PEUGEOT JET Force 125, Technical Training Manual

Page 1: ...TECHNICAL TRAINING SALES DIVISION PRESENTATION OF THE MACHINE réf JET 010 02 2003 GB ...

Page 2: ......

Page 3: ...ng 12 Fault processing principle 12 Self diagnostic principle 12 125 CC ENGINES 13 125 cc 4 stroke EFI liquid cooled engine 13 Description 14 Lubrication 14 Cooling 14 Cooling system functioning principle 14 INTRODUCTION 15 ADVANTAGES OF THE INJECTION SYSTEM 15 Fuel injector 15 INJECTION SYSTEM EFI IGNITION 16 Reminder of operation 16 FRAME 17 Frame 17 Suspension 18 Tyres 18 Suspension 19 Tyres 19...

Page 4: ...inder of the key memory procedure 33 Key memory check 33 Additional information 33 Synoptics 34 INSTRUMENT CLUSTER 36 Description 36 Instrument cluster self diagnostic when ignition is turned on 36 Description of the multi function display 37 MULTI FUNCTION DISPLAY FUNCTIONS AND SETTINGS 37 Changing the distance unit 37 Tripmeter Total Daily display 38 Daily Km reset 38 Time setting 38 Maintenance...

Page 5: ... cc 124 8 cc Max power output 3 75 kW at 7500 rpm 9 2 kW at 8750 rpm Max torque at 6500 rpm 7250 rpm Fuel system Direct electronic injection TSDI Indirect electronic injection EFI Lubrication Electric oil pump Trochoidal pump Transmission 2 variable pulleys and Vee belt Clutch Centrifugal automatic Spark plug NGK CPR8E NGK CR7EB Exhaust Catalytic Non catalytic Dimensions and weight Overall length ...

Page 6: ... FORCE Page 6 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles 50 CC ENGINES 50 cc 2 stroke TSDI liquid cooled engine 45 km h version Sport version Unlimited version registered ...

Page 7: ...MANUAL JET FORCE Page 7 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Description HL1 engine marking Separate lubrication 1 2 l tank capacity Cooling 1 2 l capacity ...

Page 8: ... the exhaust gases are fed through the catalyser cone 1 Exhaust pipe 2 Heat insulation 3 Catalyser cone FUNCTIONING OF THE CATALYTIC CONVERTER EXHAUST Definition The catalyser is a block used to facilitate and acceleration chemical reactions without being modified itself Composition of the catalytic block The catalytic block is composed of a metal grid impregnated with precious metals rolled insid...

Page 9: ...ne speed type the SYNERJECT system was developed for the following applications Monopoint sequential injection Static timing The system basic principle consists in measuring the engine speed and load throttle opening in order to determine the optimum quantity of fuel injected This system is used on the JET FORCE 50 scooter and requires NO ADJUSTMENT Ditto Looxor and Elystar 50 cc 1 Cylinder head 2...

Page 10: ...orbidden without the written consent of Peugeot Motocycles SYSTEM COMPONENTS Functioning principle 1 Crank assembly 2 Compressor 3 Throttle unit 4 Spark plug 5 Lubrication system 6 Feed rail a petrol injector b air injector c petrol pressure regulator A Fuel inlet B Fuel return C Pressurised air inlet ...

Page 11: ... Peugeot Motocycles PRESENTATION OF THE 2 STROKE INJECTION SYSTEM Fuel system 1 Fuel tank 2 Fuel pump 3 Pressure regulator Ignition system 4 Coil and suppressor 5 Resistive spark plug Injection system 6 Petrol injector 7 Air injector Lubrication system 8 Oil tank 9 Oil pump Compressed air circuit 10 Compressor Transponder circuit 11 Immobiliser module 12 Transponder ...

Page 12: ...lt processing principle Three priority levels 1 serious safety fault fault memorised in ECU and LED stays on 2 serious fault fault memorised in ECU and LED flashes 3 minor fault fault memorised in the ECU without lighting the warning light Note When the ignition is turned on the LED stays on to check it is functioning correctly Self diagnostic principle Warning light on inst cluster Injection ECU ...

Page 13: ...JET FORCE Page 13 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles 125 CC ENGINES 125 cc 4 stroke EFI liquid cooled engine Naturally aspirated version Turbo version compressor ...

Page 14: ...ion or translation even partial is forbidden without the written consent of Peugeot Motocycles Description FD5 engine markings Lubrication 1 25 l capacity Cooling 1 5 l capacity Cooling system functioning principle 1 Battery 2 Ignition switch 3 Fan 4 Heat switch ...

Page 15: ...scooter and requires NO ADJUSTMENT Ditto Elystar 125 150 cc ADVANTAGES OF THE INJECTION SYSTEM Peugeot Motocycles has developed a new generation of engines Cleaner more reliable more economical these engines comply with the most stringent emission control standards whilst maintaining a very high level of performance There are many advantages Reduction in polluting emissions Reduction in fuel consu...

Page 16: ...der of operation 1 ECU 2 Battery Fuel system 3 Fuel tank 4 Fuel pump 5 Pressure regulator Ignition system 6 HT coil 7 Resistive spark plug and suppressor Transponder circuit 8 Transponder module 9 Transponder Injection system 10 Petrol injector 11 Idle control valve 12 Air pressure and air temperature sensor Diagnostic circuit 13 Injection diagnostic lamp 14 Transponder diagnostic lamp 15 Diagnost...

Page 17: ...E TRAINING MANUAL JET FORCE Page 17 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles FRAME Frame Steel wrap round frame DIRECT PERIMETRIC FRAME DPF ...

Page 18: ...consent of Peugeot Motocycles Suspension 50 cm3 Front suspension Ø 32 mm hydraulic telescopic fork Travel 85 mm Rear suspension Central hydraulic shock absorber Travel 95 mm Tyres Front wheel 13 inch alloy Front tyre 130 60 13 Front tyre pressure 2 bar Rear wheel 13 inch alloy Rear tyre 130 60 13 Rear tyre pressure 2 2 bar ...

Page 19: ...consent of Peugeot Motocycles Suspension 125 cm3 Front suspension Ø 36 mm hydraulic telescopic fork Travel 95 mm Rear suspension Central hydraulic shock absorber Travel 90 mm Tyres Front wheel 13 inch alloy Front tyre 130 60 13 Front tyre pressure 2 bar Rear wheel 13 inch alloy Rear tyre 140 60 13 Rear tyre pressure 2 2 bar ...

Page 20: ...r translation even partial is forbidden without the written consent of Peugeot Motocycles BRAKES Reminder of functioning of the different braking systems Conventional hydraulic system SBC integral hydraulic braking system SBC2 integral hydraulic braking system ...

Page 21: ...even partial is forbidden without the written consent of Peugeot Motocycles ABS PBS hydraulic braking system 1 Braking control unit 2 Right hand brake master cylinder emergency brake 3 Front brake caliper 4 Left hand brake master cylinder integral brake 5 Rear brake caliper ...

Page 22: ...es ABS PBS SYSTEM SYNOPTICS RH brake lever contactor Hydraulic pump RH brake lever contactor Brake light Front wheel speed sensor Regulation solenoid valve Battery voltage Main relay Vehicle coding PIN code Starter relay Instrument cluster Diagnostic plug Diagnostic light Software Manages system operation Calibration Values specific to machine mapping ABS PBS ECU ...

Page 23: ...BODY PANELS TRAINING MANUAL JET FORCE Page 23 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles BODY PANELS ...

Page 24: ...NT LOWER LEGSHIELDS 4 LEGSHIELD REAR PANEL 11 MUDGUARD AND FORK GUARD 12 FOOTBOARDS 5 TUNNELS 6 FUEL TANK FAIRING 10 RIDER SADDLE 8 PASSENGER SADDLE AND GRAB HANDLE 15 REAR FAIRING AND IMMOBILISER UNIT 17 STORAGE COMPARTMENT 9 STORAGE COMPARTMENT TRIM PANELS 18 HANDLEBAR REAR FAIRING 3 BATTERY COVER 16 MUDGUARD 13 BELLYPAN 7 MUDFLAP AND NUMBER PLATE PANEL 14 LEGSHIELD TOP PANEL 1 ...

Page 25: ...nciple of the 50 cc starter and lighting circuits 1 Battery 2 Ignition switch 3 Starter button 4 Lighting control 5 Rear light 6 Instrument cluster 7 Brake light 8 High beam 9 Dip beam 10 Sidelight 11 Lighting relay 12 Starter motor relay 13 Starter motor 14 Brake light switch BA White JN BE Yellow Blue JN VE Yellow Green MR Brown NR Black RG Red RG NR Red Black VE Green VI Mauve ...

Page 26: ...lighting relay 11 is powered when the ignition is on via terminals 1 and 3 Over terminal 2 of the relay the control coil is earthed through the starter motor 13 The power circuit via relay terminal 5 powers The rear and front sidelights The number plate light 50cc IL and 125cc The instrument cluster lighting Power supply to the Dip Full Beam control 4 and the headlight flasher for the 125 cc ...

Page 27: ... starter motor Terminal 2 of the lighting relay 11 The potential on the coil two terminals is the same 12 V the magnetic field disappears the relay blade opens the lighting circuit is no longer powered Note All of the battery power will be used by the starter motor Without pressing the starter button 3 The magnetic field in the starter relay coil 12 disappears the power circuit opens Terminal 2 on...

Page 28: ...on indicator functioning principle 125 cc Direction indicator function 1 Battery 2 Ignition switch 3 Instrument cluster 4 Direction indicator switch 5 Hazard warning lights switch 6 Right direction indicator 7 Left direction indicator 8 Direction indicator unit BA NR White Black BC Light blue JN BE Yellow Blue OR Orange RG Red RG NR Red Black VE Green VI Mauve ...

Page 29: ...ELECTRICITY TRAINING MANUAL JET FORCE Page 29 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Hazard warning lights with ignition on 125 cc ...

Page 30: ...ELECTRICITY TRAINING MANUAL JET FORCE Page 30 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles Hazard warning lights without ignition on 125 cc ...

Page 31: ...written consent of Peugeot Motocycles Functioning principle of the ABS PBS system 125 cc 1 Battery 2 Ignition switch 3 Module main relay 4 Starter motor relay 5 RH brake contactor 6 LH brake contactor 7 Instrument cluster 8 Machine speed sensor 9 Control unit 10 25A fuse 11 15A fuse 12 Brake light 13 Diagnostic plug ...

Page 32: ...ELECTRICITY TRAINING MANUAL JET FORCE Page 32 43 Reproduction or translation even partial is forbidden without the written consent of Peugeot Motocycles ABS PBS ELYSTAR 125cc ...

Page 33: ...he black key and when the LED comes on turn off the ignition repeat the operation for each black key to be memorised maximum of 7 black keys 3 Within a maximum of 15 seconds of turning off the ignition with the last key memorised turn on the ignition with the red key and when the LED comes on turn off the ignition Key memory check Using the red key turn on the ignition the LED on the instrument pa...

Page 34: ...tial is forbidden without the written consent of Peugeot Motocycles Synoptics Assembly correct Cut between the immobiliser module and the ECU Cut between the antenna and the immobiliser unit or no transponder in they key Wrong key or immobiliser module from another machine Blank immobiliser module ...

Page 35: ...slation even partial is forbidden without the written consent of Peugeot Motocycles Blank ECU starting possible with red key Immobiliser module and ECU blank Programmed immobiliser module and key from another machine Blank ECU with 16 memorised switch on without diagnostic plug loop ...

Page 36: ...on light 8 ABS PBS system diagnostic light 9 Headlight warning light 10 Oil low level warning light 11 Direction indicator warning light 12 Battery charge warning light Instrument cluster self diagnostic when ignition is turned on Different functioning tests are carried out automatically for 5 seconds Display of all of the multi function display items 1 and the speed 3 Lighting of all the warning ...

Page 37: ... totaliseur ou journalier 14 Indication de l affichage de l odomètre journalier 15 Indication de l unité utilisée par l odomètre 16 Horloge 17 Indicateur de maintenance symbole clé 18 Jauge à carburant MULTI FUNCTION DISPLAY FUNCTIONS AND SETTINGS Changing the distance unit Ignition off Press button and hold down Turn on the ignition Release the button Press for 3s to select Km Miles Turn off igni...

Page 38: ...n to select the function required Daily Km reset Hold down the button for 5s Time setting The time can only be set in the tripmeter total position Ignition on press the button 5 until the time flashes Set the time by successive pushes on the control button Press the control button to confirm the hour the minutes figure flashes Proceed in the same way to set the minutes Press the control button for...

Page 39: ...er servicing the machine erase the symbol as follows Ignition off Press button and hold down Turn on the ignition only the spanner appears and flashes Press for 5s to erase the symbol Fuel gauge self diagnostic If the fuel system is cut off from the fuel gauge when the ignition is turned on the 8 LEDs light one after the other Gauge functioning 8s timer 8 LEDs represent a full tank 10 ohms 2 LEDs ...

Page 40: ...cles LOCATION OF COMPONENTS 50 cc 1 Injection ECU 2 Throttle unit 3 Engine position and speed sensor 4 Temperature sensor 5 Battery 6 Fuel injector 7 Air injector 8 Ignition coil 9 Immobiliser module 10 Fuel pump 11 Oil pump 12 Diagnostic light 13 Diagnostic plug 14 Air compressor 15 Fuses 16 Voltage regulator 17 Horn 18 Saddle lock 19 Starter lighting relay ...

Page 41: ...tion and speed sensor 4 Temperature sensor 5 Air pressure and air temperature sensor 6 Battery 7 Fuel injector 8 Idle control valve 9 Ignition coil 10 Immobiliser module 11 Fuel pump 12 Diagnostic light 13 Diagnostic plug 14 Fuel pump relay ABS relay light relay Fuse 25A 15 Heat switch 16 Motor driven fan 17 Fuse 15A starter relay 18 Voltage regulator 19 Horn 20 Saddle lock 21 ABS PBS module 22 Ma...

Page 42: ...56076 Tank gauge spanner 756716 replaces 755056 Tank ring spanner Tool N Description Used with 755990 Diagnostic tool update software Computer 755878 755806 755807 755806 Cartridge Europe 755878 755807 Cartridge Export 755878 755878 Diagnostic tool game boy color 755806 756714 replaces 755878 Diagnostic tool game boy advance 755806 755807 756017 50 cc fuel injector power supply harness 756449 ABS ...

Page 43: ...SPECIAL TOOLING TRAINING MANUAL Page 43 43 Tool N Description Used with 756607 Fork seal fitting tool 125 cc 756608 Fork seal fitting tool 50 cc 756668 Crank assembly lip seal tool 50 cc ...