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TECHNICAL TRAINING

SALES DIVISION

TWO STROKE DIRECT INJECTION SYSTEM)


(TSDI)
ref: INJ.001.12/2002.F

CONTENTS
INTRODUCTION...........................................................................................................................................................3 PRESENTATION OF THE 2 STROKE INJECTION SYSTEM......................................................................................4 Synoptics ...................................................................................................................................................................4 Functioning principle..................................................................................................................................................5 SYSTEM COMPONENTS.............................................................................................................................................7 Functioning principle..................................................................................................................................................7 Ignition coil.................................................................................................................................................................8 DIAGNOSTIC................................................................................................................................................................9 Warning .....................................................................................................................................................................9 Fault processing principle ..........................................................................................................................................9 Self-diagnostic principle.............................................................................................................................................9 LOCATION OF COMPONENTS .................................................................................................................................11 Looxor 50 cc ............................................................................................................................................................11 Elystar 50 cc ............................................................................................................................................................12 TOOLING....................................................................................................................................................................13 PARAMETER MEASUREMENT.................................................................................................................................14

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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INTRODUCTION.

INTRODUCTION. Of the throttle angle / engine 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 LOOXOR 50 cc and ELYSTAR 50 cc and requires NO ADJUSTMENT

1. 2. 3. 4.

Cylinder head Petrol injector Air injector Spark plug

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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PRESENTATION OF THE 2 STROKE INJECTION SYSTEM


PRESENTATION OF THE 2 STROKE INJECTION SYSTEM Synoptics

Throttle unit

INJECTION AND IGNITION ECU

Petrol injector

Engine position and speed sensor Software : Manages system operation Calibration: Values specific to the machine (mapping)

Air injector

Engine temperature sensor

Ignition coil

Battery voltage

Fuel pump

Altitude sensor (option)

Oil pump

ECU locking code

Temperature gauge

Immobiliser module

Diagnostic lamp Injection

Diagnostic plug

Diagnostic lamp Transponder

ANT.

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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PRESENTATION OF THE 2 STROKE INJECTION SYSTEM


Functioning principle

1 2 3 4 5 6 7 8

Injection and ignition ECU Throttle unit Engine position and speed sensor Engine temperature sensor Battery Altitude sensor (optional) Petrol injector Air injector

9 10 11 12 13 14 15

Ignition coil Fuel pump Oil pump Diagnostic light Diagnostic plug Immobiliser module Transponder antenna

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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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. Antenna

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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SYSTEM COMPONENTS
SYSTEM COMPONENTS Functioning principle

1. 2. 3.

Crank assembly Compressor Feed rail a / petrol injector b / air injector c/ petrol pressure regulator A. Fuel inlet B. Fuel return C. Pressurised air inlet

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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SYSTEM COMPONENTS
Ignition coil

Powered directly by the battery, the coil is activated by the ECU power stage on the basis of the engine load parameters (signal from throttle unit), the engine speed (signal from speed sensor), the engine temperature, etc Note: specific inductive discharge coil instead of capacitive IMPORTANT : The use of a resistive suppressor and resistive spark plug are IMPERATIVE

1. 2. 3. 4. 5. 6.

Injection/ignition ECU Battery Ignition switch Engine position and speed sensor HT coil and suppressor Resistive spark plug

7. 8. 9. 10. 11.

Immobiliser module Instrument panel Antenna Diagnostic plug Loop

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DIAGNOSTIC
DIAGNOSTIC Warning A LED is lit on the instrument panel to inform the rider of a fault/faults on the system ELECTRICAL function Fault processing principle Three priority levels 1 - serious safety fault: fault memorised in ECU and LED stays on Note: When the ignition is turned on, the LED stays on to check it is functioning correctly 2 - serious fault: fault memorised in ECU and LED flashes 3 - minor fault: fault memorised without lighting LED

Self-diagnostic principle Instrument panel warning lamp

Injection ECU Inputs Injection ignition system

Microprocessor Outputs Fault memory

Dialog with tester

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DIAGNOSTIC

1 - With the instrument panel LED (*) 2 - With the diagnostic tool (*) (**) (*) see MANUAL and METHOD N The diagnostic tool is composed of:

(**) see WORKSHOP TOOLING N8

1 - a screen, a Nintendo Game Boy Color console a - on/off button b - arrows: select key c - button A: confirm button d - button B: return button e - select button: for help 2 - a cartridge, containing the software for dialog between the machine and the screen 3 - a cable to link the machine to the tool a cable to link the tool to a PC a cartridge updating software

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LOCATION OF COMPONENTS
LOCATION OF COMPONENTS Looxor 50 cc

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LOCATION OF COMPONENTS
Elystar 50 cc

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TOOLING
TOOLING
. Tool N 755878 Description diagnostic tool (Color Gameboy) 755989 air injector drift Used with 755986 air injector setting tool

755806 French cartridge

755878

750539

Tie-wrap pliers

755807 Export cartridge

755878

755996

hose clamp

755990

diagnostic tool update software

755878 755806 755807

756056 Tank ring spanner

756017

petrol injection power supply harness

TRAINING MANUAL: 2-STROKE DIRECT INJECTION Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

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PARAMETER MEASUREMENT SHEET


PARAMETER MEASUREMENT MACHINE DATA VIN Mileage ECU N Software Calibration PARAMETER Meas. 1 engine stopped Meas. 2 idling

LOOXOR ELYSTAR

CUSTOMER CODE : NAME Tel:

Fault codes found during check:

Standard values Cold

Meas. 1 engine stopped

Meas. 2 idling

Standard values Hot

Engine speed Battery voltage Throttle valve position Potentiometer track 1 Potentiometer track 2 Engine temperature Petrol injection time Air injection time Ignition advance Sensor power supply Temperature sensor Petrol pump Oil pump Immobiliser ECU locking
TRAINING MANUAL: 2-STROKE DIRECT INJECTION

1800 to 10000 rpm 13.8 to 15 volts 0 to 100% 0.5 to 4.5 volts 4.5 to 0.5 volts -10 to +40c 0 to 20 ms 0 to 20 ms 0 to 50 4.95 to 5.05 volts 3 to 4.20 volts On On Unlock Unlock
Reproduction or translation, even partial, forbidden without the written consent of Peugeot Motocycles

1600 to 10000 rpm 13.8 to 15 volts 0 to 100% 0.5 to 4.5 volts 4.5 to 0.5 volts +40 to +200c 0 to 10 ms 0 to 10 ms 0 to 50 4.95 to 5.05 volts 4.10 to 5 volts On On Unlock Unlock
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Photocopy and sent to Peugeot Motocycles in case of problem requiring help from our network training department