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:
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