PEUGEOT Geopolis 250, Workshop Manual

Page 1: ...Direction commerciale Animation technique réseau WORKSHOP MANUAL ...

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

Page 3: ... 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 ind...

Page 4: ... 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 I...

Page 5: ...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...

Page 6: ...244 cc Max power output 16 5 kW at 8000 rpm Max torque rating 6250 rpm Fuel supply Indirect electronic injection 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 Fuel tank 13 2 l 95 or 98 lead free Engine oil 1 3 L SAE 5W40 Minimum grade API SJ Relay box 0 25 L...

Page 7: ...lic shock absorbers Travel 100 mm Overall length 2170 mm Width at handlebar 770 mm Height without rear view mirrors 1425 mm Wheelbase 1420 mm Ground clearance 140 mm Saddle height 784 mm Unladen weight 159 kg 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 markin...

Page 8: ...ay C C C C Operation of electrical equipment C C C C Condition of front and rear brake hydraulic controls C C C C Condition of petrol pipes C C C C Condition of oil pipes C C C C Tyre pressures C C C C Tyre condition pressure and wear C C C 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 ...

Page 9: ...f necessary Service operations 1000 kms or 1 months Every 5000 kms or 12 months Every 10000 kms Every 15000 kms Every 20000 kms Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms Every 7500 kms Every 100000 k ms Check and lubricate Driven pulley Moving flange and needle bush G G Drive pulley Movable face G G Reading the ECU fault codes Injection and ABS PBS system C C C C C Test machine On...

Page 10: ...p 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...

Page 11: ... 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...

Page 12: ... 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...

Page 13: ...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...

Page 14: ...liers 757877 Pressure gauge 754278 Balance support with pins Ø15 and Ø17 mm 758358 TEP 2005 755996 Hose clamp 758585 Power supply cable tool 756017 Fuel injector power supply harness 758810 Steeing head cup installation tool 756715 Tank gauge spanner 758924 24 way terminal block 757860 Steering tool 0 6 8 10 2 4 bar OK TEP 2005 by xxotest 1 24 12 23 11 22 10 21 9 20 8 19 7 18 6 17 5 16 15 14 13 26...

Page 15: ...nna 15 Diagnostic plug 16 Instrument panel 17 Kickstand switch 18 Engine temperature sensor 12V 25A 2 1 3 4 5 12V 25A 1 2 3 4 5 2 1 3 4 5 1 2 6 3 OFF ON 11 7 8 UP PE R LE VE L LO W ER LE VE L VE B1 A1 A3 VE 6 5 4 3 2 18 17 16 15 14 13 12 11 10 9 8 7 2 1 2 1 22 21 11 4 15 14 13 9 26 12 1 17 18 8 24 20 7 16 5 6 1 R 1 2 4 3 1 2 3 2 1 1 2 30A F1 15A F6 10A F2 15A F4 VE VE VE VE JN BC NR NR NR RG RG VI...

Page 16: ...tor Petrol pump Lambda sensor Fan relay F4 Instrument panel Lighting relay Fan relay F5 Instrument panel Dip switch main low headlight Horn Number plate light Sidelight Stop light contact F6 Injection ECU Transponder antenna Diagnostic plug Injection relay Lighting relay F7 Accessory socket RG GR BE GR RG GR RG B UP PE R LE VE L LO W ER LE VE L RG RG NR GR NR NR 6 5 1 2 4 7 F1 30A F6 7 5A F5 15A F...

Page 17: ...t 11 Diagnostic plug 12 Starter motor relay 13 Fuses 14 10 A fuse Accessory socket 12V 15 Oil pressure switch 16 Motor driven fan 17 Lighting relay Fan relay Power supply relay 18 Voltage regulator 19 Horn 20 Saddle lock 21 Machine speed sensor 22 Kickstand switch UP PE R LE VE L LO W ER LE VE L 12V 25A 11 8 9 14 21 3 5 15 2 7 1 6 4 12 10 19 22 20 17 13 16 OK TEP 2005 by xxotest E638 534 5039 5014...

Page 18: ...bar 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 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 13 8 12 7 1 2 6 9 10 19 3 11 18 15 14 17 16 4 ...

Page 19: ...production ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles Body component sequence of disassembly This item may be removed on its own 1 5 8 9 2 6 10 3 7 11 12 4 13 18 19 17 16 15 14 ...

Page 20: ...storage compartment Procedure 1 Remove the storage compartment 2 screws and 2 nuts Removal of a RH or LH side cover Procedure 2 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 1 ...

Page 21: ...emove 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 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 A 2 3 3 1 2 ...

Page 22: ...panel by sliding it rearwards Removal of a RH or LH footboard Procedure 4 Remove the tank cover panel See Procedure 3 page 19 On each side remove 2 washer head screws Ø6 mm 1 1 washer head screw Ø5 mm 2 5 plastic screws 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 3 3 1 2 3 3 ...

Page 23: ...crite de Peugeot Motocycles 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 Lift the footboard in order to reach the screw that secures the shield panel 2 1 ...

Page 24: ... panel Remove the footboards See Procedure 4 page 20 Remove the front legshield assembly See Procedure 5 page 21 Remove the header tank Right side 1 Remove the fuse holder Right side 2 Disconnect the accessory plug Left side 3 Remove the 2 fixing bolts 4 Remove the rear shield panel Removal of the dirt shield Remove the front legshield assembly See Procedure 5 page 21 Remove the dirt shield 1 by u...

Page 25: ...e 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 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 1...

Page 26: ...eugeot Motocycles 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 Drain the engine when it is warm Wear gloves in order not to get burnt 1 3 2 ...

Page 27: ...and 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 Add oil if necessaire Note Check the level with the machine par ked on its centre stand on leve...

Page 28: ... 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 Add oil if necessary 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 2 A B ...

Page 29: ...he 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 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 transmis...

Page 30: ...e 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 Check the coolant level in the header tank If necessar...

Page 31: ...alve clearance Remove the storage compartment See 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 1 4 V 2 V ...

Page 32: ...ke Remove the 2 spindles 1 or 1 spindle and 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 versio...

Page 33: ...nk 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...

Page 34: ... injector without 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 ...

Page 35: ...ure 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...

Page 36: ...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 Removal of the fuel gauge Remove the tank cover panel See 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...

Page 37: ...racket Disconnect the throttle unit 2 Disconnect the throttle cable 3 from the throttle unit Loosen the collars 4 Remove the throttle box by first pulling it off the intake coupling 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...

Page 38: ...autorisation écrite de Peugeot Motocycles Disconnect and remove the Lambda sensor Note When reinstalling lubricate the threads A of the sensor with gra phite grease In order not to damage the Lambda sensor never lubricate or clean the end piece B which is exposed to the exhaust gas A B ...

Page 39: ...e 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 tempe...

Page 40: ... circuit Disconnect the 4 hoses of the radiator s cooling circuit Remove the radiator Removal of the engine mounting assembly 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 t...

Page 41: ...ll the pin using standard thread lock Tightening torque 3 6 m daN 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 Tighten the 2 securing pins Note Reinstall the ...

Page 42: ...p 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 Susp...

Page 43: ...ove 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 Remove The lock washer the adjustable cone locknut the rubber washer the adjustable cone Remove the fork Rem...

Page 44: ...ans autorisation écrite de Peugeot Motocycles 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 Install new steering head cups using tool P N 758810 3 2 1 758810 ...

Page 45: ... column Install the adjustable cone and tighten it 3 Tightening torque 4 m daN Loosen and then retighten the adjustable cone Tightening torque 2 2 m daN Install the rubber washer 4 Finger tighten the adjustable cone locknut 5 so that its notches are aligned with those of the adjustable cone Fit the lock washer 6 in the notches of the locknut and adjustable cone Install the steering head locknut an...

Page 46: ...dite sans autorisation écrite de Peugeot Motocycles 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 1 2 ...

Page 47: ...ction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles 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 ...

Page 48: ...MISCELLANEOUS OPERATIONS 46 Reproduction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles ...

Page 49: ...MISCELLANEOUS OPERATIONS 47 Reproduction ou traduction même partielle interdite sans autorisation écrite de Peugeot Motocycles ...

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Page 52: ... 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 ...