PEUGEOT SATELIS - SERVICE - BODY PANELS User manual

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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.
. The 2 pivot pins.

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- 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.
- Remove the grab handle.

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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.

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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.

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- 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. (4 screws and 2 nuts).

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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.

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- 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.
- Removal of a RH or LH footboard Procedure 6.
- Remove the tank cover panel. See:
Procedure 5.
- Remove the footboard mat.
- On each side remove:
. 8 plastic screws. (1)
. 3 washer head screws. 06 mm. (2)
. I washer head screw. 05 mm. (3)

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- 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.
(C)

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- 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.
To reach the bulbs, remove the headlight.
(3 screw)

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- 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)
. 2 plastic screws that secure the footboard the underbody cover. (2)
- Push aside the underbody cover to reach the screw that secures the front shield panel. (3)
- On each side remove:
. 5 plastic screws. (4)
. I washer head screw. 06 mm. (5)
. I washer head screw. 05 mm. (6)
- Disconnect the headlights.
- Remove the front shield panel.

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- 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.
• The handlebar upper fairing (8 screw) (1).
- On each side remove:
• 2 plastic screws that secure the front leg shield to the underbody cover.
• 2 plastic screws that secure the footboard to the underbody cover.
- Push aside the underbody cover to reach the screw that secures the front shield panel. (2)

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- 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.

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- 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.
- Remove the header tank. (Right side).
- Disconnect the accessory plug. (Left side).
- Remove the rear shield panel.

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- 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.
- Remove the dirt cover by sliding it behind the wheel as shown.
- Removal of the battery holder Procedure 9.
- Remove the tank cover panel. See: Procedure 5.
- Disconnect and remove the battery.
- Unclip from the battery holder:
• The fuses. (1)
• The relays. (2)
• The diagnosis plug.(3)
- Remove the battery bracket. (2 screws and I nuts).

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- 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)
• 1 washer head screw. 06 mm. (3)
- Press the locking system (1) to actuate the
positioning lever (2) of the instrument cluster’s connector.
- Push the lever all the up (A) in order to remove the connector from the instrument cluster.
- Remove the instrument cluster fairing.
Note: When connecting, the lever must be pushed all the way to (A) in order not to damage the
connector.

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PIAGGIO MOTOR SERVICE STATION MANUAL
Engine Master 500 cc

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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. Any important changes in vehicle
or specific repair operations will be divulged by means of updates to this manual.
Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer
of this manual concerning specific tools and equipment and the special tools catalogue.
Critical information in the manual is indicated as follows.
N.B.: Important information for facilitating and explaining a procedure.
Warning - Procedures that must be followed to avoid damage to the vehicle.
Caution - Procedures that must be followed to eliminate the risk of injury to repair / service personnel.