0

X1000 r/min

0

1

2

3

4

5

6

7

8

9

10

11

12

24132623

12

5 6

7

8

10

9

11

3

4

2

1