PEUGEOT SATELIS - SERVICE MANUAL - BODY PANELS Service Manual
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PEUGEOT SATELIS - SERVICE MANUAL - BODY PANELS Service Manual

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  • Page 4 Removal of the rider’s saddle Removal of the passenger’s saddle Procedure 1. - Open the saddle cover storage compartment. - Remove: . The screw. . The saddle cover. . The rider’s saddle. Open the passenger’s saddle. - Remove: . The 2 upper pivot clips. .
  • Page 5 - Flip up the seat to the front of the vehicle. - Remove: . The 2 lower pivot clips. . The 2 pivot pins. - Remove the passenger seat. Removal of a RH or LH grab handle Procedure 2. - Remove the grab handle trim. - Remove the 2 nuts and the screw that secure the handle.
  • Page 6 Removal of a RH or LH taillight Removal of a taillight bulb - Remove the grab handle. See: Procedure 2. - Remove the taillight. (1 screw). - Remove the 4 screws from the taillight unit. - Separate the 2 parts in order to reach the bulbs.
  • Page 7 Removal of a RH or LH side cover Procedure 3 - Remove: - The rider’s saddle. See: Procedure I. Page: 30. - The grab handles. See: Procedure 2. Page: 31. S Remove the rear cover and its trim. (4 screw). Remove the 2 screws that secure the side cover linkage and the footboard.
  • Page 8 - Push aside the footboard in order to clear side cover holder eyelet. Remove the side cover. - Disconnect the taillight. Removal of the storage compartment Procedure 4. - Remove the side fairings. See: Procedure 3. Page: 32. - Disconnect the plate light and the saddle opening contact switch. Remove the storage compartment.
  • Page 9 When dismantling the splash guard, fit the screws with standard thread lock. Removal of the tank covers Procedure 5. - The rider’s saddle. See: Procedure I. - Page: 30. Open the tank filler cap door. Remove the 4 screws that secure the rear panel. Remove the upper fairing.
  • Page 10 - Remove the utility hanger. (2 screw). - Remove 1 nut and 2 screws that secure the lower fairing. - Remove the screw that secures the rear cover I footboard on each side of the vehicle. (1) - Push slightly aside the cover I footboard assembly and remover the fuel tank cover panel by sliding it backwards.
  • Page 11 Press on the underbody panel in order to separate it from the footboard. (A) - Separate the footboard from the rear fairing and bracket that anchors it to the body. (B) - Separate the front of the footboard which is linked to the rear part of the leg shield panel.
  • Page 12 - Removal of the front top cover panel - Procedure 7. - Remove the front top cover panel. (4 screw). Removal of the headlight and sidelight assemblies Removal of the headlight bulbs - Remove the front top cover panel. See: Procedure 7.
  • Page 13 - Removal of the front shield panel - Procedure 8. - Remove the front top cover panel. See: - Procedure 7. - On each side remove: . 2 plastic screws that secure the front leg shield to the underbody cover. (1) .
  • Page 14 - Removal of the rear shield panel - Remove the ignition key. - Remove the tank cover panel. See: - Procedure 5. - Remove the front top cover panel. See: - Procedure 7. - Remove: • The ignition switch trim. •...
  • Page 15 - On each side remove: • 6 plastic screws. (3) • 2 washer head screws. 06 mm. (4) - Separate the front shield panel from the rear shield panel in order to reach the bracket that connects the rear shield panel to the footboard. (A) - Pull upwards the lower part of the shield panel in order to separate it from the footboard.
  • Page 16 - Relove the eyelet (B) from the shield panel and the eyelet (C) from the instrument cluster fairing in order free the rear shield panel. - Topple the rear shield panel while separating it from the footboards in order to reach the header tank and the accessory plug.
  • Page 17 - Removal of the dirt shield - Remove the front shield panel. See: Procedure 8. - Remove the center screw which secures the dirt shield to the underbody cover. - Disconnect the speed sensor. - Pull the speed sensor control out of the dirt cover. - Lift the front of the vehicle while making sure the wheel is in line with the vehicle.
  • Page 18 - Removal of the instrument cluster - Remove: - The front top cover panel. See: Procedure 7. • The wind deflector. • The handlebar upper fairing. - On each side remove: • 1 plastic screw. (1) • 1 washer head screw. 05 mm. (2) •...
  • Page 19 PIAGGIO MOTOR SERVICE STATION MANUAL Engine Master 500 cc...
  • Page 20 SERVICE STATION MANUAL PEUGEOT SATELIS 500 cc This manual has been prepared by Piaggio & C. S.p.A. for use in the workshops of authorised Piaggio sub- agents. It is assumed that the person utilising this manual for servicing or repairing Piaggio vehicles has a knowledge principles of mechanics and standard procedures for vehicle repair.
  • Page 21 Specifications (500 cc 4-stroke, 4-valves H2 0 engine) ENGINE Type ......................single-cylinder, 4 stroke Bore............................92 mm Stroke............................69 mm Displacement........................460 cm3 Compressionratio........................10.5 : 1 Timing ....................chain-operated overhead single-shaft flywheel side, integrated phonic wheel, 4- valves and automatic starting valve lifter Valves play: intake....................... 0.20 mm exhaust......................

  • Page 22: Spark Plug

    Spark plug Check and replacement Warning - Remove the spark plug when the engine cold. Replace the spark plug every 12,000 Km. The use of unsuitable control units or spark plugs other than those specified can seriously damage the engine. Recommended spark plug: CHAMPION RG 6 YC NGK CR 7 EKB - Put the vehicle on its central stand.
  • Page 23 Warning - Do not run the engine if the air filter is not in place as this would result in excessive wear of the cylinder and piston as well as in damage to the throttle body. Engine oil level In four-stroke engines oil is used to lubricate the valve gear components, the crankshaft bearings and the thermal unit.
  • Page 24 Replacing the filter Warning - Do not dispose of the oil in the environment. Carry out the disposal of the oil, the gasket and the filter in accordance with the law. - To avoid burns, take care not to touch hot engine parts. Warning - Remove the silencer.
  • Page 25 Hub oil capacity: ~ 250 cc Recommended oil: TUTELA ZC 90 ------------------------------------------------------------------------------------------------------------------------------------------------------------ Engine cooling Adding coolant and bleeding air from the system. The level of the fluid must be checked every 6,000 km when the engine is cold. Follow these steps: - Put the vehicle on the central stand on level ground.
  • Page 26 Water pump If the water pump becomes noisy or liquid leaks through the pump drain hole, check the water pump as described in Chapter 5-Flywheel cover. Follow these steps: - Put the vehicle on the central stand on level ground. - Remove the lower right-hand side panel and the right-hand footboard as described in Chapter 8- Bodywork of the X9- 500 cc manual;...
  • Page 27 Valves play check/adjustment - Check the valves play after aligning the valve timing reference marks as described in the previous section. - Check that the valve-register play corresponds with the indicated values by means of a feeler gauge. If the valve play values, intake and exhaust respectively, do not correspond with those indicated below, adjust them by loosening the check nut and acting on the register with a screwdriver, as shown in the figure.
  • Page 28 Transmission cover - Unloose the 7 fixing screws - Remove the cover and net filter N.B.: Disassemble the net filter only if it is to be replaced. Belt antiflapping roller - Check that the roller is in good condition and that it turns freely.
  • Page 29 - First fit the specific tool stop ring on the pulley until the groove is fully in contact. - Afterwards, insert the tool so that the studs on the ring fit the holes in the tool. - Tighten, also manually, the two fixing nuts of the tool - Unloose the central nut.
  • Page 30 - Insert the specific tool on the driven pulley axle support, checking that the tooth fits the hole in the housing previously uncovered, and that it is resting on the support. - Tighten the 2 fixing screws. - Unloose the driven pulley shaft nut. Specific tool: Clutch housing stop tool 020473Y - Remove the specific tool - Unloose the 2 remaining fixing screws of the driven pulley axle support.
  • Page 31 - Check that the clutch housing shows no signs of wear or damage. - Measure the clutch housing I.D. Standard value: 160.2 mm Max value: 160.5 mm N.B.: Check that the measured eccentricity is max 0.2 mm Driven pulley assembly - Remove the driven pulley assembly and relevant belt.
  • Page 32 Pins stop collar - Remove the collar by means of 2 screwdrivers. - Remove the 4 guide pins. - Remove the mobile driven half pulley.
  • Page 33 Fixed driven half pulley bearings - Check that the bush shows no signs of wear or damage; if necessary, replace the fixed driven half pulley. - Remove the stop ring with the pliers. Remove the ball bearing by inserting the specific tool in the roller bearing. N.B.: Hold the pulley to avoid damaging the thread.

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