Direction commerciale

Animation technique réseau

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

CHARACTERISTICS......................................................................................................................................... 4
Engine........................................................................................................................................................4
Capacities ..................................................................................................................................................4
Chassis ......................................................................................................................................................5
Dimensions and weight..............................................................................................................................5
Tyres ..........................................................................................................................................................5

SERVICE SCHEDULE AND COMMISSIONING............................................................................................... 6

Check.........................................................................................................................................................6
Change ......................................................................................................................................................6
Check and lubricate ...................................................................................................................................7
Reading the ECU fault codes.....................................................................................................................7
Test machine..............................................................................................................................................7
Battery preparation (Except battery without maintenance)* ......................................................................8
Checks before handing over to the customer.............................................................................................8

SPECIAL IMPORTANT POINTS....................................................................................................................... 9

Oil and fuel.................................................................................................................................................9
Starting up after overhauling the engine ....................................................................................................9
Electricity....................................................................................................................................................9
Special features .........................................................................................................................................9

TIGHTENING TORQUES ................................................................................................................................ 10

Engine part ..............................................................................................................................................10
Body panels .............................................................................................................................................11
Cycle part.................................................................................................................................................11
Standard ..................................................................................................................................................11

SPECIAL TOOLS ............................................................................................................................................ 12

ELECTRICITY.................................................................................................................................................. 13
4 stroke indirect injection system functional diagram...............................................................................13
Fuses and energy distribution ..................................................................................................................14

LOCATION OF COMPONENTS...................................................................................................................... 15

1
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
TABLE OF CONTENTS

BODY PANELS ............................................................................................................................................... 16

Location of body components ..................................................................................................................16
Body component sequence of disassembly.............................................................................................17
Removal of the storage compartment......................................................................................................18
Removal of a RH or LH side cover...........................................................................................................18
Removal of the tank covers......................................................................................................................19
Removal of a RH or LH footboard............................................................................................................20
Removal of the front shield panel.............................................................................................................21
Removal of the rear shield panel .............................................................................................................22
Removal of the dirt shield ........................................................................................................................22
Removal of the instrument cluster ...........................................................................................................23
Removal of the battery holder..................................................................................................................23

SERVICE OPERATIONS................................................................................................................................. 24
Changing the engine oil and replacing the oil filter ..................................................................................24
Draining the relay box ..............................................................................................................................25
Replacing the air filter ..............................................................................................................................26
Removal of the spark plug .......................................................................................................................27
Replacing the rollers and drive belt..........................................................................................................27
Draining the cooling circuit.......................................................................................................................28
Installing the valve clearance ...................................................................................................................29
Replacing the brake pads ........................................................................................................................30
Front brake........................................................................................................................................................ 30
Rear brake ........................................................................................................................................................ 30

SERVICING AN ABS/PBS SYSTEM .............................................................................................................. 31

Removal of the brake modulator ..............................................................................................................31

2
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 TABLE OF CONTENTS

MISCELLANEOUS OPERATIONS ................................................................................................................. 32

Procedure for reducing the fuel circuit pressure ......................................................................................32
Checking fuel pressure ............................................................................................................................33
Removal of the fuel pump ........................................................................................................................34
Removal of the fuel gauge .......................................................................................................................34
Removal of the throttle box ......................................................................................................................35
Removal of the lambda sensor ................................................................................................................35
Removal of the thermostat.......................................................................................................................37
Removal of the temperature sensor.........................................................................................................37
Removal of the regulator..........................................................................................................................37
Removal of the radiator............................................................................................................................38
Removal of the engine mounting assembly .............................................................................................38
Installing the engine mounting assembly .................................................................................................39
Removal of the cylinder head...................................................................................................................40
Removal of the cylinder / piston ...............................................................................................................40
Removal of the fork ..................................................................................................................................41
Replacing the bearings of the steering system ........................................................................................41
Steering system tightening method..........................................................................................................43
Removal of the suspension arm ..............................................................................................................44

3
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
CHARACTERISTICS

CHARACTERISTICS

„ Engine

GEOPOLIS 250 cc.

4-stroke single-cylinder.
Type.
4 valves per cylinder with chain driven overhead camshaft
Cooling. Liquid.
Bore x stroke. 2 x 60 mm.
Cubic capacity. 244 cc.
Max. power output. 16.5 kW at 8000 rpm.
Max. torque rating. 6250 rpm.
Indirect electronic injection.
Fuel supply.
Magneti-Marelli
Lubrication. Trochoidal pump.
Transmission. By 2 variable pulleys and V-type belt.
Clutch. Centrifugal automatic.
Spark plug. Champion RG 4 PHP
Exhaust. Catalytic.
Standards. Euro 3.

„ Capacities

Fuel tank. 13.2 l 95 or 98 lead-free.

1.3 L SAE 5W40.
Engine oil.
Minimum grade: API SJ.
Relay box. 0.25 L SAE 75W85.
Coolant. 1.4 l. Peugeot coolant part number 754614
Fork. 212cc by tube Esso Univis 46 or Agip H Lift 46.

4
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 CHARACTERISTICS

„ Chassis

Chassis. Double cradle out of high-resistance steel tube.

Front suspension. Hydraulic telescopic fork. Ø37 mm.
Travel. 110 mm.
Rear suspension. 2 adjustable combined spring hydraulic shock absorbers.
Travel. 100 mm.

„ Dimensions and weight

Overall length. 2170 mm.

Width at handlebar. 770 mm.
Height. (without rear-view 1425 mm.
mirrors).
Wheelbase. 1420 mm.
Ground clearance. 140 mm.
Saddle height. 784 mm.
Unladen weight. 159 kg.

„ Tyres

Front wheel rim. 16 inch aluminium alloy.

Front tyre. .110/70 - 16.
Front tyre pressure. 2.1 bars.
Rear wheel rim. 16 inch aluminium alloy.
Rear tyre. .140/70 - 16.
Rear tyre pressure. 2.3 bars.

Chassis markings Engine marking

1
XXXXX
XXXXXXX

2
1. Manufacturer's plate. (Left side). 2. Engine number.
- VIN number of the RH side of the vehicle.

5
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING

SERVICE SCHEDULE AND COMMISSIONING

Heavy duty servicing is for vehicles used under "harsh" conditions: door-to-door deliveries, intensive
urban use (courier), short journeys with engine cold, dusty areas, ambient temperature over 30°C.

Every
1000 kms
5000 kms Every Every Every
Service operations. or
or 10000 kms 15000 kms 20000 kms
1 months
12 months
Every
Every Every Every
Heavy duty servicing. 500 kms 100000 k
2500 kms 5000 kms 7500 kms
ms
„ Check
Throttle cable play. C C C C
Steering column play. C C C C
Operation of electrical equipment. C C C C
Condition of front and rear brake
C C C C
hydraulic controls.
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 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 C
Engine oil level. C
Tightening the engine mounting and
C C C C
linkrod.
Tightness of nuts and bolts. C C C C
„ Change
Spark plug. R
Inlet silencer/air filter. N N
Front brake pads #. C C C C
Rear brake pads #. C C C C
Drive pulley bearings and guides #. C C
Transmission belt. R
Belt anti-flapping roller #. C C
Engine oil (+ clean strainer). R C R C R
Engine oil filter. R R R
Relay box oil. R C R
Brake fluid and coolant. Once every 2 years

6
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SERVICE SCHEDULE AND COMMISSIONING

Every
1000 kms
5000 kms Every Every Every
Service operations. or
or 10000 kms 15000 kms 20000 kms
1 months
12 months
Every
Every Every Every
Heavy duty servicing. 500 kms 100000 k
2500 kms 5000 kms 7500 kms
ms
„ Check and lubricate
Driven pulley: Moving flange and
G G
needle bush.
Drive pulley/Movable face. G G
„ Reading the ECU fault codes
Injection and ABS/PBS* system. C C C C C
„ Test machine
On road C C C C C

C: Check.
N: Clean.
R: Change.
G: Check and lubricate.

* Depending on equipment.
# Change if necessary.

7
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE SCHEDULE AND COMMISSIONING

„ Battery preparation (Except battery without maintenance)*

Remove the battery.
Remove the 6 filler caps and the vent plug.
Fill with electrolyte to the level marked "UPPER LEVEL".
Electrolyte: (35% sulfuric acid = 1.28g/cm3).1 litre can P/N 752740; 5 litre can P/N 752741.
Leave the battery to stand for around half an hour.
Top up if necessary.
Charge the battery for at least 2 hours with a current of 0.4A.
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

Check the wheel nuts are tight.
Check nuts and bolts are tight.
Check brake adjustment and efficiency.
Check the tyre pressures cold.
Check operation of the lights, flashers, horn, and brake light.
Check the different warning lights work.
Carry out a road test.
* Depending on equipment.

8
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SPECIAL IMPORTANT POINTS

SPECIAL IMPORTANT POINTS

„ Oil and fuel

This engine is designed to run on 95 or 98 unleaded fuel only.

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. Work in a clear and well-ventilated area.
Before carrying out any work, leave 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 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 features a diagnosis function which allows you to read memorized faults using the diagnostic
tool.

9
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
TIGHTENING TORQUES

TIGHTENING TORQUES

„ Engine part
Drive pulley 8 m.daN
Driven pulley 5.5 m.daN
Clutch plate and shoes 4.8 m.daN
Belt anti-flapping roller 1.5 m.daN
Transmission cover 1.2 m.daN
Relay box cover 2.5 m.daN
Filler cap. Relay box 1.5 m.daN
Flywheel magneto cover 1.2 m.daN
Stator 1 m.daN
Engine speed sensor 0.5 m.daN
Rotor 9.5 m.daN
Freewheel 1.4 m.daN
Starter motor 1.2 m.daN
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 1.2 m.daN
Chain tensioner 1 m.daN
Camshaft stop plat 0.5 m.daN
Cylinder head bolt 1.2 m.daN
Cylinder head Procedure
Cylinder head cover 0.7 m.daN
Inlet manifold 1.2 m.daN
Injection rail 0.7 m.daN
Oil pressure switch 1.2 m.daN
Oil pump 0.6 m.daN
Oil pump pinion 1.2 m.daN
Oil pump cover 0.8 m.daN
Oil pan 1.2 m.daN
Crankcase 1.2 m.daN
Filler cap. Engine oil 2.5 m.daN
Water pump cap 0.7 m.daN
Thermostatic valve cover 0.4 m.daN
Cooling system bleeder screw 0.3 m.daN

10
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 TIGHTENING TORQUES

„ Body panels
Front mudguard. 0.8 to 1.2 m.daN
Handlebar cover. 0.2 to 0.4 m.daN
Front shield panels. 0.2 to 0.4 m.daN
Rear shield. 0.2 to 0.4 m.daN
Bottom panel. 0.2 to 0.4 m.daN
Floor panel. 0.4 to 0.6 m.daN
Saddle storage compartment. 0.8 to 1.2 m.daN
Rear panels. 0.2 to 0.4 m.daN
Grab handle. 2 to 2.5 m.daN
Rear mudguard. 0.4 to 0.6 m.daN

„ Cycle part
Front wheel spindle. 6.5 m.daN
Rear wheel bolt. 10 m.daN
Rear wheel spindle nut. 13.5 m.daN
Linkrod to engine pivot. 5.8 m.daN
Linkrod to frame pivot. 5.8 m.daN
Linkrod connecting pin 3.6 m.daN
Linkrod to frame adjustment locknut 10 m.daN
Linkrod to frame mounting bolt 6.8 m.daN
Shock absorber top mount. 4.5 m.daN
Shock absorber bottom mount. 4.5 m.daN
Exhaust to cylinder head mounting nut. 1.8 m.daN
Exhaust to casing mounting bolt. 2.5 m.daN
Exhaust clamp. 1.8 m.daN
Upper cone (in 2 operations). 4/2.2 m.daN
Upper cone locknut. Hand tightened
Steering locknut. 7.5 m.daN
Front brake caliper. 2.5 m.daN
Rear brake caliper. 2.5 m.daN
Front brake disc. 3 m.daN
Rear brake disc. 0.9 m.daN
Handle bar. 4 m.daN

„ Standard
Nut and bolt 5 mm diameter. 0.6 m.daN
Nut and bolt 6 mm diameter. 1 m.daN
Nut and bolt 8 mm diameter. 2.2 m.daN
Nut and bolt 10 mm diameter. 3.5 m.daN
Nut and bolt 12 mm diameter. 5.5 m.daN

11
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SPECIAL TOOLS

SPECIAL TOOLS

Used Used
Tool N° Designation Tool N° Designation
with with
4
6
2

0 8

bar 10

Tie-wrap Pressure
750539 757877
pliers gauge

Balance
support with
754278 758358 TEP 2005
pins Ø15 and
Ø17 mm OK

TEP 2005

by xxo test

Power supply
755996 Hose clamp 758585
cable tool

Steeing head
Fuel injector
cup
756017 power supply 758810
installation
harness
tool

24 way
1 13 25

2 14 26

3 15

756715 Tank gauge 4

5
16

17

758924 terminal block

6 18

7 19

8 20

(*) spanner 9

10
21

22

11

12
23

24

(*)
BM 426

by xxo test

757860 Steering tool

(*) New or modified tool.

12
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 ELECTRICITY

ELECTRICITY

„ 4 stroke indirect injection system functional diagram

12 VE

10
12V - 25A 12V - 25A

13 ON
-
LO
W
R
PE LE
UP ER
L
VE L
LE VE

11
OFF
RG
6 3 3 1 4 2 5 3 2 4 1 5 1 2
9
RG-NR
VI-BA

15A 30A 15A 10A GR-RG

F6 F1 F4 F2
14 NR

1
NR

NR
RG BE-NR 8
VE-NR

3
3
2 VE
2
4

A3 1
15 MR-BA GR-RG 5
VI-NR
NR BC VI
VE A1 B1 BA-NR

16 7 5 6 20 8 + 7
80 10
1 24 VI
60
40
50 60
0
8 BE 1 4 BA-VE 1
12
0

30
70
20 4

0 140 160

0
80

12
10 20

Km

11
90 10

7
M

2
40 80

Hrs

BA 17 BE-NR
0
0

PEUGEOT Km/h

11 18 21 VE-JN 3
22 VE-NR 4

16 RG-BA 26 12 9 13 15 14
6
VE VE RG MR OR
1 VE-NR BA-BE
2 VE

17
JN 2
VE-NR
1
VE VE
VE R

1 2 2 1 2 1 5

18 4
2

1. Injection ECU. 10. Fan relay.

2. Engine speed and position sensor. 11. Injection relay.
3. Petrol injector. 12. Battery.
4. Petrol pump. 13. Ignition switch.
5. Ignition coil. 14. Transponder antenna.
6. Lambda sensor. 15. Diagnostic plug.
7. Starter motor switch. 16. Instrument panel.
8. Starter motor relay. 17. Kickstand switch.
9. Cooling fan. 18. Engine temperature sensor.

13
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
ELECTRICITY

„ Fuses and energy distribution

F6-7,5A NR
6

RG-NR F5-15A GR-NR

5

X
F7-10A GR-RG
7

X
X
RG

RG F1-30A 1
+B
L
VE L
LE VE
R
PE LE
UP ER
W
LO

F2-10A GR-RG
2 X
X

F4-15A GR-BE 4

Geopolis 250 cc

Regulator.
F1 Ignition switch.
F7.
Injection ECU.
Injection relay:
HT coil.
F2 Petrol injector.
Petrol pump.
Lambda sensor.
Fan relay.
Instrument panel.
F4 Lighting relay.
Fan relay.
Instrument panel.
Dip switch (main/low headlight).
Horn.
F5
Number plate light.
Sidelight.
Stop light contact.
Injection ECU.
Transponder antenna.
F6 Diagnostic plug.
Injection relay.
Lighting relay.

F7 Accessory socket.

14
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 LOCATION OF COMPONENTS

LOCATION OF COMPONENTS

60
40
80 10
50 60
0

4 11

20 40

12 80 90 100 0
70
30

0 14016
10 20
0
Km
12

40 80
M
Hrs

0
PEUGEOT Km/h

OK

TEP 2005

by xxo test

10 R
LE VE
PE LE
L
VE L

UP ER
W
LO

19

12

6
16 1
22

20 8
22/0
2/06 503
9 950
: 39 E63
140
853
: 07 101
4

13
CE
005 e2
4
006 1
4

14

17
12V - 25A

18

5
3 7 21
2
15

1. Injection ECU. 13. Fuses

2. Engine speed and position sensor. 14. 10 A fuse. (Accessory socket. 12V).
3. Engine temperature sensor. 15. Oil pressure switch
4. Battery. 16. Motor-driven fan.
5. Lambda sensor. 17. Lighting relay/Fan relay/Power supply
6. Petrol injector. relay.
7. Ignition coil. 18. Voltage regulator.
8. Transponder antenna 19. Horn.
9. Petrol pump. 20. Saddle lock.
10. Diagnostic light. 21. Machine speed sensor.
11. Diagnostic plug. 22. Kickstand switch.
12. Starter motor relay

15
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
BODY PANELS

BODY PANELS

„ Location of body components

2
3
1

18 14
4 15
11 9

6 17

19 10
16

7 12 13 8

1. Handlebar front fairing. 11. Rear shield.

2. Wind protector. 12. Footboard.
3. Counter panel. 13. Access door.
4. Lower handlebar cover. 14. Luggage carrier.
5. Front top cover panel. 15. Helmet compartment.
6. Front shield panels. 16. Mudflap.
7. Mudguard. 17. Rear cover.
8. Bottom panel. 18. Side panels.
9. Saddle. 19. Front mudguard.
10. Tank streamlining.

16
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 BODY PANELS

„ Body component sequence of disassembly

1* 5* 8* 9*

2 6 10

3 7 11 12

4 15*

14 13*

19* 16*

17

18

* This item may be removed on its own.

17
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
BODY PANELS

„ Removal of the storage compartment

Procedure 1.
- Remove the storage compartment.
(2 screws and 2 nuts).

„ Removal of a RH or LH side cover

Procedure 2. 1
- Remove the storage compartment. See:
Procedure 1. page 18.
- Remove the luggage carrier trim. (1)
- Remove the luggage carrier. (2 screws and
1 nut).

- Remove the splash guard. (4 screw).

- Disconnect the license plate light.

18
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 BODY PANELS

- Remove the rear body cover. (4 screw).

- Remove the access door. (1 screw).

- Remove the 2 screws that secure the
footrest. (2) 3
- Remove the rear cover 3 fixing screws. (3)
- Unclip the support (A) and remove the side
A
panel together with the footrest.
2

3
„ Removal of the tank covers
Procedure 3. 1
- Remove the saddle. (2 screw).
- Remove the battery cover. (1)
- Open the tank filler cap door.
- Remove the upper fairing. (2)
2

19
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
BODY PANELS

- Remove the 2 fixing bolts. (3)

- Remove the fuel tank cover panel by sliding
it rearwards.
3

„ Removal of a RH or LH footboard
Procedure 4.
- Remove the tank cover panel. See:
Procedure 3. page 19. 2
3
- On each side remove:
• 2 washer head screws.Ø6 mm. (1)
• 1 washer head screw.Ø5 mm. (2)
• 5 plastic screws.(3)
1

3 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.

20
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 BODY PANELS

„ Removal of the front shield panel

Procedure 5.
- Remove the front top cover panel. (5 screw).

- Remove the footboard mat.

- On each side remove:
• 2 washer head screws. Ø6 mm. (1)
• 2 plastic screws. (2)

2
- Lift the footboard in order to reach the screw
that secures the shield panel.

21
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
BODY PANELS

- On each side remove:

• 5 plastic screws. (3)

- Remove the centre screw. (4)

- Remove the front legshield assembly. 3
- Disconnect the lighting and direction 4
indicator connections.

3
3
„ Removal of the rear shield panel
- Remove the footboards. See: Procedure 4. 4
page 20.
- Remove the front legshield assembly. See:
Procedure 5. page 21.
1
- Remove the header tank. (Right side) (1)
- Remove the fuse holder. (Right side) (2) 2
- Disconnect the accessory plug. (Left
side) (3)
- Remove the 2 fixing bolts. (4)
- Remove the rear shield panel. 3

„ Removal of the dirt shield

- Remove the front legshield assembly. See: 1
Procedure 5. page 21.
- Remove the dirt shield (1) by unclipping it
from the upper bracket and by swivelling it to
the right or to the left

22
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 BODY PANELS

„ Removal of the instrument cluster

- Remove the handlebar front cover.
(2 screw).
- Remove the screen. (4 screw).

- Remove the handlebar rear cover and

instrument cluster assembly. (7 screw).
- Disconnect the instrument cluster.

„ Removal of the battery holder

Procedure 6.
- Remove the tank cover panel. See: 1
Procedure 3. page 19.
- Remove the storage compartment. See:
Procedure 1. page 18
- Disconnect and remove the battery.
- Unclip from the battery holder:
• The fuses. (1)
• The relays. (2)
- Remove the battery bracket. (3 screw).
2

23
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE OPERATIONS

SERVICE OPERATIONS

„ Changing 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)
- Remove the oil filter by unscrewing it. (3)

2 3

Drain the engine when it is warm.

Wear gloves in order not to get burnt.

24
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SERVICE OPERATIONS

- Lubricate the rubber seal of a new oil filter.

- Screw the filter until it is in contact with the 1
engine casing and then screw the filter a half
turn by hand.
- Fit the oil strainer and the drain plug.

Tightening torque: 2.5 m.daN.

- Fill the engine with 1.3 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.
- Check the oil level by using the marks on the
filler cap.

A. Oil level high.

B. Oil level low.
A
- Add oil if necessaire.
B
Note: Check the level with the machine par-
ked on its centre stand, on level
ground.
„ Draining the relay box
- Remove the relay box filler cap. (1)

25
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE OPERATIONS

- To drain the engine remove the cap and let

the oil drip. (2)

- Fit the drain plug.

Tightening torque: 1.5 m.daN.

- Fill the relay box with 0.25 L oil through the

filler hole.
- Check the oil level by using the marks on the
filler cap.

A. Oil level high.

B. Oil level low. A

- Add oil if necessary.

B
Note: Check the level with the machine par-
ked on its centre stand, on level
ground.
„ Replacing the air filter
- Remove the air filter cover (9 bolts) and its
seal.

26
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SERVICE OPERATIONS

- Remove the air filter. (1)

„ Removal of the spark plug

- Remove the storage compartment. See:
Procedure 1. page 18.
- Remove the access door.
- Disconnect 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.

„ Replacing the rollers and drive belt
- Remove the storage compartment. See: A
Procedure 1. page 18.
Remove the 3 air filter box fixing bolts (1).
(including 1 screw, 1 nut and 1 pin in (A).
- Remove the transmission cover. (Refer to
the 250cc Engine workshop manual.
4 valves. Reference 758850.

27
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE OPERATIONS

„ Draining the cooling circuit

- Remove the storage compartment. See:
Procedure 1. page 18.
- 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 1.3 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 90°C). 2

- 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 centre stand, on level
ground. A

28
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SERVICE OPERATIONS

„ Installing the valve clearance

- Remove the storage compartment. See: 1
Procedure 1. page 18
- Remove the oil vapour suction box.
(4 screw).
- Remove the rocker cover. (5 screw).

Tightening torque: 0,7 m.daN.

- Remove the transmission air filter cover.

(2 screw)

- Using a screwdriver, turn the crankshaft so

as to align the camshaft gear mark (4V)
with the cylinder head mark.
4V
2V

29
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
SERVICE OPERATIONS

- Loosen the lock nut of the rocker

adjustment screw. (1)
- By means of feeler gauges, adjust the 1
clearance of every valve by acting on the
rocker set screw.

Clearances:

• 10/100 at the intake.

• 15/100 at the exhaust.

- Immobilize the rocker set screw.

- Tighten the locknut without altering the
adjustment.
- Check the adjustment.
„ Replacing the brake pads

Front brake

- Remove the 2 spindles (1). (or 1 spindle and 1

1 pin in the ABS/PBS version).
- Remove the calliper. (2 screw).
- 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.

Rear brake

- Remove the 2 spindles (2). (or 2 spindles in

the ABS/PBS version.
- Remove the calliper. (2 screw).
- Remove the brake pads.

Mini. thickness: 1.5 mm.

- When refitting the brake pads, push the

pistons all the way into their housing.
2
Note: After refitting, actuate the brake
levers several times to bring the
brake pads against the brake disc.

30
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 SERVICING AN ABS/PBS SYSTEM

SERVICING AN ABS/PBS SYSTEM

„ Removal of the brake modulator

- Remove the front shield panel. See:
Procedure 5. page 21.
- Remove the mudguard.
- Disconnect the modulator.
- Pinch the supply hose of the tank using the
hose clamp P/N 755996
- Disconnect the supply hose.
- Disconnect the hydraulic controls.
- Remove the brake modulator.

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.
Place a pan under the modulator so that the brake fluid will drip into it.
Do not remove the master cylinder covers.

Drain the braking circuit (Refer to the workshop manual (See manual and method N° 32))

31
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

MISCELLANEOUS OPERATIONS

„ Procedure for reducing the fuel circuit

pressure 756017
Procedure 7.
- Remove the storage compartment. See:
Procedure 1. page 18.
- Disconnect the fuel injector.
- Remove the fuel injector. UP
PE
R

- Remove the fuel injector without LO LE

W VE
ER L
LE
VE
L

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 2 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 be dangerous for the skin, do not expose the hands to the jet of
fuel when opening the injector.

32
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

„ Checking fuel pressure 4

2
6

- Remove the tank cover panel. See: ba

r 10
8

Procedure 3. page 19.

- Carry out the procedure for lowering the
pressure in the fuel system. See:
Procedure 7. page 33.
- Disconnect 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 reinstall the hoses with new hose clamps.

33
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

„ Removal of the fuel pump

- Remove the tank cover panel. See:
Procedure 3. page 19.
- Carry out the procedure for lowering the
pressure in the fuel system. See:
Procedure 7. page 33.
- Disconnect the fuel pump.
- Disconnect the 2 fuel pipes.
- Loosen by hand the pump locking ring. (1)
- Remove the fuel pump.

1
„ Removal of the fuel gauge
- Remove the tank cover panel. See: 756715
Procedure 3. page 19.
- Disconnect the fuel gauge.
- Using tool P/N 756715, remove the fuel
gauge

Note: Modify the tool P/N 756715 as shown

in the sketch in order to use it with
the Geopolis.

34
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

„ Removal of the throttle box

- Remove the storage compartment. See: 2
Procedure 1. page 18.
- Disconnect the battery.
1
- Remove the screw (1) that secures the
wiring harness clamp and the fuel hose
anchor bracket.
- Disconnect the throttle unit. (2)
- Disconnect the throttle cable (3) from the
throttle unit. 4
- Loosen the collars. (4) 4
- Remove the throttle box by first pulling it off
the intake coupling. 3
Reassembly: Make sure the throttle box is
properly positioned in the flexible
couplings and that the centring pins
are locked in. (A)

Check: Using the diagnostic tool, check for

fault codes, clear them if necessary.

„ Removal of the lambda sensor

- Remove the bottom panel.
- Remove the exhaust. (1 collar and
3 screws).
- Remove the header pipe.

35
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

- Disconnect and remove the Lambda sensor.

Note: When reinstalling, lubricate the

threads (A) of the sensor with gra- A
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.

36
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

„ Removal of the thermostat

- Remove the storage compartment. See:
Procedure 1. page 18.
- Disconnect the battery.
- Remove the screw that secures the wiring
harness clamp and the fuel hose anchor
bracket.
- Disconnect the lower pump from the coolant
pump to drain the cooling system. 1
- Remove the top (1) from the thermostat (2
screws) without disconnecting the hose.
- Remove the thermostat.

Note: After refitting, bleed the engine cir-

cuit hot and check the coolant level
in the header tank. (Peugeot appro-
ved coolant).
„ Removal of the temperature sensor
- Remove the storage compartment. See:
Procedure 1. page 18.
- Disconnect the battery.
- Remove the screw that secures the wiring
harness clamp and the fuel hose anchor
bracket.
- Disconnect the temperature sensor. (1)
- Remove the engine temperature sensor.

Note: After refitting, bleed the engine cir-

cuit hot and check the coolant level 1
in the header tank.

„ Removal of the regulator

- Remove the tank cover panel. See:
Procedure 3. page 19.
- Remove the RH fairing. See: Procedure 2.
page 18.
- Disconnect and remove the regulator. (1)

37
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

„ Removal of the radiator

- Remove the tank cover panel. See:
Procedure 3. page 19.
- Disconnect the fan.
- Remove the front shield panel. See:
Procedure 5. page 21.
- Remove the mudguard.
- Remove the upper fixing bolts.
- Drain the cooling circuit.
- Disconnect the 4 hoses of the radiator's
cooling circuit.
- Remove the radiator.

„ Removal of the engine mounting

assembly 3 1
- Remove the side fairings. See:
Procedure 2. page 18.
- Remove the bottom panel.
- Suspend or immobilize the machine
securely.
- Remove the tension spring. (1)
- Remove the adjusting ring locknut. (2)
- Remove the screw that secures the silent
block holder. (3)
- Remove the engine 2 pins securing it to
the frame linkrod and engine linkrod. (4) 2 4
- Remove the engine mounting assembly.
- Remove the circlip. (5)
- Remove the linkrod connecting pin. (6)
6

38
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

- Check the condition of the spacers and

needle bearings. (7)
- Make sure that the silent block is not 6
cracked.(8) 8 7
Note: We recommend greasing all needle
bearings when refitting these parts.

„ Installing the engine mounting assembly

- Assemble the engine linkrod assemmbly. 3
- Fit and tighten the linkrod connecting pin.

Note: Reinstall the pin using standard

thread lock.
2
Tightening torque: 3.6 m.daN.
1
- Install the engine mounting assembly in the
frame.
- Fit the 2 pins but do not tighten them. (1)
- Fit screw that secures the silent block
holder.(2)
- Screw but do not tighten the adjusting ring,
so that it comes against the linkrod.(3)
- Tighten the adjusting ring locknut.(4)

Tightening torque: 10 m.daN.

4
- Tighten the 2 securing pins.

Note: Reinstall the pins using standard

thread lock.

Tightening torque: 5.8 m.daN.

- Tighten the screw that secures the silent

block holder. 3
Tightening torque: 6.8 m.daN.

Note: When refitting, respect the way the

pins are installed as shown in the
figure.

39
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

„ Removal of the cylinder head

„ Removal of the cylinder / piston

Note: To remove the cylinder head, remove the power propulsion unit.

- Remove the side fairings. See: Procedure 2. page 18.

- Remove the tank cover panel. See: Procedure 3. page 19.
- Carry out the procedure for lowering the pressure in the fuel system. See: Procedure 7. page 33.

- Disconnect the 2 fuel injector supply hoses.

- Disconnect the lower pump from the coolant pump to drain the cooling system. (1)
- Disconnect the coolant outlet to the thermostat.

- Disconnect:
• The battery.
• The fuel injector.
• The throttle box.
• The temperature sensor.
• The lambda sensor.
• The magneto.
• The starter motor.
• The suppressor.

- Dieconnect the the throttle control cable from the throttle box.
- Remove the calliper.
- Remove the hydraulic control from its guides on the engine casing.
- Suspend or wedge the machine frame before removing the power unit.
- Remove the shock absorber lower mounts.
- Remove the linkrod-to-engine connecting pin.
- Remove the power propulsion unit from the frame.

Note: For removal of the cylinder head, cylinder and piston, see the workshop manual:
4 stroke engine. 4 valves. Reference: 758850.

40
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

„ Removal of the fork

„ Replacing the bearings of the steering

1 757860
system
- Remove the front top cover panel.
- Remove the handlebar front and rear
covers.
- Remove the 2 upper screws that secure the
rear shield panel.
- Remove the braking units on the
handlebars.(1)
- Remove the handlebars from the fork tube.
- Remove the front mudguard.
- Remove the front brake caliper from the fork
tube.
- Remove the front wheel.
- Using tool P/N 757860 remove the steering
locknut. 757860
- 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.

41
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de 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

- Install new steering head cups using tool

P/N 758810. 758810

42
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

„ Steering system tightening method

- Grease the cup bearing races. 7
- Fit the caged ball bearing. (1 and 2).
- Fit the fork into the steering column. 5 6
- Install the adjustable cone and tighten it. (3)
2
Tightening torque: 4 m.daN. 3 4
- Loosen and then retighten the adjustable
1
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.

43
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

„ Removal of the suspension arm

- Remove the exhaust. (1 collar and
3 screws)

- Remove the pin, the nut retainer and the

wheel nut. (1)
- Remove the suspension arm (3 screws and
1 nut).

- Remove the circlip. (2)

- Using a drift, remove the bearing.

44
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

- Using a press and a drift driver, place a new

bearing in the suspension arm, by pushing
against the outer cage of the bearing.
- Install the circlips.

45
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
MISCELLANEOUS OPERATIONS

46
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
 MISCELLANEOUS OPERATIONS

47
Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles
P/N. 758915

Dans un souci constant d'amélioration Peugeot Motocycles se réserve le droit de supprimer, modifier, ou ajouter
toutes références citées.
DC/PS/APV Imprimé en E.U. 11/2006 (photos non contractuelles)