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PEUGEOT TSDI, Workshop Manual

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PEUGEOT TSDI Workshop Manual Download Page 8

SPECIAL TOOLS

Page: 8

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

754171

Battery charger

754306

bleed syringe

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

Summary of Contents for TSDI

Page 1: ...WORKSHOP MANUAL 50 cc INJECTION ENGINE SALES DIVISION NETWORK TECHNICAL INFORMATION ...

Page 2: ...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...

Page 3: ...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 ...

Page 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 Capac...

Page 5: ... 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 aft...

Page 6: ... 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 ...

Page 7: ... 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...

Page 8: ...artridge 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...

Page 9: ...nt 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...

Page 10: ...f 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 th...

Page 11: ...bine 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 ...

Page 12: ...xing 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...

Page 13: ...lley 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 ...

Page 14: ...n 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 c...

Page 15: ...e 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...

Page 16: ...e 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 ...

Page 17: ...ve 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 ...

Page 18: ... 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 ...

Page 19: ...onsent of Peugeot Motocycles 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 ...

Page 20: ...s 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...

Page 21: ...tted 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 lo...

Page 22: ...y 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 fl...

Page 23: ... 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 2 stroke 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...

Page 24: ...der 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 ...

Page 25: ...n 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...

Page 26: ... 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 Imperat...

Page 27: ...nd 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 quadra...

Page 28: ...move 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 disassem...

Page 29: ...ng 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 temp...

Page 30: ...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 ...

Page 31: ...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 f...

Page 32: ...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 inj...

Page 33: ... 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 dri...

Page 34: ...bly 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 co...

Page 35: ...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 ...

Page 36: ...e 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 nec...

Page 37: ...se 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 instru...

Page 38: ...d 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 o...

Page 39: ... 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 ...

Page 40: ...on 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...

Page 41: ...elivery 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 ...

Page 42: ...hrottle 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 ...

Page 43: ...bidden 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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