E-Viva Werkplaatshandboek PDF

Quality Management
After-Sales
WORKSHOP MANUAL
Direc
TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................................................... 1
PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4
CHARACTERISTICS......................................................................................................................................... 6
Engine........................................................................................................................................................6
Capacities ..................................................................................................................................................6
Chassis ......................................................................................................................................................6
Dimensions and weight ..............................................................................................................................7
Tyres ..........................................................................................................................................................7
Brakes ........................................................................................................................................................7
SERVICE SCHEDULE AND COMMISSIONING ............................................................................................... 8

First use............................................................................................................................................................... 8
Maintenance schedule ........................................................................................................................................ 8
To be checked at each service...................................................................................................................8
Service operations .....................................................................................................................................9
TIGHTENING TORQUES ................................................................................................................................ 10

Engine part ..............................................................................................................................................10
Electric part..............................................................................................................................................10
Body panels .............................................................................................................................................10
Cycle part.................................................................................................................................................10
Standard ..................................................................................................................................................11
SPECIAL TOOLS ............................................................................................................................................ 12
STANDARD TOOLS........................................................................................................................................ 13
SPECIFIC ELECTRICAL EQUIPMENT .......................................................................................................... 14
LOCATION OF COMPONENTS...................................................................................................................... 15
ELECTRIC LOCKOUT OF THE VEHICLE...................................................................................................... 16
METHOD TO MAKE A MODULE INERT ........................................................................................................ 20
1
Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Scooters
TABLE OF CONTENTS
BODY PANELS ............................................................................................................................................... 22

Location of body components ..................................................................................................................22
Body component sequence of disassembly.............................................................................................23
Removal of the central cover panel..........................................................................................................24
Removal of the rear storage compartment ..............................................................................................24
Removal of the rear cover assembly and mudflap ...................................................................................25
Removal of the front storage compartment..............................................................................................25
Removal of the rear shield panel .............................................................................................................26
Removal of the front shield panel.............................................................................................................27
Removal of the RH or LH under body panel ............................................................................................28
Removal of the footboard .........................................................................................................................28
Removal of the instrument cluster............................................................................................................29
SERVICE OPERATIONS................................................................................................................................. 30
Front brake pads ......................................................................................................................................30
Replacing the brake pads ........................................................................................................................30
Checking the brake fluid level ..................................................................................................................31
Rear brake linings ....................................................................................................................................31
Reassembly....................................................................................................................................................... 33
Changing the belt.....................................................................................................................................34
Checking the drive belt...................................................................................................................................... 35
Draining the front fork...............................................................................................................................35
MISCELLANEOUS OPERATIONS ................................................................................................................. 38

Removal of the fork ..................................................................................................................................38
Replacing the bearings of the steering system ........................................................................................38
Reassembly....................................................................................................................................................... 39
Steering system tightening method..........................................................................................................40
Changing the front fork seals ...................................................................................................................42
Removal of the fork tubes.................................................................................................................................. 42
The fork and its components....................................................................................................................44
On the fork tube................................................................................................................................................. 45
2
TABLE OF CONTENTS
ELECTRICITY.................................................................................................................................................. 47
Removing/fitting modules.........................................................................................................................47
Removing the horizonal module........................................................................................................................ 47
Removing the vertical module ........................................................................................................................... 49
Connecting of the modules................................................................................................................................ 49
Connecting order............................................................................................................................................... 50
On the horizontal module .................................................................................................................................. 50
On the vertical module ...................................................................................................................................... 50
Removing the main relay .........................................................................................................................51
Removing the 24/48 volt relay..................................................................................................................52
Removing the current sensor ...................................................................................................................53
Removing the motor control ECU ............................................................................................................53
Removing the electric traction ECU .........................................................................................................55
Removing the C ECU...............................................................................................................................56
Removing the traction battery chargers ...................................................................................................57
Removing the limiting resistance .............................................................................................................58
Removing the converter 48/12 V................................................................................................................................ 58
Removal of diodes...................................................................................................................................................... 59
Removing the single track accelerator potentiometer ................................................................................................ 59
POWER UNIT .................................................................................................................................................. 60

Removal of the power unit .......................................................................................................................60
TRANSMISSION .............................................................................................................................................. 62
Removal of the primary drive ...................................................................................................................62
Checking the drive belt.............................................................................................................................63
Removal of the secondary transmission ..................................................................................................63
Draining the relay box........................................................................................................................................ 64
Replacing the bearings of the relay box...................................................................................................66
Crankcase ......................................................................................................................................................... 66
Relay box cover ...............................................................................................................................66
ANNEX : .......................................................................................................................................................... 67
Electric vehicle documents ......................................................................................................................67
Vehicle identification.......................................................................................................................................... 67
Safe for work certificate..................................................................................................................................... 68
End of work notification ..................................................................................................................................... 69
3
PRODUCTS DANGER SYMBOLS USED
Protection of individuals and of the environment.

Means that the product or the package
can be recycled. However, this does not
Möbius band Recyclable.
guarantee that the product will be
recycled.
Avoid contact with skin and clothes. Wear

The product can irritate the gloves, safety glasses and appropriate
Irritant skin, eyes and respiratory clothing such as a cotton overall. Do not
organs. breath fumes. If in contact, wash
thoroughly with water.
Keep it away from flames or any heat

Flammable The product is flammable. source (barbecue, radiator, heating, etc.).
Do not leave the product in the sun.
Avoid contact with skin and clothes. Wear

The product can damage living gloves, safety glasses and appropriate
Corrosive
tissues or other surfaces. clothing such as a cotton overall. Do not
breath fumes.
The product can explode under

Explosive certain circumstances (flame, Avoid impacts, friction, sparks and heat.
heat, impact, friction).
The product affects fauna and The ideal solution is to bring this product
Hazardous to
flora. Do not dump it in to your nearest household waste recycling
the environment
garbage cans, sinks or nature. centre.
The product can seriously Avoid direct contact with the body, even by
Toxic affect health if it is inhaled, inhalation. If you feel unwell, seek medical
ingested or in contact with skin. advice immediately.
This symbol informs the consumer that the

One of the product's
Do not throw used product shall not be thrown away into
component is toxic and can be
away into a a garbage can, but shall be brought back
hazardous to environment.
garbage can to the merchant or dropped at a specific
i.e.:. Used batteries.
collection point.
People's safety can be seriously affected if

Compulsory Operation that can be
the recommendations are not fully
gloves dangerous for people.
respected.
4
People's safety can be seriously affected if

Operation that can be
People's safety the recommendations are not fully
dangerous for people.
respected.
Indicate the specific procedures that shall

Operation that can be
Important be followed in order not to damage the
hazardous to the vehicle.
vehicle.
Serious damage to the vehicle and in

Good operating The operation must be carried
certain cases a cancellation of the
condition of the out in strict compliance with the
warranty can be involved if the
vehicle documents.
recommendations are not fully respected.
Indicate a note which gives key

Note Operation that can be difficult.
information to make the procedure easier.

Lubricate the parts to be
Lubricate be followed in order not to damage the
assembled.
vehicle.

Grease the parts to be
Grease be followed in order not to damage the
assembled.
vehicle.

GLU
E Glue the parts to be
Glue be followed in order not to damage the
assembled.
vehicle.
N
New part Use a new part. be followed in order not to damage the
vehicle.
These documents indicate, inform a third

party that the vehicle has been made
Documentation to be
Document electrically safe and gives information
completed by the operators.
concerning the state of progress of the
work.
5
CHARACTERISTICS
CHARACTERISTICS
Engine
45 km/h version 60 km/h version

Marking EA2 EA3
Type Three-phase synchronous motor with permanent magnets
Max. power output 3 kW at 6000 rpm
Fuel supply 2 modules SAFT li-ion 24 Volts
Transmission By 2 fixed pulleys and toothed-type belt
Immobiliser Transponder-equipped immobiliser
Capacities
0.12 l SAE 80W90.

Relay box oil
Minimum grade: API GL4
Fork oil 0.085 I per tube SAE 10W
Chassis
Chassis Steel tube

Hydraulic telescopic fork. Ø32 mm
Front suspension
Travel: 89 mm
Combined spring and hydraulically-damped shock absorber
Rear suspension
Travel: 75 mm
6
CHARACTERISTICS
Dimensions and weight
Overall length 1923 mm

Width at handlebar 670 mm
Height. (without rear-view 1170 mm
mirrors)
Wheelbase 1353 mm
Unladen weight 114 kg
Tyres
Front wheel rim 12 inch aluminium alloy

Front tyre 120/70 - 12
Front tyre pressure 1.8 bars
Rear wheel rim 12 inch aluminium alloy
Rear tyre 120/70 - 12
Rear tyre pressure 2.2 bars
Brakes
Front brake Single disc type, hydraulic control

Disc diameter and
200 mm - 3.5 mm
thickness
Rear brake Single-cam drum type, controlled by cable
Brake drum diameter 110 mm
Brake lining thickness 4 mm
Chassis markings Engine marking
1
X*
XXXXX
xxxxxxx
EA2
0J
1AAAA
*VGAV
(1) number and manufacturer's plate Engine number. (2)
7
SERVICE SCHEDULE AND COMMISSIONING
The servicing must be carried out by a registered representative.
First use
- Charge the battery.

- Carry out a road test.
Maintenance schedule
Heavy duty servicing applies to vehicles used under rugged operating conditions: door-to-door deliveries,
intensive urban use (courier), short journeys with engine cold, dusty areas, ambient temperature
over 30°C.
500 kms or Every

Service operations Every 5000 kms
1 month 10000 kms
Heavy duty servicing 500 kms Every 2500 kms Every 5000 kms
To be checked at each service
Steering column play V V V
Wheel bearing play C C C
Throttle cable play V V V
Operation of electrical equipment V V V
Condition of the front brake hydraulic control C C C
Brake fluid level V V V
Brake pad wear C C C
Rear brake lining wear C C C
Tyre condition, pressure and wear C C C
Condition of the front suspension. Condition of
C C C
the rear suspension
Headlight height adjustment V V V
Tightness of nuts and bolts V V V
Overall operation. Road test V V V
V: Check, clean, adjust. C: Inspect and change if necessary.

R: Change. * Depending on equipment.
G: Check, clean, lubricate.
8
The servicing must be carried out by a registered representative.
500 kms or Every Every

Service operations
1 month 5000 kms 10000 kms
Every Every
Heavy duty servicing 500 kms
2500 kms 5000 kms
Service operations
State of the charge cable C C C
Operation of the running modes V V V
Memory download and parameter records V V V
Clearing the maintenance symbol Every 5000 kms
Transmission belt R Every 20000 kms
Joints. (Central stand, Brake levers...) G G
Fork oil R Every 20000 kms
Brake fluid Once every 2 years
V: Check, clean, adjust. C: Inspect and change if necessary.

R: Change. * Depending on equipment.
G: Check, clean, lubricate.
Note: The data records will be sent systematically to Peugeot Scooters.
Normal servicing in km 0 500 5000

Servicing time in tenths of an hour (0.5 h = 30 min)
E-Vivacity 1 0.9 1
9
TIGHTENING TORQUES
TIGHTENING TORQUES
Engine part
Drive pulley 35 to 45 Nm
Driven pulley 35 to 45 Nm
Transmission cover 8 to 12 Nm
Relay box cover 8 to 12 Nm
Relay box filler cap 13 to 17 Nm
Relay box drain plug 8 to 12 Nm
Shock absorber support 8 to 12 Nm
Electric part
Battery terminal 8 to 10 Nm
Main contactor terminal 8 to 10 Nm
Motor controller terminal 6 to 8 Nm
Motor controller attachment 9 to 13 Nm
Body panels
Front mudguard 8 to 10 Nm
Handlebar cover 2 to 4 Nm
Front shield panel 2 to 4 Nm
Rear shield 2 to 4 Nm
Bottom panel 2 to 4 Nm
Floor panel 6 to 8 Nm
Saddle storage compartment 8 to 10 Nm
Rear body panels 6 to 8 Nm
Grab handle 20 to 25 Nm
Rear mudguard 4 to 6 Nm
Cycle part
Front wheel spindle 60 to 70 Nm
Rear wheel spindle nut 100 to 120 Nm
Linkrod to engine pivot 13 to 17 Nm
Linkrod to frame pivot 55 to 61 Nm
Shock absorber top mount 43 to 50 Nm
Shock absorber bottom mount 20 to 25 Nm
Upper cone (in 2 operations) 38 to 42 Nm/15 to 19 Nm
Upper cone locknut Hand tightened
Steering locknut 70 to 80 Nm
Fastening screw for fork stanchion on tee 40 to 60 Nm
Front brake caliper 19 to 28 Nm
Front brake disc 27 to 32 Nm
Rear brake cam 8 to 11 Nm
Handle bar 35 to 45 Nm
Kickstand locknut 40 to 55 Nm
Kickstand pin 19 to 28 Nm
10
TIGHTENING TORQUES
Standard
Nut and bolt 5 mm diameter 5 Nm
11
SPECIAL TOOLS
SPECIAL TOOLS
Used Used
Tool N° Designation Tool N° Designation
with with
Adjustable Extraction
752237 802638
pin wrench tool*
Steeing head Control point

753726 802644 802809
cup push tool 23 way*
1 13 25
2 14 26
3 15 27
4 16 28
5 17 29
6 18 30
7 19 31
8 20 32
9 21 33
10 22 34
11 23 35
12 24
BM 432
by xxotest
Crank
Control point
756668 assembly lip 802645 802809
35 way*
1 11
2 12
3 13
seal tool
4 14
5 15
6 16
7 17
8 18
9 19
10 20
BM 420
by xxotest
Battery
757860 Steering tool 802653 securing
tool*
Diagnostic 802644
Steeing head
757990 802809 tool TEP 802645
cup push tool
2010 802812
OK
SDO1/0/ by xxo test
50V
Protective
Control point
768051 cap 802812 802809
1
5
10
11
12
13
14
19
20
21
22
23
26 way*
BM 426
BM 426
6 15 24
7 16 25
8 17 26
9 18
by xxotest
(*) New or modified tool.
12
STANDARD TOOLS
STANDARD TOOLS
Designation Designation
Screwdriver socket set 1/2" for 6

Lip seal insertion kit for fork tube
metric 5 mm to 19 mm hexagon
diameter 30 mm to 45 mm
socket screws
Type: Marolotest 601055
Type: Facom STM.J9
Automatic resetting type torque Automatic resetting type torque

wrench wrench
5 to 25 Nm 10 to 50 Nm
Type: Facom R.306A25 Type: Facom J.208A50
Automatic resetting type torque

wrench
Heat gun
40 to 200 Nm
Type: Facom S.208A200
Intertia type extractor tool for DC

200 m
10A
20 m
bearings from 6 to 18 mm VΩ
Ω
VAC
VDC
COM
OFF
mA
Multimeter
Type: Facom U.49PJ3
5 mm pipe wrench Antistatic bracelet + Cord

Type: Facom 94A.5 Type: Radiospares 787-7379
13
SPECIFIC ELECTRICAL EQUIPMENT
SPECIFIC ELECTRICAL EQUIPMENT
Designation Designation
(P)ersonal (P)rotective
(E)quipment
SO
TEN US
Visibility equipment Pair of insulating gloves
TIO
N
(Complies with standards NF EN-
60903)
IL CON (P)ersonal (P)rotective

RE
(E)quipment
DA
APPA
MNE
Warning notice (forbidden to

Protecting face-shield
move or remove)
DEF
ER
(Complies with standards

VR
EN
SE E
DE MANO
NF EN-166)
1000 volt insulated tool

(V)erification of (A)bsent
Type: Facom
(T)ension
8 mm pipe wrench. 94T.8AVSE
(Complies with standards
4 mm male offset wrench.
NF EN-50110)
83.4AVSE
UTE
Electrical norms documentation Insulating sheet
14
LOCATION OF COMPONENTS
LOCATION OF COMPONENTS
2 4
512
1 3
6
10
100
9 8
12
13 15
11 OK
TEP 2005
by xxo test
14 e2 CE 0
4
00 51
64
0
22
50 /02
E6 39 /06
38 50
53 14 9 : 3
4 01 9
01 : 0
7
22 16
• •••
• •••
• •••
••••
• •••
• ••• • ••
• ••
•
• 9
17
7
12V - 25A
21 9
20 19 18
1. Acceleration potentiometer 12. Diagnostic plug
2. Instrument panel/Immobilizer 13. Fuses
3. Electrical traction calculator 14. Self-holding relay
4. Traction battery regulating calculator 15. Transponder antenna
5. Current captor 16. Outside temperature sensor
6. Main relay 17. Horn
7. Traction battery charger 18. Limiting resistance
8. 100 A fuse 19. Converter relay
9. Anti-back circuit diode 20. Stop relay
10. Converter 48/12V 21. Traction battery/Control module
11. Free-wheel diode calculators
22. Pilot motor calculator
15
ELECTRIC LOCKOUT OF THE VEHICLE
Work to be carried out by a B2-L accredited technician.
Analysis of the work sheet information.

Identification of the vehicle in maintenance.
Isolate a working area around the

SO
TEN US
vehicle using posts, straps and
TIO
N
notices.
Preperation of the consignation notice for the BCL.
Work to be carried out by a BCL accredited technician.
The technician in charge of the safety immobilisation (BCL) must fill in the safety declaration
(consignation).
16
- Turn off the ignition.

- Open the saddle.
- Remove the key from the ignition switch.
- Remove the 4 screws from the central fairing.
- Close the saddle.

- Remove the central cover panel. (3 screw)
Wear a pair of insulating gloves and a

face shield.
2
1
- Open the fuse box (1).

- Disconnect the negative power cable (2).
(1 nuts)
Tightening torque: 8.5 Nm.
- Close the fuse holder. (1)
17
- Remove the storage compartment. (5 screw)

- Disconnect the accessory plug.
- Disconnect the mains power cable.
- Disconnect the traction battery ECU.
- Disconnect the positive cable (3) of the vertical

module. (1 screw and 1 flexible washer) 3
Cover the positive connection of the
EIL
CON vertical module with the 802653 tool
R
DA
and using the warning labels (Do not

APPA
MNE
remove and replace). Lock off the

DEF
ER
VR
EN
SE
DE MANO
E
power supply cable (3) using the tool
ref 768051. 753726
- Check the absence of tension

between the positive (3) and
negative (2) cables.
3
between the positive cable (3)
and the body of the vehicle (4).
between the negative cable (2)
on its motor side and the body of 4
the vehicle (4).
The tension meter emits a warning
sound because the body is 2
connected to the negative of the
circuit 48 volts.
18
CON Cover the negative cable connection

IL
RE using the warning labels (Do not
DA
APPA
MNE
remove and replace). Lock off the
DEF
ER
power supply cable (3) using the tool

VR
EN
SE E
DE MANO
ref 768051.
- Take off the Personal Protection Equipments.
The technician in charge of the safety immobilisation (BCL) must fill in the safety declaration
(consignation).
The form must be signed by the technician in charge of the safety immobilisation (BCL) and
given to the technician in charge of carrying out the work together with the work sheet order
to be signed as well and carried out B2-L.
Work to be carried out by a B2-L accredited technician.
Vehicle to be repaired.
The consignation technician (BCL) and the technician carrying out the repair (B2-L) must fill
in and sign the form at the end of the work.
Wear a pair of insulating gloves and a face shield.

- Measure the lack of voltage between the negative power supply cable (2) and the fuse
holder (1)
The consignation technician must reconnect all components and remove the warning signs and the
fencing of the working area.
He will give the vehicle back to its owner together with the work notice after checking that the vehicle is
in working order.
When refitting, position the rubber protectors on the power terminals.
19
METHOD TO MAKE A MODULE INERT
This method only applies if a module is leaking.
You are strongly advised to read the method to render a module inert in its entirety before
starting any operations.
Once this method is applied, it is irreversible, the module is unusable.
The power to the vehicle must be

switched off for this operation.
Take up the procedure at chapter:
Electric lockout of the vehicle (see
page 14).
- Remove the damaged module. See

chapter: Removing/fitting modules (see
page 47).
- Place the module into a recipient into which it

fits completely.
The recipient must be in a well-

ventilated place protected from the rain.
- Pour the salt into the bottom of the recipient,

using 10 g of salt per litre of water.
20
- Pour water into the recipient so that it totally

covers the module.
Bubbles form on the module's

electrodes. This gas can explode in
presence of a naked flame or spark.
The water may become coloured and a
deposit may appear on the surface.
Leave the module in the salt water until
no more gas is released. This may take
48 hours to 1 week.
- - Remove the battery from the water

and check the voltage on its
terminals.
- The voltage on the battery
terminals should be less than 3
volts.
- Recycle the module:

• Consult the SAFT site for all the corresponding information.
http://www.saftbatteries.com/TheSaftGroup/Environment/tabid/98/language/en-
US/Default.aspx
Recycle the water:

• The water must be sent for destruction to a facility designed for this purpose.
21
BODY PANELS
BODY PANELS
Location of body components

Description.
2
1
3
9 12
5
4
13
8
10
6
7
14 11
1. Handlebar front fairing 8. Front shield panel

2. Handlebar rear fairing 9. Saddle and storage compartment
3. Tool compartiment cover 10. Central panel
4. Front storage compartment 11. Footboard
5. Rear shield 12. Grab handle
6. Front mudguard 13. Rear body panels
7. Front wheel 14. Bottom panel
22
BODY PANELS
Body component sequence of disassembly
1* 9*
2 3*
10* 12
6* 4 5*
13
7* 8 14* 11
1. Handlebar front fairing 8. Front shield panel

2. Handlebar rear fairing 9. Saddle and storage compartment
3. Tool compartiment cover 10. Central panel
4. Front storage compartment 11. Footboard
5. Rear shield 12. Grab handle
6. Front mudguard 13. Rear body panels
7. Front wheel 14. Bottom panel
*This item may be removed on its own.
23
BODY PANELS
Removal of the central cover panel

page 14).
Procedure 1.
- Open the saddle.
- Remove the 4 screws from the central fairing.
- Close the saddle.

- Remove the central cover panel. (3 screw)
Removal of the rear storage compartment

page 14).
Procedure 2.
- Lift the saddle.
- Remove the storage compartment. (5 screw).
- Disconnect the accessory plug.
- Disconnect the traction battery ECU.
- Disconnect the mains power cable 220 V.
24
BODY PANELS
Removal of the rear cover assembly and mudflap

page 14).
Procedure 3.
- Remove the rear storage compartment. See:
Procedure 2. page 24.
- Remove the grab handle. (3 screw). (1)
Tightening torque: 22 Nm. 1
- Remove the rear cover assembly

(5 screw) (2).
- Disconnect the taillights.
2
Removal of the front storage compartment

Procedure 4.
- Remove the storage compartment lid.
(5 screw)
25
BODY PANELS
- Remove the storage compartment. (11 screw)

- Disconnect the horn.
Removal of the rear shield panel

Procedure 5.
- Remove the 4 upper screws that secure the
rear shield panel.
- Remove the 7 screws that secure the rear

shield panel.
- Remove the rear shield panel.
26
BODY PANELS
Removal of the front shield panel

Procedure 6.
- Remove the front storage compartment. See: 1
- Remove the rear shield panel. See:
- Suspend or immobilize the machine securely.

- Remove the wheel spindle nut.
N When re-installing, use a new nut.
- Remove the front wheel.

- Remove the front mudguard. (1). (4 screw)
- Remove the 5 screws that secure the front
shield panel.
- Disconnect the direction indicators.

- Disconnect the outer temperature sensor.
- Remove the 6 screws that secure the front
shield panel.
- Unclip the mud splash guard from the front leg
shield panel.
- Remove the front shield panel.
27
BODY PANELS
Removal of the RH or LH under body panel

Procedure 7.
- Remove the LH under body panel. (8 screw)
- Repeat the operation with the right underbody
panel.
Removal of the footboard

page 14).
Procedure 8.
- Remove the central cover panel. See:
- Remove the rear storage compartment. See:
- Remove the RH and LH under body panel.
See: Procedure 7. page 28.
- Remove the footboard. (4 screw)
28
BODY PANELS
Removal of the instrument cluster

- Remove the handlebar front cover. (6 screw)
- Press the locking system (1) to actuate the

positioning lever (2) of the instrument cluster's
connector. A
- Push the lever all the up (A) in order to remove
the connector from the instrument cluster.
- Disconnect the instrument cluster. 1
- Remove the handlebar rear cover and

instrument cluster assembly. (4 screw)
- Remove the instrument cluster. (4 screw)
29
SERVICE OPERATIONS
SERVICE OPERATIONS
Front brake pads

- If one of the 2 brake pads is worn down to the A = 1.5mm
minimum dimensions (A), the 2 brake pads
must be changed.
A. Mini. thickness: 1.5 mm.
Replacing the brake pads

- Remove the calliper. (2 screw)
Tightening torque: 25 Nm.
- Unscrew the 2 caps (1) covering the pins

securing the brake pads 2
- Remove the2 pins (2). 1
- Remove the brake pads (3)
When refitting the brake pads, push the

pistons all the way into their housing.
2
After refitting, actuate the brake levers
several times to bring the brake pads
against the brake disc.
30
SERVICE OPERATIONS
Checking the brake fluid level

- Position the handlebars so that the master
A
cylinder will be horizontal.
- Check the brake fluid level and if necessary B
top up in the master cylinder.
A. Maximum brake fluid level.

B. Minimum brake fluid level.
- Remove the handlebar front cover. (6 screw)

- Remove the cover and the diaphragm from
the master cylinder. (2 screw)
- Add brake fluid until it reaches the maximum
level.
Rear brake linings

- Actuate the brake control lever and check the
position of the wear mark on the cam
tierod (A) compared to the mark (B) on the
engine housing.
- If the cam tierod mark is lined up with or
passes the wear mark on the engine housing,
the brake lining must be replaced. A
31
SERVICE OPERATIONS
- Remove the screw fastening the rear

mudguard on right.
- Remove the wheel spindle nut and
washer. (3) 3
- Remove the rear wheel.
- Remove the brake linings. (4)

- Remove the adjusting nut, the barrel (5) and
the brake control cable. (6)
- Remove the brake arm (7), the brake cam (8)
and the spring. (1 screw)
4
8
5 6
32
SERVICE OPERATIONS
Reassembly
8
Lubricate the brake cam spindle and fit
it into the casing.
- Fit the brake arm onto the cam and align the
9
punched marks. (A)
5
A
- Slightly lubricate the brake cam and pin.

- Install the brake linings.
- Install the spring (9).
- Install the brake control cable, the barrel and
the adjusting nut. (5)
- Install the wheel.
- Measure the free travel of the rear brake

control lever.
- Ajust the lever free travel using the adjusting
nut. B
B. Brake control free travel: 10 to 20 mm.
33
SERVICE OPERATIONS
Changing the belt

- Remove the transmission cover. (6 screw)
- Immobilise the drive pulley using the tool ref.

752237.
- Removez the nut (1) and the washer from the 1
drive pulley.
752237
- Remove the drive pulley using the tool ref.

802638.
- Remove the belt. 802638
34
SERVICE OPERATIONS
Checking the drive belt
- Make sure the belt is not cracked. (A)
Draining the front fork

- Suspend or immobilize the machine securely.
- Remove the caliper 2 fixing bolts.
1
- Remove the front shield panel. See:
- Unscrew and remove the 2 upper screws (1)

from the fork Tee. 2
- Before, loosen the fork tube caps.
- Unscrew the 2 lower screws (2) from the fork
Tee.
- Remove the fork stanchions.
- Remove the fork tube cap (3).

- Remove the spring. (4)
3
35
SERVICE OPERATIONS
Turn the fork tube upside down to drain

the oil into a recipient.
- Pour new oil into the fork tube. Type: SAE10W.
Quantity: 0.085 l.
- Install the spring.

- Fit and screw the cap home.
Tightening torque: 18-20 Nm.
- Insert the fork stanchions into the fork tee.

- Fit and tighten the 4 clamping bolts.
- Fit the front shield panel.
36
SERVICE OPERATIONS
- Fit the front mudguard.

- Fit the speedometer drive gear assembly to the
wheel drive pins.
- Fit the wheel, matching the speedometer drive
gear assembly to the pin (A) on the fork
stanchion.
- Fit the wheel spindle and tighten.
N
A
When re-installing, use a new nut.
- Refit the other items in the reverse order to

disassembly.
37
MISCELLANEOUS OPERATIONS
Removal of the fork
Replacing the bearings of the steering

system
- Remove the handlebars from the fork tube.
(1 screw and 1 nut) (1)
1

- Suspend or immobilize the machine
securely.
- Remove the front mudguard.
- Remove the front brake caliper from the fork
tube.
- Remove the front wheel.

2
- Remove the brake control cable grommet

and the speed sensor located under the fork
triple clamp. (2) (1 screw)
- Using tool P/N 757860 remove the steering
locknut.
- Remove: 757860
• The brake washer.
• The nut.
• The rubber washer.
• The nut.
• The dust cover.
• The upper cone.
- Remove the fork.

- Remove the caged ball bearings.
38
- Using a drift, remove the steering head cups.
- Using a chisel, pry the steering head cup off

by pressing the tool behind the dust cover.
Reassembly
- Install the following new parts:

• The dust cover. (1)
• The fork cone. (2)
1 2
39
Steering system tightening method

- Using push tool P/N 753726, fit a new upper 753726
cup into the steering tube.
- Using push tool P/N 757990, fit a lower cup
into the steering tube.
- Grease the cup bearing races.

- Install new caged ball bearings. (3)
- Fit the fork into the steering column.
- Install the upper cone. (4)

- Install the dust cover. (5)
- Fit and tighten the nut. (6)
6 5
- Loosen and re-tighten the steering head nut.

4
40
- Install the rubber washer. (7)

- Fit and finger tighten the nut (8) so that its
notches are aligned with those of the nut.
- Fit the lock washer (9) in the notches of the
2 nuts. 9
- Install the steering head locknut and tighten

it. (10)
10
When refitting the fork, check:

• That the plastic collar (A)
attaching all the control cables
and the wiring harness apart
from the throttle control cable A
is present.
• That the reclosable clip (B) is
correctly positioned and
clipped on the accelerator
potentiometer harness.
• Ajust the lever free travel
using the adjusting nut.
B
After refitting, initialise the single track potentiometer (consult the

instrument panel operating principles).
41
Changing the front fork seals

- Unscrew and remove the 2 upper screws (1)
from the fork Tee.
- Before, loosen the fork tube caps.
- Unscrew the 2 lower screws (2) from the fork 1
Tee.
- Remove the fork stanchions.
Removal of the fork tubes
- Remove the fork tube cap (1).

- Remove the spring. (2) 1
42
Turn the fork tube upside down to

drain the oil into a recipient.
- Remove the stanchion assembly screw (12)

and its seal.
- If necessary use a mallet to dislodge the
screws.
12
11
- Separate the fork's tube (9) from the

cover (11).
- Remove the compression stop cone (10).
- Remove the calibrated hydraulic tube (3).
5 6
- Remove the expansion stop spring (4).
- Remove the dust cover (5).
- Remove the retaining clip (6).
- Remove the seals (7). 7
- Remove the washer (8). 8
11
43
The fork and its components

1. Fork tube cap.
2. Spring. 1
3. Calibrated hydraulic tube.
4. Expansion stop spring.
5. Dust cover.
6. Retaining clip.
7. Tightness seal.
8. Plain washer. 2
9. Fork tube.
10. End of compression cone.
11. Hollow shaft.
3
12. Stanchion assembly screw.
5 4
11 6
7
8
9
12 10
PRE-ASSEMBLY CHECKS
- Clean all the parts with a degreasing agent:
• Biosane type ref. 754748.
• Or use an ultrasonic cleaning tank.
- Check the condition of the fork tube, there shall be no corrosion or impact marks, and the tube shall
be perfectly straight and clean.
44
REASSEMBLY
On the fork tube

9
- Install the expansion stop spring (4).
4
- Install the calibrated hydraulic tube (3).
- Install the compression stop cone (10) on the
calibrated hydraulic tube.
3 10
- Fit the fork sleeve (11) to the slightly oiled fork

tube (9).
- Install the stanchion assembly screw (12) and
its seal.
11
9
11
- Fit the plain washer (8).

- Install the new lightly lubricated seal (7).
- Using the marolotest lip seal insertion kit tool,
push the seal (7) under the groove in the
retaining ring.
11
45
- Install the retaining ring (6).

- Fit a new, lightly greased dust cover (5).
6
11
- Pour 0.085 l SAE10W hydraulic oil into the

fork tube.
- Install the spring (2).
- Fit and screw the cap home (1).
- Fit the fork tubes into the fork triple clamps.

- Fit and tighten the 4 clamping bolts.
- Refit the fairings in reverse order to removal.
46
ELECTRICITY
ELECTRICITY
Removing/fitting modules
The power to the vehicle must be switched off for this operation.
Electric lockout of the vehicle (see page 14).
- Remove the footboard. See: Procedure 8.

page 22.
Removing the horizonal module

1
- Remove the screw (1) from the fuse holder.
2
- Disconnect the electric traction ECU (2).
- Remove the clamp (3) from the vertical

module with the electric traction
ECU (2 screw).
- Remove the clamp (4) and the 2 floor supports

(5) from the horizontal module. (4 screw)
5
Ensure the clamp is fitted the right way
round (4).
4 5
47
ELECTRICITY
- Disconnect the intermodule cable (4) on the

vertical module. (1 screw and 1 flexible
washer)
1
Tightening torque: 8.5 Nm. 6
- Remove the plastic cover (6).
- Disconnect the connection (1) between the
module control ECUs(ribbon cable) on the
vertical module.
- Remove the O ring. 4
- Remove the horizontal module.

- Remove the intermodule cable (4). (1 screw
and 1 flexible washer) 7
- Remove the plastic cover (7). 4

- Remove the connection (1) between the
module control ECUs.
- Remove the O ring.
- Remove the fuse holder. (A) (1 screw and 1

flexible washer)
IL CON Disable the positive termiinal on the

RE
DA
module using the tool ref. 802653 of the

APPA
MNE
warning measures (must not be

DEF
ER
VR
EN
SE
DE MANO
E
handled and then refitted).
753726
48
ELECTRICITY
Removing the vertical module
- Disconnect the connection (2) between the

module control ECU and the traction battery 2
control ECU(ribbon).
- Remove the O ring.
- Remove the vertical module.
Connecting of the modules
Composition - 2
5
1. Communication channel between the
1
different calculators of module
control (Nappe).
2. Communication channel between the
4
calculator of module control and the calculator
of regulation of the traction battery (Nappe).
3. Negative power cable.
+ +
4. Inter-units cable.
5. Positive power cable.
3
A. 100 A fuse.
A
-
49
ELECTRICITY
Connecting order
- Place the vertical module in the frame.
On the horizontal module

- Remove the protection caps on the
electrodes. 7
- Fit the O rings.
- Connect the intermodule cable (4) to the
positive terminal. 4
- Position the rubber protector on the power
terminals.
- Connect the connection (1) between the 1
module control ECUs (ribbon).
- Connect the plug with electric function.
- Fit the plastic cover (7).
- Fit the horizonal module in the frame.
On the vertical module
- Fit the O rings. 1 2
- Connect the connection (1) between the
module control ECUs (ribbon). 6
- Connect the connection (2) between the
module control ECU and the traction battery
control ECU (ribbon).
- Fit and lock the plastic cover (6) in its guide.
- Connect the intermodule cable (4) and the
harness to the negative terminal. (1 screw and
1 flexible washer) 4
- Position the rubber protector.
50
ELECTRICITY
When refitting, take care that the power

cables are the right way round. (4) (5)
4. Inter-units cable.
5. Positive power cable.
4 5
Refit the other items in the reverse

order to disassembly.
Removing the main relay
- Remove the rear cover assembly. See:

- Remove the motor control ECU. (see relevant
1
chapter)
- Remove the protective cap.

- Disconnect the main relay. (2 nuts) (1)
(4 terminals) (2)

2
- Remove the main terminal. (2 screw)
51
ELECTRICITY
Removing the 24/48 volt relay

1
- Remove the relay concerned:
2
1. Converter relay.
2. Stop relay.
3. Self-holding relay.
52
ELECTRICITY
Removing the current sensor

1
- Remove the protective cap.
- Disconnect the cable 48v from the battery to
the main relay. (1 nuts) (1)
- Disconnect the current sensor. (2) 2

- Remove the current sensor.
If it is changed, it is essential to initialise it to inform the battery control ECU of its base value.
Initialisation is carried out by programming its gain and offset in the battery control ECU via
the TEP 2010. Values indicated on the sensor.
Removing the motor control ECU

- Remove the 4 screws of the motor

control ECU.
- Disconnect the ECU:

• 35 pin connector. (1)
1
53
ELECTRICITY
• The 3 motor phases. (3 screw)

2
Make a note of the way the motor

phases are fitted.
(Refit the motor control ECU at the rear of

the vehicle.)
• The negative power supply cable, the

earthing braid and the harness. (3)
(1 screw) 4
• The positive power supply

cable. (4) (1 screw)
- Remove the motor control ECU.

When remounting remember to
3
fit the heat sink between the
frame and the ECU.
When remounting, ensure the

polarity of the phases (2) of the
motor are respected.
Pilot motor calculator Motor phase

M1 W M1 Red
M2 U M2 Black
M3 V M3 Grey
When refitting, position the rubber protectors on the power terminals.
54
ELECTRICITY
Removing the electric traction ECU
- Remove the central cover panel. See:

- Disconnect the electric traction ECU (1).
- Remove the electric traction ECU (1) by

pulling upwards.
55
ELECTRICITY
Removing the C ECU
- Remove the saddle storage compartment.

- Remove the 5 attachment screws from the

double bottom.
- Remove the storage compartment

partition. (1)
- Remove the double bottom. (2)
1
2
- Remove the 4 screws from the traction
battery ECU.
56
ELECTRICITY
Put on the antistatic bracelet and

connect the end of the cord to the 3
earth.
- Remove the traction battery control ECU.

(7 screw)
Check the condition of the O-ring

and change it if necessary. (3)
If the traction battery control ECUis changed, it is essential to program it via the TEP 2010.
Removing the traction battery chargers

- Unlock the connector by pulling on the A

lock (A).
- Disconnect the ECU by pressing on the
tab (B).
B
- Remove the traction battery charger (2).
(3 screw)
57
ELECTRICITY
Removing the limiting resistance

- Disconnect the limiting resistance

- Removing the limiting resistance (1). (1
nuts)
Removing the converter 48/12 V

- Remove the resistance (2). (1 nuts)

- Disconnect the converter 48/12 V. (1)
- Remove the converter. (3 nuts)
58
ELECTRICITY
Removal of diodes
- Remove the fairings required to remove

the diode. 1
- Press to unlock. (1)
- Remove the diode. (2)
2
Removing the single track accelerator potentiometer

Procedure 5. page 21. 1
- Open the reclosable clip.
- Disconnect the accelerator potentiometer. (1)
- Disconnect the throttle control cable. (2)
- Remove the accelerator
potentiometer. (3) (2 screw)
2
When refitting the fork, check:

• That the plastic collar (A)
attaching all the control cables and
the wiring harness apart from the
throttle control cable is present. A
• That the reclosable clip (B) is
correctly positioned and clipped on
the accelerator potentiometer
harness.
• Ajust the lever free travel using
the adjusting nut. B
After refitting, initialise the single track potentiometer (consult the instrument
panel operating principles).
59
POWER UNIT
POWER UNIT
Removal of the power unit

- Remove the 4 screws of the motor control

ECU.
- Disconnect:
• 35 pin connector. (1)
1
(Refit the motor control ECU at the rear of the

vehicle.) 2
• The 3 motor phases. (2) (3 screw)
When remounting, ensure the polarity of the phases (2) of the motor are respected.
60
POWER UNIT
• The motor sensor. (3)
- Suspend the rear of the machine.

- Remove the shock absorber lower mount (4). 4
- Remove the adjusting nut, the barrel (5) and

the brake control cable.
- Remove the 4 tie rod/motor attachment

screws. (6)
61
TRANSMISSION
- Lift the rear of the machine.

- Remove the power propulsion unit from the
frame.
TRANSMISSION
Removal of the primary drive

- Remove the transmission cover. (6 screw)
- Immobilise the drive pulley using the tool ref.

752237.
- Removez the nut (1) and the washer from the 1
drive pulley.
752237
62
TRANSMISSION
- Remove the drive pulley using the tool ref.

802638.
- Remove the belt. 802638
Make a note of the direction of rotation of

the belt
Checking the drive belt

- Make sure the belt is not cracked. (A)
Removal of the secondary transmission

- Immobilise the driven pulley with the pin wrench
752237.
- Remove the nut (2) from the driven pulley.
2
752237
63
TRANSMISSION
- Remove the driven pulley using the tool ref.

802638 with hooks.
802638
Draining the relay box
1
Put on protective gloves.
2
- Place the vehicle on its central stand on flat

ground.
- Remove the rubber plug (1).
- Remove the wheel spindle nut and washer. (2)
- Remove the screw fastening the rear

mudguard on right.
- Remove the rear wheel.
64
TRANSMISSION
- Remove the relay box filler cap (A).
Tightening torque: 15 Nm
Remove the bolt (B) and its seal .
A
Use a drip pan to catch the transfer box

oil when the cover is removed.
Quantity: 0.1 l SAE 80W-90

- Remove the secondary transmission
cover. (5 screw) B
- Remove the secondary shaft. (3)
- Remove the paper gasket (4) and the

2 locating pins (5).
- Remove the primary shaft. (6)
5
5
6
4
65
TRANSMISSION
Replacing the bearings of the relay box
Crankcase
Wear gloves in order not to get burnt.
- Remove the seal.

- Using a heat gun, heat the crankcase to a
temperature between 80 and 90°C.
- Use an inertia type extractor tool to remove the
bearings.
- While the casing is expanded fit the new
bearing fully home in its housing.
- Using fitting tool P/N 756608, fit a new lightly
greased gasket (1).
756608
Relay box cover
- Remove the seal.

756608
- Place the cover on its gasket seat surface, heat
it (80 to 90°C) until the bearing falls out by itself.
- While the casing is expanded fit the new
bearing fully home in its housing.
- Using fitting tool P/N 756608, fit a new lightly
greased gasket (2).
66
ANNEX :
Annex :
Electric vehicle documents
Vehicle identification
Electric vehicle in maintenance
-VIN: VGA......................................................
-Colour: ............................................................
67
ANNEX :
Safe for work certificate
SAFE FOR WORK CERTIFICATE (LOCKOUT) N°:.............
Name: ...........................................................................
Person in charge of work ......................
Authorisation:
is in charge of performing the following work: ................................................................................................
............................................................................................................................................................................
............................................................................................................................................................................
On the following vehicle:
Type: .................................................................... Colour: ..............................................................
VIN: VGA..........................................................
For the employer Person in charge of work
Name: ...........................................................................
Lockout manager ......................
Authorisation:
Certifies that in view of the performance of this work he has locked out the above-mentioned
vehicle
Date: .........../........../.......... Time: ..........h..........
Person in charge of work
68
ANNEX :
End of work notification
END OF WORK NOTIFICATION
Name: ......................................................................
Person in charge of work ........................
Authorisation:
notifies
Name: ......................................................................
Lockout manager ......................
Authorisation:
That the work described on the safe for work (lockout) certificate N°........................
is terminated,
Date:.........../........../.......... Time: ..........h..........
and that the personnel has been informed that the work is finished.
The person in charge of the work declares that he has removed all the safety devices and other equipment he
fitted beforehand and has restored the vehicle to working order, for his part but has not switched the power
back on.
Lockout manager Person in charge of work
69
P/N. MA0026GB
Peugeot Motocycles is constantly improving its vehicles. It therefore reserves the right to remove, modify or add
any reference mentioned in this manual.
DC/PS/APV Printed in the E.U. 06/2012. (non contractual pictures)

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Quality Management

PRODUCTS DANGER SYMBOLS USED......................................................................................................... 4

SERVICE SCHEDULE AND COMMISSIONING ............................................................................................... 8

TIGHTENING TORQUES ................................................................................................................................ 10

SPECIAL TOOLS ............................................................................................................................................ 12

SPECIFIC ELECTRICAL EQUIPMENT .......................................................................................................... 14

ELECTRIC LOCKOUT OF THE VEHICLE...................................................................................................... 16

METHOD TO MAKE A MODULE INERT ........................................................................................................ 20

BODY PANELS ............................................................................................................................................... 22

MISCELLANEOUS OPERATIONS ................................................................................................................. 38

POWER UNIT .................................................................................................................................................. 60

PRODUCTS DANGER SYMBOLS USED

Protection of individuals and of the environment.

Avoid contact with skin and clothes. Wear

Keep it away from flames or any heat

Avoid contact with skin and clothes. Wear

The product can explode under

This symbol informs the consumer that the

People's safety can be seriously affected if

People's safety can be seriously affected if

Indicate the specific procedures that shall

Serious damage to the vehicle and in

Indicate a note which gives key

Indicate the specific procedures that shall

Indicate the specific procedures that shall

Indicate the specific procedures that shall

These documents indicate, inform a third

45 km/h version 60 km/h version

0.12 l SAE 80W90.

Chassis Steel tube

 Dimensions and weight

Overall length 1923 mm

Front wheel rim 12 inch aluminium alloy

Front brake Single disc type, hydraulic control

Chassis markings Engine marking

(1) number and manufacturer's plate Engine number. (2)

SERVICE SCHEDULE AND COMMISSIONING

The servicing must be carried out by a registered representative.

- Charge the battery.

500 kms or Every

V: Check, clean, adjust. C: Inspect and change if necessary.

The servicing must be carried out by a registered representative.

500 kms or Every Every

V: Check, clean, adjust. C: Inspect and change if necessary.

Note: The data records will be sent systematically to Peugeot Scooters.

Normal servicing in km 0 500 5000

Steeing head Control point

SDO1/0/ by xxo test

(*) New or modified tool.

Screwdriver socket set 1/2" for 6

Automatic resetting type torque Automatic resetting type torque

Automatic resetting type torque

Intertia type extractor tool for DC

5 mm pipe wrench Antistatic bracelet + Cord

SPECIFIC ELECTRICAL EQUIPMENT

IL CON (P)ersonal (P)rotective

Warning notice (forbidden to

(Complies with standards

1000 volt insulated tool

Electrical norms documentation Insulating sheet

ELECTRIC LOCKOUT OF THE VEHICLE

Work to be carried out by a B2-L accredited technician.

Analysis of the work sheet information.

Dimensions and weight

Location of body components

Body component sequence of disassembly

Removal of the central cover panel

Removal of the rear storage compartment

Removal of the rear cover assembly and mudflap

Removal of the front storage compartment

Removal of the rear shield panel

Removal of the front shield panel

Removal of the RH or LH under body panel

Removal of the footboard

Removal of the instrument cluster

Front brake pads

Replacing the brake pads

Checking the brake fluid level

Rear brake linings