PEUGEOT ELYSTAR Workshop Manual Download Page 9

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SPECIAL TOOLS

Page : 9

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

SPECIAL TOOLS

Tool N°

Description

Used with

750539

Tie-wrap pliers

755878

diagnostic tool

(Color Gameboy)

755806
755807

755806

French cartridge

755878

755807

Export cartridge

755878

755990

Diagnostic tool

update software

755878
755806
755807

755996

Hose clamp

756056 Tank ring spanner

756017

Petrol injection

power supply

harness

TSDI

756076 Tank gauge spanner

EFI

756449 ABS/PBS interface

cable for diagnostic

tool

755878
755806
755807

Summary of Contents for ELYSTAR

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

Page 2: ...G ON 4 STROKE INJECTION SYSTEMS 17 To remove the fuel pump 17 To remove the air injector 20 To remove the throttle housing and idle valve 21 WORKING ON THE ABS PBS SYSTEM 22 ABS PBS diagnostic 22 Troubleshooting chart 22 Incidents which cannot be detected by the ECU 25 ABS PBS principle diagram 27 Parameter reading 28 To remove the control unit 29 To refit the control unit 32 ABS PBS SYSTEM BLEED ...

Page 3: ...rpm Gross compression ratio 11 4 Timing Chain driven overhead camshaft 2 valve Engine oil capacity 1 25 L Relay box capacity 0 12 L Injection system TSDI Two Stroke Direct Injection EFI Electronic Fuel Injection Ignition Carburettor Synerject ECU Synerject ECU Synerject ECU Petrol injector Siemens green 37 028 Siemens black 8884 Air injector Synerject blue 37 073 Fuel pressure regulator Synerject ...

Page 4: ...TEM EFI Synoptics Throttle unit Petrol injector Engine position and speed sensor Idle control valve Engine temperature sensor Ignition coil Battery voltage Fuel pump Inlet air pressure and temperature sensor Engine temperature gauge Diagnostic plug Diagnostic lamp Immobiliser module INJECTION IGNITION ECU Software Manages system functioning Calibration Values specific to machine mapping ECU lockin...

Page 5: ...sole a on off button b arrows select key c button A confirm button d button B return button e select button for help 2 Cartridge containing the software for dialog between the machine and the screen 3 Interface cable between the machine and the tool for diagnostic of the 4 stroke injection system EFI 4 Interface cable between the machine and interface cable 3 for diagnostic of the ABS PBS system ...

Page 6: ...ove the diagnostic plug loop 1 3 Connect the diagnostic tool to the machine using a Interface cable 2 for EFI system diagnostic b Interface cable 2 special interface 3 ref 756449 for diagnostic of the ABS PBS system 4 Turn on the diagnostic tool Note Never forget to re connect the diagnostic plug loop The loop provides the link between the immobiliser module and the injection ignition ECU and is e...

Page 7: ...cannot withstand impurities Perfectly clean working conditions are therefore essential Note Before carrying out any work leave the engine to cool for a minimum of 2 hours Petrol is highly inflammable do not smoke in the working area and avoid proximity to flames or sparks Work in a clear and well ventilated area The fuel pipes must be changed if they show signs of wear cracks etc Moreover the hose...

Page 8: ...arter 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 125 150 cc Engine Cylinder head 2 3 m daN Cylinder casings 1 m daN Covers 1 m daN Starter motor 1 m daN Rotor 7 m daN Stator 1 m daN Engine speed sensor 0 65 m daN Drive pulley 7 m daN Driven pul...

Page 9: ... wrap pliers 755878 diagnostic tool Color Gameboy 755806 755807 755806 French cartridge 755878 755807 Export cartridge 755878 755990 Diagnostic tool update software 755878 755806 755807 755996 Hose clamp 756056 Tank ring spanner 756017 Petrol injection power supply harness TSDI 756076 Tank gauge spanner EFI 756449 ABS PBS interface cable for diagnostic tool 755878 755806 755807 ...

Page 10: ...es on then goes off when the engine is started If there is an injection system fault the lamp flashes or stays on 3 The ABS PBS Anti Blocking System Powered Braking System diagnostic warning light 3 comes on then goes off once the vehicle is on the move over 5 km h Elystar only If there is an ABS PBS fault the lamp stays on 4 The battery charge light 4 does not come on However this warning light c...

Page 11: ...he choice is confirmed by pressing the control button 7 for more than 2 seconds Service function Note This function is only available on Elystar 125 150 cc and if the machine has covered over 10 kms As from 5000 kms and once this distance is exceeded when the ignition is turned on the message change oil appears for 10 seconds in place of the clock display This display tells the customer that his m...

Page 12: ...the ignition 2 Within a maximum of 15 seconds of cutting off the ignition with the master key turn on the ignition with the black key and when the LED comes on turn off the ignition repeat the operation for each black key to be memorised maximum of 7 black keys 3 Within a maximum of 15 seconds of turning off the ignition with the last key memorised turn on the ignition with the master key and when...

Page 13: ...before checking the other parts of the ignition system Note Do not remove the diagnostic plug loop In case of a fault do not use an immobiliser module or ECU from another machine to carry out tests The keys immobiliser module and ECU programmed on another machine form an assembly are linked by a code and must under no circumstances be separated Important If an ECU is changed without memorising the...

Page 14: ...ter key and start the engine or turn on the ignition for 3 seconds to memorise the keys in the system 0 5 s Permanent Black key and programmed immobiliser module from another machine Refit the immobiliser and the original keys or replace by a new one and program the system using the original keys 0 5 s 0 5 s Permanent No diagnostic plug loop or faulty immobiliser ECU link Refit the diagnostic plug...

Page 15: ...sition sensor 2 Ignition switch 3 Immobiliser module 4 Injection ECU 5 HT coil 6 Resistive suppressor 7 Resistive spark plug 8 Instrument panel LED 9 Battery 10 25A fuse 11 15A fuse 12 Transponder antenna 13 Diagnostic plug 14 Diagnostic plug loop BA White BA NR White Black JN Yellow JN BE Yellow Blue MR BA Brown White NR Black RG Red RG NR Red Black VE Green VE NR Green Black ...

Page 16: ... Emergency circuit rear brake caliper This is a fixed two opposed piston caliper 3 Left hand brake lever This is a conventional dual output master cylinder operating the main circuit front caliper 5 and the rear caliper 6 simultaneously This circuit acts as the main brake 4 Rear braking limiter This is a valve which limits the braking pressure to main circuit rear caliper used to prevent rear whee...

Page 17: ... 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 ventilated area Remove the ignition key Remove the lower panel 2 fixing screws 1 Remove the rear panel 4 fixing screws 3 Remove the rear panel by pulling it rearwards Remove the side panel assembly 7 6 screws 5 and the 2 plasti rivets 6 Relea...

Page 18: ...nd the 2 screws 9 in the storage compartment Remove the mudguard without removing the boa lock if it is not necessary Remove the storage compartment 12 5 screws 11 Remove the storage compartment with the saddle Disconnect the gauge 1 Disconnect the fuel gauge 2 Note Put a rag over the fuel pipe 3 to catch any fuel splashes Disconnect the fuel feed pipe 3 and the regulator vacuum pipe 4 ...

Page 19: ...ew and remove the fuel pump assembly 6 with its seal using tool P N 756056 Note None of the components fuel pump pressure regulator and strainer are removable It is only possible to clean the outside of the strainer Reassembly Re assemble in the reverse order to dismantling Tighten the fuel pump with the ring spanner P N 756056 in order to line up the arrow A with the centre mark B on the tank Fit...

Page 20: ...e the air injector Remove the ignition key Remove the side panels Remove the injector assembly 1 Disconnect the fuel injector 2 Fit the hose clamp P N 755996 to the feed pipe 3 Disconnect the hose Remove the fuel injector 4 Reassembly Re assemble in the reverse order to dismantling Check Using the diagnostic tool check for fault codes clear them if necessary ...

Page 21: ...move the inlet silencer 2 fixing bolts 4 Remove the inlet silencer 5 Disconnect the throttle cable 6 Disconnect the throttle unit 7 and the idle valve 8 Unclip the clip type hose clip Remove the throttle unit Reassembly Proceed in reverse order to disassembly ensuring the throttle unit positioning pin A is properly located in its housing on the inlet manifold the accelerator cable is properly tens...

Page 22: ...o Peugeot Motocycles with the filled out parameter sheet 2 Fault codes B 5 6 11 Control unit power supply fault Test the battery connections and condition 0 V With ECU connector disconnected ignition on Use a voltmeter to check the control unit power supply between terminal 16 ignition fully on and terminal 20 battery 12 V Check the electrical connections 0 V With the ECU connector disconnected ig...

Page 23: ...hine not to spec check machine history and return to spec YES The harness PIN code is part of the PIN codes authorised for this ECU NO Control unit does not conform Change control unit YES YES Erase the ECU PIN code with the diagnostic tool cut off the ignition and turn it on again Erase the fault codes and check that they do not re appear Note The control unit is not the original check machine hi...

Page 24: ...S The speed sensor and its harness are in good condition visually Check there is a voltage on the sensor terminals between terminals 12 and 21 of the ECU when the wheel is turned by hand Check the harness Check the sensor gap Check the condition of the pulse wheel NO Change the faulty components YES Change the control unit 5 Fault code 130 No wheel speed information Check there is a voltage on the...

Page 25: ...ht and left contactors Check the brake contactor harness continuity isolation Check the warning light harness continuity isolation Check the speed sensor wrong gap pulse wheel distorted sensor faulty etc Check the control unit electric motor terminal 15 and terminal 18 If these checks prove OK and the fault persists change the control unit Warning light does not go off at a speed of over 5 km h ev...

Page 26: ...oes not operate when braking at a speed of over 5 km h warning light off Checks Check the right and left contactors Check the brake contactor harness continuity isolation Check electrical power supply to the control unit terminal 30 If these checks prove OK and the fault persists change the control unit Note When the machine is stationary at a traffic light for example the control unit assistance ...

Page 27: ...attery 2 Ignition switch 3 Main relay 4 Starter motor relay 5 RH brake contactor 6 LH brake contactor 7 Instrument panel 8 Speed sensor and pulse wheel 9 Control unit 10 25A fuse 11 15A fuse 12 Brake light 13 Diagnostic plug BA White BE Blue JN BA Yellow White JN BE Yellow Blue JN RG Red Yellow JN VE Yellow Green MR Brown NR Black OR Orange RG Red RG NR Red Black VE Green ...

Page 28: ...oftware version Control unit version Fault codes found during check PARAMETERS Meas 1 engine stopped Meas 2 driving Standard values Vehicle speed 0 to 120 km h Battery voltage 13 8 to 15 volts LH brake light switch On off RH brake light switch On off pump On off Harness PIN code xxx ECU PIN code xxx Possible ECU codes xxx xxx xxx xxx xxx Photocopy and sent to Peugeot Motocycles in case of problem ...

Page 29: ... partial are forbidden without the written consent of Peugeot Motocycles To remove the control unit Remove the ignition key Remove the handlebar upper cover 2 nine fixing bolts 1 Remove the lower panel 4 three fixing screws 3 Remove the bottom panel 6 four fixing bolts 5 ...

Page 30: ... 5 screws 7 Remove the lower legshield panel 10 two fixing screws 9 Note Lock the right hand lever 20 mm from the rest position with a hook or cable tie 11 This operation enables the circuit to be closed and avoids emptying the hydraulic hose when it is disconnected from the control unit It also facilitates bleeding of the main circuit left hand brake Hook diagram full scale 1 ...

Page 31: ...connector 12 Disconnect the control unit Clamp the reservoir feed hose 13 with hose clamp P N 755996 Disconnect the feed pipe Disconnect the 4 hydraulic controls 14 Note Put a recipient under the control unit to catch the brake fluid Do not remove the master cylinder covers Remove the control unit Remove the clip 15 cap 16 and filter 17 to drain off the reservoir Note The control unit must not be ...

Page 32: ...t Note Fit new copper seals each time it is removed Fit the hydraulic hoses in the following order The hydraulic hose 1 from the left master cylinder The hydraulic hose 2 to the rear brake caliper and fit it over hydraulic hose 1 The hydraulic hose 3 from the right master cylinder The hydraulic hose 4 to the front brake caliper Connect the control unit 5 Connect the feed pipe 6 Remove the feed hos...

Page 33: ...onnect the hydraulic hoses to the control unit Remove the control unit from its mounts so that it is as vertical as possible Rear brake circuit main brake 1 Protect any plastics which may be exposed to brake fluid splashes Remove the left master cylinder cover Position the handlebar in order to create a high point on the master cylinder to enable the bubbles in the circuit to rise more easily Chec...

Page 34: ...othly whilst topping up the fluid in the master cylinder Stop when there are no more bubbles coming from the control unit Close the bleed screw Re fit the bleed screw cap 4 Remove the rear caliper bleed screw cap Connect the bleed screw to a recipient containing brake fluid using a transparent pipe The recipient must be kept higher than the brake caliper to facilitate checking that the air bubbles...

Page 35: ...level in the master cylinder and top up if necessary Note It is essential to avoid being under the master cylinder during bleeding to avoid brake fluid splashes 2 Operate the right brake lever evenly and smoothly several times very slowly with a maximum movement of 2 cm from its rest position until no more bubbles can be seen coming up through the master cylinder reservoir 3 Remove the bleed screw...

Page 36: ...iper to facilitate checking that the air bubbles are being expelled Open the caliper bleed screw half a turn Operate the brake lever evenly and smoothly whilst topping up the fluid in the master cylinder Stop when there are no more bubbles coming from the caliper Close the bleed screw Disconnect the pipe connecting it to the master cylinder Operate the pump using the diagnostic tool Check the leve...

Page 37: ...ed screw cap Note If the integral circuit is to be bled left lever the right lever must be immobilised with a hook or cable tie as described in the note on page 30 Connect the bleed screw to a recipient containing brake fluid using a transparent pipe The recipient must be kept higher than the brake caliper to facilitate checking that the air bubbles are being expelled Open the caliper bleed screw ...

Page 38: ...in order to guarantee correct operation of the brake circuits Position the handlebar in order to create a high point on the master cylinder to enable the bubbles in the circuit to rise more easily Essential precautions 1 pumping with the brake lever must be carried out slowly 2 the lever must not come into contact with the handlebar Protect any plastics which may be exposed to brake fluid splashes...

Page 39: ... brake fluid Position the handlebar in order to create a high point on the master cylinder to enable the bubbles in the circuit to rise more easily Essential precautions 1 pumping with the brake lever must be carried out slowly 2 the lever must not come into contact with the handlebar Operate the brake lever slowly with a maximum movement of 2 cm from its rest position until no more bubbles can be...

Page 40: ...the bleed screw Disconnect the pipe connecting it to the recipient Using the diagnostic tool operate the pump to assess lever firmness Note If the lever does not feel sufficiently hard bleed the power braking circuit Operate the brake lever again slowly to check there are no more bubbles in the circuit Check the brake fluid level in the master cylinder top up if necessary and fit the cover Importa...

Page 41: ...e fluid Position the handlebar in order to create a high point on the master cylinder to enable the bubbles in the circuit to rise more easily Essential precautions 1 pumping with the brake lever must be carried out slowly 2 the lever must not come into contact with the handlebar Operate the brake lever slowly with a maximum movement of 2 cm from its rest position until no more bubbles can be seen...

Page 42: ...ter cylinder Stop when there are no more bubbles coming from the caliper bleed screw Close the bleed screw Disconnect the pipe connecting it to the recipient Check the lever is firm without operating the lever violently to prevent brake fluid splashes Note If the lever does not feel sufficiently firm repeat the circuit bleed operation Operate the brake lever again slowly to check there are no more...

Page 43: ...Position the handlebar in order to set the master cylinder horizontal Check the brake fluid level in the master cylinder and top up if necessary Remove the front caliper bleed screw cap Connect a transparent pipe containing brake fluid from the front caliper bleed screw to the right master cylinder reservoir Using the diagnostic tool operate the control unit pump and exert a small pressure on the ...

Page 44: ...nition Disconnect the transparent pipe by clamping the other end to stop the fluid running out Check the brake fluid level in the master cylinder and top up if necessary Important The brake fluid level in the master cylinders in the horizontal position must always be above the sight gauge level Check the brake fluid level in the control unit reservoir and top up if necessary Refit the master cylin...

Page 45: ...ttery 2 Ignition switch 3 LH direction indicators relay 4 RH direction indicators relay 5 Instrument panel 6 Hazard warning lights switch 7 Hazard warning lights relay 8 Direction indicator switch 9 RH direction indicators 10 LH direction indicators 11 Direction indicator unit BA White BA NR White Black BC Light blue NR Black OR Orange RG Red RG NR Red Black VC Light Green VE Green VI Mauve ...

Page 46: ...on indicators 10 Relay 4 powers the RH direction indicators 9 Relay 7 powers the hazard warning lights switch 6 with the battery 2 Ignition to OFF The power supply to the direction indicator unit 11 is no longer through the ignition switch 2 but through relay 7 using the battery Functioning of the hazard warning lights is identical with the previous chapter ignition to ON Note If the hazard warnin...

Page 47: ...t of Peugeot Motocycles LOCATION OF COMPONENTS Elystar 50 cc 1 Injection ECU 2 Throttle unit 3 Engine position and speed sensor 4 Engine temperature sensor 5 Battery 6 Petrol injector 7 Air injector 8 Ignition coil 9 Immobiliser module 10 Petrol pump 11 Oil pump 12 Diagnostic lamp 13 Diagnostic plug 14 Compressor ...

Page 48: ...ttle unit 3 Engine position and speed sensor 4 Engine temperature sensor 5 Atmospheric pressure and air temperature sensor 6 Battery 7 Petrol injector 8 Idle valve 9 Ignition coil 10 Immobiliser module 11 Petrol pump 12 Diagnostic lamp 13 Diagnostic plug 14 Control unit 15 Petrol pump ABS PBS direction indicators and hazard warning lights relays 16 Speed sensor and pulse wheel ...

Page 49: ...en without the written consent of Peugeot Motocycles RECOMMENDS REF 756445 With a constant concern for improvement Peugeot Motocycles reserves the right to delete modify or add any quoted reference DC PS ATR printed in E U 06 2002 photos non contractual ...

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