WORKSHOP
MANUAL
50 cc INJECTION
ENGINE
SALES DIVISION
NETWORK TECHNICAL INFORMATION
CONTENTS
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CONTENTS
CONTENTS.......................................................................................................................................... 2
CHARACTERISTICS......................................................................................................................... 4
Characteristics ................................................................................................................................................ 4
Capacities ....................................................................................................................................................... 4
Engine markings............................................................................................................................................. 4
SPECIAL IMPORTANT POINTS .................................................................................................... 5
Oil and fuel:.................................................................................................................................................... 5
Starting: .......................................................................................................................................................... 5
Electricity: ...................................................................................................................................................... 5
Special features............................................................................................................................................... 5
TIGHTENING TORQUES................................................................................................................. 6
Tightening torques:......................................................................................................................................... 6
SPECIAL TOOLS ............................................................................................................................... 7
Introduction .................................................................................................................................................... 9
DISASSEMBLY................................................................................................................................... 9
To remove the engine from the machine........................................................................................................ 9
Putting the engine on the stand..................................................................................................................... 10
To remove the cooling system...................................................................................................................... 10
To remove the magneto flywheel................................................................................................................. 11
To remove the stator and sensor assembly................................................................................................... 12
To remove the primary transmission cover.................................................................................................. 12
To remove the drive pulley .......................................................................................................................... 12
To remove the driven pulley ........................................................................................................................ 13
To remove the secondary transmission cover .............................................................................................. 13
To remove the secondary transmission ........................................................................................................ 14
To remove the starter motor ......................................................................................................................... 14
To remove the cylinder head/cylinder assembly.......................................................................................... 14
To remove the air injector ............................................................................................................................ 15
To remove the piston.................................................................................................................................... 15
To remove the inlet manifold and valve....................................................................................................... 16
Opening the casings...................................................................................................................................... 17
To remove the crankshaft ............................................................................................................................. 18
Checking the crank....................................................................................................................................... 19
REFITTING SPECIFIC COMPONENTS...................................................................................... 20
To fit bearings .............................................................................................................................................. 20
Assembling the casings ................................................................................................................................ 21
To fit the piston ............................................................................................................................................ 23
To fit the cylinder ......................................................................................................................................... 24
To fit the cylinder head ................................................................................................................................ 24
To fit the magneto flywheel ......................................................................................................................... 25
To remove the cooling system...................................................................................................................... 25
To fit the injection manifold and compressor .............................................................................................. 26
To fit the drive pulley assembly ................................................................................................................... 26
MISCELLANEOUS OPERATIONS ............................................................................................... 27
To remove the starter system........................................................................................................................ 27
To fit starter system...................................................................................................................................... 27
To remove/refit the drive pulley rollers ....................................................................................................... 28
To remove the clutch lining assembly.......................................................................................................... 29
To refit the clutch lining assembly ............................................................................................................... 29
To remove the fuel tank................................................................................................................................ 30
CONTENTS
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Procedure used to lower the pressure in the fuel system instruction 1....................................................... 31
Fuel circuit bleeding procedure instruction 2 ............................................................................................. 32
To remove the Injection rail ......................................................................................................................... 32
To remove the air injector ............................................................................................................................ 33
To remove the air compressor...................................................................................................................... 34
To remove the throttle unit........................................................................................................................... 35
To remove the fuel pump ............................................................................................................................. 37
To remove the strainer.................................................................................................................................. 38
To remove the ECU...................................................................................................................................... 39
To remove the temperature sensor ............................................................................................................... 39
To remove the HT coil ................................................................................................................................. 40
Setting the spark plug electrode gap............................................................................................................. 40
To remove the oil pump ............................................................................................................................... 41
Parameter reading ............................................................................................................................. 42
CHARACTERISTICS
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CHARACTERISTICS
Characteristics
Engine
Air-cooled, single-cylinder
2-stroke injection
Bore x stroke 40,3 x 39,1
Cubic capacity 49.1 cc
Max. power
output
3.4 kW at 6900 rpm
Maximum torque 4.7 Nm at 6800 rpm
Gross
compression ratio
11.4
Ignition /
Carburation
Synerject ECU
Petrol injector Siemens green 37.028
Air injector Synerject blue 37.073
Pressure regulator Synerject
Petrol pump Synerject
Throttle unit Bing 235 011
Temperature
sensor
Synerject
Oil pump Mikuni ESOP-03
Spark plug NGK CPR8E
Magneto
flywheel
Mitsuba 180W
Starter motor
Mitsuba 150 W
Capacities
Transfer box 0.12 L.
Engine markings
Long type engine FC5J
Short type engine FB5
SPECIAL IMPORTANT POINTS
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SPECIAL IMPORTANT POINTS
Oil and fuel:
This engine is designed to run on 95 or 98 unleaded fuel only
The oil used for the separate lubrication system is Esso 2T special, approved by the machine manufacturer.
The oil is injected directly into the inlet manifold as the engine requires.
Never run the machine with a petrol/oil mixture.
Starting:
Bleed of the oil circuit must be tested with the diagnostic tool: check if there are fault codes and clear them
where necessary.
Starting should not be with a 2-stroke mixture, as the fuel pump and injectors are not designed to operate
with oil.
Do not accelerate when hot or cold starting
Electricity:
All components of the electrical system are powered with 12 volts DC.
The battery is essential to operate the petrol pump and the ECU which are used for engine starting.
The battery must not be disconnected while the engine is running.
The battery voltage must be a minimum of 8.5 volts for the ECU to able to function and authorise starting.
Special features
The ignition is controlled by the ECU which determines the advance based on the information given by:
- the engine speed sensor located opposite a pulse wheel fitted to the magneto flywheel
- the quantity of air intake into the engine, measured by the throttle unit, is transmitted to the ECU which
will define just the right quantities of oil and petrol necessary for engine optimum running.
The throttle unit must be re-initialised after disconnecting or changing the ECU.
The oil pump controlled by the ECU must be bled before restarting the engine using the procedure described
in the relevant chapter.
The fuel pump controlled by the ECU must be bled before restarting the engine using the procedure
described in the relevant chapter.
The ECU has a diagnostic function enabling the mechanic to test the injection system using the LED on the
instrument panel or the diagnostic tool.
The fuel inlet and injection manifold return pipes must only be replaced by genuine service parts. The
fuel pressure of 8 bars requires special pipes.
The fuel pipes must be changed if they show signs of wear, cracks, etc.
The fuel pipe clips are also specific, other clips must never be used.
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.
TIGHTENING TORQUES
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TIGHTENING TORQUES
Tightening torques:
Cylinder head 1.2 m.daN
Cylinder casings 1 m.daN
Covers 1 m.daN
Inlet manifold 1 m.daN
Starter motor 1 m.daN
Rotor 4 m.daN
Stator 1 m.daN
Engine speed sensor. 1 m.daN
Turbine 1 m.daN
Drive pulley 4 m.daN
Driven pulley 4.5 m.daN
Spark plug 1 m.dan
Compressor 0.65 m.daN
Injection rail 0.65 m.daN
SPECIAL TOOLS
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SPECIAL TOOLS
. Tool N° Designation Used with
64706 Casing extractor
and opening tool
casing
opening
plate + pin
64710 Shoulder locator 64706
64765 Engine support engine
support
bracket
68007 Protective cap
small model
69254
68994 Torque wrench 8
Nm to 54Nm
extension
752235
adapter
752236
69092 Interior circlip
pliers
103 old
generation
69098 Protective cap
large model
754003
69104 Wing nut 750069 +
64711 +
64712 +
64754
69117 Exterior circlip
pliers
750069 Stud Ø10 pitch
125
69104
750539 Tie-wrap pliers
750808 Thrust washer 64706
752000 Piston circlip pliers
752127 Clutch compression
tool
752361
752235 1/2 extension 69802 or
753977
752236 1/2-3/8 adapter 69802 or
753978
752237 Adjustable pin
wrench
752361 39 mm box wrench 752127
753977 Torque wrench 30
Nm to 54Nm
extension
752235
adapter
752237
754086 Steering tool
SPECIAL TOOLS
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754171 Battery charger
754306 bleed syringe 061764 +
752410
755585 bearing extractor
tool
755806 French cartridge 755878
755807 Export cartridge 755878
755874 fixed flange locking
tool
755878 diagnostic tool
(Color Gameboy)
755982 Engine support
adapter
64765
755983 Casing opening
tool
64706
755984 Casing cover plate 64706
755985 flywheel extractor 68007
755986 air injector setting
tool
755989 air injector drift
755990 diagnostic tool
update software
755878
755806
755807
755996 hose clamp
756017 petrol injection
power supply
harness
756056 Tank ring spanner
756057 Crank assembly lip
seal tool
DISASSEMBLY
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Introduction
The injection system is composed of precision components and cannot withstand impurities. Perfectly
clean working conditions are therefore essential.
DISASSEMBLY
To remove the engine from the machine
Compulsory: wash the power unit
- Disconnect and remove the battery
- Remove the saddle/locker assembly, the grab handle, mud-flap and rear panelling assembly
- Remove the injection manifold soundproofing
- Raise the fuel tank in order to withdraw the injection manifold soundproofing.
- Remove the injection manifold without disconnecting the fuel supply pipes (see relevant chapter),
- Move the injection manifold clear and protect from impurities with a clean rag.
- Disconnect the air injector
- Put a clean rag over the air injector to protect it from impurities
- Remove the upper handlebar fairing, the rear panel and floor panel
- Disconnect the flywheel output harness and the starter motor
- Remove the air intake, the air filter box with the throttle unit
- Disconnect the throttle unit
- Move the air filter box clear with the throttle valve without disconnecting the throttle cable
- Disconnect the temperature sensor
- Disconnect the inlet manifold oil inlet pipe
- Unclip the harness assembly from the cylinder cover
- Disconnect the suppressor and rear brake cable
- Remove the exhaust
- Slacken the rear wheel nut
- Suspend the machine
- Remove the shock absorber lower mount and the engine linkrod fixing bolt
- Remove the power unit
- Remove the rear wheel
- Remove the stand with its bracket
DISASSEMBLY
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Putting the engine on the stand
- Fit the engine to adapter P/N 755982
- Put the assembly on stand P/N 64765 clamped in
the jaws of a vice
To remove the cooling system
- Remove the 2 bolts (1) from injection manifold
(2) and the 4 bolts (3) from the compressor (4)
- Remove the injection manifold and compressor
(with its 2 centring dowels and its O-ring) without
disconnecting the pipe linking them together (5)
- Remove the temperature sensor (6)
- Remove the spark plug (7)
- Remove the 4 bolts (8) from the cooling volute
and the cylinder cover
- Remove the 2 parts (9) the cooling volute and the
cylinder cover
DISASSEMBLY
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- Remove turbine (11) three (10) fixing bolts
- Remove the turbine
To remove the magneto flywheel
- Hold the rotor (1) with the pin wrench
P/N 752237
- Remove the nut
- Fit protective cap P/N 68007 to the end of the
crank assembly
- Tighten flywheel extractor P/N 755985 on the
rotor
- Lock the flywheel extractor and turn the thrust
bolt until the rotor is released
DISASSEMBLY
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To remove the stator and sensor assembly
- Remove the engine speed sensor 2 fixing bolts
(2) and the stator assembly 2 fixing bolts (3)
- Remove the stator and sensor assembly (4)
- Remove the key (5) from the crank
To remove the primary transmission cover
- Remove the transmission cover 8 fixing bolts (1)
- Remove the cover and its locating pin
To remove the drive pulley
- Lock the fixed flange (2) with tool
P/N 755874
- Remove the fixed flange nut (1)
- Remove the fixed flange
- Remove the starter dog (3)
DISASSEMBLY
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- Remove the belt (4)
- Remove the drive pulley (5)
To remove the driven pulley
- Lock the clutch drum (1) with the pin wrench
P/N 752237
- Remove the nut
- Remove the clutch drum (1) and the clutch-drive
pulley assembly
To remove the secondary transmission cover
Note: use a container to catch the transfer box oil
when the cover is removed
- Remove the cover (2) six fixing bolts (1)
- Remove the cover with the primary shaft
DISASSEMBLY
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To remove the secondary transmission
- Remove the paper gasket (3) and the 2 locating
pins (4)
- Remove the first thrust washer (5) (14x27x0.5)
from the intermediate shaft (6)
- Remove the secondary shaft (7)
Note: take care not to damage the seal on the
wheel side when removing the secondary shaft, as
the oil could leak out through a drain hole in the
casing located between the seal on the wheel side
and the bearing
- Remove the intermediate shaft (6) and its second
thrust washer (14x27x0.5) located behind it
To remove the starter motor
- Remove the starter motor (2) two fixing bolts (1)
and washers
- Remove the starter motor and its O-ring
Note: the bottom bolt is used to earth the
battery to the engine (green wire)
The upper bolt is used to mount the harness clamp
To remove the cylinder head/cylinder assembly
- Slacken off the cylinder head/cylinder 4
mounting bolts in the order shown, in 2 or 3 stages
- Remove the 4 bolts
- Remove the cylinder head and its gasket
- Remove the cylinder and the bottom seal
Note: do not remove the air injector if this is not
necessary
DISASSEMBLY
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To remove the air injector
- Drift out the air injector (1) with drift P/N
755989
- Remove the O-ring from under the air injector
(the O-ring must be renewed each time it is
removed)
Compulsory: Put the injector in the holder tool
P/N 755986 until ready for refitting
Note: The air injector can only be extracted for a
short instant from its housing in the cylinder head,
as the air injector has a Teflon seal which expands
if it is not kept compressed
To remove the piston
- Remove the circlips (1) with pliers
P/N 752000
- Remove the gudgeon pin
- Remove the piston (2)
- Remove the needle bearing race from the
connecting rod end
DISASSEMBLY
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To remove the inlet manifold and valve
- Remove the 4 fixing bolts (1) (one is of the
tamper-proof type)
- Remove the inlet manifold (2)
- Remove the first paper gasket (3)
- Remove the valve assembly (4)
- Remove the second paper gasket (5)
Note: The gaskets must be renewed each time they
are removed
- Check that the valve assembly blades and
support are in perfect condition
Note: the position of the limiter must be 3 mm
from the valve support
DISASSEMBLY
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Opening the casings
- Remove the RH casing (2) six fixing bolts (1)
- Fit the protective cap P/N 68007 to the crank
- Fit to the RH casing tool P/N 755983 secured by
2 bolts
- Hold the connecting rod to prevent it from
coming into contact with the casings
- Tighten the tool centre screw until the casings
separate
- Remove the RH casing
- Remove the paper gasket (3) and the 2 locating
dowels (4)
DISASSEMBLY
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To remove the crankshaft
- Fit the crank end fit protective cap P/N 69098
- Fit to the casing tool P/N 64706 fitted with plate
P/N 755984
- Fit the assembly to the casing with 4 bolts (1)
(the plate opening facing the cylinder side)
- Tighten the tool centre screw holding the crank
with one hand on the other side until it is fully
extracted
DISASSEMBLY
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Checking the crank
- The maximum side float on the connecting rod
end must not exceed: 5/10 mm
- The out-of-round values measured on the ends of
the crank should not exceed 1/10 mm and must be
measured:
- 25 mm from the transmission side end
- 40 mm from the magneto flywheel end
REFITTING SPECIFIC COMPONENTS
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REFITTING SPECIFIC COMPONENTS
To fit bearings
Note:
- the bearings and crank seals must be changed
each time the casings are opened
- when the casings are opened, if the bearings stay
on the crank, use tool P/N 755585 to remove them
- if the bearings stay in the casings, the casings
should be heated with a heat gun to remove them
This operation should be done quickly in order
to remove and refit a bearing to each casing
- Set one of the casings on its mating surface, heat
it (80 to 90°C) until the bearing drops out of its
own accord
- Remove the seal
- While the casing is expanded fit the new bearing
fully home in its housing
- Fit the new seal with tool P/N 756057
Proceed in the same way for the other casing
The seals should be positioned as follows:
- the seal on the drive pulley side 3 mm from the
outer edge of the casing
- the seal on the magneto flywheel side 6 mm from
the outer edge of the casing
REFITTING SPECIFIC COMPONENTS
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Assembling the casings
- Insert the crank into the LH casing bearing
- Tighten pin P/N 750069 on the end of the crank
- Fit tool P/N 64706 fitted with plate P/N 755984
to the pin and centre the assembly on the casing
with the 4 bolts (1)
- Fit centring tool P/N 64710 to tool P/N 64706
- Tighten pin nut P/N 69104 on pin P/N 750069 in
order to bring the crank into contact with the
bearing ensuring that the connecting rod is facing
towards the top of the engine
Note: hold the crank on the RH side with the rotor
fitted over the key
- Fit the two locating dowels (2) and a new paper
gasket (3) with no oil or grease to the LH casing
REFITTING SPECIFIC COMPONENTS
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- Fit the RH casing to the LH casing and crank
assembly taking care not to damage the seal, over
the key if the key has stayed on the crank
- Tighten pin P/N 750069 on the end of the
crankshaft
- Fit the following in order to the casing:
- washer P/N 750808 (50x29x3mm)
- tool P/N 64706
- centring tool P/N 64710
- Tighten pin nut P/N 69104 until the casings are
fully closed
Note: hold the crank by the fixed flange fitted to
the splines
- Fit the 6 fixing bolts (4)
- Check the crank turns freely in the casings
- Cut the casing seal flush at (A)
- Grease the crank and bearings with 2-stroke oil
REFITTING SPECIFIC COMPONENTS
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To fit the piston
- Check the cylinder/piston assembly pairing (A)
There are two possible types, A and B
Cylinder A with piston A
Cylinder B with piston B
- Fit the needle bearing race (1) into the
connecting rod end after lubricating it with 2stroke oil
- Fit the piston to the connecting rod, the
positioning spigots on the piston rings facing the
inlet side
- Fit the gudgeon pin and circlips
Imperative: the circlips must be renewed each
time they are removed
The circlip gaps must face upwards or downwards,
but under no circumstances to the side (2)
REFITTING SPECIFIC COMPONENTS
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To fit the cylinder
- Fit a new bottom gasket (1) without grease or oil
to the casing which has been previously cleaned of
all impurities
- Ensure that the piston ring gaps are opposite the
piston positioning spigots
- Fit the cylinder (2) and lower it while
compressing the rings by hand
- Check the bottom seal is properly positioned on
the casing using the 2 cylinder head fixing screws
(3)
To fit the cylinder head
- Check the cylinder head mating surface is in
perfect condition
- Fit the 4 fixing bolts to the cylinder head with
their washers
- Fit a new gasket to the cylinder head, with the
bead (A) on the cylinder head side
Important: if one or more bolts are changed,
genuine original parts must be used
Their design guarantees a constant tightening
torque whatever the cylinder/piston assembly
temperature
REFITTING SPECIFIC COMPONENTS
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- Fit the bolt-washer, cylinder head and gasket
assembly to the cylinder
- Tighten the 4 bolts in 2 or 3 steps in the order
shown
Note: this operation is carried out without
removing the air injector
To fit the magneto flywheel
- Fit the key (1) to the crank
- Fit the stator (2) and engine speed sensor (3)
assembly
- Fit the 2 fixing bolts for each of the parts
- Fit the rotor to the crank ensuring it is perfectly
positioned on the key
- Lock the rotor with the adjustable pin wrench
P/N 752237
- Fit and tighten the rotor nut
To remove the cooling system
- Fit the cooling turbine and its 3 bolts
- Fit the volute and cylinder cover (1) with the 4
bolts (2)
REFITTING SPECIFIC COMPONENTS
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To fit the injection manifold and compressor
(If they were removed together)
- Fit the spark plug (1)
- Fit the temperature sensor (2)
- Fit the injection manifold (3) (2 bolts) checking
the gaskets are correctly fitted
- Fit the compressor (4) (4 bolts) with its two
locating dowels and a new lightly greased O-ring
To fit the drive pulley assembly
- Fit the drive pulley with its guide hub onto the
crank
- Fit the belt (1) to the guide hub
- Fit the fixed flange (2) to the crank checking it is
properly positioned on the crank splines
- Fit the nut (3) and tighten finger tight
- Fit locking tool P/N 755874
- Tighten the nut with a torque wrench to the
required torque
Note: it is forbidden to use a power driver, this
may upset the crank position
Imperative: Precautions when refitting the drive
pulley
Certain parts of the drive pulley must not be
discarded or cut down to a smaller size. Any
modifications may cause the nut to tighten against
the crank splines instead of the fixed flange and
damage the crank splines
MISCELLANEOUS OPERATIONS
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MISCELLANEOUS OPERATIONS
To remove the starter system
- Operate the starter quadrant (1) by hand and
remove the kick start drive gear (2) and its washer
- Turn the cover over and remove the circlip (3)
with circlip pliers P/N 69117
- Remove the washer, the starter quadrant (1) and
the spring (4) from the transmission cover
To fit starter system
- Fit the return spring (A), with the longest loop on
peg (A) in the cover
- Fit the starter quadrant (1) into the bearing bush
- Hook the second loop (B) of the spring onto the
starter quadrant
- Set the spring so that the starter quadrant is
positioned against its stop (C) in the cover
- Turn the cover over and fit the washer and circlip
to the quadrant shaft
- Fit the washer (5) into the ratchet shaft housing
- Set the quadrant at around 1/8 turn in order to be
able to fit the kick start drive gear
- Fit the kick start drive gear pin (6) in the cover
housing (D)
MISCELLANEOUS OPERATIONS
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To remove/refit the drive pulley rollers
- Remove the transmission cover 8 fixing bolts
- Remove the cover and its locating pin
- Lock the fixed flange (2) with tool
P/N 755874
- Remove the fixed flange nut (1)
- Remove the fixed flange
- Remove the guide hub (1)
- Remove the cover three fixing bolts (2)
- Remove the cover (3)
- Remove the coil (4)
- Remove the holder (5) and its 3 plastic guides (6)
- Remove the 6 rollers (7)
- Remove the O-ring (8) from the rotating flange
(9)
After cleaning, check the condition of the rollers,
they must be changed if they show flats due to
excessive wear
To re-assemble, proceed in reverse order to
disassembly after lightly greasing the rollers and
rotating flange inside (high temperature grease)
Note: Do not over-grease to avoid splashing the
belt
MISCELLANEOUS OPERATIONS
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To remove the clutch lining assembly
- Remove the transmission cover 8 fixing bolts
- Remove the cover and its locating pin
- Lock the clutch drum (1) with the pin wrench
P/N 752237
- Remove the nut
- Clamp the two strands of the belt to lower it
between the flanges
- Remove the clutch drum and the clutch-drive
pulley assembly
- Lock the assembly with tool P/N 752127
clamped in the jaws of a vice
- Remove nut (1) using spanner P/N 752361
- Decompress tool P/N 752127
- Remove the clutch lining assembly (2)
- remove the upper centring sleeve (3) from the
spring
- Remove the spring (4)
- Remove the lower centring sleeve (5) from the
spring
- Remove the 3 pins (6) from the governor seat
- Separate the fixed (7) and rotating (8) flanges
To refit the clutch lining assembly
After checking the 2 lip seals (9) and the 2 O-rings
of the rotating flange (8) are in good condition,
grease the governor seat 3 pins (6) (high
temperature grease) and assemble the parts in
reverse order to removal
- Compress the assembly with tool P/N 752127
- Tighten the nut (1) to the recommended torque
Note: Before fitting the drive pulley to the input
shaft, fit the belt into the pulley bottom by opening
the flanges by hand
- Fit the clutch cover
- Fit and tighten the nut to the recommended
torque
- Fit the cover with its locating pin
- Fit the cover 8 fixing bolts
SPECIAL WORK AND PROCEDURES
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To remove the fuel tank
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly (1)
- Remove the grab handle (2)
- Remove the mud flap (3)
- Remove the rear panel assembly (4)
- Disconnect the fuel gauge (5)
- Disconnect the fuel return pipe (6)
- Clamp the fuel inlet hose (7) with hose clamp P/N
755996
- Disconnect the fuel inlet pipe (7) from the pump
(8)
- Unclip the fuel pipe from the plastic clip (9)
- Remove the tank (10)
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 well ventilate area
SPECIAL WORK AND PROCEDURES
Page: 31
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
Procedure used to lower the pressure in the fuel
system instruction 1
Imperative: wash the power unit
- Remove the saddle/locker assembly
- Raise the fuel tank in order to with draw the
injection manifold (1) soundproofing.
- Disconnect the fuel injector (2)
- Remove the 2 bolts (3) from the injection
manifold (4)
- Remove the injection manifold without
disconnecting the feed pipes (5)
- Connect the fuel injector harness tool P/N 756017
to the fuel injector and the battery
- Put the manifold into a container (6) to catch the
fuel
- Operate the tool contactor 5 times stopping for 5
seconds between each operation in order to lower
the pressure in the injection manifold feed pipe
, Correctly secure the injection rail in the
container as the pressurised fuel jet may be
dangerous for the skin, do not expose the hands
to the petrol jet when the injector is opened
SPECIAL WORK AND PROCEDURES
Page: 32
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
Fuel circuit bleeding procedure instruction 2
- After refitting the assembly, operate the fuel pump
by turning on the ignition key (turning on the
ignition operates the fuel pump for 3 seconds)
- Carry out this operation twice
To remove the Injection rail
Imperative: wash the power unit
- Carry out the procedure used to lower the pressure in
the fuel system (see instruction 1)
- Remove the clips from the 3 pipes (1 and 2)
(if changed, these clips must not be replaced by
screw-type clips)
- Disconnect the 2 fuel pipes (1)
- Disconnect the air pipe (2) from the compressor
- Remove the injection manifold (3)
- Remove the O-ring (4) from under the injection
manifold (the O-ring must be renewed each time it is
removed)
Re-assembly: Proceed in reverse order to
disassembly and bleed the fuel system (see
instruction 2)
SPECIAL WORK AND PROCEDURES
Page: 33
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the air injector
Imperative: wash the power unit
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Remove the grab handle
- Remove the mud-flap
- Remove the rear panel assembly
- Disconnect the fuel gauge
- Remove the fuel tank fixing nuts and move it clear
as shown
- Remove the injection manifold soundproofing
from the injection manifold
- Remove the 2 bolts from the injection manifold
(1)
- Withdraw the injection manifold without
disconnecting it
- Remove the O-ring (2) from under the injection
manifold (the O-ring must be renewed each time it is
removed)
- Disconnect the air injector (3)
- Remove the air injector (4)
Imperative: Immediately put the air injector in the
holder tool P/N 755986 if it is to be re-used
Note: Removal of the air injector from a machine
which has already been driven may need the
cylinder head removing to drift out the injector with
drift tool P/N 755989 (see relevant chapter)
- Remove the O-ring (5) from under the air injector
(the O-ring must be renewed each time it is
removed)
Note: The injector may be extracted for only a very
short instant from its housing in the cylinder head,
since the expansion of its seal makes it unusable
Re-assembly: Re-assemble in the reverse order to
dismantling
Check: Using the diagnostic tool, check for fault
codes, clear them if necessary
SPECIAL WORK AND PROCEDURES
Page: 34
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the air compressor
Imperative: wash the power unit
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Remove the air intake (1)
- Remove the exhaust (2)
- Remove the motor to rod fixing nut (3)
- Suspend the machine
- Remove the motor to rod fixing bolt (4)
- Remove the spacer (5)
- Remove the motor from the chassis
- Remove the compressor (7) 4 fixing bolts (6)
- Remove the compressor with the 2 locating
dowels and the O-ring
- Disconnect the air pipe (8)
Re-assembly: Re-assemble in the reverse order to
dismantling
Note: The compressor O-ring must be renewed each
time it is removed and refitted lightly greased
SPECIAL WORK AND PROCEDURES
Page: 35
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the throttle unit
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Remove the air intake (1)
- Remove the from the throttle unit to inlet manifold
clip (3)
- Remove the air filter box (5) mounting bolt (4)
- Remove the air filter box (5) and throttle unit (6)
assembly
- Disconnect the throttle unit (7)
- Disconnect the accelerator cable (2)
- Cut the plastic tie (8) holding the throttle unit to
the air filter box
- Remove the throttle unit (6)
SPECIAL WORK AND PROCEDURES
Page: 36
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
Re-assembly: Proceed in reverse order to
disassembly ensuring:
- the throttle unit is properly positioned on the air
filter box
- the throttle unit positioning point is properly
located in its housing on the inlet manifold
- the throttle cable is properly tensioned
- Use the diagnostic tool to initialise the throttle unit
(refer to the documentation "Using the Diagnostic
Tool for the Injection Engine)
Check: Using the diagnostic tool, check for fault
codes, clear them if necessary
SPECIAL WORK AND PROCEDURES
Page: 37
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the fuel pump
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Remove the grab handle
- Remove the mud-flap
- Remove the rear panel assembly
- Clamp the fuel inlet hose (1) with hose clamp P/N
755996
- Disconnect the fuel inlet pipe (1) from the fuel
pump (2)
- Carry out the procedure used to lower the pressure
in the fuel system (see instruction 1)
- Disconnect the fuel inlet pipe (3) from the fuel
pump (2)
- Remove the fuel pump 2 fixing volts (4)
- Remove the fuel pump
- Disconnect the fuel pump
Re-assembly: Proceed in reverse order to
disassembly and bleed the fuel system (see
instruction 2)
(if changed, these clips must not be replaced by
screw-type clips)
Check: Using the diagnostic tool, check for fault
codes, clear them if necessary
SPECIAL WORK AND PROCEDURES
Page: 38
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the strainer
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Empty the fuel tank proceeding as follows:
- Disconnect the vent (A) pipe (1) from the gauge
(2) and put into a container in order to drain out the
fuel
- Reconnect the pipe (1) once the tank is empty
- Disconnect the fuel gauge
- Unscrew and remove the fuel gauge (2) with its
seal using tool P/N 756056
- Remove the strainer (3) by passing one hand
inside the gauge well, wearing a protective glove
- Clean or change the strainer in accordance with
the service instructions
Re-assembly: Re-assemble in the reverse order to
dismantling
- Tighten the fuel gauge with the ring spanner P/N
756056 in order to line up the arrow with the
centring mark on the tank
SPECIAL WORK AND PROCEDURES
Page: 39
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the ECU
- Remove the ignition key
- Remove the instrument cluster upper fairing
- Remove the rear leg shield panel
- Remove the ECU 2 fixing bolts (1)
- Disconnect the ECU
- Remove the ECU
Re-assembly: Re-assemble in the reverse order to
dismantling
Note: If the ECU is changed, the diagnostic tool
must be used to initialise the throttle unit (see
documentation Use of the Diagnostic Tool for the
Injection Engine)
To remove the temperature sensor
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Raise the fuel tank in order to with draw the
injection manifold soundproofing.
- Disconnect temperature sensor (connector 1)
- Remove the temperature sensor (2)
Re-assembly: Re-assemble in the reverse order to
dismantling
Check: Connect the diagnostic tool and check there
are no fault codes, erase them if necessary
SPECIAL WORK AND PROCEDURES
Page: 40
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the HT coil
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Disconnect the suppressor (1)
- Remove the rubber washer (2) and the suppressor
rubber cap (3)
- Remove the spark plug lead from the 2 plastic
clips (4)
- Remove the high tension coil 2 bolts from the
right -hand side of the machine
- Disconnect the high tension coil
- Remove the coil (5)
Re-assembly: Re-assemble in the reverse order to
dismantling
Check: Connect the diagnostic tool and check there
are no fault codes, erase them if necessary
Setting the spark plug electrode gap
The spark plug electrode gap setting is between 0.5
and 0.6 mm
Spark plug protrusion check
B=3,5
±0,4
mm
The position of the spark plug electrode in the
combustion chamber is important therefore it is
essential that the spark plug setting is correct. If one
of these values cannot be obtained, the plug must be
changed
SPECIAL WORK AND PROCEDURES
Page: 41
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
To remove the oil pump
- Remove the ignition key after unlocking the
saddle
- Remove the saddle/locker assembly
- Remove the air intake
- Disconnect the oil delivery pipe (1) from the inlet
manifold (2)
- Disconnect the oil pump
- Remove the pump (4) fixing bolts (3)
- Disconnect the oil inlet pipe (5) from the pump
- Remove the oil pump
Imperative: never operate the oil pump without oil
Re-assembly: Re-assemble in the reverse order to
dismantling
Imperative: Bleed the oil pump using the diagnostic
tool (see documentation Use of the Diagnostic Tool
for the Injection Engine)
Check: Connect the diagnostic tool and check there
are no fault codes, erase them if necessary
PARAMETER MEASUREMENT SHEET
SALES DIVISION
NETWORK TECHNICAL INFORMATION
Page: 42
Parameter reading
MACHINE DATA
VIN
Mileage/Kilometres
ECU N°
Software
Calibration
Fault codes found during check:
PARAMETER Meas. 1
engine
stopped
Meas. 2
idling
Standard values
Cold
Meas. 1
engine
stopped
Meas. 2
idling
Standard values
Hot
Engine speed 1800 to 10000 rpm 1600 to 10000 rpm
Battery voltage 13.8 to 15 volts 13.8 to 15 volts
Throttle valve position 0 to 100% 0 to 100%
Potentiometer track 1 0.5 to 4.5 volts 0.5 to 4.5 volts
Potentiometer track 2 4.5 to 0.5 volts 4.5 to 0.5 volts
Engine temperature -10 to +40°c +40 to +200°c
Petrol injection time 0 to 20 ms 0 to 10 ms
Air injection time 0 to 20 ms 0 to 10 ms
Ignition advance 0 to 50 ° 0 to 50 °
Sensor power supply 4.95 to 5.05 volts 4.95 to 5.05 volts
Temperature sensor 3 to 4.20 volts 4.10 to 5 volts
Petrol pump On On
Oil pump On On
Immobiliser Unlock Unlock
ECU locking Unlock Unlock
Photocopy and send to Peugeot Motocycles in case of problem requiring help from our network training department
Page: 43
Reproduction or translation, even partial, are forbidden without the written consent of Peugeot Motocycles
RECOMMENDS
REF: 756012
With a constant concern for improvement Peugeot Motocycles reserves the right to delete, modify, or add any quoted reference
DC/PS/ATR printed in E.U. 02/2002 (photos non-contractual)
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