TECHNICAL TRAININGSALES DIVISION

TWO STROKE DIRECT INJECTIONSYSTEM)

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

CONTENTS

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INTRODUCTION...........................................................................................................................................................3PRESENTATION OF THE 2 STROKE INJECTION SYSTEM......................................................................................4

Synoptics ...................................................................................................................................................................4Functioning principle..................................................................................................................................................5

SYSTEM COMPONENTS.............................................................................................................................................7Functioning principle..................................................................................................................................................7Ignition coil.................................................................................................................................................................8

DIAGNOSTIC................................................................................................................................................................9Warning .....................................................................................................................................................................9Fault processing principle ..........................................................................................................................................9Self-diagnostic principle.............................................................................................................................................9

LOCATION OF COMPONENTS.................................................................................................................................11Looxor 50 cc ............................................................................................................................................................11Elystar 50 cc ............................................................................................................................................................12

TOOLING....................................................................................................................................................................13PARAMETER MEASUREMENT.................................................................................................................................14

INTRODUCTION.

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INTRODUCTION.

Of the throttle angle / engine speed type, the SYNERJECT system was developed for the following applications:Monopoint sequential injectionStatic timing

The system basic principle consists in measuring the engine speed and load ( throttle opening ) in order to determinethe optimum quantity of fuel injected

This system is used on the LOOXOR 50 cc and ELYSTAR 50 cc and requires NO ADJUSTMENT

1. Cylinder head2. Petrol injector3. Air injector4. Spark plug

PRESENTATION OF THE 2 STROKE INJECTION SYSTEM

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PRESENTATION OF THE 2 STROKE INJECTION SYSTEMSynoptics

Throttle unit Petrol injector

Engine position andspeed sensor Air injector

Engine temperaturesensor Ignition coil

Battery voltage Fuel pump

Altitude sensor(option) Oil pump

Temperature gauge

Immobiliser module

Diagnostic lampInjection Diagnostic plug Diagnostic lamp

TransponderANT.

Software :Manages system

operation

Calibration:Values specific to

the machine(mapping)

INJECTION AND IGNITION ECU

ECU locking code

PRESENTATION OF THE 2 STROKE INJECTION SYSTEM

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Functioning principle

1 Injection and ignition ECU2 Throttle unit3 Engine position and speed sensor4 Engine temperature sensor5 Battery6 Altitude sensor (optional)7 Petrol injector8 Air injector

9 Ignition coil10 Fuel pump11 Oil pump12 Diagnostic light13 Diagnostic plug14 Immobiliser module15 Transponder antenna

PRESENTATION OF THE 2 STROKE INJECTION SYSTEM

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Fuel system1. Fuel tank2. Fuel pump3. Pressure regulator

Ignition system:4 Coil and suppressor5 Resistive spark plug

Injection system6 Petrol injector7 Air injector

Lubrication system8 Oil tank9 Oil pump

Compressed air circuit10. Compressor

Transponder circuit11. Immobiliser module12. Antenna

SYSTEM COMPONENTS

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SYSTEM COMPONENTSFunctioning principle

1. Crank assembly2. Compressor3. Feed rail

a / petrol injectorb / air injectorc/ petrol pressure regulator

A. Fuel inletB. Fuel returnC. Pressurised air inlet

SYSTEM COMPONENTS

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Ignition coilPowered directly by the battery, the coil is

activated by the ECU power stage on the basis of theengine load parameters (signal from throttle unit), theengine speed (signal from speed sensor), the enginetemperature, etc…

Note: specific inductive discharge coil instead ofcapacitive

IMPORTANT : The use of a resistive suppressor andresistive spark plug are IMPERATIVE

1. Injection/ignition ECU2. Battery3. Ignition switch4. Engine position and speed sensor5. HT coil and suppressor6. Resistive spark plug

7. Immobiliser module8. Instrument panel9. Antenna10. Diagnostic plug11. Loop

DIAGNOSTIC

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DIAGNOSTICWarning

A LED is lit on the instrument panel to inform therider of a fault/faults on the system ELECTRICALfunction

Fault processing principleThree priority levels

1 - « serious safety » fault: fault memorised inECU and LED stays onNote: When the ignition is turned on, the LED stays onto check it is functioning correctly

2 - « serious » fault: fault memorised in ECU andLED flashes

3 - « minor » fault: fault memorised withoutlighting LED

Self-diagnostic principle

Instrument panel warning lamp

InjectionECU

Inputs Outputs

Dialog withtester

Microprocessor

Injectionignitionsystem

Fault memory

DIAGNOSTIC

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1 - With the instrument panel LED (*)2 - With the diagnostic tool (*) (**)

(*) see « MANUAL and METHOD » N° (**) see « WORKSHOP TOOLING » N°8The diagnostic tool is composed of:

1 - a screen, a Nintendo © Game Boy ™ Color consolea - on/off buttonb - arrows: select keyc - button A: confirm buttond - button B: return buttone - select button: for help

2 - a cartridge, containing the software for dialog between the machine and the screen3 - a cable to link the machine to the tool• a cable to link the tool to a PC• a cartridge updating software

LOCATION OF COMPONENTS

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LOCATION OF COMPONENTSLooxor 50 cc

LOCATION OF COMPONENTS

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Elystar 50 cc

TOOLING

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TOOLING

. Tool N° Description Used with

755878 diagnostic tool(Color Gameboy)

755806 French cartridge 755878

755807 Export cartridge 755878

755990 diagnostic toolupdate software

755878755806755807

756017 petrol injectionpower supply

harness

755986 air injector settingtool

755989 air injector drift

750539 Tie-wrap pliers

755996 hose clamp

756056 Tank ring spanner

PARAMETER MEASUREMENT SHEET

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PARAMETER MEASUREMENT

MACHINE DATAVINMileageECU N°SoftwareCalibration

Fault codes found during check:

PARAMETER Meas. 1engine

stopped

Meas. 2idling

Standard valuesCold

Meas. 1engine

stopped

Meas. 2idling

Standard valuesHot

Engine speed 1800 to 10000 rpm 1600 to 10000 rpmBattery voltage 13.8 to 15 volts 13.8 to 15 voltsThrottle valve position 0 to 100% 0 to 100%Potentiometer track 1 0.5 to 4.5 volts 0.5 to 4.5 voltsPotentiometer track 2 4.5 to 0.5 volts 4.5 to 0.5 voltsEngine temperature -10 to +40°c +40 to +200°cPetrol injection time 0 to 20 ms 0 to 10 msAir injection time 0 to 20 ms 0 to 10 msIgnition advance 0 to 50 ° 0 to 50 °Sensor power supply 4.95 to 5.05 volts 4.95 to 5.05 voltsTemperature sensor 3 to 4.20 volts 4.10 to 5 voltsPetrol pump On OnOil pump On OnImmobiliser Unlock UnlockECU locking Unlock Unlock

Photocopy and sent to Peugeot Motocycles in case of problem requiring help from our network training department

LOOXOR ELYSTAR

CUSTOMER CODE :NAMETel: