PEUGEOT Satelis 400 Workshop Manual Download Page 38

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BODY PANELS

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

Removal of the headlight and sidelight

assemblies

Removal of the headlight bulbs

- Remove the front top cover panel. See:

Procedure 7. Page: 35

- To reach the bulbs, remove the headlight.

(3 screw)

Removal of the front shield panel

Procedure 8.

- Remove the front top cover panel. See:

Procedure 7. Page: 35

- On each side remove:

• 2 plastic screws that secure the front leg

shield to the underbody cover. (1)

• 2 plastic screws that secure the footboard to

the underbody cover. (2)

- Push aside the underbody cover to reach the

screw that secures the front shield panel. (3)

- On each side remove:

• 5 plastic screws. (4)
• 1 washer head screw. Ø6 mm. (5)
• 1 washer head screw. Ø5 mm. (6)

- Disconnect the headlights.
- Remove the front shield panel.

Summary of Contents for Satelis 400

Page 1: ...Sales division Technical network leadership WORKSHOP MANUAL ...

Page 2: ...Workshop manual Technical network leadership Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Page 3: ...lt 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 EL...

Page 4: ...ting 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 ...

Page 5: ...ICING 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...

Page 6: ... 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 recycl...

Page 7: ...ge 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 pa...

Page 8: ... 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 ...

Page 9: ...hock 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 Eng...

Page 10: ...ondition of front and rear brake hydraulic controls C C C C 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 Transmissi...

Page 11: ...r 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...

Page 12: ...ound 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 ...

Page 13: ...e 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 disconnec...

Page 14: ...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...

Page 15: ... 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...

Page 16: ...7860 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 10 2 4 bar OK TEP 2005 by xxotest 1 24 12 23 11 22 10 21 9 20 8 19 7 18 6 17 5 1...

Page 17: ...t 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 ...

Page 18: ...edometer 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 Contro...

Page 19: ...ied 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 ...

Page 20: ... 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 fl...

Page 21: ... 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 volt...

Page 22: ...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 specific 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...

Page 23: ...ycles 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 ...

Page 24: ...switch 18 Emergency stop switch 19 Engine temperature sensor 12V 25A 2 1 3 4 5 12V 25A 1 2 3 4 5 2 1 3 4 5 1 2 6 3 OFF ON 8 14 2 1 UP PE R LE VE L LO W ER LE VE L VE B1 A1 A3 VE 6 5 4 3 2 19 16 15 14 13 12 11 10 9 8 7 2 1 2 1 22 11 4 15 14 13 9 26 12 2 1 17 18 8 24 20 7 16 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 BC NR NR NR RG RG VI VE NR RG BA BA BE VE NR BE NR BA VE VI...

Page 25: ...n indicator switch 18 Hazard warning lights switch 19 RH direction indicators 20 LH direction indicators UP PE R LE VE L LO W ER LE VE L 3 6 OFF ON 11 20 12 22 23 15 24 17 10 0 1 2 3 4 5 6 7 8 9 10 11 12 12V 25A 2 1 5 4 3 30A F1 15A F4 15A F5 4 5 14 2 1 8 17 2 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 10W 12V 10W VE VE JN MF VC BE BA GR RS RS BC OR RG RG VE VE...

Page 26: ...ion 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 23 9 11 3 14 5 17 19 21 25 20 13 10 1 U PP ER LE VE L LO W ER LE VE L 12V 25A 1 2 3 4 5 12V 25A 1 2 3 4 5 12V 25A 1 2 3 4 5 6 3 OFF ON 24 ABS km C C F E H Trip EFI km h mph 70 10 20 30 40...

Page 27: ...l Petrol injector Fuel pump Lambda sensor F3 40A Accessory socket Saddle opening module option F4 45A Instrument panel Lighting relay Starter motor relay control relay F5 5A Instrument panel Dip switch main low headlight Horn Number plate light Sidelight Stop light contact switch Saddle opening module option RG GR BE GR RG GR RG B UP PE R LE VE L LO W ER LE VE L RG RG NR GR NR NR F1 30A F6 7 5A F5...

Page 28: ...Satelis 400 500cc F6 7 5A Injection ECU Transponder antenna Diagnostic plug Injection relay ABS diode F7 30A Pressure control unit ABS relay Power supply relay ABS RG GR BE GR RG GR RG B UP PE R LE VE L LO W ER LE VE L RG RG NR GR NR NR F1 30A F6 7 5A F5 15A F2 15A F3 10A F4 15A RG F7 30A X X X X X X X X X X X X 12V 25A ...

Page 29: ...es 14 Oil pressure switch 15 Motor driven fan 16 Lighting relay Fan relay Power supply relay Starter motor relay control relay ABS relay 17 Voltage regulator 18 Horn 19 Saddle lock 20 Machine speed sensor 21 Outside temperature sensor 22 Emergency stop switch 23 Kickstand switch 19 14 6 9 2 5 8 10 16 13 12 11 23 22 21 1 18 7 15 3 4 20 17 UP PE R LE VE L LO W ER LE VE L 12V 25A OK TEP 2005 by xxote...

Page 30: ... Upper handlebar cover 2 Front top cover panel 3 Rider saddle 4 Lower handlebar cover 5 Wind protector 6 Tank streamlining 7 Counter panel 8 Front shield panels 9 Bottom panel 10 Footboard 11 Rear shield 12 Front mudguard 13 Mudguard 14 Rear cover 15 Side panels 16 Mudflap 17 Passenger backseat 18 Helmet compartment 17 14 16 15 18 3 6 4 1 5 2 8 11 12 9 13 10 7 ...

Page 31: ...roduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Body component sequence of disassembly This item may be removed on its own 9 2 8 11 6 12 13 10 1 7 4 3 14 17 18 15 16 5 ...

Page 32: ... saddle Removal of the passenger s saddle Procedure 1 Open the saddle cover storage compartment Remove The screw The saddle cover The rider s saddle Open the passenger s saddle Remove The 2 upper pivot clips The 2 pivot pins Flip up the seat to the front of the vehicle Remove The 2 lower pivot clips The 2 pivot pins Remove the passenger seat ...

Page 33: ...dle Procedure 2 Remove the grab handle trim Remove the 2 nuts and the screw that secure the handle Remove the grab handle Removal of a RH or LH taillight Removal of a taillight bulb Remove the grab handle See Procedure 2 Page 31 Remove the taillight 1 screw Remove the 4 screws from the taillight unit Separate the 2 parts in order to reach the bulbs ...

Page 34: ...3 Remove The rider s saddle See Procedure 1 Page 30 The grab handles See Procedure 2 Page 31 Remove the rear cover and its trim 4 screw Remove the 2 screws that secure the side cover linkage and the footboard Push aside the footboard in order to clear the side cover holder eyelet Remove the side cover Disconnect the taillight 1 5 1 5 5 1 0 1 0 1 0 1 0 1 5 1 5 5 ...

Page 35: ...ugeot Motocycles Removal of the storage compartment Procedure 4 Remove the side fairings See Procedure 3 Page 32 Disconnect the plate light and the saddle opening contact switch Remove the storage compartment 4 screws and 2 nuts When dismantling the splash guard fit the screws with standard thread lock ...

Page 36: ...and 2 screws that secure the lower fairing Remove the screw that secures the rear cover footboard on each side of the vehicle 1 Push slightly aside the cover footboard assembly and remover the fuel tank cover panel by sliding it backwards Removal of a RH or LH footboard Procedure 6 Remove the tank cover panel See Procedure 5 Page 34 Remove the footboard mat On each side remove 8 plastic screws 1 3...

Page 37: ...derbody panel in order to separate it from the footboard A Separate the footboard from the rear fairing and bracket that anchors it to the body B Separate the front of the footboard which is linked to the rear part of the leg shield panel C Removal of the front top cover panel Procedure 7 Remove the front top cover panel 4 screw A C B ...

Page 38: ...f the front shield panel Procedure 8 Remove the front top cover panel See Procedure 7 Page 35 On each side remove 2 plastic screws that secure the front leg shield to the underbody cover 1 2 plastic screws that secure the footboard to the underbody cover 2 Push aside the underbody cover to reach the screw that secures the front shield panel 3 On each side remove 5 plastic screws 4 1 washer head sc...

Page 39: ...ont top cover panel See Procedure 7 Page 35 Remove The ignition switch trim The handlebar upper fairing 8 screw 1 On each side remove 2 plastic screws that secure the front leg shield to the underbody cover 2 plastic screws that secure the footboard to the underbody cover Push aside the underbody cover to reach the screw that secures the front shield panel 2 On each side remove 6 plastic screws 3 ...

Page 40: ...d A Pull upwards the lower part of the shield panel in order to separate it from the footboard Relove the eyelet B from the shield panel and the eyelet C from the instrument cluster fairing in order free the rear shield panel Topple the rear shield panel while separating it from the footboards in order to reach the header tank and the accessory plug Remove the header tank Right side Disconnect the...

Page 41: ...pper fairing On each side remove 1 plastic screw 1 1 washer head screw Ø5 mm 2 1 washer head screw Ø6 mm 3 Press the locking system 1 to actuate the positioning lever 2 of the instrument cluster s connector Push the lever all the up A in order to remove the connector from the instrument cluster Remove the instrument cluster fairing Note When connecting the lever must be pushed all the way to A in ...

Page 42: ... sensor control out of the dirt cover Lift the front of the vehicle while making sure the wheel is in line with the vehicle Remove the dirt cover by sliding it behind the wheel as shown When removing the dirt cover make sure it doesn t rub against the radiator Removal of the battery holder Procedure 9 Remove the tank cover panel See Procedure 5 Page 34 Disconnect and remove the battery Unclip from...

Page 43: ... the engine oil and replacing the oil filter Remove the engine s oil filler cap 1 Remove the cap and the filter to drain oil from the engine 2 Check the condition of the O ring and change it if necessary Using a facom D155 type oil filter notched cap wrench remove the oil filter Drain the engine when it is warm Wear gloves in order not to get burnt 1 2 ...

Page 44: ... 2 5 m daN Fill the engine with 1 7 L motor oil through the filler hole Fit the filler cap Start the engine let it run for a few minutes and then stop it Remove the filler cap and wipe up the oil Fit and screw the cap home Remove the engine s oil filler cap Check the oil level by using the marks on the filler cap A Oil level high B Oil level low Add oil if necessaire Note Check the level with the ...

Page 45: ... box with 0 25 L oil through the filler hole Fit and screw the cap home Remove the relay box filler cap Check the oil level by using the marks on the filler cap A Oil level high B Oil level low Add oil if necessaire Note Check the level with the machine par ked on its centre stand on level ground Replacing the air filter Remove the LH side fairing See Procedure 3 Page 32 Remove the air filter cove...

Page 46: ...en consent of Peugeot Motocycles Remove the air filter 1 Clean or change the filter according to the maintenance recommendations Lubricate the air filter with a special oil for air filters and squeeze out the excess oil Remove the inlet silencer drain plug to let humidity and oil drip out 2 1 2 ...

Page 47: ...rollers and the drive belt Remove the bottom panel Left side Remove the 2 air filter box fixing bolts 1 Remove the transmission cover trim 2 4 screw Remove the transmission cover hood 3 3 screw Remove the transmission air filter 4 Blow the air filter with compressed air Remove the transmission cover Refer to the workshop manual 400 500cc engine 4 valves Reference 759533 1 2 4 3 ...

Page 48: ...t the suppressor Remove the spark plug Essential precautions When re installing srew in the spark plug a few turns by hand For torquing use a spark plug wrench equipped with a dial Tighten the spark plug Tightening torque 1 2 m daN Draining the cooling circuit Note The cooling system is drained when the engine is cold Remove the footboards See Procedure 6 Page 34 Remove the header tank cap Disconn...

Page 49: ...ew 2 to remove air contained in the engine Close the bleeder screw Tightening torque 0 3 m daN Start the engine and accelerate in order to warm it up Stop the engine once it reaches its operating temperature Approximately 90 C Check the coolant level in the header tank If necessary add coolant in the header tank A Maximum level B Minimum level Note Check the level with the machine par ked on its c...

Page 50: ...ket See Procedure 9 Page 40 Disconnect the lambda sensor 1 Remove the exhaust assembly Remove the fuel injector without disconnecting the supply hose 2 Tightening torque 0 8 m daN Remove the rocker cover 6 screw Tightening torque 0 8 m daN Rotate the engine by hand in the operating direction in order to align the A mark on the pinion with the mark on the cylinder head B Note With a 500 cc engine e...

Page 51: ...tocycles Loosen the lock nut of the rocker adjustment screw 3 By means of feeler gauges adjust the clearance of every valve by acting on the rocker set screw Clearances 15 100 at the intake 15 100 at the exhaust Immobilize the rocker set screw Tighten the locknut without altering the adjustment Check the adjustment 3 ...

Page 52: ...ck the pis tons if the 2 calipers have been removed Remove the brake pad pin cap 1 Remove the brake pad pin 2 Remove the brake pads Mini thickness 1 5 mm When refitting the brake pads push the pistons all the way into their housing After refitting actuate the brake levers several times to bring the brake pads against the brake disc Carry out the same operation for the RH side Rear brake Remove the...

Page 53: ...partial is forbidden without the written consent of Peugeot Motocycles Remove the heat shield 3 screw Loosen the collars 1 Remove the upper fixing bolts 2 Remove the exhaust Tightening torque 1 m daN Remove the collar retaining pin 3 Remove the collar 1 2 3 ...

Page 54: ...lts 4 from the mudflap Remove the 2 screws that secure the stand support 5 Tightening torque 2 2 m daN Remove the 2 nuts that secure the arm 6 Tightening torque 2 8 m daN Remove the shock absorber lower mount 7 Tightening torque 4 5 m daN Remove the pin the nut retainer and the wheel nut 8 Tightening torque 13 5 m daN Remove the suspension arm 4 6 5 7 8 ...

Page 55: ... wheel 5 screw Tightening torque 2 5 m daN Remove the calliper 2 screw Tightening torque 2 5 m daN Remove the 2 spindles 10 Remove the brake pads Mini thickness 1 5 mm When refitting the brake pads push the pistons all the way into their housing Note After refitting actuate the brake levers several times to bring the brake pads against the brake disc 9 10 ...

Page 56: ...n the handlebars so that the master cylinder will be horizontal Check the brake fluid level and if necessary top up in the master cylinder A Maximum brake fluid level B Minimum brake fluid level Remove the handlebar upper fairing 8 screw Remove the cover and the diaphragm from the master cylinder 2 screw Add brake fluid until it reaches the maximum level 2 LOW A B ...

Page 57: ...c light of the system only goes off when the machine reaches 5 km h The rider brakes with the left lever integral braking and the right lever braking on the front wheel only becomes an emergency brake For diagnosing the ABS MBS system see document ABS MBS braking system functioning principle Reference 759568 Removal of the brake modulator Remove the front shield panel See Procedure 8 Page 36 Remov...

Page 58: ...itten consent of Peugeot Motocycles Disconnect the modulator Disconnect the hydraulic controls Remove the brake modulator 2 nuts Place a pan under the modulator so that the brake fluid will drip into it The modulator shall not be open the manufacturer is the only one allowed to service this component ...

Page 59: ...er Place the modulator in its support Tightening torque 2 2 m daN Position the hydraulic controls in the indicated order The hydraulic control coming from the LH master cylinder 1 The hydraulic control going to the rear brake calliper 2 Place it over the hydraulic control 1 The hydraulic control coming from the RH master cylinder 3 The hydraulic control going to the front brake calliper 4 Tighteni...

Page 60: ...k or plastic strap in order to free the control lever Equipment required 500 ml brake fluid of minimum grade DOT4 Bleed syringe P N 754306 Transparent pipe 2 additional 100 ml reservoirs Draining the rear brake circuit Remove the cover from the LH master cylinder Using the syringe empty the LH master cylinder Position the handlebars so that the master cylinder is in its uppermost position in order...

Page 61: ...sily check that the air bubbles are being expelled Open the bleed screw by 1 to 2 turns Actuate the LH brake lever in an even way and without undue haste while topping up with brake fluid in the master cylinder Note Don t lean over the master cylinder when bleeding the circuit in order not to get splashed by brake fluid Stop the operation when no more bubbles are expelled from the calliper bleeder...

Page 62: ...voir screw plug 1 and fill Open the screw plug by 2 or 3 turns Connect the reservoir containing brake fluid to the front brake calliper bleed screw using a transparent pipe The reservoir must be kept higher than the brake calliper to easily check that the air bubbles are being expelled Open the bleed screw by 1 to 2 turns Turn on the ignition Connect the diagnostic tool and actuate the modulator p...

Page 63: ...in order to expell the air bubbles from the circuit Fill the syringe equippd with a transparent pipe with brake fluid Connect the syringe to the bleed screw of the front calliper Open the bleed screw by 1 to 2 turns Inject the brake fluid slowly into the circuit until the level inside the reservoir is halfway up Close the bleeder screw Slowly actuate the brake control lever by displacing it 2 cm A...

Page 64: ...be kept higher than the modulator to easily check that the air bubbles are being expelled Open the bleed screw by 1 to 2 turns Actuate the RH brake lever in an even way and without undue haste while topping up with brake fluid in the master cylinder Note Don t lean over the master cylinder when bleeding the circuit in order not to get splashed by brake fluid Stop the operation when no more bubbles...

Page 65: ...cylinder Stop the operation when no more bubbles are expelled from the calliper bleeder screw Close the caliper bleed screw Check the firmness of the lever Otherwise repeat the operation from the beginning Check the brake fluid level and if necessary top up in the master cylinder and re fit the master cylinder cover Integral braking system static test Wedge the machine frame so that the front whee...

Page 66: ...ithout disconnecting the supply hose Connect the fuel injector power supply harness tool P N 756017 to the fuel injector and the battery Place the injector above a pan Actuate the contact switch of the tool 3 times for 5 seconds while respecting a released time of 5 seconds between each action in order to drop the pressure inside the supply hose of the fuel manifold The pressurised jet of fuel may...

Page 67: ... the fuel supply hose Insert the pressure gauge P N 757877 between the gauge well and the supply hose Always use hose clamps that are in good condition Turn the ignition on 3 times to bleed the fuel system With the engine stopped check the fuel pressure which must be 2 5 bars when switching on the fuel pump Before disconnecting the pressure gauges lower the fuel pressure in the fuel system Always ...

Page 68: ...pressure in the fuel system See Procedure 10 Page 64 Disconnect the fuel pump 1 Disconnect the fuel pipe by pressing against the ring A to remove the quick disconnect coupler 2 Loosen by hand the pump locking ring 3 Remove the fuel pump Removal of the fuel gauge Remove the tank cover panel See Procedure 5 Page 34 Disconnect the fuel gauge Using tool P N 756715 remove the fuel gauge 2 1 A 3 756715 ...

Page 69: ...e 40 Remove the LH footboard See Procedure 6 Page 34 Remove the screw that secures the wiring harness clamp and the fuel hose anchor bracket A Disconnect The throttle box The temperature sensor The fuel injector The lambda sensor Remove the inlet coupling 3 fixing bolts 5 Remove the 3 screws that secure the throttle box 6 Disconnect the throttle control cables 7 Remove the throttle box A 2 1 3 4 5...

Page 70: ...ect the lambda sensor Using a box end wrench remove the lambda sensor Tightening torque 2 5 m daN Note When reinstalling lubricate the threads A of the sensor with gra phite grease In order not to damage the Lambda sensor never lubricate or clean the end piece B which is exposed to the exhaust gas Removal of the regulator Remove the RH footboard See Procedure 6 Page 34 Disconnect and remove the re...

Page 71: ...r Remove the tank cover panel See Procedure 5 Page 34 Disconnect the fan 1 Remove the front shield panel See Procedure 8 Page 36 Remove the mudguard Remove the footboard linking cross member Remove the upper fixing bolts 2 Drain the cooling circuit Disconnect the 4 hoses of the radiator s cooling circuit Remove the radiator Remove the fan 3 3 screw 1 2 3 ...

Page 72: ... mounting assembly Remove the storage compartment See Procedure 4 Page 33 Remove the footboards See Procedure 6 Page 34 Suspend the rear of the machine Remove the intake silencer 1 2 clips and 3 screws Remove the sheath holder A Loosen the 2 nuts 2 Tightening torque 9 5 m daN Remove the 2 nuts from the torque rods 3 Tightening torque 3 6 m daN A 1 2 3 3 ...

Page 73: ...ing pin 4 Remove the linkrod to frame connecting pin 5 Remove the linkrod connecting pin 6 Check the condition of the spacers and needle bearings 7 Make sure that the silent block is not cracked 8 Note We recommend greasing all needle bearings when refitting these parts When re installing fit the rubber bushings with the colours shown A Black B Grey 5 4 6 2 7 B A 8 8 ...

Page 74: ...torage compartment See Procedure 4 Page 33 Remove the footboards See Procedure 6 Page 34 Remove the bottom panel Remove the battery bracket See Procedure 9 Page 40 Disconnect the lambda sensor 1 Remove the exhaust assembly Remove the intake silencer 2 Remove the rear mudguard 3 Remove the screw that secures the wiring harness clamp and the fuel hose anchor bracket A Disconnect The fuel injector 4 ...

Page 75: ...n partial is forbidden without the written consent of Peugeot Motocycles Disconnect Oil pressure switch 10 Disconnect The starter motor 11 Disconnect the lower pump from the coolant pump to drain the cooling system Disconnect the cylinder head hose 12 10 11 12 ...

Page 76: ...orbidden without the written consent of Peugeot Motocycles Remove the suspension arm Remove the wheel Remove the calliper 13 Re install the wheel Suspend the rear of the machine Remove the shock absorber lower mount 14 Remove the linkrod to engine connecting pin 15 13 14 15 ...

Page 77: ...5 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Lift the rear of the machine Disconnect the throttle control cables 16 Remove the engine Remove the 4 spacers 17 16 17 17 ...

Page 78: ... the front brake caliper from the fork tube Left hand side 2 Tightening torque 2 5 m daN Remove the nut 3 Tightening torque 6 5 m daN Remove the front brake caliper from the fork tube Right hand side 4 Tightening torque 2 5 m daN Loosen the wheel spindle clamping screw 5 Remove the wheel spindle Remove the front wheel Remove the brake control cable grommet and the speed sensor located under the fo...

Page 79: ... Motocycles Using tool P N 757860 remove the steering locknut Remove the lock washer the adjustable cone locknut the rubber washer the adjustable cone Remove the fork Remove the balls Using a drift remove the steering head cups Using a chisel pry the steering head cup off by pressing the tool behind the dust cover 757860 ...

Page 80: ... or translation even partial is forbidden without the written consent of Peugeot Motocycles Install the following new parts The plain washer 1 The dust cover 2 The fork cone 3 Install new steering head cups using tool P N 758810 3 2 1 758810 ...

Page 81: ...ring column Install the adjustable cone and tighten it 3 Tightening torque 4 m daN Loosen and then retighten the adjustable cone Tightening torque 2 2 m daN Install the rubber washer 4 Finger tighten the adjustable cone locknut 5 so that its notches are aligned with those of the adjustable cone Fit the lock washer 6 in the notches of the locknut and adjustable cone Install the steering head locknu...

Page 82: ...MISCELLANEOUS OPERATIONS 80 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Page 83: ...MISCELLANEOUS OPERATIONS 81 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ...

Page 84: ...P N 759562 In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress modify or add any reference mentioned Printed in the E U 10 2007 non contractual pictures ...

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