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WORKSHOP MANUAL
-
Workshop manual Technical network leadership Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS.
TABLE OF CONTENTS.
TABLE OF CONTENTS. ................................................................................................................................... 1 PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4 CHARACTERISTICS......................................................................................................................................... 6 Engine........................................................................................................................................................6 Capacities ..................................................................................................................................................6 Chassis ......................................................................................................................................................7 Dimensions and weight..............................................................................................................................7 Tyres ..........................................................................................................................................................7 SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 8 Check.........................................................................................................................................................8 Change ......................................................................................................................................................8 Check and lubricate ...................................................................................................................................9 Reading the ECU fault codes.....................................................................................................................9 Test machine .............................................................................................................................................9 Time required for maintenance ..................................................................................................................9 Battery preparation (Except battery without maintenance)*.....................................................................10 Checks before handing over to the customer ..........................................................................................10 SPECIAL IMPORTANT POINTS..................................................................................................................... 11 Oil and fuel...............................................................................................................................................11 Starting up after overhauling the engine ..................................................................................................11 Electricity..................................................................................................................................................11 Special features .......................................................................................................................................11 TIGHTENING TORQUES. ............................................................................................................................... 12 Engine part...............................................................................................................................................12 Body panels .............................................................................................................................................13 Cycle part.................................................................................................................................................13 Standard ..................................................................................................................................................13 SPECIAL TOOLS ............................................................................................................................................ 14 ELECTRICITY.................................................................................................................................................. 15 4 stroke indirect injection system functional diagram...............................................................................15 ABS/MBS system schematic diagram .....................................................................................................16 Fuses and energy distribution..................................................................................................................17
1 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS. LOCATION OF COMPONENTS...................................................................................................................... 18 BODY PANELS ............................................................................................................................................... 19 Location of body components ..................................................................................................................19 Body component sequence of disassembly.............................................................................................20 Removal of the storage compartment......................................................................................................21 Removal of a RH or LH side cover ..........................................................................................................21 Removal of the tank covers .....................................................................................................................22 Removal of a RH or LH footboard............................................................................................................23 Removal of the front shield panel ............................................................................................................24 Removal of the rear shield panel .............................................................................................................25 Removal of the dirt shield ........................................................................................................................25 Removal of the instrument cluster ...........................................................................................................26 Removal of the battery holder..................................................................................................................26 SERVICE OPERATIONS................................................................................................................................. 27 Changing the engine oil and replacing the oil filter ..................................................................................27 Draining the relay box ..............................................................................................................................29 Replacing the air filter ..............................................................................................................................30 Removal of the transmission air filter.......................................................................................................32 Changing the drive pulley bearings..........................................................................................................32 Removal of the spark plug .......................................................................................................................33 Draining the cooling circuit.......................................................................................................................33 Installing the valve clearance...................................................................................................................34 Replacing the brake pads ........................................................................................................................36
Front brake........................................................................................................................................................ 36 Rear brake ........................................................................................................................................................ 36
Checking the brake fluid level ..................................................................................................................40 SERVICING THE ABS/MBS SYSTEM............................................................................................................ 41 Reminder .................................................................................................................................................41 Removal of the brake modulator..............................................................................................................41 Re-installing the modulator ......................................................................................................................42 Bleed procedure.......................................................................................................................................43
Draining the rear brake circuit........................................................................................................................... 43 Bleeding the assistance circuit.......................................................................................................................... 45 Draining the front brake circuit .......................................................................................................................... 46
2 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TABLE OF CONTENTS. MISCELLANEOUS OPERATIONS ................................................................................................................. 49 Procedure for reducing the fuel circuit pressure ......................................................................................49 Checking fuel pressure ............................................................................................................................50 Removal of the fuel pump ........................................................................................................................51 Removal of the fuel gauge .......................................................................................................................52 Removal of the throttle box ......................................................................................................................53 Removal of the lambda sensor ................................................................................................................53 Removal of the regulator..........................................................................................................................54 Removal of the radiator............................................................................................................................55 Removal of the engine mounting assembly .............................................................................................56 Removal of the engine .............................................................................................................................58 Removal of the fork..................................................................................................................................62 Replacing the bearings of the steering system ........................................................................................62 Steering system tightening method..........................................................................................................64
3 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Mbius band
Recyclable
Irritant
The product can irritate the skin, eyes and repiratory organs
Flammable
Corrosive
Avoid contact with the skin and clothes. The product can damage living Wear gloves, safety glasses and tissues or other surfaces appropriate clothes such as a cotton overall. Do not breath fumes. The product can explode under certain circumstances (flame, Avoid impacts, friction, sparks and heat. heat, impact, friction)
Explosive
The product affects fauna and The ideal solution is to bring this product Hazardous to flora. Do not dump it in to your nearest household waste recycling the environment garbage cans, sinks or nature. centre.
Toxic
The product can seriously Avoid direct contact with body even by affect health if it is inhaled, inhalation. If you feel unwell, seek medical ingested or in contact with skin advice immediately. This symbol informs the consumer that the One of the product's used product shall not be thrown away into component is toxic and can be a garbage can, but shall be brought back hazardous to environment. Ex. to the merchant or dropped at a specific Used batteries collection point Operation that can be dangerous for people People's safety can be seriously affected if the recommendations are not fully respected.
Compulsory gloves
4 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
People's safety can be seriously affected if the recommendations are not fully respected. Indicate the specific procedures that shall be followed in order not to damage the vehicle
Important
Serious damage to the vehicle and in Good operating The operation must be carried certain cases a cancellation of the condition of the out in strict compliance with the warranty can be involved if the vehicle documents recommendations are not fully respected. Note Operation that can be difficult Indicate a note which gives key information to make the procedure easier Indicate the specific procedures that shall be followed in order not to damage the vehicle.
Lubricate
Grease
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
GLU
Glue
Indicate the specific procedures that shall Glue the parts to be assembled be followed in order not to damage the vehicle.
New part
Indicate the specific procedures that shall be followed in order not to damage the vehicle.
5 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS Engine
400 cc Marking Type Cooling Bore x stroke Cubic capacity Max. power output Max. torque rating Lubrication Transmission Clutch Exhaust Starter motor Spark plug Magneto flywheel Fuel supply M564M 4-stroke single-cylinder 4 valves per cylinder with chain driven overhead camshaft Liquid 85.8 x 69 mm 399 cc 25 kW at 7500 rpm 5500 rpm Trochoidal pump By 2 variable pulleys and V-type belt Centrifugal automatic Catalytic Mitsuba 900 W 1 spark plug NGK CR7EKB Electrode gap 0.7-0.8 mm Mitsuba 350 W Indirect electronic injection Magneti-Marelli
Capacities
Engine oil Relay box oil Coolant Fork oil Fuel tank 1.7 l SAE 5W40. Minimum grade: API SJ. 0.25 l SAE 80W90. Minimum grade: API GL4. 1.4 l Peugeot coolant part number 754614. 212 cc per tube (Esso Univis 46 or Agip HLift 46) 13.2 l / Version ABS 10.5 l
6 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
Chassis
Chassis Front suspension Travel Rear suspension Travel Double cradle out of high-resistance steel tube Hydraulic telescopic fork. 37 mm 100 mm 2 adjustable combined spring hydraulic shock absorbers 100 mm
Tyres
Front wheel rim Front tyre Front tyre pressure Rear wheel rim Rear tyre Rear tyre pressure 16 inch aluminium alloy 110/70 - 16 2.2 bars 14 inch aluminium alloy 150/70 - 14 2.4 bars
Chassis markings
Engine marking
1
xxxxx xx M461 xxx M
2
1. Manufacturer's plate.(Left side) - VIN number of the RH side of the vehicle 2. Engine number
7 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Check
Throttle cable play Steering column play Operation of electrical equipment Condition of front and rear brake hydraulic controls Condition of petrol pipes Condition of oil pipes Tyre pressures Tyre condition, pressure and wear Condition of the front suspension Condition of the rear suspension Brake fluid level Battery electrolyte level * Coolant level Engine oil level Valve clearances Transmission air filter Intake silencer drain Tightening the engine mounting and linkrod Tightness of nuts and bolts C C C C C C C C C C C C
N C
N N C C
Change
Spark plug Inlet silencer/air filter Front brake pads Rear brake pads Drive pulley bearings and guides Transmission belt Belt anti-flapping roller Engine oil Engine oil filter Relay box oil Brake fluid and coolant R N C C C C C R C R R C Once every 2 years
R R R
8 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Test machine
On road (at least 2 km)
9 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
10 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc. The clips are specific, they must always be changed each time they are removed and replaced with new genuine parts clips.
Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. Before carrying out any work, leave the engine to cool for at least 2 hours.
Electricity
All components of the electrical system are powered with 12 volts DC. The battery must not be disconnected while the engine is running and the voltage must be at least 7 volts for the ECU to function and enable engine starting.
Special features
An immobiliser built in the ECU provides the antitheft function by means of a transponder. The ECU has a diagnostic function which via the instrument cluster LED or the diagnostic tool, enables reading of the faults in the memory.
11 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TIGHTENING TORQUES.
12 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
TIGHTENING TORQUES.
Body panels
Front mudguard Handlebar cover Front shield panels Rear shield Bottom panel Floor panel Saddle storage compartment Rear panels Grab handle Rear mudguard 0.8 to 1.2 m.daN 0.2 to 0.4 m.daN 0.2 to 0.4 m.daN 0.2 to 0.4 m.daN 0.2 to 0.4 m.daN 0.4 to 0.6 m.daN 0.8 to 1.2 m.daN 0.2 to 0.4 m.daN 2 to 2.5 m.daN 0.4 to 0.6 m.daN
Cycle part
Front wheel spindle Rear wheel bolt Rear wheel spindle nut Linkrod to engine pivot Linkrod to frame pivot Linkrod connecting pin Linkage torque arms Shock absorber top mount Shock absorber bottom mount Exhaust to cylinder head mounting nut Exhaust to casing mounting bolt Exhaust system strap Exhaust clamp Centre stand holder Suspension arm Lambda sensor Upper cone (in 2 operations) Upper cone locknut Steering locknut Front brake caliper Rear brake caliper Front brake disc Rear brake disc Handle bar 6.5 m.daN 2.5 m.daN 13.5 m.daN 8 m.daN 8 m.daN 8 m.daN 3.8 m.daN 4.5 m.daN 4.5 m.daN 2.2 m.daN 2.2 m.daN 1.8 m.daN 1.8 m.daN 2.2 m.daN 2.8 m.daN 4.5 m.daN 4/2.2 m.daN Hand tightened 7.5 m.daN 2.5 m.daN 2.5 m.daN 3 m.daN 3 m.daN 4 m.daN
Standard
Nut and bolt 5 mm diameter Nut and bolt 6 mm diameter Nut and bolt 8 mm diameter Nut and bolt 10 mm diameter Nut and bolt 12 mm diameter 0.6 m.daN 1 m.daN 2.2 m.daN 3.5 m.daN 5.5 m.daN
13 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SPECIAL TOOLS
SPECIAL TOOLS
Tool N Designation Used with
4
Tool N
2
6
Designation
Used with
0
bar
10
750539
Tie-wrap pliers
757877
Pressure gauge
754278
758358
OK
TEP 2005
TEP 2005
by
xxo test
755996
Hose clamp
758585
756017
758810
756715 (*)
10
11
12
13
14
15
758924
16
17
18
19
20
21
22
23
24
25
26
BM 2005
by
xxo test
757860
Steering tool
14 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
ELECTRICITY
12 13
ON
L VE L LE VE R PE LE UP ER W LO
VE
12V - 25A 12V - 25A
OFF
6
RG-NR
11
3 1 4 2 5 3 2 4 1 5
10
1
VI-BA
RG
9 8
14
1 3 2
7,5A F5
NR NR
30A F1a
RG
15A F2
GR-RG GR-RG
VE-NR NR
12V - 25A
VE
3 2 4 1
15
VE
A3
MR-BA GR-RG NR BA-NR BC VI-NR VI
A1 B1
16
60
16
20
+ 7
24 4 11 22
VI BA-VE BE-NR
20 40
40
80 10 0 50
60
70
30
10 20
40 80
Km M Hrs
12
8 7 11
RG-BA
BE BA
1 17 18
0 140 16 12 80 90 10 0
PEUGEOT
Km/h
1 2
17
26 12
0 1
13 15 14
RG MR OR
1 2 1 2
GR-VE BA-BE
JN GR-VE VE-NR VE VE
2 1
18
19
2 3 4
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Injection ECU. Engine speed and position sensor. Petrol injector. Fuel pump. Ignition coil. Lambda sensor. Starter motor switch. Starter motor relay. Cooling fan. Fan relay.
Injection relay. Battery. Ignition switch. Transponder antenna. Diagnostic plug. Instrument panel. Kickstand switch. Emergency stop switch Engine temperature sensor.
15 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
ELECTRICITY
10
60
80 10
40
50 60
4
0
12 0 140 160
12 0
80
3
LO
VE
5
12V - 25A
EL V LE VEL ER LE PP ER U W
20 40
70
30
10 20
Hrs
PEUGEOT
Km/h
7
12V - 25A
40 80
Km M
ON OFF
RG
90 10
0
17 14
VE
6
RG/NR
3
RG
F1a 30A
F1b 30A
RG
1
VI
2
VI
5
MR/BA
GR
RG/NR
24
1
VI
BA OR
10 13
14 5 17
JN/BA
20 21 25 9 11 23
RG BE RG
PIN
VE
8
JN/VE
19
VE
A2 B3
START
A3 A1 B1
VE
6 2
1. 2. 3. 4. 5. 6.
Pressure control unit. Speed sensor and pulse wheel. Battery. Ignition switch. ABS/MBS relay. Starter motor switch.
7. Starter motor relay. 8. Injection ECU. 9. Diagnostic plug. 10. Instrument panel (diagnostic lamp, machine speed).
16 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
ELECTRICITY
RG-NR
F4-15A
GR-NR
F7-10A
RG
GR-RG
X
X
X
X
RG
L VE L LE VE R LE PE UP ER W LO
F1a-30A
+B
F1b-30A F2-15A
GR-RG
12V - 25A
12V - 25A
F3-15A
GR-BE
Geopolis 400cc F1a 30A F1b 30A F2 15A F3 15A Regulator Ignition switch F7 ABS relay Pressure control unit Injection ECU. Power supply relay Fan relay Instrument panel Lighting relay Starter motor relay control relay Instrument panel Dip switch (main/low headlight) Horn Number plate light Sidelight Stop light contact switch Injection ECU Transponder antenna Diagnostic plug Injection relay Lighting relay Accessory socket
F4 15A
F5 7.5A
F7 10A
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
17
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
60
80 10
40
50 60
0
140 16 120 80 90 100 0
120
30
10 20
Hrs
PEUGEOT
Km/h
40 80
Km M
4
OK
12
TEP 2005
by
20 40
70
xxo test
11
-
L VE L LE VE R PE LE UP ER W LO
20
13 7
6 17
24
1 23 10 21 16
12V - 25A
E63 503 4 853 22/0 950 2/06 140 101 9 : 39 : 07
19
14
2 5
1. Injection ECU. 2. Engine speed and position sensor. 3. Engine temperature sensor. 4. Battery. 5. Lambda sensor. 6. Petrol injector. 7. Ignition coil. 8. Transponder antenna. 9. Fuel pump. 10. Fuel gauge. 11. Diagnostic lights. 12. Diagnostic plug. 13. Starter motor relay.
14. Oil pressure switch. 15. 10 A fuse.(Accessory socket. 12V.) 16. Fuses. 17. Motor-driven fan. 18. Lighting relay/Fan relay/Power supply relay. 19. Voltage regulator. 20. Horn. 21. Saddle lock. 22. Machine speed sensor. 23. Emergency stop switch. 24. Kickstand switch.
18 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
e2
CE
18
8
4 006 1 005
15
22
BODY PANELS
2 1 4 5 6 19 10 16 11 9 3 18 14
15
17
7
1. Handlebar front fairing. 2. Wind protector. 3. Counter panel. 4. Lower handlebar cover. 5. Front top cover panel. 6. Front shield panels. 7. Mudguard. 8. Bottom panel. 9. Saddle. 10. Tank streamlining.
12
13
8
11. Rear shield. 12. Footboard. 13. Access door. 14. Luggage carrier. 15. Helmet compartment. 16. Mudflap. 17. Rear cover. 18. Side panels. 19. Front mudguard.
19 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
1*
5*
8*
9*
10
11
12
15*
14
13*
19*
16*
17
18
20 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- Remove the splash guard. (4 screw). - Disconnect the license plate light.
21 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- Remove the access door. (1 screw). - Remove the 2 screws that secure the footrest.(2) - Remove the rear cover 3 fixing screws.(3) - Unclip the support (A) and remove the side panel together with the footrest.
3 A 2
3
Removal of the tank covers
Procedure 3. - Remove the saddle. (2 screw). - Remove the battery cover.(1) - Open the tank filler cap door. - Remove the upper fairing.(2)
22 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- Remove the 2 fixing bolts.(3) - Remove the fuel tank cover panel by sliding it rearwards.
Removal of a RH or LH footboard
Procedure 4. - Remove the tank cover panel. See: Procedure 3. page 22. - On each side remove: 2 washer head screws. 6 mm.(1) 1 washer head screws. 5 mm.(2) 5 plastic screws.(3)
3 1
3
- Remove the access door. - Separate the front of the footboard which is linked to the rear part of the leg shield panel. - Remove the footboard.
23 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- Remove the footboard mat. - On each side remove: 2 washer head screws. 6 mm.(1) 2 plastic screws.(2)
2
- Lift the footboard in order to reach the screw that secures the shield panel.
24 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- On each side remove: 5 plastic screws.(3) - Remove the centre screw.(4) - Remove the front legshield assembly. - Disconnect the lighting and direction indicator connections.
3 3
Removal of the rear shield panel
- Remove the footboards. See: Procedure 4. page 23. - Remove the front legshield assembly. See: Procedure 5. page 24. - Remove the header tank. (Right-hand side (1)) - Remove the fuse holder. (Right-hand side (2)) - Disconnect the accessory plug. Left side (3) - Remove the 2 fixing bolts.(4) - Remove the rear shield panel.
4 1 2 3
25 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
BODY PANELS
- Remove the handlebar rear cover and instrument cluster assembly. (7 screw). - Disconnect the instrument cluster.
26 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
SERVICE OPERATIONS Changing the engine oil and replacing the oil filter
1
- 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.
27 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- Lubricate the rubber seal of a new oil filter. - Using a facom D155 type oil filter notched cap wrench, install the oil filter. Tightening torque: 1.4 m.daN. - Fit the drain plug. Tightening torque: 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 machine parked on its centre stand, on level ground.
A B
28 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- Remove the screw (2) in order to drain the relay box. Note: Replace the copper seal every time you change oil
2
- Fit the drain plug. Tightening torque: 1.5 m.daN. - Fill the relay 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 parked on its centre stand, on level ground.
A
50 04 T4 V
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SERVICE OPERATIONS
30 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- Clean or change the filter according to the maintenance recommendations. - Clean the air filter with a cleaning and degreasing agent for air filters. Note: Do not use a flammable product to clean the air filter. - 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)
31 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
1
Changing the drive pulley bearings
- Remove the 2 air filter box fixing bolts (1). - Remove the transmission cover trim.(2) (4 screw)
2
- Remove the transmission cover hood.(1) (3 screw) - Remove the transmission air filter.(2) - Blow the air filter with compressed air.
- Remove the transmission cover. Refer to the 400/500cc Engine workshop manual. 4 valves. Reference 759533.
32 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- Remove the storage compartment. See: Procedure 1. page 21. - Remove the header tank cap. - Disconnect the lower pump from the coolant pump to drain the cooling system.(1) Note: The cooling system is drained when the engine is cold. - Connect the lower hose to the water pump. - Fill the circuit with 1.4 L of coolant. - Loosen the bleeder screw (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 90C)
33 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- 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 parked on its centre stand, on level ground.
A B
- Remove the 2 air filter box fixing bolts (1). - Remove the transmission cover trim.(2) (4 screw)
34 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- 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)
- 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.
35 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
36 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- Loosen the collars.(1) - Remove the upper fixing bolts.(2) - Remove the exhaust. Tightening torque: 1 m.daN.
1
- Remove the collar retaining pin.(3) - Remove the collar.
37 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- 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.
6 5
- 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.
7 8
- Remove the spacer.(9) - Remove the wheel. (5 screw) Tightening torque: 2.5 m.daN.
38 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
- 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.
10
39 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
SERVICE OPERATIONS
A B
LOW
- Remove the screen. - Remove the handlebar rear cover and instrument cluster assembly. (7 screw) - Remove the cover and the diaphragm from the master cylinder. (2 screw) - Add brake fluid until it reaches the maximum level.(A)
40 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
For diagnosing the ABS/MBS system, see document: ABS/MBS braking system functioning principle. Reference: 759568.
20 mm
Plastic parts must be protected from brake fluid splashes. Hold the brake levers at 20 mm from the rest position using plastic straps. This operation allows you to close the circuits and to avoid emptying the hydraulic controls when disconnecting the modulator. Do not remove the master cylinder covers.
41 Reproduction or translation, even partial, is forbidden without the written 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.
3 1
Change the copper seals each time they are removed. - Connect the modulator. - Bleed the hydraulic system according to the required procedure.
42 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Bleed procedure
Reminder: - The rear brake hydraulic system is drained using the LH lever. - The front brake hydraulic system is drained using the RH lever. - The front and rear brake systems are drained the usual way. - The brake assistance circuit is drained by actuating the modulator pump by means of the diagnostic tool. Note: - Plastic parts must be protected from brake fluid splashes. - Remove the hook 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 to expell the air bubbles from the circuit.
- Fill the syringe with brake fluid. - Connect the syringe to the bleed screw of the rear calliper. - Open the bleed screw by 1 to 2 turns. - Inject the brake fluid slowly into the circuit until the level inside the reservoir of the master cylinder is halfway up. - Close the caliper bleed screw.
43 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Slowly actuate the brake control lever by displacing it 2 cm (A) maximum from its rest position until no more bubbles can be seen coming up through the master cylinder. - This operation can take a few minutes.
- Connect a reservoir containing brake fluid to the rear 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.
- 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 screw. - Close the caliper bleed screw. - Check the firmness of the lever without roughly squeezing the lever to avoid the brake fluid from splashing out. - 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.
44 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Bleeding the assistance circuit Note: Before servicing the assistance system you must absolutely be sure that the battery is perfectly charged, as a considerable voltage drop would immediately turn off the assistance pump. - Connect the additional reservoir equipped with a transparent pipe to the modulator's reservoir 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 pump. - Regularly add brake fluid in the additional reservoir. - Stop the operation when there are no more bubbles in the transparent pipe. - Close the caliper bleed screw.
As a precautionary measure, the pump shall not continuously operate for more than 2 minutes.
45 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
Draining the front brake circuit - Remove the cover from the RH master cylinder. - Using the syringe, empty the RH master cylinder. - Position the handlebars so that the master cylinder is in its uppermost position, 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 caliper bleed screw.
- Slowly actuate the brake control lever by displacing it 2 cm (A) maximum from its rest position until no more bubbles can be seen coming up through the master cylinder. - This operation can take a few minutes.
46 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- Connect the reservoir containing brake fluid to the modulator bleed screw (1) using a transparent pipe. The reservoir must 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 are expelled from the modulator. - Close the bleeder screw.
47 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
- 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. - Actuate the RH brake lever in an even way and without undue haste while topping up with brake fluid in the master 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 wheel is not in contact with the floor. - Turn on the ignition. - Turn the front wheel at over 5 km/h, and operate one of the brake levers to check that the high pressure pump operates with both levers. - Check by actuating the LH control lever: the front wheel stops. - If not, repeat the operation: Bleeding the assistance circuit.
48 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
756017
UP
LO
PE W
ER
LE
VE
LE
L L
VE
The pressurised jet of fuel may be dangerous for the skin, do not expose the hands to the jet of fuel when opening the injector.
49 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
4
6
- Remove the tank cover panel. See: Procedure 3. page 22. - Carry out the procedure for lowering the pressure in the fuel system. See: Procedure 7. page 49. - Disconnect the fuel supply hose. (1 "click" collar). - 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.
8
ba r
10
Before disconnecting the pressure gauges, lower the fuel pressure in the fuel system. Always reinstall the hoses with new hose clamps.
50 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
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.
51 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
756715
Note: Modify the tool P/N 756715 as shown in the sketch in order to use it with the Geopolis.
52 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
53 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
Note: When reinstalling, lubricate the threads (A) of the sensor with graphite grease.
A B
In order not to damage the Lambda sensor, never lubricate or clean the end piece (B) which is exposed to the exhaust gas.
- When re-installing, make absolutely sure there is the fuel tank heat shield (1) and its pin.(2)
2 1
54 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
- Remove the front shield panel. See: Procedure 5. page 24. - Remove the mudguard. - Remove the upper fixing bolts.(2) - Drain the cooling circuit. - Disconnect the 4 hoses of the radiator's cooling circuit. - Remove the radiator.
55 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
- Loosen the linkrod connecting pin nut.(1) - 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.
56 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
- Remove the linkrod-to-engine connecting pin.(1) - Remove the linkrod-to-frame connecting pin.(2)
1
- Remove the linkrod connecting pin.(3)
3
- 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. Blue B. Black C. Grey
7 8
A C B
2 8
57 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
2
- Remove the screw that secures the wiring harness clamp and the fuel hose anchor bracket.(A) - Disconnect: The fuel injector.(4) The throttle box.(5) The temperature sensor.(6) The magneto.(7) The suppressor. - Disconnect the injector fuel feed hose.(8)
4 6 5 A
58 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
10
11
- Disconnect the lower pump from the coolant pump to drain the cooling system. - Disconnect the cylinder head hose.(12)
12
59 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
Remove the suspension arm. Remove the wheel. Remove the calliper.(13) Re-install the wheel.
13
- Suspend the rear of the machine. - Remove the shock absorber lower mount (14).
14
- Remove the linkrod-to-engine connecting pin.(15)
15
60 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
- Lift the rear of the machine. - Disconnect the throttle control cables.(16) - Remove the engine.
16
- Remove the 4 spacers.(17)
17
17
- When re-installing, make absolutely sure there is the fuel tank heat shield (1) and its pin.(2)
2 1
61 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
757860
757860
62 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
- Using a chisel, pry the steering head cup off by pressing the tool behind the dust cover.
- Install the following new parts: The plain washer.(1) The dust cover.(2) The fork cone.(3)
3 1 2
758810
63 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
MISCELLANEOUS OPERATIONS
7 5 2 3 1 4 6
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 locknut and tighten it.(7) Tightening torque: 7.5 m.daN.
64 Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles
P/N. 759538
In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/PS/APV Printed in the E.U. 07/2007 (non contractual pictures)