JetForce - Scooter PEUGEOT - Free user manual and instructions

USER MANUAL JetForce PEUGEOT

Red and silver sports scooter with black seat and silver body, no visible text or symbols

PRESENTATION OF THE MACHINE

CONTENTS

CHARACTERISTICS ....5

Engine....5

Dimensions and weight 5

50 CC ENGINES....6

50 cc 2-stroke TSDI liquid cooled engine....6

Description 7

Separate lubrication....7

Cooling....7

CATALYTIC EXHAUST 8

Composition of the catalytic exhaust system: 8

FUNCTIONING OF THE CATALYTIC CONVERTER EXHAUST....8

Definition......8

INJECTION SYSTEMS / TSDI IGNITION....9

Introduction 9

SYSTEM COMPONENTS....10

Functioning principle 10

PRESENTATION OF THE 2 STROKE INJECTION SYSTEM ....11

DIAGNOSTIC....12

Warning....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

BRAKES....20

Reminder of functioning of the different braking systems....20

ABS/PBS hydraulic braking system....21

ABS/PBS SYSTEM SYNOPTICS....22

BODY PANELS....23

ELECTRICITY 25

Functioning principle of the 50 cc starter and lighting circuits....25

50 cc ignition on or engine running....26

50 cc starting function 27

Direction indicator functioning principle (125 cc)....28

Hazard warning lights with ignition on (125 cc)....29

CONTENTS

Hazard warning lights without ignition on (125 cc)....30

Functioning principle of the ABS/PBS system (125 cc)....31

ABS/PBS ELYSTAR 125cc ....32

TRANSPONDER IMMOBILISER ....33

System programming 33

Reminder 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 reset....39

Fuel gauge self-diagnostic....39

Gauge functioning (8s timer) 39

LOCATION OF COMPONENTS 40

50 cc 40

125 cc 41

SPECIAL TOOLING....42

CHARACTERISTICS

CHARACTERISTICS

Engine

50 cm	^3 125 cm	^3
Type Single	cylinder 2-stroke direct injection	Single cylinder 4-stroke indirect injection
Cooling Liquid
Bore x stroke	39.9 x 39.8 mm 57 x 48.9 mm
Cubic capacity	49.9 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	1914 mm	1918 mm
Width at handlebar	740 mm
Height with rear view mirror	1260	1279
Wheelbase	1314 mm	1369 mm
Saddle height:	820 mm	845 mm
Unladen weight	115 kg	149 kg

50 CC ENGINES

50 cc 2-stroke TSDI liquid cooled engine

45 km/h version

Sport version

Unlimited version (registered)

Exterior view of a modern electric motor assembly with a black and silver housing (no visible text or symbols)

Technical line drawings of various mechanical components, including motor casings and housing (no text or labels)

Description

HL1 engine marking

Separate lubrication

1.2 l tank capacity

Technical line drawing of a mechanical assembly with orange cable and component (no text or symbols)

Cooling

1.21 capacity

Diagram of a mechanical assembly with blue and red tubing connecting components (no text or labels)

CATALYTIC EXHAUST

Composition of the catalytic exhaust system:

The catalytic exhaust system is distinguished by the fitting of a « catalyser cone » just after the exhaust inlet cone. All the exhaust gases are fed through the catalyser cone.

Technical diagram showing two views of a vehicle exhaust system with labeled components

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 inside a steel tube forming a honeycomb.

Diagram illustrating a layered structure with labeled components: a meshed circular component, a wavy layer with red ribbons, and a wavy bottom layer.

1. Metal grid
2. Steel tube
3. Honeycomb
4. Impregnation with precious metals (Platinum, palladium, rhodium, etc...)

INJECTION SYSTEMS / TSDI IGNITION

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 JET FORCE 50 scooter and requires NO ADJUSTMENT (Ditto Looxor and Elystar 50 cc).

Technical diagram of a mechanical assembly with numbered parts for identification

1. Cylinder head
2. Petrol injector
3. Air injector
4. Spark plug

SYSTEM COMPONENTS

Functioning principle

Technical diagram of a mechanical assembly with labeled parts, including components A through N and numbered parts 1 to 6.

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

PRESENTATION OF THE 2 STROKE INJECTION SYSTEM

Technical diagram of an engine assembly with numbered components and labeled parts including TSDI, FIAMM, and motor control.

Fuel system

1. Fuel tank
2. Fuel pump
3. Pressure regulator

Ignition system:

1. Coil and suppressor
2. Resistive spark plug

Injection system

1. Petrol injector
2. Air injector

Lubrication system

1. Oil tank
2. Oil pump

Compressed air circuit

1. Compressor

Transponder circuit

1. Immobiliser module
2. Transponder

DIAGNOSTIC

Warning

125 1200 x 1000 mm 0 km/h

A LED comes on on the instrument cluster to warn the rider of a fault on the injection and ignition system ELECTRICS

Fault 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

graph TD
    A["Warning light on inst. cluster"] --> B["Microprocessor"]
    C["INPUTS OUTPUTS"] --> D["Injection ECU"]
    D --> B
    B --> E["Injection Ignition System"]
    B --> F["Fault memory"]
    E --> G["Select function"]
    F --> G
    G --> H["Service functions"]
    H --> I["Clear fault codes *"]
    H --> J["Initialization potentiome *"]
    H --> K["Priming the oil pump *"]
    H --> L["Measuring the petrol flow *"]
    G --> M["Read fault codes"]
    G --> N["Read parameter"]
    G --> O["Activate actuators"]
    G --> P["Service functions"]
    G --> Q["ECU identification"]
    G --> R["ECU update"]
    M --> S["Dialogue with the tester"]
    N --> S
    O --> S
    P --> S
    Q --> S
    R --> S
    S --> T["Back to Dialogue with the tester"]

125 CC ENGINES

125 cc 4-stroke EFI liquid cooled engine

Naturally aspirated version

Turbo version (compressor)

Two industrial mechanical components, one metallic and one black, displayed against a white background (no visible text or symbols)

Exploded view diagram of a mechanical assembly showing exploded and assembled views (no text or labels)

Description

FD5 engine markings

Lubrication

1.25 l capacity

Cooling

1.5 l capacity

Diagram of a vehicle battery pack connected to a mechanical component, showing red and blue tubing (no text or labels)

Cooling system functioning principle

graph TD
    A["ON"] --> B["6"]
    C["OFF"] --> D["3"]
    B --> E["RG-NR"]
    D --> E
    E --> F["15A"]
    F --> G["NR"]
    G --> H["2"]
    H --> I["1"]
    I --> J["VE-NR"]
    K["VE"] --> L["25A"]
    L --> M["RG"]
    N["HEV"] --> O["1"]
    P["HEV"] --> Q["4"]

1. Battery
2. Ignition switch
3. Fan
4. Heat switch

INTRODUCTION

Of the throttle angle / engine speed type, the EFI 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 125 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 consumption
• Improved rider comfort

Fuel injector

The injectors are of the electro-magnetically operated single-jet type

The ECU electrical pulses generate a magnetic field in the magnet winding, the core is attracted, the injector plate raised off its seat and releases the pressurised fuel upline of the inlet valve

Technical diagram showing three stages of a mechanical valve or actuator assembly with labeled voltage and component layout.

INJECTION SYSTEM / EFI IGNITION

Reminder of operation

Technical schematic diagram of an engine cylinder system with numbered components and wiring connections

1. ECU
2. Battery

Fuel system

1. Fuel tank
2. Fuel pump
3. Pressure regulator

Ignition system:

1. HT coil
2. Resistive spark plug and suppressor

Transponder circuit

1. Transponder module
2. Transponder

Injection system

1. Petrol injector
2. Idle control valve
3. Air pressure and air temperature sensor

Diagnostic circuit

1. Injection diagnostic lamp
2. Transponder diagnostic lamp
3. Diagnostic plug

FRAME Frame

Technical line drawing of automotive chassis components (no text or labels)

Steel wrap-round frame (DIRECT PERIMETRIC FRAME - DPF)

Suspension

	50 cm ^3
Front suspension:	∅ 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

Technical diagram of a vehicle suspension system with spring, chain, and wheel components (no text or labels)

Suspension

	125 cm ^3
Front suspension	∅ 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

Technical illustration of a vehicle suspension system with colored components (no text or labels)

BRAKES

Reminder of functioning of the different braking systems

Conventional hydraulic system

Pure electrical circuit lines without any symbols

SBC integral hydraulic braking system

Pure electrical circuit lines without any symbols

SBC2 integral hydraulic braking system

graph TD
    A["Port 1"] --> B["Component 1"]
    B --> C["Component 2"]
    C --> D["Component 3"]
    D --> E["Component 4"]
    E --> F["Port 5"]
    F --> G["Component 6"]
    G --> H["Port 7"]
    H --> I["Component 8"]
    I --> J["Port 9"]
    J --> K["Component 10"]
    K --> L["Port 11"]
    L --> M["Component 12"]
    M --> N["Port 13"]
    N --> O["Component 14"]
    O --> P["Port 15"]
    P --> Q["Component 16"]
    Q --> R["Port 17"]
    R --> S["Component 18"]
    S --> T["Port 19"]
    T --> U["Component 20"]
    U --> V["Port 21"]
    V --> W["Component 22"]
    W --> X["Port 23"]
    X --> Y["Component 24"]
    Y --> Z["Port 25"]

ABS/PBS hydraulic braking system

Technical schematic diagram of a mechanical or electrical device with numbered components and labeled parts

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

ABS/PBS SYSTEM SYNOPTICS

graph TD
    A["RH brake lever contactor"] --> B["ABS/PBS ECU"]
    C["RH brake lever contactor"] --> B
    D["Front wheel speed sensor"] --> B
    E["Battery voltage"] --> B
    F["Vehicle coding (PIN code)"] --> B
    B --> G["Software: Manages system operation"]
    B --> H["Calibration: Values specific to machine (mapping)"]
    G --> I["Diagnostic plug"]
    H --> J["Diagnostic light"]
    K["Hydraulic pump"] --> L["Brake light"]
    M["Regulation solenoid valve"] --> N["Main relay"]
    O["Starter relay"] --> P["Instrument cluster"]
    B -.-> Q["Dashed line"]
    Q -.-> R["Diagnostic plug"]

BODY PANELS

BODY PANELS

Exploded view diagram of car body components with numbered labels for identification

TRAINING MANUAL: JET FORCE

graph TD
    A["BODY PANELS"] --> B["LEGSHIELD TOP PANEL (1)"]
    A --> C["FOOTBOARDS (5)"]
    A --> D["RIDER SADDLE (8)"]
    A --> E["PASSENGER SADDLE AND GRAB HANDLE (15)"]
    B --> F["HANDLBAR FRONT FAIRING (2)"]
    C --> G["FRONT LOWER LEGSHIELDS (4)"]
    D --> H["TUNNELS (6)"]
    E --> I["BATTERY COVER (16)"]
    F --> J["HANDLEBAR REAR FAIRING (3)"]
    G --> K["MUDGUARD AND FORK GUARD (12)"]
    H --> L["BELLYPAN (7)"]
    I --> M["FUEL TANK FAIRING (10)"]
    J --> N["MUDGUARD (13)"]
    K --> O["LEGSHIELD REAR PANEL (11)"]
    L --> P["MUDFLAP AND NUMBER PLATE PANEL (14)"]
    M --> Q["REAR FAIRING AND IMMOBILISER UNIT (17)"]
    N --> R["STORAGE COMPARTMENT TRIM PANELS (18)"]

TRAINING MANUAL: JET FORCE
Page: 24/43
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

ELECTRICITY

Functioning principle of the 50 cc starter and lighting circuits

graph TD
    A["①"] --> B["VE"]
    B --> C["ON"]
    B --> D["OFF"]
    C --> E["7.5A"]
    D --> F["6"]
    D --> G["3"]
    E --> H["RG-NR"]
    F --> I["15A"]
    G --> J["RG"]
    K["②"] --> L["VE"]
    M["③"] --> N["VE"]
    O["④"] --> P["VE"]
    Q["⑤"] --> R["VE"]
    S["⑥"] --> T["VE"]
    U["⑦"] --> V["VE"]
    W["⑧"] --> X["VE"]
    Y["⑨"] --> Z["VE"]
    AA["⑩"] --> AB["VE"]
    AC["⑪"] --> AD["VE"]
    AE["⑫"] --> AF["VE"]
    AG["⑬"] --> AH["VE"]
    AI["⑭"] --> AJ["VE"]
    AK["⑮"] --> AL["VE"]
    AM["⑯"] --> AN["VE"]
    AO["⑰"] --> AP["VE"]
    AQ["⑱"] --> AR["VE"]
    AS["⑲"] --> AT["VE"]
    AU["⑳"] --> AV["VE"]
    AW["㉑"] --> AX["VE"]
    AY["㉒"] --> AZ["VE"]
    BA["㉔"] --> BB["VE"]
    BC["㉕"] --> BD["VE"]
    BE["㉖"] --> BF["VE"]
    BG["㉗"] --> BH["VE"]
    BI["㉘"] --> BJ["VE"]
    BK["㉛"] --> BL["VE"]
    BM["㉜"] --> BN["VE"]
    BO["㉝"] --> BP["VE"]
    BQ["㉓"] --> BR["VE"]
    BS["㉔"] --> BT["VE"]
    BU["㉔"] --> BV["VE"]
    BW["㉕"] --> BX["VE"]
    BY["㉖"] --> BZ["VE"]
    CA["㉗"] --> CB["VE"]
    CC["㉘"] --> CD["VE"]
    CE["㉙"] --> CF["VE"]
    DG["㉚"] --> DH["VE"]

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

50 cc ignition on or engine running

graph TD
    subgraph Unit_1
        A["①"] --> B["VE"]
        B --> C["ON"]
        C --> D["OFF"]
        D --> E["6"]
        E --> F["3"]
        F --> G["15A"]
        G --> H["RG"]
        H --> I["12"]
        I --> J["3"]
        J --> K["1"]
        K --> L["4"]
        L --> M["2"]
        M --> N["3"]
        N --> O["5"]
        O --> P["7"]
        P --> Q["VE"]
        Q --> R["⑤"]
        R --> S["⑦"]
        S --> T["⑦"]
        T --> U["⑦"]
        U --> V["⑦"]
        V --> W["⑦"]
        W --> X["⑦"]
        X --> Y["⑦"]
        Y --> Z["⑦"]
        Z --> AA["⑦"]
        AA --> AB["⑦"]
        AB --> AC["⑦"]
        AC --> AD["⑦"]
        AD --> AE["⑦"]
        AE --> AF["⑦"]
        AF --> AG["⑦"]
        AG --> AH["⑦"]
        AH --> AI["⑦"]
        AI --> AJ["⑦"]
        AJ --> AK["⑦"]
        AK --> AL["⑦"]
        AL --> AM["⑦"]
        AM --> AN["⑦"]
        AN --> AO["⑦"]
        AO --> AP["⑦"]
        AP --> AQ["⑦"]
        AQ --> AR["⑦"]
        AR --> AS["⑦"]
        AS --> AT["⑦"]
        AT --> AU["⑦"]
        AU --> AV["⑦"]
        AV --> AW["⑦"]
        AW --> AX["⑦"]
        AX --> AY["⑦"]
        AY --> AZ["⑦"]
        AZ --> BA["⑦"]
        BA --> BB["⑦"]
        BB --> BC["⑦"]
        BC --> BD["⑦"]
        BD --> BE["⑦"]
        BE --> BF["⑦"]
        BF --> BG["⑦"]
        BG --> BH["⑦"]
        BH --> BI["⑦"]
        BI --> BJ["⑦"]
        BJ --> BK["⑦"]
        BK --> BL["⑦"]
        BL --> BM["⑦"]
        BM --> BN["⑦"]
        BN --> BO["⑦"]
        BO --> BP["⑦"]
        BP --> BQ["⑦"]
        BQ --> BR["⑦"]
        BR --> BS["⑦"]
        BS --> BT["⑦"]
        BT --> BU["⑦"]
        BU --> BV["⑦"]
        BV --> BW["⑦"]
        BW --> BX["⑦"]
        BX --> BY["⑦"]
        BY --> BZ["⑦"]
        BZ --> CA["⑦"]
        CA --> CB["⑦"]
        CB --> CC["⑦"]
        CC --> CD["⑦"]
        CD --> CE["⑦"]
        CE --> CF["⑦"]
        CF --> CG["⑦"]
        CG --> CH["⑦"]
        CH --> CI["⑦"]
        CI --> CJ["⑦"]
        CJ --> CK["⑦"]
        CK --> CL["⑦"]
        CL --> CM["⑦"]
        CM --> CN["⑦"]
        CN --> CO["⑦"]
        CO --> CP["⑦"]
        CP --> CQ["⑦"]
        CQ --> CR["⑦"]
        CR --> CS["⑦"]
        CS --> CT["⑦"]
        CT --> CU["⑦"]
        CU --> CV["⑦"]
        CV --> CW["⑦"]
        CW --> CX["⑦"]
        CX --> CY["⑦"]
        CY --> CZ["⑦"]
        CZ --> DA["⑦"]
        DA --> DB["⑦"]
        DB --> DC["⑦"]
        DC --> DV["⑦"]
        DV --> DW["⑦"]
        DW --> DX["⑦"]
        DX --> DXB["⑦"]
    end
    subgraph Unit_1
    A
    B
    C
    D
    E
    F
    G
    H
    I
    J
    K
    L
    M
    N
    O
    P
    Q
    R
    S
    T
    U
    V
    W
    X
    Y
    Z
    AA
    AB
    AC
    AD
    AE
    AF
    AG
    AH
    AI
    AJ
    AK
    AL
    AM
    AN
    AO
    AP
    AQ
    AR
    BA
    BB
    BC
    BD
    BE
    BF
    BG
    BH
    BI
    BJ
    BK
    BL
    BM
    BN
    BO
    BP
    BPB
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA
    BA

The 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

50 cc starting function

graph TD
    subgraph Component_1
        A["①"] --> B["②"]
        B --> C["③"]
        C --> D["④"]
        D --> E["⑤"]
        E --> F["⑥"]
        F --> G["⑦"]
        G --> H["⑧"]
        H --> I["⑨"]
        I --> J["⑩"]
        J --> K["⑪"]
        K --> L["⑫"]
        L --> M["⑬"]
        M --> N["⑭"]
        N --> O["⑮"]
        O --> P["⑯"]
        P --> Q["⑰"]
        Q --> R["⑱"]
        R --> S["⑲"]
        S --> T["⑳"]
        T --> U["⑪"]
        U --> V["⑫"]
        V --> W["⑬"]
        W --> X["⑭"]
        X --> Y["⑮"]
        Y --> Z["⑯"]
        Z --> AA["⑰"]
        AA --> AB["⑱"]
        AB --> AC["⑲"]
        AC --> AD["⑳"]
        AD --> AE["⑪"]
        AE --> AF["⑫"]
        AF --> AG["⑬"]
        AG --> AH["⑭"]
        AH --> AI["⑮"]
        AI --> AJ["⑯"]
        AJ --> AK["⑰"]
        AK --> AL["⑱"]
        AL --> AM["⑲"]
        AM --> AN["⑳"]
        AN --> AO["㉑"]
        AO --> AP["㉒"]
        AP --> AQ["㉓"]
        AQ --> AR["㉔"]
        AR --> AS["㉕"]
        AS --> AT["㉖"]
        AT --> AU["㉗"]
        AU --> AV["㉘"]
        AV --> AW["㉙"]
        AW --> AX["㉚"]
        AX --> AY["㉜"]
        AY --> AZ["㉝"]
        AZ --> BA["㉞"]
        BA --> BB["㉟"]
        BB --> BC["㉟A"]
        BC --> BD["㉞A"]
        BD --> BE["㉟B"]
        BE --> BF["㉟C"]
        BF --> BG["㉟D"]
        BG --> BH["㉟E"]
        BH --> BI["㉟F"]
        BI --> BJ["㉟G"]
        BJ --> BK["㉟H"]
        BK --> BL["㉟I"]
        BL --> BM["㉟J"]
        BM --> BN["㉟K"]
        BN --> BO["㉟L"]
        BO --> BP["㉟M"]
        BP --> BQ["㉟N"]
        BQ --> BR["㉟O"]
        BR --> BS["㉟P"]
        BS --> BT["㉟Q"]
        BT --> BU["㉟R"]
        BU --> BV["㉟S"]
        BV --> BW["㉟T"]
        BW --> BX["㉟U"]
        BX --> BY["㉟V"]
        BY --> BZ["㉟W"]
        BZ --> CA["㉟X"]
        CA --> CB["㉟Y"]
        CB --> CC["㉟Z"]

Press starter button (3):

Pressing the starter button (3) earths the starter relay winding (12) which then powers:

• The 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 the lighting relay is earthed through the starter motor

- The lighting circuit is powered

Direction indicator functioning principle (125 cc)

graph TD
    A[" meters"] --> B[" ON "]
    A --> C[" OFF "]
    B --> D[" RG-NR "]
    C --> E[" RG "]
    D --> F[" 15A "]
    E --> G[" 25A "]
    F --> H[" 19 "]
    G --> I[" 18 "]
    H --> J[" BA-NR "]
    I --> K[" 3 "]
    J --> L[" OR "]
    K --> M[" BC "]
    L --> N[" BC "]
    M --> O[" 4 "]
    N --> P[" 6 "]
    O --> Q[" 7 "]
    P --> R[" 7 "]
    Q --> S[" 7 "]
    R --> T[" 7 "]
    S --> U[" 7 "]
    T --> V[" 7 "]
    U --> W[" 7 "]
    V --> X[" 7 "]
    W --> Y[" 7 "]
    X --> Z[" 7 "]
    Y --> AA[" 7 "]
    Z --> AB[" 7 "]

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

Hazard warning lights with ignition on (125 cc)

graph TD
    A["①"] --> B["VE"]
    B --> C["25A"]
    C --> D["RG-NR"]
    D --> E["15A"]
    E --> F["NR"]
    F --> G["19"]
    G --> H["1"]
    H --> I["18"]
    I --> J["BA-NR"]
    J --> K["⑤"]
    K --> L["1"]
    L --> M["3"]
    M --> N["2"]
    N --> O["OFF"]
    P["⑥"] --> Q["VE"]
    Q --> R["OR"]
    R --> S["OR"]
    S --> T["VE"]
    U["⑦"] --> V["VE"]
    V --> W["OR"]
    W --> X["OR"]
    X --> Y["VE"]
    Z["⑧"] --> AA["BC"]
    AA --> AB["VE"]
    AC["⑨"] --> AD["OR"]
    AD --> AE["OR"]
    AE --> AF["VE"]
    AG["⑩"] --> AH["BC"]
    AH --> AI["VE"]
    AJ["⑪"] --> AK["OR"]
    AK --> AL["OR"]
    AL --> AM["VE"]

Hazard warning lights without ignition on (125 cc)

graph TD
    A["ON"] --> B["6"]
    C["OFF"] --> D["3"]
    B --> E["RG-NR"]
    D --> F["15A"]
    F --> G["NR"]
    G --> H["19"]
    H --> I["1"]
    I --> J["18"]
    J --> K["BA-NR"]
    K --> L["1"]
    L --> M["3"]
    M --> N["2"]
    N --> O["5"]
    P["VE"] --> Q["3"]
    R["OR"] --> S["7"]
    T["VE"] --> U["7"]
    V["OR"] --> W["7"]
    X["VE"] --> Y["7"]
    Z["OR"] --> AA["7"]
    AB["VE"] --> AC["7"]
    AD["OR"] --> AE["7"]
    AF["VE"] --> AG["7"]
    AH["OR"] --> AI["7"]
    AJ["VE"] --> AK["7"]
    AL["OR"] --> AM["7"]
    AN["VE"] --> AO["7"]
    AP["OR"] --> AQ["7"]
    AR["VE"] --> AS["7"]
    AT["OR"] --> AU["7"]
    AV["VE"] --> AW["7"]
    AX["OR"] --> AY["7"]
    AZ["VE"] --> BA["7"]
    BB["OR"] --> BC["7"]
    BD["VE"] --> BE["7"]
    BF["OR"] --> BG["7"]
    BH["VE"] --> BI["7"]
    BJ["OR"] --> BK["7"]
    BL["VE"] --> BM["7"]
    BN["OR"] --> BO["7"]
    BP["VE"] --> BQ["7"]
    BR["OR"] --> BS["7"]
    BT["VE"] --> BU["7"]
    BV["OR"] --> BW["7"]
    BX["VE"] --> BY["7"]
    BZ["OR"] --> BQ
    CA["VE"] --> CB["7"]
    CC["OR"] --> CC
    DD["VE"] --> DE["7"]
    DF["OR"] --> DG["7"]
    DH["VE"] --> DI["7"]
    DJ["OR"] --> DJ
    DK["VE"] --> DL["7"]
    DV["OR"] --> DV
    DW["VE"] --> DX["7"]
    DX --> DXB["7"]
    DXB --> DXC["7"]
    DXC --> DXD["7"]
    DXD --> DXE["7"]
    DXE --> DXF["7"]
    DXF --> DXG["7"]
    DXG --> DXH["7"]
    DXH --> DXI["7"]
    DXI --> DXJ["7"]
    DXJ --> DXK["7"]
    DXK --> DXL["7"]
    DXL --> DXM["7"]
    DXM --> DXN["7"]
    DXN --> DXO["7"]
    DXO --> DXP["7"]
    DXP --> DXQ["7"]
    DXQ --> DXR["7"]
    DXR --> DXS["7"]

Functioning principle of the ABS/PBS system (125 cc)

graph TD
    A["1"] --> B["25A"]
    C["2"] --> D["ON OFF 6 3"]
    E["3"] --> F["4 2 5"]
    G["4"] --> H["5 15A"]
    I["5"] --> J["6 19"]
    K["6"] --> L["7 20 1"]
    M["7"] --> N["8 14"]
    O["8"] --> P["9 25 24 CODE PIN"]
    Q["9"] --> R["A3 B3 A2 B2 A1 B1"]
    S["10"] --> T["1 25A"]
    U["11"] --> V["2 25"]
    W["12"] --> X["3 4 5"]
    Y["13"] --> Z["4"]

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

ABS/PBS ELYSTAR 125cc

graph TD
    A["1"] --> B["25A"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    G --> H["8"]
    H --> I["9"]
    I --> J["A3 B3"]
    I --> K["A2 B2"]
    I --> L["A1 B1"]
    M["OFF ON 6"] --> N["15A"]
    O["25A"] --> P["3"]
    Q["10"] --> R["25A"]
    S["14"] --> T["5"]
    U["24"] --> V["10"]
    W["25"] --> X["10"]
    Y["24"] --> Z["10"]
    AA["10"] --> AB["25A"]
    AC["10"] --> AD["25A"]
    AE["10"] --> AF["25A"]
    AG["10"] --> AH["25A"]
    AI["10"] --> AJ["25A"]
    AK["10"] --> AL["25A"]
    AM["10"] --> AN["25A"]
    AO["10"] --> AP["25A"]
    AQ["10"] --> AR["25A"]
    AS["10"] --> AT["25A"]
    AU["10"] --> AV["25A"]
    AW["10"] --> AX["25A"]
    AY["3"] --> AZ["15A"]
    BA["6"] --> BB["15A"]
    BC["7"] --> BD["15A"]
    BE["8"] --> BF["15A"]
    BG["9"] --> BH["15A"]
    BI["10"] --> BJ["15A"]
    BK["10"] --> BL["15A"]
    BM["10"] --> BN["15A"]
    BO["10"] --> BP["15A"]
    BQ["3"] --> BR["25A"]
    BS["4"] --> BT["25A"]
    BU["5"] --> BV["25A"]
    BW["6"] --> BX["25A"]
    BY["7"] --> BZ["25A"]
    CA["8"] --> CB["25A"]

TRANSPONDER IMMOBILISER

Precautions:

Check that the diagnostic plug jumper is fitted. The jumper provides the link between the immobiliser module and the injection/ignition ECU, and is essential to be able to start the engine

If the jumper is not fitted, the transponder LED diagnostic is always the same (no link between the immobiliser and the ECU)

Note: Fitting of a 5 kΩ resistive suppressor along with a resistive spark plug is essential for the proper functioning of the engine

System programming

The machine is supplied with a red key (master) and a black key

The system is programmed in the factory

It is possible to program up to 7 black keys

The key memory procedure is the same as the AEC400 and ACI100 system

Reminder of the key memory procedure

1. Using the red key, set the ignition to on, and when the LED lights, turn off the ignition

2. Within a maximum of 15 seconds of cutting off the ignition with the red key, turn on the ignition with the 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 panel comes on for 0.5 seconds and flashes a number of times. The number of flashes indicates the number of keys memorised, including the red key

Additional information

Before carrying out any work on the transponder immobiliser, have the machine red key and black key to hand

If the engine will not start, a first diagnostic may be carried out using the LED before checking the other parts of the ignition system

Note: Do not remove the diagnostic plug jumper

In case of a fault, do not use an immobiliser module or ECU from another machine to carry out tests. The keys, immobiliser module and ECU programmed on another machine form an assembly, are linked by a code and must under no circumstances be separated

Important: If an ECU is changed without memorising the keys, do not turn on the ignition more than 16 times if the diagnostic jumper is disconnected as beyond this number, the ECU immobiliser function is erased.

TRANSPONDER IMMOBILISER

Synoptics

	Assembly correct	H — —
	Cut between the immobiliser module and the ECU	H H I—
	Cut between the antenna and the immobiliser unit or no transponder in they key	H HH I—
	Wrong key or immobiliser module from another machine	H HHH I—
	Blank immobiliser module	I— I H H H I—

TRANSPONDER IMMOBILISER

	Blank ECU(starting possible with red key)	H — —
	Immobiliser module and ECU blank	H
	Programmed immobiliser module and key from another machine	H H
	Blank ECU, with 16 memorised switch on without diagnostic plug loop	H H H

INSTRUMENT CLUSTER

Description

1 5 6 2 9 7 4 188888 km/min Trip 38:88 x 1000 t/min 120 188 MPH km/ft ABS 10 11 3 8

1. Multi-function display
2. Rev counter
3. Speedometer
4. Engine temperature gauge
5. Control button
6. Injection system diagnostic warning light
7. Transponder immobiliser dissuasion 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 lights (except ABS/PBS depending on version)

- Test of rev counter stepper motors (2) and engine temperature (4) giving one sweep of the needles and zero reset where necessary

Description of the multi-function display

13 15 km Trip 14 16 17 18

MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS

Changing the distance unit

km

miles

• Ignition off
  -Press button and hold down
  -Turn on the ignition
  -Release the button
  -Press for <3s to select Km/Miles
  -Turn off ignition to confirm

Tripmeter Total/Daily display

1952 km 3:15 165 km Trip 3:15

- Turn on the ignition

-Press and release the button to select the function required

Daily Km reset

-Hold down the button for >5s

Time setting

1952 km -15:25 1952 km 1952 km -15:25 1952 km -15:25

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 more than 3 seconds to confirm the time

Maintenance reset

Every 5000 km a « spanner » symbol appears informing the rider that his machine is due for service. After servicing the machine, erase the symbol as follows:

19:25 km 15:25

• 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 flash (75 ohms)
1 LED flashes (98 ohms)
8 LEDs flash (R> 87 ohms) means an empty tank

Technical diagram of a motorcycle with numbered parts and labeled components, including battery pack, motors, and gear assembly.

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

125 cc

Technical diagram of a motorcycle with numbered parts and labeled components for identification.

1. Injection ECU
2. Throttle unit
3. Engine position 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. Machine speed sensor

SPECIAL TOOLING

SPECIAL TOOLING

. Tool N°			Description	Used with
		756717 Engine mount adapter 125 cc
		750539 Tie-wrap pliers
		755996 Pipe clamp
		755986 air injector setting tool 50 cc
		755989 air injector drift 50 cc
		replaces 756076	Tank gauge spanner
		756716 replaces 755056	Tank ring spanner

. Tool N°		Description	Used with
	755990	Diagnostic toolupdate software	Computer755878755806755807
	755806	CartridgeEurope	755878
	755807	Cartridge Export	755878
	755878	Diagnostic tool(game boycolor)	755806
	756714replaces755878	Diagnostic tool(game boyadvance)	755806755807
	756017	50 cc fuelinjector powersupply harness
	756449	ABS/PBSinterface cablefor diagnostictool125 cc

SPECIAL TOOLING

. 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