Peugeot Motorcycles Scoot'elec Instruction manual

WORKSHOP
MANUAL
SERVICE AND REPAIR
SALES DIVISION
NETWORK TECHNICAL INFORMATION

CONTENTS
Page: 2
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CHARACTERISTICS ............................................................................................................................... 3
Machine markings.................................................................................................................................... 3
Characteristics......................................................................................................................................... 3
Frame....................................................................................................................................................... 3
Capacities ................................................................................................................................................ 3
Dimensions............................................................................................................................................... 3
Weight...................................................................................................................................................... 3
Tyres ........................................................................................................................................................ 3
Motor markings........................................................................................................................................ 3
SERVICE AND COMMISSIONING INSTRUCTIONS.......................................................................... 4
Check:...................................................................................................................................................... 4
Change:.................................................................................................................................................... 4
Check and change:................................................................................................................................... 4
Test machine:........................................................................................................................................... 4
Battery commissioning and maintenance procedure ................................................................................. 5
Commissioning......................................................................................................................................... 5
Charging after prolonged immobilisation................................................................................................. 6
Procedure: ............................................................................................................................................... 6
Checks before handing over to the customer:............................................................................................ 7
SPECIAL IMPORTANT POINTS............................................................................................................ 8
TIGHTENING TORQUES AND SPECIAL TOOLS............................................................................... 9
Tightening torques.................................................................................................................................... 9
Frame:.................................................................................................................................................. 9
Motor:.................................................................................................................................................. 9
Standard:.............................................................................................................................................. 9
Special tools:............................................................................................................................................ 9
BODY........................................................................................................................................................ 10
To remove lower body fairings Step 1..................................................................................................... 10
To remove the footboard Step 2.............................................................................................................. 10
To remove the saddle Step 3................................................................................................................... 10
To remove the saddle cover and lock Step 4 ........................................................................................... 11
ELECTRICITY........................................................................................................................................ 12
To remove the charger Step 5................................................................................................................. 12
Removal of the 200 Amp fuse Step 6....................................................................................................... 12
To remove the ECU Step 7 ..................................................................................................................... 13
Setting the throttle sensor....................................................................................................................... 13
To remove the batteries .......................................................................................................................... 14
Cell fitting order..................................................................................................................................... 15
MOTOR.................................................................................................................................................... 16
To remove the power unit ....................................................................................................................... 16
To remove the brushes............................................................................................................................ 17
Removal of the motor mounting rod and the stand.................................................................................. 18
To remove the transmission system......................................................................................................... 19
To remove the motor............................................................................................................................... 20
To remove the speed sensor.................................................................................................................... 20
Relay module removal............................................................................................................................ 21
MISCELLANEOUS OPERATIONS....................................................................................................... 23
Keypad removal...................................................................................................................................... 23

CHARACTERISTICS
Page: 3
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CHARACTERISTICS
Machine markings
Model code E1A
Characteristics
Motor
Characteristics Direct current and
separate excitation
Energy recovery
motor brake
Marque Leroy Somer or
Schabmüller
Max. power
output 2.8 kW
Motor speed 2100 rpm
Torque speed 2000 rpm
Frame
1Manufacturer’s plate
2VIN number
Capacities
Relay module 0.12 litres
Esso Gear Oil (EZL
848) P/N 753054
Dimensions
Length 1755 mm
Width 695 mm
Height without rear
view mirror 1100 mm
Ground clearance
Wheelbase 1300 mm
Weight
Weight 115 kg
Tyres
Front wheel 2.5"x10"
Front tyre 100/80x10
Front tyre pressure 2.5 bar
Rear wheel 2.5"x10"
Rear tyre 110/80x10
Rear tyre pressure 2.5 bar
Motor markings
Motor type EA1

SERVICE AND COMMISSIONING INSTRUCTIONS
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SERVICE AND COMMISSIONING INSTRUCTIONS
Heavy duty servicing is aimed at machines used under “harsh” conditions: door-to-door call, intensive urban
use (courier service)
Servicing operations 500 Kms
or 3 months Every 5000 Kms or months Every 10000 Kms
Heavy duty service 500 Kms Every 2500 Kms Every 5000 Kms
Check:
Diagnostic readout X X X
Throttle control X X X
Functioning of electrical equipment X X X
Front and rear brake control X X X
Tyre pressures X
Tyre condition, pressure and wear X X
Tightness of nuts and bolts X X X
Change:
Front and rear brake lining # X
Grease cam spindle X X
Drive belt 10000 km for
heavy duty
service
Check and change:
Motor brushes #
(Leroy Somer only) 10000 km for heavy duty
service
X
Test machine:
On road X X X
# if necessary

SERVICE AND COMMISSIONING INSTRUCTIONS
Page: 5
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Battery commissioning and maintenance procedure
Remark: the maintenance procedure is identical to the commissioning procedure
Important:
It is essential to use distilled water supplied by PEUGEOT MOTOCYCLES under P/N: 973582
The use of distilled water from any other source will destroy the battery and result loss of warranty.
It is forbidden to pour in distilled water before the end of charging.
Commissioning
Ensure you have 3 litres of PEUGEOT distilled water, P/N: 973582.
•Connect the charge cable to the 230 V – 10/16 A mains.
•The charge lamp comes on with a beep, the battery lamp flashes
•Press « V » on the keypad (a minimum of 2 seconds) and do not release it until the 2 confirmation beeps
are given.
•Release the « V » key, a series of 3 beeps indicates the operation is to commence, the charge lamp
flashes.
•If it does not flash, repeat the operations more quickly.
The commissioning procedure has started and will take 1à to 15 minutes.
At the end of charging, the lamps stay on indicating that the water may be added to the battery.
Note:
From this point on, you may leave the machine connected to the mains for a period of 72 hours. Beyond this
time, you will have to repeat the procedure from the start.
•Disconnect the charging cable, the lamps stay on. You now have a maximum of 30 minutes to
add water to the battery.
•Open the maintenance cover with a Torx screwdriver and slowly pour in the distilled water (P/N:
973582) until the water runs out of the overflow under the scooter.
•Close and tighten the maintenance cover, the lamps go off indicating the end of
commissioning.
•Wait for a minimum of 15 seconds before turning on the ignition.

SERVICE AND COMMISSIONING INSTRUCTIONS
Page: 6
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Charging after prolonged immobilisation
After not being used for a few months, the battery voltage may drop below 8 volts and it is impossible to
charge the machine.
In this case, the battery needs to be “woken up” by one or more connections/disconnections
to and from the mains socket.
Procedure:
1. Connect the charging connector the mains.
Important:
•The charge lamp does not come on on the instrument panel.
•No beep on the multifunction keypad.
•The fan does not run.
This is normal.
Do not turn on the scooter lights.
Do not connect the TEP96.
2. Leave the connector connected 5 minutes to the mains
3. Disconnect the connector from the mains and reconnect it immediately
Repeat operations 2 and 3 until:
•The charge lamp comes on on the instrument panel.
•The multifunction key pad sounds a beep.
•The charger fan starts.
After 5 minutes charging (for ECU, electronic control unit, Soft version 4.2.4, production prior to July 97)
Connect the TEP96 to the machine
The DISCHARGE value must be between 0 and 110 Ah
If the number of discharged Ah is over 110, use the TEP96 to carry out a « Exchange battery » procedure
Press the two buttons (A) for 3
seconds
OTHER FUNCTIONS
♦ Reading variables
♦ Memory battery
♦ Check in disjunct.
⇓
All variables
♦ Large amperemeter
♦ Large voltmeter
♦ Large speedometer
*VARIABLE (PAGE 2)*
Charge =0.0Ah
Discharge = 65.2Ah
Overcharg = 0.0Ah
OTHER FUNCTIONS
♦ Identity UCE
♦ Identity TEP
♦ SPECIAL FUNCTIONS
TO OPENING SPECIALS
FUNCTIONS
REQUEST AGREEMENT
PEUGEOT MOTOCYCLES
SPECIAL FUNCTIONS
♦ Exchange ECU
♦ Exchange battery
A

SERVICE AND COMMISSIONING INSTRUCTIONS
Page: 7
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Checks before handing over to the customer:
Check the wheel nuts are tight
Front wheel: 6 m.daN
Rear wheel 10 m.daN
Check all nuts and bolts are tight
Check brake adjustment and efficiency
Check the tyre pressures cold
Front wheel: 2.5 bar
Rear wheel 2.5 bar
Check operation of the lights, flashers, road and pedestrian horn, and brake light
Check operation of the various instrument panel lamps
Check the power reserve
Carry out a road test

SPECIAL IMPORTANT POINTS
Page: 8
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SPECIAL IMPORTANT POINTS
The scoot'elec is fitted with a coded immobiliser. This system prevents the machine from being started if the
user has not entered the secret code number. See instructions page 19.
Charging of the 3 Cadmium-Nickel batteries is by means of the on-board charger fitted with a 220V 10/16A
power connector with earth.
A partial charge may be carried out, and each charge of 10 minutes enables approximately 5 km to be
covered in ECO mode.
If the battery temperature is high, charging will only commence after the time it takes to cool down which is
controlled automatically by the charger and the ECU (which means that the charging time will be prolonged
by the same time). The lamp will flash until the charge is triggered automatically. See instructions page
6.

TIGHTENING TORQUES AND SPECIAL TOOLS
Page: 9
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TIGHTENING TORQUES AND SPECIAL TOOLS
Tightening torques
Lower body fairing 0.2m.daN
Footboard 0.4 m.daN
Speedo casing 0.1 m.daN
Saddle cover 0.6 m.daN
Front panel 0.1 m.daN
Rear panel 0.1 m.daN
Side fairings 0.1 m.daN
Rear mudguard * 0.8/0.1 m.daN
Mudflap * 0.6/0.8m.daN
Saddle locking plate 1.2 m.daN
Frame:
Front wheel spindle nut 6 m.daN
Rear wheel spindle nut 10 m.daN
arm to frame mounting 4.6 m.daN
Shock absorber upper mount 4.3 m.daN
Shock absorber lower mount 2.5 m.daN
Steering locknut 7 m.daN
Motor:
Arm to motor mount 2.3 m.daN
Battery terminal nut 12 m.daN
Strap and 200 A fuse 1.2 m.daN
Brush fixing screws
Standard:
Nut and bolt 5 mm diameter 0.5 m.daN
Nut and bolt 6mm diameter 1 m.daN
Nut and bolt 8mm diameter 2.2 m.daN
Nut and bolt 10mm diameter 3.5 m.daN
Nut and bolt 12mm diameter 5.5 m.daN
Special tools:
Steering column spanner 754086
Discharge bench 753012
TEP 96 753011
Optional charger 5409
* depending on size of bolt

BODY PANELS
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BODY
To remove lower body fairings Step 1
Remove the 4 screws (1)
Remove the lower body fairings (2)
To remove the footboard Step 2
Remove the 5 screws (1)
Remove the footboard (2)
To remove the saddle Step 3
Remove the 2 bolts (1)
Remove the saddle (2)

BODY PANELS
Page: 11
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To remove the saddle cover and lock Step 4
Remove the footboard (see step 2)
Remove the saddle (see step 3)
Disconnect the batteries
Imperative:
Begin with the negative cable (1), the thick
cable marked green on the rear left cell.
Then continue with the positive (2), the
thick cable marked red on the front cell.
This operation must be carried out
before any work in order to avoid short-
circuits
Remove the 4 screws (3) and the 2 screws (4) from
the lock
Unclip the diagnostic plug
Raise the saddle cover and pull rearwards (5)
(it fits at the front in the frame crossmember)
Disconnect the charging cable (6) from the charger
Disconnect the maintenance switch 2 wires (7)
Disconnect the water pipe (8)
Remove the saddle cover (5)

ELECTRICITY
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ELECTRICITY
To remove the charger Step 5
Remove the lower body fairings (see step 1)
Remove the footboard (see step 2)
Remove the saddle cover (see step 4)
Disconnect the 2-pin connector (1) from the charger
Disconnect the ECU and the red wire (2) the green
wire (3) connected to the charger (fixed to the frame
with a plastic tie-wrap)
Remove the 4 self-tapping screws (4) (2 screws on the
frame – 2 screws on the support)
Remove the charger (5)
The charger must not be opened
Only the manufacturer is authorised to service this
component
Removal of the 200 Amp fuse Step 6
Remove the lower body fairings (see step 1)
Remove the footboard (see step 2)
Remove the saddle (see step 3)
Remove the saddle cover (see step 4)
Disconnect the ECU 4 central wires for access to the
fuse (1)
Remove the fuse cover
Remove the 2 nuts and washers (2)
Remove the fuse (1)

ELECTRICITY
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To remove the ECU Step 7
Important:
If changing the ECU it is essential to copy the ECU
parameters into the TEP 96 before disconnecting
the batteries
(see troubleshooting manual)
Remove the charger (see step 5)
Disconnect the power cables (1) from the batteries
and (2) from the motor to the ECU
Release and unclip the 37-pin connector (3) from the
ECU
Remove the 2 nuts (4) which also secure the charger
bracket (note fitting position)
Remove the ECU (5)
Check the 37-pin connection is in perfect condition.
The contacts must be properly aligned
The ECU must not be opened
Only the manufacturer is authorised to service this
component
Setting the throttle sensor
With the lever (1) in the rest position the sensor must
be against the stop (A) on the sensor body
if it is not in this position the machine will not start
Turn the throttle to fully open and check that the
sensor lever is in contact with the sensor stop (B)

ELECTRICITY
Page: 14
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To remove the batteries
Remove the 200 Amp fuse (see step 6)
Remove the protection from the strap between the
front and the rear right cell
Remove the strap (1) (2 nuts)
Remove the water pipes (2)
The pipes must be removed along the axis of the cell
end in order to avoid breaking it
Remove the front cell securing clamp (3), 2 screws (4)
Check that the springs and cups are fitted under the
clamp
Remove the front cell (5)
Remove the temperature sensor (6) (clip on the rear
left cell)
Remove the rear cells securing clamp (7)
Check that the springs and cups are fitted under the
clamp
Slide the 2 rear cells towards the front of the machine
Remove the plastic securing clamp (8) behind the two
cells
Disconnect the water pipe (9)
Remove the 2 cells (10) (11)
Important:
If changing one or two cells, the cell(s) must be
discharged separately using the discharge bench
(see troubleshooting manual)

ELECTRICITY
Page: 15
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Cell fitting order
If the 3 cells are changed
Fit a cell, marked G at (A), on the right-hand side of
the machine with the red terminal at the front
Fit a cell, marked D at (A), on the left-hand side of the
machine with the red terminal at the rear
Fit the plastic clamp (8) for the 2 rear cells (2 screws)
Connect the water pipes (2) (9)
Push the 2 cells into the frame housings
Fit the securing clamp (3) for the 2 cells (with the
washers and cups)
Clip the temperature sensor (12) to the left cell
Fit the last cell marked D with the red terminal at the
front
Fit the strap between the front and rear right-hand
cells (2 nuts)
Fit the strap protection
Fit the front cell securing clamp (with washers and
cups)
Fit the 200A fuse (13) (2 nuts and 2 washers)
connecting the blue terminal of the rear right-hand
cell to the red terminal of the rear left-hand cell
Fit the fuse cover
Connect the thick cable with the red end (+)
connected to the ECU to the red terminal on the front
cell
Connect the thick cable with the green end (-) to the
blue terminal on the rear left-hand cell
Important:
A battery commissioning procedure must be
carried out (see procedure page 5) and the ECU
parameters initialised using the TEP96

MOTOR
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MOTOR
To remove the power unit
Remove the lower body fairings (see step 1)
Remove the saddle cover (see step 2)
Disconnect the 3 wires (1) connecting the motor to the
ECU
Clear these 3 wires away from the frame
Remove the right (3 screws) and left (4 screws) covers
Disconnect the 2-pin connector from the speed sensor
Disconnect the rear brake control from the brake plate
Suspend the machine
Remove the shock absorber lower mount
Remove the shaft (3) from the power unit

MOTOR
Page: 17
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Remove the power unit (4)
Unclip the mudflap (5) from the stand bracket (6)
Remove the mudguard (7) (5 screws) and its stiffener
plate (8)
To remove the brushes
On Leroy-Somer motor only
Remove the brush weather protection strap
Remove and if necessary change the 4 brushes one y
one so that the connecting wires retain their shape and
position
Note:
it is essential that the tightening torques of the brushes
are complied with xx mN
Check there is not contact between the wires
connected to the brushes and the motor body
Any contact will destroy the ECU

MOTOR
Page: 18
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Removal of the motor mounting rod and the stand
Note the position and remove the motor bracket rod
(1) (4 nuts and bolts)
Remove the stand springs (2)
Remove the stand to bracket 2 mounting nuts and
bolts (3)
Remove the stand (4) with its 2 shoulder bushes (5)
Note the position of the bushes
Remove the stand bracket (6) 2 nuts and bolts (7)

MOTOR
Page: 19
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To remove the transmission system
Remove the bolt from the 34-tooth pulley (1)
Remove the pulley using 2 ∅6mm bolts (2)
Remove the belt (3)
Bolt tightening torque: 40 ±5 mN
Remove the indexer ring (4) and the 64-tooth pulley
(5)
The pulley fits both ways round
Note how the pulley washers and bush are stacked
Bolt tightening torque: 40 ±5 mN

MOTOR
Page: 20
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To remove the motor
Remove the 5 bolts (1) securing the motor to the
casing
Remove the motor
The motor cannot be refurbished
Only replacement is possible if necessary
To remove the speed sensor
Remove the sensor wire securing clamp (1)
Remove the speed sensor (3) 2 bolts (2)
The 2 self-tapping screws must be removed wit care
in order to avoid breakage and coated with grease
when refitting