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Related Manuals for PEUGEOT Geopolis 250
Summary of Contents for PEUGEOT Geopolis 250
- 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...
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Page 3: Table Of Contents
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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 4 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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 5 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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 6: Characteristics
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 7: Chassis
.140/70 - 16. Rear tyre pressure. 2.3 bars. Chassis markings Engine marking 1. Manufacturer's plate. (Left side). 2. Engine number. - VIN number of the RH side of the vehicle. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 8: Service Schedule And Commissioning
Drive pulley bearings and guides #. Transmission belt. Belt anti-flapping roller #. Engine oil (+ clean strainer). Engine oil filter. Relay box oil. Brake fluid and coolant. Once every 2 years Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 9: Check And Lubricate
Reading the ECU fault codes Injection and ABS/PBS* system. Test machine On road C: Check. N: Clean. R: Change. G: Check and lubricate. * Depending on equipment. # Change if necessary. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 10: Battery Preparation (Except Battery Without Maintenance)
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 11: Special Important Points
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 12: Tightening Torques
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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 13: Body Panels
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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 14: Special Tools
Fuel injector 756017 power supply 758810 installation harness tool 24 way 756715 Tank gauge 758924 terminal block spanner BM 426 757860 Steering tool (*) New or modified tool. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 15: Electricity
Ignition coil. 14. Transponder antenna. Lambda sensor. 15. Diagnostic plug. Starter motor switch. 16. Instrument panel. Starter motor relay. 17. Kickstand switch. Cooling fan. 18. Engine temperature sensor. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 16: Fuses And Energy Distribution
Fan relay. Instrument panel. Dip switch (main/low headlight). Horn. Number plate light. Sidelight. Stop light contact. Injection ECU. Transponder antenna. Diagnostic plug. Injection relay. Lighting relay. Accessory socket. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 17: Location Of Components
19. Horn. 8. Transponder antenna 20. Saddle lock. 9. Petrol pump. 21. Machine speed sensor. 10. Diagnostic light. 22. Kickstand switch. 11. Diagnostic plug. 12. Starter motor relay Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 18: Body Panels
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 19: Body Component Sequence Of Disassembly
BODY PANELS Body component sequence of disassembly * This item may be removed on its own. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 20: Removal Of The Storage Compartment
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 21: Removal Of The Tank Covers
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) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 22: Removal Of A Rh Or Lh Footboard
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 23: Removal Of The Front Shield Panel
• 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 24: Removal Of The Rear Shield Panel
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 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 25: Removal Of The Instrument Cluster
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). Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 26: Service Operations
(2) - Remove the oil filter by unscrewing it. (3) Drain the engine when it is warm. Wear gloves in order not to get burnt. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 27: Draining The Relay Box
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) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 28: Replacing The Air Filter
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 29: Removal Of The Spark Plug
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 30: Draining The Cooling Circuit
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 31: Installing The Valve Clearance
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 32: Replacing The Brake Pads
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 33: Servicing An Abs/Pbs System
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)) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 34: Miscellaneous Operations
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 35: Checking Fuel Pressure
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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 36: Removal Of The Fuel Pump
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 37: Removal Of The Throttle Box
Removal of the lambda sensor - Remove the bottom panel. - Remove the exhaust. (1 collar and 3 screws). - Remove the header pipe. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 38 (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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 39: Removal Of The Thermostat
- 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) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 40: Removal Of The Radiator
- Remove the engine 2 pins securing it to the frame linkrod and engine linkrod. (4) - Remove the engine mounting assembly. - Remove the circlip. (5) - Remove the linkrod connecting pin. (6) Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 41: Installing The Engine Mounting Assembly
- Tighten the screw that secures the silent block holder. Tightening torque: 6.8 m.daN. Note: When refitting, respect the way the pins are installed as shown in the figure. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 42: Removal Of The Cylinder Head
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 43: Removal Of The Fork
• the adjustable cone locknut. • the rubber washer. • the adjustable cone. - Remove the fork. - Remove the balls. - Using a drift, remove the steering head cups. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 44 - 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. 758810 Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
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Page 45: Steering System Tightening Method
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... -
Page 46: Removal Of The Suspension Arm
- 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles... - Page 47 - 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. Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 48 MISCELLANEOUS OPERATIONS Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 49 MISCELLANEOUS OPERATIONS Reproduction ou traduction, même partielle, interdite sans autorisation écrite de Peugeot Motocycles...
- Page 52 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)