Gilera 633721 Workshop Manual

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WORKSHOP MANUAL

633721 - 633728

Nexus 500 euro 3

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Page 1 WORKSHOP MANUAL 633721 - 633728 Nexus 500 euro 3...
Page 2 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Page 3 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of scooter mounting techniques and procedures. Any important changes made to the scooters or to specific mounting operations will be promptly reported by updates to this manual.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
Nexus 500 euro 3 Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the vehicle. Safety rules • Should it be necessary to keep the engine running while servicing, make sure that the area or room is well ventilated, and use special exhaust fans, if required.
Page 8: Vehicle Identification
Nexus 500 euro 3 Characteristics Vehicle identification Characteristic Engine prefix: M351M Chassis prefix: ZAPM35200 Dimensions and mass WEIGHT Specification Desc./Quantity Dry weight 199 kg Width 765 mm Length 2090 mm Wheel base 1515 mm Saddle height 780 mm Height 1045 mm CHAR - 8...
Page 9 Nexus 500 euro 3 Characteristics Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, four-stroke Bore 92 mm Stroke 69 mm Cubic capacity 460 cm³ Compression ratio 10.5: 1 Timing system Single overhead camshaft with integrated tone wheel, control from flywheel side chain, 4 valves and automatic start-up valve lifting device.
Page 10: Wheels And Tyres
Nexus 500 euro 3 Characteristics Specification Desc./Quantity Battery Dry-cell lead-acid battery, 12V-14Ah Generator Three-phase alternating current Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc./Quantity Chassis Welded steel pipes with pressed sheet metal stiffening Front suspension Hydraulic telescopic fork with diameter 41 mm stems Front fork max.
Page 11: Tightening Torques
Nexus 500 euro 3 Characteristics Tightening Torques FRAME Name Torque in Nm Electric pump locking ring nut BRAKE SYSTEM Name Torque in Nm Brake calliper coupling 20 - 24 Front brake disc mounting 5 ÷ 6 • Rear brake disc mounting 11 ÷...
Page 12 Nexus 500 euro 3 Characteristics Name Torque in Nm Head fixing stud bolts Head fixing nuts 10 - 12 Exhaust / intake head fixing nuts 10 - 12 Head lubrication control jet 5 - 7 coolant temperature sensor: 10 - 12 Lambda probe on exhaust manifold 10 - 12 injector fixing screw...
Page 13: Assembly Clearances
Nexus 500 euro 3 Characteristics LUBRICATION Name Torque in Nm Oil pump cover screws 0.7 ÷ 0.9 Screws fixing oil pump to crankcase 5 - 6 See also Refitting Refitting Fuel tank Overhaul Overhaul data This section provides the main information for scooter servicing. Assembly clearances Cylinder - piston assy.
Page 14 Nexus 500 euro 3 Characteristics Piston rings * Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the openings in the rings as shown here. *** Value «A» of sealing ring inside the cylinder **** Ring opening SEALING RINGS Name Initials...
Page 15 Nexus 500 euro 3 Characteristics Diameter of crankshaft bearings. Measure the capacity on both axes x-y. CRANKSHAFT Specification Desc./Quantity Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022 Crankshaft alignment Specific tooling 020335Y Magnetic support for dial gauge MAX.
Page 16 Nexus 500 euro 3 Characteristics AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 0.8 ± 0.025 D= 0.20 - 0.40 shoulder Transmission-side half- 19.6 + 0.050 D= 0.20 - 0.40 shaft Connecting rod 22 0.10-0.15 D= 0.20 - 0.40 Flywheel-side shoulder 13 ±...
Page 17 Nexus 500 euro 3 Characteristics N.B. DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B» Products PRODUCTS Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re- quirements of API GL3 specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-...
Page 18 INDEX OF TOPICS TOOL OOLING...
Page 19: Special Tools
Nexus 500 euro 3 Tooling SPECIAL TOOLS GOOD Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings 001467Y008 Pliers to extract 17 mm ø bearings 001467Y014 Pliers to extract ø...
Page 20 Nexus 500 euro 3 Tooling Stores code Description 001467Y031 Bell 001467Y034 Pliers to extract ø 15-mm bearings 001467Y035 Belle for OD 47-mm bearings 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from headstock TOOL - 20...
Page 21 Nexus 500 euro 3 Tooling Stores code Description 020055Y Wrench for steering tube ring nut 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for assembling valve seal rings TOOL - 21...
Page 22 Nexus 500 euro 3 Tooling Stores code Description 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger TOOL - 22...
Page 23 Nexus 500 euro 3 Tooling Stores code Description 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020364Y 25-mm guide 020376Y Adaptor handle 020382Y012 bush (valve removing tool) TOOL - 23...
Page 24 Nexus 500 euro 3 Tooling Stores code Description 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020439Y 17 mm guide TOOL - 24...
Page 25 Nexus 500 euro 3 Tooling Stores code Description 020444Y Tool for fitting/ removing the driven pulley clutch 020456Y Ø 24 mm adaptor 020458Y Puller for lower bearing on steering tube 020459Y Punch for fitting bearing on steering tube 020460Y Scooter diagnosis and tester 020467Y Flywheel extractor TOOL - 25...
Page 26 Nexus 500 euro 3 Tooling Stores code Description 020468Y Piston fitting band 020469Y Reprogramming kit for scooter diagnosis tester 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench TOOL - 26...
Page 27 Nexus 500 euro 3 Tooling Stores code Description 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set 020478Y Punch for driven pulley roller casing 020479Y Countershaft lock wrench 020480Y Petrol pressure check set TOOL - 27...
Page 28 Nexus 500 euro 3 Tooling Stores code Description 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner TOOL - 28...
Page 29 Nexus 500 euro 3 Tooling Stores code Description 020623Y Pre-service gas extraction set 020625Y Kit for sampling gas from the exhaust manifold 020640y software euro3 TOOL - 29...
Page 30 INDEX OF TOPICS MAIN AINTENANCE...
Page 31: Maintenance Chart
Nexus 500 euro 3 Maintenance Maintenance chart EVERY 2 YEARS Action Coolant - change Brake fluid - change AFTER 1,000 KM Action Safety locks - check Throttle lever - adjustment Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement...
Page 32: Spark Plug
Nexus 500 euro 3 Maintenance Action Crankcase breather - empty AFTER 20,000 KM AFTER 40,000 KM AFTER 60,000 KM AND AFTER 80,000 KM Action Safety locks - check Bushing of driven pulley Spark plug - replacement Driving belt - replacement Throttle lever - adjustment Air filter - check Air filter belt compartment - check...
Page 33 Nexus 500 euro 3 Maintenance - Disconnect the shielded spark plug cap - Unscrew the spark plug. - Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or grimy, the conditions of the washer, and measure the distance between the elec- trodes using the appropriate feeler gauge.
Page 34 Nexus 500 euro 3 Maintenance - Pull out the dipstick and check that the oil level is between the MAX and MIN notches indicated on the dipstick; if the level is below the MIN value, re- store the proper amount of oil in the hub. -Retighten the oil dipstick again and make sure it is locked properly into place.
Page 35 Nexus 500 euro 3 Maintenance Air filter - Raise the saddle. - Remove the piston ring and the battery cover. - Loosen the 4 mounting screws shown in the fig- ure. - Loosen the mounting screw located under the intake manifold. - Replace the air filter and reassemble the various components, reversing the removal procedure.
Page 36: Engine Oil
Nexus 500 euro 3 Maintenance N.B. FAILURE TO OBSERVE THE RULES REGARDING CLEAN- ING OF THE FILTER ELEMENT CAN LEAD TO IMPROPER LUBRICATION OF THE ELEMENT. POOR LUBRICATION AFFECTS THE FILTERING CAPACITY. EXCESSIVE LUBRI- CATION AS WITH A SOILED FILTER CAUSES AN EXCES- SIVELY RICH FUEL/AIR MIXTURE.
Page 37: Engine Oil Filter
Nexus 500 euro 3 Maintenance The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc. Engine oil filter CAUTION DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. OIL, GASKET AND FILTER SHOULD BE DIS- POSED OF ACCORDING TO THE REGULATIONS IN FORCE.
Page 38: Engine Oil Drainage Plug
Nexus 500 euro 3 Maintenance IF THE OIL IS CHANGED WITHOUT CHANGING THE CARTRIDGE FILTER (1ST COUPON) ADD AROUND 1500 CC OF OIL INSTEAD OF 1700 CC SINCE PART OF THE LUBRICATION CIRCUIT IS FILLED. Characteristic Engine oil: 1700 cm³ Locking torques (N*m) Engine oil drainage plug 24 ÷...
Page 39 Nexus 500 euro 3 Maintenance Cooling system If noise or loss of liquid at the drain bore of the water pump is discovered, it will be necessary to overhaul the pump as described in chapter "Flywheel cover". Proceed to carry out a few preliminary operations as described below: - Place the scooter on its centre stand and on flat ground.
Page 40: Braking System
Nexus 500 euro 3 Maintenance DO NOT EXCEED THE MAX. LEVEL WHEN FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN THE vehicle IS IN USE. N.B. THE COOLANT CONSISTS OF A MIXTURE OF DE-IONISED WATER AND FLUID FOR SEALED CIRCUITS.
Page 41: Headlight Adjustment
Nexus 500 euro 3 Maintenance CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS.
Page 42 Nexus 500 euro 3 Maintenance - Otherwise, adjust the right headlight by the screw shown in the figure, which can be accessed by re- moving the front shield connecting member. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS.
Page 43 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 44 Nexus 500 euro 3 Electrical system KEY: 1. Magneto flywheel 2. Voltage regulator 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepping motor for idle nozzle 7. Electric fan 8. Engine temperature sensor 9. Remote control for electric fan 10.
Page 45 Nexus 500 euro 3 Electrical system 20. Battery 21. Starter motor 22. Start-up remote control switch 23. Starter push button 24. Starter enable remote control 25. Engine stop switch 26. Centre stand switch 27. Rear brake stop button 28. Front brake stop button 29.
Page 46 Nexus 500 euro 3 Electrical system 51. Emergency light switch 52. Oil pressure sensor 53. Instrument panel A. Rpm indicator B. Instrument panel bulbs 54. Instrument panel A. Instrument panel bulbs B. Immobilizer LED C. Speedometer D. Digital display E. Engine Warning indicator light F.
Page 47 Nexus 500 euro 3 Electrical system During assembly, observe the installation direction shown in the figure. H.V. coil In order to access the high-voltage coil, remove the left-hand side fairing. Saddle opening ECU remote control. Resetting of the remote control Electronic control unit ECU In order to access the immobilizer control unit, re- move the upper shield back plate.
Page 48 Nexus 500 euro 3 Electrical system In order to access the connector, remove the wind- shield with the respective support and the metal plate holding the control unit ECU, decoder and saddle opener remote control. N.B. AFTER INSERTING THE INTERFACE CABLE OR THE ELECTRONIC CONTROL UNIT, RETIGHTEN THE SCREW AND THE GROUND CABLE.
Page 49 Nexus 500 euro 3 Electrical system Lambda probe The lambda probe is mounted on the exhaust manifold Conceptual diagrams Ignition KEY: 3. Engine rpm sensor 11. Injection load remote control 12. Key switch 13. Fuse box A 14. Main fuse 15.
Page 50 Nexus 500 euro 3 Electrical system 19. Diode 20. Battery 25. Engine stop switch 26. Centre stand switch 54. Instrument panel A. Instrument panel bulbs B. Immobilizer LED C. Speedometer D. Digital display E. Engine Warning indicator light F. Low fuel warning light G.
Page 51 Nexus 500 euro 3 Electrical system 1. Magneto flywheel 2. Voltage regulator 12. Key switch 14. Main fuse 15. Fuse box B 18. Engine stop remote control 19. Diode 20. Battery 21. Starter motor 22. Start-up remote control switch 23. Starter push button 24.
Page 52 Nexus 500 euro 3 Electrical system 3. Engine rev sensor 4. Throttle valve position sensor 5. Ambient temperature sensor 6. Stepping motor for idle nozzle 8. Engine temperature sensor 11. Injection charge remote control 12. Key switch 13. Fuse box A 14.
Page 53 Nexus 500 euro 3 Electrical system Devices and accessories 7. Electric fan 8. Engine temperature sensor 9. Remote control for electric fan 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 16. Horn button 17. Horn 18.
Page 54 Nexus 500 euro 3 Electrical system 32. Helmet compartment light switch 33. Helmet compartment bulb 64. Fuel injection electronic control unit Lights and turn indicators LEGENDA 12. Commutatore a chiave 13. Scatola portafusibili A 14. Fusibile principale 15. Scatola portafusibili B 20.
Page 55 Nexus 500 euro 3 Electrical system 41. Gruppo ottico anteriore Sx B. Luce di posizione C. Lampada abbagliante 42. Lampada indicatore di direzione anteriore Dx 43. Teleruttore proiettore 44. Pulsante abbagliante modalità Pass 45. Deviatore luci 46. Dispositivo lampeggiatori 47. Spie gruppo manubrio A.
Page 56 Nexus 500 euro 3 Electrical system - Immobilizer aerial - Master key with integrated transponder (brown key) - Service key with integrated transponder (black key) - H.V. coil - Diagnostic LED The diagnostic LED also control the function of the immobiliser lamp. This function is activated every time the key switch is turned to position "OFF"...
Page 57 Nexus 500 euro 3 Electrical system Virgin circuit When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the rec- ognition of the "master"...
Page 58 Nexus 500 euro 3 Electrical system oughly inspected: In any case it is advisable to use resistive spark plugs. Characteristic MASTER key: BROWN KEY SERVICE key. BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig- nition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit sta- tuses can be seen and various light codes dis- played.
Page 59 Nexus 500 euro 3 Electrical system pleted, the LED remains permanently OFF. The engine can be started. 5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be trans- mitted are: •...
Page 60 Nexus 500 euro 3 Electrical system Diagnostic code - 3 flashes The 3-flash code indicates a system where the de- coder does not recognise the key. Turn the switch to ON using several keys: If the error code is re- peated even with the Master key, replace the de- coder.
Page 61 Nexus 500 euro 3 Electrical system 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check VOLTAGE REGULATOR/RECTIFIER Specification Desc./Quantity Type Non-adjustable three-phase transistor Voltage 14 ÷...
Page 62 Nexus 500 euro 3 Electrical system Turn signals system check The circuit of the turn indicators is controlled by the electrical control device and the instrument panel. In the event of a malfunction, proceed as follows: 1. Check the function of the bulbs 2.
Page 63 Nexus 500 euro 3 Electrical system TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). USIBILE PRINCIPALE Specification Desc./Quantity Generale Nominazione: Fuse 1 Soglia di intervento: 30A Collocazione: Vano batteria PORTAFUSIBILI «B» Specification Desc./Quantity Non utilizzato Nominazione: - Soglia di intervento: - Collocazione: Vano portacasco...
Page 64 Nexus 500 euro 3 Electrical system Specification Desc./Quantity Location: Shield back plate HV coil - fuel injector - fuel pump - remote control injec- Designation:Fuse 12 tion load Threshold of operation: 10 A Location: Shield back plate Remote control switches The electrical system has 6 remote control switches located under the front shield.
Page 65 Nexus 500 euro 3 Electrical system Dashboard The digital display has two service symbols: SERVICE (Service coupon): The lamp should come on after reaching 1000 km or 1 year after initial activation, then every 6000 km or 1 year after the last activation. BELT: This lamp should come on every 12000 km.
Page 66 Nexus 500 euro 3 Electrical system - Spare warning light - The emergency control unit may be switched ON and OFF only with the key in position "ON" and must continue to function with the key in position "OFF". • Digital instrument The digital section provides the displays of: - Injection warning light (amber) - Low fuel warning light (amber)
Page 67 Nexus 500 euro 3 Electrical system 4. Momentary consumption The fuel symbol and km/h or mph appear. 5. Range The fuel icon appears. If the range drops below 40 km, the symbol appears automatically and flashes for 60 seconds. When the low fuel warning light comes on permanently, dashes appear instead of the range value. 6.
Page 68 Nexus 500 euro 3 Electrical system Press button "CLOCK" again and the figures showing the minutes start to flash. Set the minutes with the «ODO/SET» button. Press the «CLOCK» button again to start the clock moving normally. During the reset process, not pressing any buttons for 8 seconds ends the process and the display will automatically show the modified time.
Page 69 Nexus 500 euro 3 Electrical system -Charge current equal to 1/10 of the nominal capacity of the battery - Charge time: 5 h Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Cleaning the battery The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.
Page 70 Nexus 500 euro 3 Electrical system - After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery re- charge". Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger 1 Keep the pipe in vertical position 2 Inspect visually 3 The float must be freed...
Page 71 Nexus 500 euro 3 Electrical system The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline. CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Page 72 Nexus 500 euro 3 Electrical system Connectors Layout of the system-side connectors and the con- nectors on the electronic control unit. Specification Desc./Quantity Throttle potentiometer power supply +5 V Oxygen sensor Rpm indicator / consumption counter Engine temperature 86 electric fan remote control switch Stepper motor Stepper motor Engine rpm sensor...
Page 73 Nexus 500 euro 3 Electrical system Seat opening receiver RECEIVER CONTROL UNIT FOR SADDLE OPENER Specification Desc./Quantity Radio aerial Actuator positive output 1 Reset / Input clearing Battery positive (Not connected) Live positive lead Ground lead (Not connected) (Not connected) Selection input CH1 / CH3 Positive output actuator 1 Data for alarm output...
Page 74 Nexus 500 euro 3 Electrical system Engine rev. sensor REV SENSOR Specification Desc./Quantity Male Female Shielding Dashboard The instrument panel is provided with two connec- tors ("A" with 20 pins and "B" with 12 pins) shown in the figure. Connector "A" KEY: 1.
Page 75 Nexus 500 euro 3 Electrical system 10. Left turn indicator 11. Fixed battery 12. Immobilizer LED 13. Permanent power supply (+) 14. Turn indicator assembly 15. Pump level sensor 16. - 17. Injection LED 18. Right turn indicator warning light 19.
Page 76: Battery Replacement
Nexus 500 euro 3 Electrical system This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device. If the remote control is lost, a new one can be requested and reprogram it by resetting the ECU memory and following the same steps as per programming the immobilizer system in the keys.
Page 77 Nexus 500 euro 3 Electrical system 2. Turn the key to ON, press the button on the remote control, release the button, turn the key back to OFF from the ON position, all within four seconds. 3. Wait 1 to 8 seconds 4.
Page 78 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 79 Nexus 500 euro 3 Engine from vehicle Exhaust assy. Removal - Loosen the two mountings of the exhaust mani- fold at the cylinder head. - Remove the Lambda probe from its support and disconnect it. Remove the screw indicated in the photograph. - Loosen the screw shown in the figure so as to loosen the muffler strap and remove the whole muffler.
Page 80 Nexus 500 euro 3 Engine from vehicle N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO ACTUATE ON THE SCREW PERPENDICULARLY TO RE- MOVE IT; USE A COMMERCIALLY AVAILABLE «BON- DUS» MALE HEXAGONAL WRENCH. Remove the lambda probe from the manifold. Removal of the engine from the vehicle Installing the engine on the scooter - Carry out the removal operations but in reverse order and respect the locking torques indicated in the...
Page 81 Nexus 500 euro 3 Engine from vehicle - Remove the air filter coupling and the collector. - Disconnect the ground cable from the engine. - Disconnect the carburettor electrical devices and the starter motor power supply cable. - Disconnect the fuel delivery and return pipes from the carburettor and the cooling system piping (outlet from the head and inlet to the thermostat).
Page 82 INDEX OF TOPICS NGINE...
Page 83: Transmission Cover
Nexus 500 euro 3 Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap. - Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.
Page 84: Transmission Cover
Nexus 500 euro 3 Engine - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. Air duct - Remove the transmission cover.
Page 85: Transmission Cover
Nexus 500 euro 3 Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the Seeger ring.
Page 86: Transmission Cover
Nexus 500 euro 3 Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.
Page 87: Removing The Driven Pulley
Nexus 500 euro 3 Engine - Check that the roller does not show signs of wear and that it turns freely. - Loosen the retaining bolt using a 13 mm spanner. - Remove the complete roller with bearing. N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE THE COMPLETE ROLLER.
Page 88: Removing The Clutch
Nexus 500 euro 3 Engine Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool; - Arrange the tool with the mean pins screwed in position "E" on the inside; - Install the driven pulley unit onto the tool inserting the pins into the ventilation holes;...
Page 89 Nexus 500 euro 3 Engine Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage; otherwise replace the fixed driven half- pulley. - Remove the lock ring using pliers. - Using the special tool inserted through the roller bearing, pull out the ball bearing.
Page 90 Nexus 500 euro 3 Engine Inspecting the driven fixed half-pulley - Check that the belt contact surface is free from wear. - Measure the outer diameter of the pulley bushing. Characteristic Minimum admissible diameter 49.91 mm Standard diameter: 50.00 -0.015 -0.035 mm Inspecting the driven sliding half-pulley - Check that the belt contact surface is free from wear.
Page 91: Refitting The Driven Pulley
Nexus 500 euro 3 Engine Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing - Install a new ball bearing using the special tool. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020363Y 20 mm guide - Insert the Seeger lock ring.
Page 92 Nexus 500 euro 3 Engine Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length: 125.5 mm Admissible limit after use: 120 mm - Check the thickness of the clutch mass friction material.
Page 93: Clutch Ring Nut
Nexus 500 euro 3 Engine Refitting the clutch Bell assembly - Install the bell and the spacer. - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool.
Page 94: Removing The Driving Pulley
Nexus 500 euro 3 Engine Refitting the driven pulley - Install the driven pulley assembly with belt. Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 25 mm Standard width: 26.2 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut...
Page 95 Nexus 500 euro 3 Engine - First install the lock ring of the special tool onto the pulley so that the splines are completely en- gaged. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.
Page 96 Nexus 500 euro 3 Engine - Measure the pulley sliding bushing outside di- ameter shown in the figure. Characteristic Minimum admissible diameter Ø 29.95 mm Standard diameter: Ø 29.959 mm - Check that the rollers are not damaged or worn. Characteristic Minimum admissible diameter Ø...
Page 97 Nexus 500 euro 3 Engine Refitting the driving pulley Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the moving driving pulley. - Remove the flat washer and the spring washer as shown in the figure.
Page 98: Driving Pulley Nut
Nexus 500 euro 3 Engine - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN- SERTED INTO THE PULLEY AND IN THE ENGINE CRANK- CASE.
Page 99: Transmission Cover
Nexus 500 euro 3 Engine - Assembly the half-pulley with the roller contrast plate and sliding blocks. - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Refitting the transmission cover - Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase.
Page 100: M8 Retainers For Transmission Cover
Nexus 500 euro 3 Engine - Ensure the correct installation on the crankcase of the 2 centring dowels. - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷...
Page 101 Nexus 500 euro 3 Engine End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine. - Drain the rear hub oil through the oil drainage cap located under the engine. -Remove the 7 fastening screws.
Page 102 Nexus 500 euro 3 Engine - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts. Specific tooling 001467Y014 Pliers to extract ø 15-mm bearings 001467Y034 Pliers to extract ø...
Page 103 Nexus 500 euro 3 Engine - Remove the oil guard using a screwdriver. Removing the driven pulley shaft bearing - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as descri- bed in the Automatic transmission chapter.
Page 104 Nexus 500 euro 3 Engine Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm Connection diameter for wheel shaft: B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Bearing diameter for driven pulley shaft: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm F = diameter 25 - 0.01 -0.02 mm...
Page 105 Nexus 500 euro 3 Engine - Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020363Y 20 mm guide...
Page 106 Nexus 500 euro 3 Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the column kit. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.
Page 107 Nexus 500 euro 3 Engine - Support the hub cover using the column kit. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm...
Page 108 Nexus 500 euro 3 Engine Locking torques (N*m) Rear hub cover screws 24 ÷ 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
Page 109 Nexus 500 euro 3 Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support. N.B.
Page 110: Removing The Stator
Nexus 500 euro 3 Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
Page 111 Nexus 500 euro 3 Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Remove the water pump impeller by unscrewing it from the relevant shaft. N.B.
Page 112: Minimum Oil Pressure Sensor
Nexus 500 euro 3 Engine - Remove the sealing ring. - Remove the ceramic ring and the relevant gas- ket. - Remove the sealing ring for the pump shaft lu- brication using a suitably shaped tool. - Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing.
Page 113 Nexus 500 euro 3 Engine Inspecting the cover components - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque. Locking torques (N*m) Engine oil filter 12 - 16 - Install the supply hose to the cylinder and con- nect the return hose to the pump cover using 3 new clamps.
Page 114 Nexus 500 euro 3 Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω...
Page 115 Nexus 500 euro 3 Engine - Check that the oil filter union and matching sur- face exhibit no deformations or wear. Refitting the stator - Install the stator assembly together with the wir- ing harness, tightening the 3 screws to the pre- scribed torque.
Page 116 Nexus 500 euro 3 Engine - Insert the spring and the by-pass piston on the flywheel cover. N.B. LUBRICATE THE BY-PASS VALVE. Refitting the flywheel cover components - Before reassembling, check that all components are perfectly clean. - For the cover, carefully check all lubrication chan- nels, in particular: - The 3 by-pass channels.
Page 117: Supporting Screws With Bulkhead 0.3 -
Nexus 500 euro 3 Engine - Oil pressure sensor feeding duct. - Oil vapour decantation chamber - Reinstall the blow-by reed valve using a new sealing gasket. - Reinstall the support with head and tighten the screws to the prescribed torque. Locking torques (N*m) Supporting screws with bulkhead 0.3 - 0.4...
Page 118 Nexus 500 euro 3 Engine - Pre-assemble the ceramic seal and the relevant gasket. N.B. PLACE THE CHAMFERING TOWARDS THE GASKET BE- ING CAREFUL NOT TO FOUL THE CERAMIC RING WITH OIL OR GREASE, WHICH WOULD IMPAIR THE SEAL. - Insert the ceramic seal on the flywheel cover. N.B.
Page 119 Nexus 500 euro 3 Engine - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure).
Page 120 Nexus 500 euro 3 Engine N.B. - THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE) ARE SLIGHTLY LONGER. Locking torques (N*m) Flywheel cover screws 11 - 13 Flywheel and starting The starter is sold as a complete part.
Page 121 Nexus 500 euro 3 Engine 80 - 120 A Revolution speed = approx. 300-400 rpm YES go to 6 NO go to 7 NO go to 8 NO go to 9 5 - Restore the connections 6- The values are correct. Finally carry out a check of the power consumption at idle speed.
Page 122 Nexus 500 euro 3 Engine N.B. IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE, CHECK THE FREEWHEEL OF THE TORQUE LIMITER (SEE THE "FLYWHEEL AND STARTER SYSTEM" CHAPTER). STARTER MOTOR Specification Desc./Quantity Type Mitsuba sm13d Power 0.9 kW BATTERY...
Page 123 Nexus 500 euro 3 Engine Removing the starter motor N.B. THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED. - Loosen the two fastening screws. - Extract the complete starter motor. Removing the flywheel magneto N.B. IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST.
Page 124 Nexus 500 euro 3 Engine - Tighten the bushing of the flywheel lock tool on the removing tool threading. - Insert the special tool as shown in the figure, making sure that the pins are perfectly inserted in- to the previously aligned holes and that it is per- fectly abutted and almost flush with the flywheel.
Page 125 Nexus 500 euro 3 Engine - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED; THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS.
Page 126 Nexus 500 euro 3 Engine - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws. SINCE THE FREEWHEEL MUST BE REMOVED, IT IS AD- VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.
Page 127 Nexus 500 euro 3 Engine Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers" of the freewheel and on the surface of the starter ring gear hub. - Check the hub outside diameter. Characteristic Hub outside diameter: Diameter 45.665 + 0.008 +0.005 mm...
Page 128 Nexus 500 euro 3 Engine Also check the shaft diameter on the flywheel cov- er and on the engine crankcase. Characteristic Bearing diameter on the flywheel cover 12 + 0.034 -0.016 mm Bearing diameter on the engine crankcase: 12 + 0.034 -0.016 mm N.B.
Page 129: Screw Fixing Freewheel To Flywheel
Nexus 500 euro 3 Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 130 Nexus 500 euro 3 Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the flywheel magneto - Insert the key on the crankshaft. - Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear with the start-up rim.
Page 131: Flywheel Fixing Nut
Nexus 500 euro 3 Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS RULE CAUSES THE LOCK- ING OF THE GUIDE ON THE FLYWHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
Page 132 Nexus 500 euro 3 Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START- UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC- TION.
Page 133 Nexus 500 euro 3 Engine Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket. Removing the timing system drive - Turn the engine to close the intake valves, i.e., moving the reference on the tone wheel to the top,...
Page 134 Nexus 500 euro 3 Engine - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer. N.B.
Page 135 Nexus 500 euro 3 Engine Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft. - Remove the timing belt rim. - Remove the tone wheel. - Remove the engine revolution timing sensor and relevant O-ring by loosening the fastening screw and removing the mounting band from the special hole obtained on the head gasket.
Page 136: Removing The Cylinder Head
Nexus 500 euro 3 Engine Removing the cam shaft - Unscrew the 3 fastening screws and remove camshaft retaining bracket. N.B. REMOVING THE FASTENING SCREWS MAY BE DIFFI- CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX- AGON. IF NECESSARY, SEPARATE THE THREADS IN ADVANCE.
Page 137 Nexus 500 euro 3 Engine - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE AN- ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER. - Remove the 2 fastening nuts on the head, on the exhaust and on the intake side.
Page 138: Removing The Valves
Nexus 500 euro 3 Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool) CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLY- WHEEL SIDE AND TRANSMISSION SIDE).
Page 139 Nexus 500 euro 3 Engine Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 140: Inspecting The Small End
Nexus 500 euro 3 Engine Inspecting the small end - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 141: Inspecting The Piston
Nexus 500 euro 3 Engine Inspecting the piston - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Take the measurement in the position shown in the figure. Characteristic 43.2 mm Piston diameter: 92 mm - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure.
Page 142: Removing The Piston
Nexus 500 euro 3 Engine Fitting clearance (Cylindrin/Pison) Standard coupling clearance A 0.9 - 0.005 -0.030mm B 1.5 - 0.005 -0.03mm Maximum permissible clearance after use C 0.9 + 0.03 +0.01mm D 2 + 0.05 +0.02mm Standard coupling clearance </> 1.2 - 0.005 mm </>...
Page 143 Nexus 500 euro 3 Engine - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a punch - Install the pin lock using the key shown in the figure.
Page 144 Nexus 500 euro 3 Engine - Using an abutment plane, reset the comparator with a preload of a few millimetres. - Finally fix the comparator. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the comparator position.
Page 145: Inspecting The Cylinder Head
Nexus 500 euro 3 Engine Refitting the piston rings - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening op- posed to the spring junction and with the writing "top" facing the piston top. The chamfered side of the oil scraper ring should always be facing the piston crown.
Page 146 Nexus 500 euro 3 Engine Characteristic Maximum allowable run-out: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the intake and ex- haust manifold. - Check that the bearings of the camshaft and the rocker pins exhibit no wear.
Page 147 Nexus 500 euro 3 Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
Page 148 Nexus 500 euro 3 Engine Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Inlet: 4.987 - 4.972 mm Outlet: 4.975 - 4.960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Inlet:...
Page 149 Nexus 500 euro 3 Engine Inspecting the valve stem guide clearance - After measuring the valve guide diameter and the valve stem diameter, check the clearance between guide and stem. INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm OUTLET Specification...
Page 150 Nexus 500 euro 3 Engine - If the checks above give no failures, you can use the same valves. To obtain better sealing perform- ance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve ax- es in a horizontal position.
Page 151 Nexus 500 euro 3 Engine Refitting the valves - Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the spe- cial tool. - Lubricate the oil guards and the valve guides. Specific tooling 020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the caps.
Page 152 Nexus 500 euro 3 Engine -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity Intake 33.988 mm Exhaust: 33.417 mm ADMISSIBLE LIMITS Specification Desc./Quantity Intake 33.740 mm Exhaust: 33.170 mm Standard axial clearance: 0 - 0.22 mm Maximum admissible axial clearance: 0.3 mm - If any of the above dimensions are outside the specified limits, or there are signs of excessive...
Page 153 Nexus 500 euro 3 Engine - Check that the cam contact sliding block and the articulated register plate is free from wear. - In case of wear, replace the component. Refitting the head and timing system components - Insert the chain guide sliding block. - Insert the two centring dowels between head and cylinder.
Page 154: Head Fixing Nuts
Nexus 500 euro 3 Engine - Tighten the 4 fastening columns crosswise to the prescribed torque as shown in the figure. - Tighten the 4 screws by 90° in the sequence shown in the figure. - Further tighten by 90° in the sequence shown in the figure.
Page 155: Tensioner Sliding Block Fixing Screw
Nexus 500 euro 3 Engine - Insert the timing control belt on the crankshaft according to the initial direction of rotation. - Install the tensioner shoe with its spacer, tight- ening the bolt to the prescribed torque, using the recommended product. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock...
Page 156: Camshaft Retaining Bracket Screws:
Nexus 500 euro 3 Engine - Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque, being careful not to damage the inside hexagon. Locking torques (N*m) Camshaft retaining bracket screws: 4 ÷ 6 - Check that the toothing and the housing of the tone wheel timing peg are free from deformations or dents.
Page 157 Nexus 500 euro 3 Engine - Install the intermediate gear with torque limiter, the flywheel and its cover, as described in Chapter "Flywheel and start-up system", and in Chapter "Flywheel cover". N.B. FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES. - Using the TORX wrench, remove the timing check cap.
Page 158 Nexus 500 euro 3 Engine - Insert the belt on the camshaft control timing rim. - Insert the timing rim on the camshaft checking that the references are aligned. N.B. DURING THE STROKE CHECK, KEEP THE BELT TEN- SIONED BY PRESSING ON THE TIGHTENER COMPART- MENT SIDE.
Page 159: Valve Lifter Mass Stop Bell Fixing Screws
Nexus 500 euro 3 Engine - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product. N.B.
Page 160 Nexus 500 euro 3 Engine Refitting the timing chain This section described the operations to be carried out on the manifold components. Ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to interpret the reference values based on the engine rpm. The ignition advance value is detectable at any time using the diagnostic tester.
Page 161 Nexus 500 euro 3 Engine - Repeat for the reference between driving pulley and transmission housing. - Replace the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameter» function in this menu. - Select the stroboscopic light command in the tra- ditional four-stroke engine position (1 spark 2 revs).
Page 162 Nexus 500 euro 3 Engine - Repeat the check at 3 - 4 points. - Place the tightener cursor in the rest position, keeping the retain tab pressed. - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque.
Page 163: Tappet Cover Fixing Screws
Nexus 500 euro 3 Engine Refitting the rocker-arms cover - Check that the gasket is in good working order. - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a crossed se- quence (3, 4, 5, 6).
Page 164: Inlet Manifold Screws
Nexus 500 euro 3 Engine Refitting the intake manifold - Install the intake manifold on the engine. - Insert the 3 fastening screws, one of which with a support band for the cooling system sleeve, and tighten to the prescribed torque. Locking torques (N*m) Inlet manifold screws 11 ÷...
Page 165 Nexus 500 euro 3 Engine - Remove the thermal group (cylinder, head, pis- ton) as described in the «Thermal group and timing system chapter». - Before opening the crankcase, check the crank- shaft axial clearance. For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.
Page 166 Nexus 500 euro 3 Engine Splitting the crankcase halves - Remove the engine support retain screw on the flywheel side half-crankcase. - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION. - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase.
Page 167 Nexus 500 euro 3 Engine - Remove the crankshaft with the shim adjustment washer on the flywheel side. CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT, CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BEARING.
Page 168 Nexus 500 euro 3 Engine - Remove the special tool and extract the counter- shaft with the control gear. Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it. Flywheel-side half-crankcase - Remove the inside Seeger ring.
Page 169 Nexus 500 euro 3 Engine - Before installing a new bearing, heat the flywheel side half-crankcase using the special tool. - Place the half-crankcase on a wooden base. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
Page 170 Nexus 500 euro 3 Engine - Insert a new bearing on the special tool after greasing the guide seat. - Install the new bearing on the engine crankcase using the special tool. N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 171 Nexus 500 euro 3 Engine CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VALUES AND THE SUR- FACES ARE FREE FROM SCRATCHES. Shimming - Check the overall height of the crankshaft - shoulders - gear assembly. Characteristic Standard thickness: 71.804 - 72.000 mm...
Page 172 Nexus 500 euro 3 Engine MAX ADMISSIBLE DISPLACEMENT: Specification Desc./Quantity = 0.15 mm = 0.01 mm = 0.01 mm = 0.10 mm - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
Page 173 Nexus 500 euro 3 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - For the transmission-side half-crankcase, special attention should be given to the bushings, to the cooling jet on the transmission side (see figure) and to the lubrication duct.
Page 174 Nexus 500 euro 3 Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 175 Nexus 500 euro 3 Engine Coupling chart COUPLING THE SEMI-SHAFTS WITH THE SEMI-CHASSIS AND BUSHES Name Description Dimensions Initials Quantity Half-shaft category 1 - Spare crankcase set-up Bushing category B FC1 - Dis. CM1033015001 Half-shaft category 2 - Spare crankcase set-up Bushing category C FC1 - Dis.
Page 176: Gear Mounting On Crankshaft Screws
Nexus 500 euro 3 Engine - Before installing the gear on the crankshaft, care- fully clean the two matching surfaces removing any residues of LOCTITE from the holes using a brush. Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE grip.
Page 177: Bulkhead Screws For Oil Pump Housing Cover
Nexus 500 euro 3 Engine - Insert the crankshaft on the pin and into the bush- ing. - Before inserting thoroughly, make the oil pump gear align with the control gear. - Insert thoroughly and remove the special tool. N.B. WHEN INSERTING THE SHAFT ON THE HALF-CRANKCASE, BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM- ING CONTROL TOOTHED PINION.
Page 178 Nexus 500 euro 3 Engine - Insert the gasket on the flywheel side half-crank- case. - Lubricate the main bearing on the transmission side half-crankcase. - Couple the 2 half-crankcases being careful not to damage the bushing on the transmis- sion side half-crankcase with the threaded tang of the crankshaft.
Page 179 Nexus 500 euro 3 Engine - Install the flywheel with start-up control as de- scribed in the "Flywheel and start-up" chapter. - Install the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover chap- ter". - Install the complete driving pulley, the transmis- sion cover and the relevant mesh filter and the outside transmission cover as described in the section "Automatic transmission".
Page 180: Head Lubrication Control Jet
Nexus 500 euro 3 Engine OIL PUMP Specification Desc./Quantity Type Trochoidal Rotor washers 8 mm Assembly clearances Lobe ends 0.05-0.008 mm External rotor radial clearance 0.05- 0.12 mm Rotor axial clearance 0.025 - 0.065 mm BY-PASS Specification Desc./Quantity Type with piston Plunger diameter 13.9 - 0.039 -0.057 mm Spring free length...
Page 181 Nexus 500 euro 3 Engine Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump impeller Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics The lubrication system is divided into two sections: - High pressure - Low pressure...
Page 182 Nexus 500 euro 3 Engine The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the pressure of the circuit.
Page 183 Nexus 500 euro 3 Engine 3 Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and fit the special tool with the relevant gasket. Specific tooling 020193Y Oil pressure gauge 020434Y Oil pressure control fitting - Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied with the special tool.
Page 184: Oil Pressure Check
Nexus 500 euro 3 Engine 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. AHEAD go to 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C. YES go to 10 NO go to 13 10 - The failure was fixed.
Page 185 Nexus 500 euro 3 Engine 020434Y Oil pressure control fitting AHEAD go to 3 3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to 4 NO go to 5 4 - Replace the damaged components.
Page 186 Nexus 500 euro 3 Engine - Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper. - Remove the gasket. - Remove the two screws and the oil pump cover. - Remove the inside rotor retaining snap ring turn- ing it to move the opening at the shaft face.
Page 187 Nexus 500 euro 3 Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible - Insert the shaft with the gear and install the lock ring;...
Page 188 Nexus 500 euro 3 Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Inspection - For tests on the oil pump, see the "Lubrication" chapter.
Page 189 Nexus 500 euro 3 Engine Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body. Locking torques (N*m) Screws fixing oil pump to crankcase 5 - 6 - Insert the countershaft with gearing into the fly- wheel-side half-crankcase.
Page 190 Nexus 500 euro 3 Engine Oil pump cover screws 0.7 ÷ 0.9 ENG - 190...
Page 191 INDEX OF TOPICS INJEC NJECTION...
Page 192 Nexus 500 euro 3 Injection EMS injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tonne wheel pivoted on the camshaft control and a reluctance variation sensor.
Page 193 Nexus 500 euro 3 Injection - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester.
Page 194 Nexus 500 euro 3 Injection Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults. 2. The fuel supply system is pressurised at 300 kPa (3 BAR). Before disconnecting the quick coupler of a pipe in the fuel supply system, check that there are no naked flames.
Page 195 Nexus 500 euro 3 Injection ELECTRONIC CONTROL UNIT SIDE SYSTEM SIDE Specification Desc./Quantity Throttle potentiometer power supply +5 V Oxygen sensor Rpm indicator / consumption counter Engine temperature 86 electric fan remote control switch Stepper motor Stepper motor Engine rpm sensor Oxygen sensor EMS diagnostic connector EMS diagnostic connector...
Page 196 Nexus 500 euro 3 Injection IMMOBILIZER DECODER Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Negative Electronic control unit EMS (serial) Continuous power supply (positive) Immobilizer aerial EMS circuit diagram KEY: 3. Engine rev sensor 4. Throttle valve position sensor INJEC - 196...
Page 197 Nexus 500 euro 3 Injection 5. Ambient temperature sensor 6. Stepper motor for idle nozzle 8. Engine temperature sensor 11. Injection load remote control 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 18. Engine stop remote control 19.
Page 198 Nexus 500 euro 3 Injection Possible Cause Operation System not efficient, repair according to the indi- cations of the self-diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Fuel supply Fuel in the tank Fuel pump activation Fuel pressure (low) Injector capacity (low)
Page 199 Nexus 500 euro 3 Injection Possible Cause Operation Air temperature Coolant temperature. Atmospheric pressure Ignition efficiency Spark plug Ignition timing Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system sealing (infiltrations)
Page 200 Nexus 500 euro 3 Injection Possible Cause Operation H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold Intake sleeve...
Page 201 Nexus 500 euro 3 Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature.
Page 202 Nexus 500 euro 3 Injection Decoder master-box circuit This section describes the operations to be carried out to check the power supply circuit. Constant supply circuit check The decoder basic power supply is necessary for the deterrent flashing management. The injection control unit power supply is necessary for the Stepper motor management.
Page 203 Nexus 500 euro 3 Injection 8 - Fix any wiring short circuits and replace the fuse. YES go to 1 NO go to 9 9 - Check any short circuit on decoder or control unit and replace, if necessary. YES go to 1 10 - Place the special tool between control unit and power supply system.
Page 204 Nexus 500 euro 3 Injection Specific tooling 020460Y Scooter diagnosis and tester 1 - Check whether the immobilizer system LED in- dicates switching to "ON" YES go to 2 NO go to 4 2 - Raise the side stand. Set the emergency switch to "OFF".
Page 205 Nexus 500 euro 3 Injection 9 - Control unit with proper continuous power sup- ply. 10 - If only one component is not powered check the relevant connector. If the problem involves both the decoder and CPU check the continuity of the decoder CPU power supply line.
Page 206 Nexus 500 euro 3 Injection Diagnostic circuit * CONNECTOR FOR DIAGNOSTIC TESTER A = INJECTION CONTROL UNIT Connect the diagnostic tester. Specific tooling 020460Y Scooter diagnosis and tester If the diagnostic tester displays «No reply from the control unit», disconnect the continuous power supply for 10 seconds and switch to «ON»...
Page 207 Nexus 500 euro 3 Injection 5 - Check the following conditions: PIN 1 diagnostic socket - PIN 10 control unit = continuity PIN 2 diagnostic socket - PIN 23 control unit = continuity with earth PIN 3 diagnostic socket - PIN 9 control unit = con- tinuity 10 - 23 = insulation (>1 MΩ) 9 - 23 = insulation (>1 MΩ)
Page 208 Nexus 500 euro 3 Injection 19. Diode 20. Battery 25. Engine stop switch 26. Centre stand switch 54. Instrument panel A. Instrument panel light B. Immobilizer LED C. Speedometer D. Digital display E. Engine Warning indicator light F. Low fuel warning light G.
Page 209 Nexus 500 euro 3 Injection 4 - Switch in «ON» position Emergency switch on «RUN». Side stand up Wait more than 5 seconds. 15 - 23 = battery voltage YES go to 5 NO go to 6 5 - Check the CPU connector. Check the electronic control unit.
Page 210 Nexus 500 euro 3 Injection Checking stored failures Connect the diagnostic tester to the scooter sys- tem. Select the function "ERROR" in the menu. Specific tooling 020460Y Scooter diagnosis and tester The tester pages display the list of errors detecta- ble by the auto-diagnosis.
Page 211 Nexus 500 euro 3 Injection Deleting stored failures After mounting any failures, connect the diagnostic tester. Select the menu on the "errors deleting" function. Press "OK" and follow the instructions. Perform a trial cycle and check whether the failure occurs again.
Page 212 Nexus 500 euro 3 Injection Circuit diagram 11. Injection load remote control 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 18. Engine stop remote control 19. Diode 20. Battery 25. Engine stop switch 26. Centre stand switch 56.
Page 213: Injector Fixing Screw
Nexus 500 euro 3 Injection Removing the injector N.B. ONLY REMOVE THE INJECTOR FROM THE MANIFOLD IN THE EVENT OF A PROVEN DEFECT. OPERATING TEST OF THE INJECTOR MUST BE PERFORMED WITH THE INJECTOR INSTALLED ON THE MANIFOLD (SEE "INJECTION"). - To remove the injector, remove the central set screw of the "T"...
Page 214 Nexus 500 euro 3 Injection ONCE THE ENGINE IS REPAIRED CHECK THE CO% VALUE WHILE IDLING TO MAKE SURE IT IS WITHIN THE PRESCRIBED LIMITS. IF THE CO% IS NOT IN CONFORMITY, PROCEED WITH CALIBRATION AS DESCRIBED IN THE ADJUSTING IDLE CARBURETION PARAGRAPH. Removing the butterfly valve N.B.
Page 215: Throttle Body Fixing Screws
Nexus 500 euro 3 Injection ONCE THE ENGINE IS REPAIRED CHECK THE CO% VALUE WHILE IDLING TO MAKE SURE IT IS WITHIN THE PRESCRIBED VALUES. IF THE CO% IS NOT IN CONFORMITY, PROCEED WITH CALIBRATION AS DESCRIBED IN THE ADJUSTING IDLE CARBURETION CHAPTER. throttle body Upon analysing the material sent and covered by the warranty, it seems several throttle bodies have been mistakenly replaced due to valve fouling.
Page 216 Nexus 500 euro 3 Injection - If the rpm-timing signal is received. Continuous supply. The initial timing is useful to bleed the system especially after a stop with engine in temperature. In these conditions, the fuel altered by boiling will be mixed with that in the tank. During use, the pump operation will be subject to the engine speed.
Page 217 Nexus 500 euro 3 Injection 10 - Line to earth. In this case, the pump always starts to rotate if there is a continuous power supply. YES point 12 11 - Interrupted line. The relay cannot control the pump feeding YES go to 13 12 - Check and restore the earth insulation of the control unit line 19 and of the pump remote control switch line 85.
Page 218 Nexus 500 euro 3 Injection 19 - Disconnect the following connectors: fuel pump, H.V. coil, injector YES go to 22 20 - Check the efficiency of the pump remote con- trol switch. Check the wiring continuity between remote control switch and pump. 87 (remote control switch) - green/black (pump) = continuity NO go to 21...
Page 219 Nexus 500 euro 3 Injection - Relay closure - Pump rotation - Relay opening YES go to 31 NO go to 32 31 - The pump is fed. Perform a functional check of the pump. 32 - Check the efficiency of the pump connector. YES go to 33 NO go to 34 33 - Replace the fuel pump.
Page 220 Nexus 500 euro 3 Injection Check that the throttle body is not tampered. YES go to 2 2 - Preheat and check the zero setting of the ex- haust fumes analyser. Remove the exhaust manifold cover and connect the extension to the coupling clamp for the analy- ser pipe.
Page 221 Nexus 500 euro 3 Injection YES point 12 12 - «TRIMMER VALUE» is displayed. The numbers displayed can be positive or nega- tive. YES go to 13 13 â To increase the CO the injection time needs to be increased. To decrease the CO the injection time needs to be decreased.
Page 222 Nexus 500 euro 3 Injection WHEN THE CO PERCENTAGE IS RIGHT AND THE CO2 PERCENTAGE DOES NOT FALL INTO THE SPECIFIED VALUES, THE LAMBDA VALUE IS ALSO DISTORTED. IF THIS OCCURS, CARE- FULLY CHECK THE EXHAUST SYSTEM FOR ADEQUATE SEALING. When the CO percentage is correct and the HC (PPM) value exceeds the maximum limit allowed, check: - spark plug - valve clearance...
Page 223 Nexus 500 euro 3 Injection The special tool is equipped with fast-release fit- tings, similar to those provided for the circuit. In order to disconnect the female terminals (injec- tor side), it is necessary to press the two exten- sions and draw them. CAUTION DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME LOOSE;...
Page 224 Nexus 500 euro 3 Injection Select the menu on the "ACTIVE DIAGNOSIS" function. Select the "PUMP DIAGNOSIS" function. YES go to 2 2 - Enable the function with continuous power sup- ply on and engine off. The control unit starts the pump for 30 seconds YES go to 3 3 - Let the system bleed for a few seconds.
Page 225 Nexus 500 euro 3 Injection 1 - Select the diagnostic tester menu on the «AC- TIVE DIAGNOSIS» function. Select the «PUMP DIAGNOSIS» function. The pump starts for 30 seconds. YES go to 2 2 - Let bleed for a few seconds. Make sure that there are no leaks.
Page 226 Nexus 500 euro 3 Injection 7 - Check whether the pressure decreases with the same trend as the system when free from bottle- necks AHEAD go to 8 8 - Pressure decreases much more slowly YES go to 9 NO go to 10 9 - Replace the pressure regulator.
Page 227 Nexus 500 euro 3 Injection 16 - Disconnect the pump connector, start the en- gine, wait until it stops and connect the connector again. Disconnect the fuel return pipe from the pump sup- port (left pipe). AHEAD go to 17 17 - Introduce the return pipe into a graduated container.
Page 228 Nexus 500 euro 3 Injection With infinite resistance, the pump does not rotate. With resistance close to 0 Ω, the pump power consumption is too high, with the possibility of blowing the fuse No. 12. Carry out the following check. Pump consumption check The pump power consumption may vary according - Power supply voltage...
Page 229 Nexus 500 euro 3 Injection N.B. DO NOT BLOW THE FILTER WITH COMPRESSED AIR. A DAMAGED FILTER MAY CAUSE THE INJECTOR CLOGGING. Pump bracket overhaul To remove the pump support from the tank, pro- ceed as follows: - Disconnect the electric connector. - Start the engine and wait for the spontaneous stop.
Page 230 Nexus 500 euro 3 Injection To replace the components, proceed as follows: (1) Level indicator: - Note the assembly position and the path of the two connecting wires. pos 2 = wire connected to the circuit pos 3 = wire connected to the movable arm Pass the wires through the hole found between fil- ter and pressure regulator.
Page 231 Nexus 500 euro 3 Injection TO OVERCOME THE RESISTANCE OF THE O-RINGS, LEVER WITH A SCREWDRIVER THROUGH THE OPENINGS OBTAINED ON THE STOP INSERTION SIDE. - Lubricate the O-rings and repeat the operations in the reverse order for reassembly. (3) Fuel pump - Note the position of the power supply wires on the support pos 1 = positive (red) pos 4 = negative (black)
Page 232 Nexus 500 euro 3 Injection - Remove the pump mounting washer - Remove the filter coupling pipe - Remove the pump with annular support and pre- filter. - If the pump requires replacement, remove the pre-filter and the annular support. - For reassembly, perform the removal operations but in the reverse order using a new clamp for the delivery pipe and a new pump mounting washer.
Page 233 Nexus 500 euro 3 Injection (4) Fuel filter The fuel filter is supplied already assembled to the pump support. To replace the support, move the level indicator, the pressure regulator and the pump from the old to the new support. For these operations, follows the instructions giv- en above.
Page 234 Nexus 500 euro 3 Injection Inspecting the injector circuit 11. Injection load remote control 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 18. Engine stop remote control 19. Diode 20. Battery 25. Engine stop switch 26.
Page 235 Nexus 500 euro 3 Injection 1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Select the "INJECTOR" function. YES go to 2 Specific tooling 020460Y Scooter diagnosis and tester 2 - Enable the function with continuous power sup- ply on and engine off.
Page 236 Nexus 500 euro 3 Injection 10 - There are also fault messages for: pump relay YES go to 13 NO go to 11 11 - There is also a fault message for the HV coil. YES point 12 12 - Check the power supply circuit with the fuse 12 and the remote control switch. Common feeding to the fuel pump.
Page 237 Nexus 500 euro 3 Injection 18 - No continuity. Disconnect the connector and repeat the resistive check directly at the injector terminals. Resistance = 14.5 Ω ± 2% YES go to 21 NO go to 22 19 - Check the earth insulation of the injector negative line. Disconnected control unit and injector connectors.
Page 238 Nexus 500 euro 3 Injection 2 - Prepare a graduated container with minimum capacity of 100 cm3 and a resolution of 10-20 cm3 Connect the injector to the wire supplied with the injection tester. The wire is provided with alligator clips for direct connection to the battery.
Page 239: Troubleshooting
Nexus 500 euro 3 Injection about 80°. The jet thus formed impinges both in- take valves. N.B. - AN INJECTOR WITH LOW FLOW RATE AF- FECTS THE MAXIMUM PERFORMANCE. - AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND THE START-UP FEATURES AF- TER A SHORT STOP WITH HOT ENGINE.
Page 240: System Components
Nexus 500 euro 3 Injection The instruments to be preferred have a definition of more than 0.1V and 0.5Ω and an accuracy of more than ± 2%. Immobiliser circuit The EMS system is integrated with the immobiliser anti-theft device. Its functions are: - Start-up enabled by key recognition.
Page 241 Nexus 500 euro 3 Injection To connect the diagnostic tester, open the spark plug inspection port and pull out the EMS Diagno- sis socket. Remove the protection cap and con- nect the tester terminal. Power the diagnostic tester by connecting the ter- minals to the battery poles, or the specific connec- tor to the socket inside the gloves compartment.
Page 242 Nexus 500 euro 3 Injection - Control unit - Decoder - Immobilizer aerial - Master key with integrated transponder (brown key) - Service key with integrated transponder (black key) - H.V. coil - Diagnostic LED The diagnostic LED also control the function of the immobiliser lamp. This function is activated every time the key switch is turned to position "OFF"...
Page 243 Nexus 500 euro 3 Injection LED signals When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The keys can only be recognised when the decoder has been correctly programmed. The procedure for programming a new decoder requires the rec- ognition of the "master"...
Page 244 Nexus 500 euro 3 Injection If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thor- oughly inspected: In any case it is advisable to use resistive spark plugs. Characteristic MASTER key: BROWN KEY SERVICE key.
Page 245 Nexus 500 euro 3 Injection - WHEN NOT PROGRAMMED, THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIAGNOSIS ON THE ENGINE. 4 Replacing or duplicating service keys Keys can be duplicated using the blank keys and the original master key. A copy may also be requested using the scooter CODE CARD. Program the system again using the master key and all service keys (see System programming).
Page 246 Nexus 500 euro 3 Injection pleted, the LED remains permanently OFF. The engine can be started. 5. Decoder programmed - fault detected: a light code is displayed according to the fault detected, after which the LED remains on steadily. The engine cannot be started. The codes that can be trans- mitted are: •...
Page 247 Nexus 500 euro 3 Injection 5 - Replace the decoder. Connect the battery. Repeat the programming. YES go to 7 NO go to 6 6 - Disconnect the battery, replace the control unit, connect the battery. Repeat the programming. 7 - The system is OK Code 2 A 2-flash code indicates a system where the de- coder does not recognise the transponder signal.
Page 248 Nexus 500 euro 3 Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Engine rpm sensor The sensor allows the rotations and the angular position of the crankshaft to be recognised by reference to the TDC. Since the wheel speed sensor is pivoted on the camshaft it is also possible to recognise the 4-stroke cycle.
Page 249 Nexus 500 euro 3 Injection The fault continues to be signalled, but the circuit is only checked when turning to "ON". Therefore faults which occur or disappear after turning to "ON" are not acknowledged. During and after the start phase, the self-diagnosis checks the alternating current produced by the sensor (synchronisation of the signal panel).
Page 250 Nexus 500 euro 3 Injection THE FAULT HAS BEEN RECORDED IN CUR- RENT STATUS: The control circuit gave a negative result when switching to "ON". AHEAD go to 8 3 Select the "PARAMETERS" function on the menu. Check the number of «lost synchronisations»: 1 TOOTH and >...
Page 251 Nexus 500 euro 3 Injection RESISTANCE OF THE RPM TIMING SENSOR: ( 25°C) Specification Desc./Quantity 860 Ω ± 130 Ω Model with 1 clamp: 680 Ω ± 100 Ω Model with 2 clamps: YES go to 11 NO go to 12 11 - Check the earth isolation between a pole and the shielding.
Page 252 Nexus 500 euro 3 Injection 15 - Check the connectors carefully. Disconnect and check the continuity between connector and pin 7-12 Electric characteristic Connector - 7 = Continuity Connector - 12 = Continuity Fix the connectors or replace the cable harness. Electric characteristic Resistance Repair or replace the injection wiring (short circuit)
Page 253 Nexus 500 euro 3 Injection -A POOR CABLE SHIELDING CAN IMPAIR THE ENGINE PERFORMANCE AT HIGH SPEED. HT coil This section describes the ignition system operation. Circuit diagram Electric characteristic TERMINALS: 20 - 23 CONDITIONS : During the pump timing with engine off. STANDARD: Battery voltage 11.
Page 254 Nexus 500 euro 3 Injection 26. Centre stand switch 56. Fuel pump / fuel level transmitter 58. Fuel injector 59. Spark plug 61. HV coil 64. Fuel injection electronic control unit The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two important parame- ters: - Ignition advance...
Page 255 Nexus 500 euro 3 Injection YES go to 6 NO go to 5 4 - Test failed YES go to 6 5 - The coil control circuit is efficient. Check the H.V. coil secondary, the cable and the screened cap 6 - Install the special tool between the injection system and the control unit.
Page 256 Nexus 500 euro 3 Injection Repair or replace the cable harness. N.B. A FAILURE OF THE REMOTE CONTROL SWITCH WOULD CAUSE THE PUMP ROTATION FAIL- 10 - The positive power supply is conforming. Check the continuity between the pink-black wire of the connector and pin 20.
Page 257 Nexus 500 euro 3 Injection YES go to 15 NO go to 14 13 - Repair or replace the faulty system. Repeat the check with the menu on "ACTIVE DIAGNOSIS". 14 - Repeat the earth insulation check in the two sections. Repair or replace the wiring. Repeat the check with the menu on "ACTIVE DIAGNOSIS"...
Page 258 Nexus 500 euro 3 Injection YES go to 17 NO go to 1 9 17 - Check the secondary resistance. Measure the resistance between one of the primary terminals and the spark plug cable output Electric characteristic Primary HV cable output = 3.1 K ±...
Page 259 Nexus 500 euro 3 Injection If different values are measured (<1; >20KΩ), re- place the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM. FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE- NANCE»...
Page 260 Nexus 500 euro 3 Injection - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC. - Repeat for the reference between driving pulley and engine crankcase. - Replace the inspection cap on the flywheel side. - Connect the diagnostic tester.
Page 261 Nexus 500 euro 3 Injection 80° = 308 ± 6 Ω 1 Central control unit 2 Valve position sensor 3 Air temperature sensor 4 Coolant temperature sensor 5 Digital display The coolant temperature sensor is installed on the engine head and provides the indications for the digital instrument and for the injection.
Page 262 Nexus 500 euro 3 Injection 1 - Connect the injection diagnostic tester and select the menu on the "errors" function. Check whether faults have been recorded regarding the coolant temperature sensor. YES go to 3 NO go to 2 Specific tooling 020460Y Scooter diagnosis and tester 2 - The EMS system has received no indications of temperatures out of the range of possible temper- atures.
Page 263 Nexus 500 euro 3 Injection 5.975KW. 0 3.81KW +10° C . 2.5KW +20° C 1.68KW +30° C 0.3KW +80° C YES go to 10 NO go to 9 9 - Replace the sensor. 10 - Connect the sensor connector and repeat the resistive check at terminals 4 and 22; Electric characteristic 4-22 = Resistance equal to the value directly detected at the sensor.
Page 264 Nexus 500 euro 3 Injection 4-23 = Ω infinite (>1MΩ) 22-23 = Ω infinite (>1MΩ) YES go to 15 NO go to 14 14 - Repair or replace the wiring. Check the air temperature lines and the throttle valve position. YES go to 13 15 - Connect the special tool to the control unit.
Page 265 Nexus 500 euro 3 Injection Electric characteristic Measured value = 5±0.2 V Repeat the wiring and sensor continuity checks. YES go to 18 Electric characteristic Measured value = Repeat the sensor and circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector.
Page 266 Nexus 500 euro 3 Injection 1 Central control unit 2 Valve position sensor 3 Air temperature sensor 4 Coolant temperature sensor 5 Digital display The sucked air temperature sensor is installed in the bottom side of the throttle body on the filter box side.
Page 267 Nexus 500 euro 3 Injection To check the sensor and related circuit, proceed as follows: 1 - Connect the diagnostic tester. Select the function "ERRORS" in the menu. Check whether there are any indications regarding the sucked air temperature sensor. YES go to 3 NO go to 2 Specific tooling 020460Y Scooter diagnosis and tester...
Page 268 Nexus 500 euro 3 Injection YES go to 10 NO go to 9 9 - Replace the sensor. 10 - Connect the sensor connector and repeat the resistive check at terminals 18 and 22. Electric characteristic 18-22 = Resistance equal to the value directly detected at the sensor. YES go to 13 NO go to 11 11 - If slightly higher values are detected, check the connectors.
Page 269 Nexus 500 euro 3 Injection 12 - Repair or replace the cable harness. YES go to 10 13 - Check that the sensor circuit is earth insulated. Electric characteristic 18-23 = infinite (>1MΩ) 22-23 = infinite (>1MΩ) YES go to 15 NO go to 14 14 - Repair or replace the wiring.
Page 270 Nexus 500 euro 3 Injection YES go to 21 NO go to 17 Electric characteristic Measured value = 5±0.2 V Repeat the wiring and sensor continuity checks. YES go to 18 Electric characteristic Measured value = Repeat the sensor circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector.
Page 271 Nexus 500 euro 3 Injection Pressure sensor This sensor does not have a system since it is di- rectly installed into the control unit. The sensor allows the control unit to optimise the engine performance based on altimetric varia- tions. To check the sensor, proceed as follows: 1 - Connect the diagnostic tester.
Page 272 Nexus 500 euro 3 Injection STANDARD: 5 V TERMINALS: 11 - 22 CONDITIONS: Opening the throttle gradually STANDARD: Volt= Progressive increase CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor The throttle valve position sensor is not removable and is installed on the throttle body.
Page 273 Nexus 500 euro 3 Injection even though not in an optimum way, always safe- guarding the catalytic converter integrity. The throttle valve position signal is especially im- portant at the small valve openings. These areas are also where the sensor works more frequently, and therefore they require more frequent checks after a high number of kilometres run.
Page 274 Nexus 500 euro 3 Injection 020481Y Control unit interface wiring Electric characteristic Light blue/green-22 = 0 Ω (continuity) Brown-yellow-1 = 0 Ω (continuity) Orange-light blue-11 = 0 Ω (continuity) YES go to 8 NO go to 7 7 - Repair or replace the injection wiring. YES go to 6 8 - Check the earth insulation of the three circuit lines.
Page 275 Nexus 500 euro 3 Injection Measure voltage between terminals 1 and 22 of the special tool. Specific tooling 020481Y Control unit interface wiring Electric characteristic 1-22 = 5±0.2 V YES go to 12 NO go to 11 11 - Check the control unit connector. Replace the control unit, if necessary.
Page 276 Nexus 500 euro 3 Injection The possible variations of the limit values are caused by the sensor installation tolerances. YES go to 15 NO go to 14 14 - Replace the throttle body along with sensors and Stepper. YES point 12 15 - Check that the voltage measured at pins 11 and 22 matches that indicated by the diagnostic tester set to "PARAMETERS".
Page 277 Nexus 500 euro 3 Injection Connect the diagnostic tester. Set the switch to "ON" with switch in "RUN" and side stand raised. Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw.
Page 278 Nexus 500 euro 3 Injection THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION. Step motor CIRCUIT LAYOUT Specification Desc./Quantity...
Page 279 Nexus 500 euro 3 Injection To prevent wear of the adjustment piston, opera- tion at full speed is obtained with a minimum open- ing of 43 - 45 "steps". To recover possible adjustments, every switching to "OFF" causes the piston to close up to end of travel and to open up again by a fixed number of steps (self-reset).
Page 280 Nexus 500 euro 3 Injection YES go to 3 NO go to 4 3 - Start the engine and let it warm up. With a coolant temperature of more than 70°C, the control unit must control the Stepper with about 45 «steps».
Page 281 Nexus 500 euro 3 Injection Resistance = approx. 51 Ω YES go to 11 NO go to 10 9 - Test successful. No variations of revolutions. Remove the throttle body. Check the auxiliary air circuit cleaning. Switch from "ON" to "OFF" and again to "ON" and check wheth- er the piston valve moves.
Page 282 Nexus 500 euro 3 Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the 4 Stepper lines. Electric characteristic 14-23 = >1 MΩ (infinite) 6-23 = >1 MΩ (infinite) 21-23 = >1 MΩ (infinite) 24-23 = >1 MΩ...
Page 283 Nexus 500 euro 3 Injection YES go to 16 NO go to 15 15 - Check cable harness and connectors more carefully. 16 - Connect the control unit connector. Set the switch to «ON» with switch to «RUN» and side stand raised. Repeat the «ON» «OFF» «ON» switching.
Page 284 Nexus 500 euro 3 Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Connect the multimeter probes between pin 2 (-) and pin 8 (+) With the engine running at idle speed, check that the voltage oscillates between 0V and 1V...
Page 285 Nexus 500 euro 3 Injection KEY: 4. Throttle valve position sensor 5. Ambient temperature sensor 7. Electric fan 8. Engine temperature sensor 9. Remote control for electric fan 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 18.
Page 286 Nexus 500 euro 3 Injection E. Engine Warning indicator light F. Low fuel warning light G. Oil warning light 64. Fuel injection electronic control unit The electric fan system is powered by a remote control switch connected to the continuous power supply controlled by the electronic control unit of the injection system.
Page 287 Nexus 500 euro 3 Injection 3 - Test successful. The fan is rotating. YES go to 5 4- Test failed. The fan is not rotating. YES go to 8 NO go to 6 5- The electric fan system is OK 6 - Test successful.
Page 288 Nexus 500 euro 3 Injection 14 - Check the earth insulation. 5 - 23 >1 MΩ (infinite) YES go to 16 NO go to 15 15 - Repair or replace the cable harness. 16 - Connect the remote control switch and check for battery voltage between terminals 5 and 23 with the key switch in position "ON".
Page 289 INDEX OF TOPICS SUSP USPENSIONS...
Page 290: Removing The Front Wheel
Nexus 500 euro 3 Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the fixing nut from the wheel axle on the left side of the vehicle. - Loosen the two screws fixing the wheel axle clamp and remove the clamp.
Page 291 Nexus 500 euro 3 Suspensions - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle, 24 mm adaptor and 15 mm guide) from the brake disc side to permit the removal of the opposite side bearing and the spacer bushing.
Page 292 Nexus 500 euro 3 Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube - Refit the cap and tighten the five fixing screws.
Page 293: Front Fork
Nexus 500 euro 3 Suspensions - Heat the bearing seat on the side the brake disc with the heat gun. 2 - Insert the two bearings one at a time using the punch consisting of adaptor handle, 32x35 mm adaptor and 15 mm guide, and take it to the stop. Specific tooling 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor...
Page 294 Nexus 500 euro 3 Suspensions Using the special tool, loosen and remove the up- per ring nut, the spacer washer and the counter- ring nut. - Extract the fork. N.B. TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT IT FROM COMING OFF ABRUPTLY Specific tooling 020055Y Wrench for steering tube ring nut...
Page 295 Nexus 500 euro 3 Suspensions In case of replacement, proceed as follows: - Using a bearing removal punch, inserted from the bottom, remove the top seat on the steering head. Then, remove the bottom seat of the tapered bear- ing inserting the punch from the top of the head- stock.
Page 296 Nexus 500 euro 3 Suspensions - Remove the dust guard ring using a screwdriver as shown in the figure. N.B. BE CAREFUL NOT TO DAMAGE THE DUST GUARD AND THE STEM. - Remove the oil guard safety lock using a screw- driver.
Page 297 Nexus 500 euro 3 Suspensions - Insert the following from the top of the stem: 1 Bushing "B" 2 Abutment washer "C" 3 Oil guard "D" - Insert the pumping member guiding bushing at the bottom end of the stem. - Insert the stem into the casing being careful not to let the guiding bushing come out of the stem.
Page 298 Nexus 500 euro 3 Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping member into the stem. - Insert the stem into the fork leg being careful not to let the guiding bushing come out of the stem. - Insert and screw the pumping member screw with a new copper washer and tighten to the prescribed torque.
Page 299 Nexus 500 euro 3 Suspensions - Loosen the fork clamp screws and move the stem closing cap in abutment with the clamp. - Tighten the clamp screws to the prescribed tor- que. Locking torques (N*m) Fork clamp screws 20 ÷ 25 - Grease the tapered bearing using the specified product.
Page 300 Nexus 500 euro 3 Suspensions - Install the handlebars on the steering tube, pay- ing attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the prescribed torque. - Install the front and rear handlebar covers as described in the section "Scooter body".
Page 301 Nexus 500 euro 3 Suspensions - Insert the special tool as shown in the figure. - Insert the retaining band of the two half-rings. - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering tube Refitting Reassembly of tapered bearing in steering...
Page 302 Nexus 500 euro 3 Suspensions Reassembly of steering tapered bearing seats Using the special tool, reassemble the tapered bearing housings on the head as described below: - Place a new top housing on the head and a new bearing seat on the bottom side. - Insert the screw of the special tool set-up with the adapters for inserting bearing and seat, into the steering head, as shown in the figure.
Page 303: Removing The Rear Wheel
Nexus 500 euro 3 Suspensions The scooter has a "Power Drive" progressive rear suspension system combined with the "Direct Link" system of engine mounting on the frame that gives exceptional rigidity to the whole system. The scooter has a special connecting strut between engine and frame that allows the travel gear to be adjusted to 15 positions.
Page 304 Nexus 500 euro 3 Suspensions - Remove the cotter pin, the cap, the wheel axle fixing nut and the outer one of the two spacers. - Remove the two screws fixing the mudguard to the bracket - Remove the two screws fixing the bracket to the engine - Slide off the wheel axle bracket, using the heat gun if necessary.
Page 305 Nexus 500 euro 3 Suspensions Refitting the rear wheel To fit, follow the removal steps but in the reverse sequence, being careful to fit the spacers on the wheel axle as shown in the photograph. Locking torques (N*m) Muffler arm clamping screws Rear wheel 27 ÷...
Page 306: Shock Absorbers
Nexus 500 euro 3 Suspensions - Remove the central and the right spacer. - To refit, follow the removal operations but in re- verse order, being careful to observe the original torque and to lubricate the sliding area «A» of the right spacer on the engine bearing.
Page 307: Side Stand
Nexus 500 euro 3 Suspensions Centre-stand - Remove the two return springs from the centre stand. - Loosen the fastening nuts. - Remove the centre stand. - On refitting tighten the nut to the specified torque. Locking torques (N*m) Central stand retainers 25 ÷...
Page 308 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 309 Nexus 500 euro 3 Braking system Specifications The scooter has an integral brake system. This is obtained with the left-hand brake pump connected simultaneously to the rear brake calliper and the front right calliper. The connection to the rear calliper is direct. The front calliper is connected via a pressure control valve with two thresholds.
Page 310: Rear Brake Calliper
Nexus 500 euro 3 Braking system Specification Desc./Quantity Rear brake pressure Front brake pressure Rear brake calliper Removal - Remove the rear wheel. - Remove the snap ring of the pad retaining pin. - Using a key, partially slide off the pad retaining pin until the circlip is released.
Page 311 Nexus 500 euro 3 Braking system Overhaul - Remove the rear brake calliper - Suitably support the brake calliper in a vice - Remove the two calliper coupling screws as shown in the photograph. - Remove the two plungers from the calliper body with the aid of short blasts of compressed air through the brake fluid feed holes.
Page 312 Nexus 500 euro 3 Braking system Refitting - The rear break calliper can be recognised by its Ø 34 mm plungers and the bleed screw as shown in the figure. - Insert the break pads in the pliers according to the arrow that indicates the break disc direction of rotation as shown in the photograph.
Page 313 Nexus 500 euro 3 Braking system - Keep the brake pads in contact with the plungers and insert the calliper in the brake disc. - Fix the calliper to the support with the two screws with spring washer to the prescribed torque as shown in the photograph.
Page 314 Nexus 500 euro 3 Braking system Overhaul - Remove the front brake calliper and the corre- sponding pads. - Remove the two pistons from the calliper body with the aid of small blasts of compressed air through the brake fluid feeding hole. A piece of rubber pipe may be needed to seal with the com- pressor gun.
Page 315 Nexus 500 euro 3 Braking system - Decouple the floating support of the calliper body separating the 2 rubber dust-covers off their seats. N.B. TO EXTRACT THE LONG DUST-COVER PULL IT BY ITS HEAD AND INTRODUCE THE BELLOWS ( LOCATED ON THE OTHER SIDE) INTO THE CALLIPER HOLE.
Page 316 Nexus 500 euro 3 Braking system Refitting - To reassemble the brake disc on the hub, carry out the removal operations in the reverse order ar- ranging the brake disc on the hub on the side opposed the wheel keying - Follow the direction of rotation shown by the ar- row and tighten to the prescribed torque.
Page 317: Front Brake Disc
Nexus 500 euro 3 Braking system - Repeat the measurement at no fewer than six points on the disc. - Check that the measurements do not deviate over 0.1 mm - Remove the front calliper. - Place the magnetic base with the dial gauge on the brake calliper support bracket as shown in the photograph.
Page 318 Nexus 500 euro 3 Braking system Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Brake disc fixing screw 5 ÷ 6.5 - Carry out the operations in the reverse order from the removal being careful to respect the direction of disc rotation shown by the arrow printed on it - Tighten the six screws to the specified torque.
Page 319: Front Brake Pads
Nexus 500 euro 3 Braking system 020335Y Magnetic support for dial gauge Front brake pads Removal - Remove the front brake calliper unscrewing the 2 retainers but leaving the hoses connected. - Disengage the upper part of the pad from the seat located into the calliper body.
Page 320 Nexus 500 euro 3 Braking system Refitting - Assemble the brake pads into the calliper insert- ing the upper tip into the groove and pressing it towards the thrust spring to facilitate inserting the pin. - Insert the pad fixing pin from the reaction plate side, so that the pin head clicks in the seat in the groove on that plate.
Page 321 Nexus 500 euro 3 Braking system Removal - Remove the rear brake calliper - Remove the brake pad and check there are no faults or warping. If it does, replace it. - Check that the thickness of the friction material is over 1.5 mm.
Page 322 Nexus 500 euro 3 Braking system Rear - combined To bleed the integral system, first bleed the rear break calliper. - Remove the rubber cap from the bleed screw and insert a rubber pipe to recover the brake fluid. - With the left-had brake lever, load the system and bring it up to the required pressure.
Page 323 Nexus 500 euro 3 Braking system Circuit bleed calliper fitting 12 - 16 Front - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the right-hand brake lever, load the system and bring it up to the required pressure.
Page 324 Nexus 500 euro 3 Braking system Removal - Remove the front handlebar cover. - Drain off the braking system corresponding to the circuit being tested. - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 325 Nexus 500 euro 3 Braking system Removal Replace the pressure distribution valve If problems are discovered in the brake force dis- tribution between the front left brake calliper and the rear brake calliper (e.g. equal surface contact and braking of both the wheels, the rear brake en- gages but the front brake does not operate or vice versa, or the brakes function in completely differ- ent modes, or the distribution valve does not func-...
Page 326 Nexus 500 euro 3 Braking system - Tighten the screws fixing the valve to the chassis, but above all tighten the brake piping to the pre- scribed locking torques. - Fill and purge the braking system as described in the relevant section. Locking torques (N*m) Coupling for oil on the integral braking system pump...
Page 327 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 328 Nexus 500 euro 3 Cooling system Circuit diagram The cooling system is a forced circulation type system, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal group. The two-way thermostat support is connected in output to the head.
Page 329 Nexus 500 euro 3 Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
Page 330 Nexus 500 euro 3 Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and stop temperatures. - Select the «PARAMETERS»...
Page 331: Coolant Replacement
Nexus 500 euro 3 Cooling system DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OB- SERVE THIS REGULATION CAN CAUSE IRREVERSIBLE DEFORMATION TO THE SEALING GASKETS. Coolant replacement System top-up instructions - Prepare the mixture of 50% water and 50% cool- ant.
Page 332: Water Pump Cover Screws
Nexus 500 euro 3 Cooling system - Refit the water pump cover, tightening the 6 fixing screws to the prescribed torque. Locking torques (N*m) Water pump cover screws 3 ÷ 4 Water pump ceramic seal Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject.
Page 333 Nexus 500 euro 3 Cooling system - Check that the water pump cover is not damaged or deformed. - Check that the sealing O-Ring is in good condi- tion - Check that the rotor does not show deformations or dents. - Check that the plastic rotor forms an integral unit with the metal part.
Page 334 Nexus 500 euro 3 Cooling system - Check the free length of the spring. Characteristic Standard length: 65.2 mm Length limit after use: 64.0 mm Thermostat Check Before proceeding to disassemble, carry out a few checks: - Connect the diagnostic tester and select the «PA- RAMETERS»...
Page 335 Nexus 500 euro 3 Cooling system - Visually check that the thermostat exhibits no mechanical faults. - Prepare a metal container with approx. 1 litre of water. - Immerse the thermostat, keeping it in the centre of the container. - Immerse the multimeter temperature probe close to the thermostat.
Page 336 Nexus 500 euro 3 Cooling system N.B. THE CAP IS EQUIPPED WITH A PRESSURE RELIEF VALVE CALIBRATED AT 0.9 BAR. There is also a valve that must allow air inlet during the cooling step. YES go to 2 NO go to 3 2 - Check the head gasket seal (see «Thermal group and timing system»...
Page 337 INDEX OF TOPICS CHAS HASSIS...
Page 338 Nexus 500 euro 3 Chassis This section is devoted to the operations that can be carried out on the vehicle bodywork. CAUTION WE STRONGLY RECOMMEND NOT TO CLEAN THE PAINTED PLASTIC PARTS WITH SOLVENTS CONTAINING PETROL OR PETROL BY-PRODUCTS. Seat - Remove the two clamping screws on the frame.
Page 339: Instrument Panel
Nexus 500 euro 3 Chassis - Remove the frames of the brake pump on the left and right secured with 2 locking tabs. - Loosen the 4 retaining screws of the front han- dlebar cover with the handlebar proper. Remove the 4 pressure indicator lights from the warning light group, pulling them downwards. Instrument panel - Remove the upper shield back plate.
Page 340 Nexus 500 euro 3 Chassis Headlight assy. - Remove the centre cover of the shield. - Remove the 4 front retainers of the front light as- semblies. - To remove the right-hand light assembly, remove the screw located near the cover of the expansion tank.
Page 341 Nexus 500 euro 3 Chassis Frame central cover - Remove the saddle. - Remove the two screws in the battery compart- ment shown in the figure. - Remove the fuel tank flap. - Remove the 5 screws indicated in the figure. CAUTION PROVISIONALLY PROTECT THE NECK OF THE FUEL TANK USING A CLEAN CLOTH TO PREVENT ANY DIRT OR...
Page 342 - Remove the front shield, disconnecting the wiring and the connectors of the headlights and lights. - Remove the Gilera emblem. - Remove the screw shown in the figure. CHAS - 342...
Page 343 Nexus 500 euro 3 Chassis - Paying attention not to damage the plastic parts, release the 3 upper retainers of the windshield support and the 4 side retainers of the front shield. Knee-guard - Remove the centre union. - Remove the 4 lateral screws (2 on each side) in- dicated in the figure.
Page 344 Nexus 500 euro 3 Chassis - Unscrew the 4 screws indicated in the figure. - Loosen the two upper screws on the front of the scooter holding the plate. - Remove the handlebar retaining bolt, unscrewing upwards and pushing towards the lower shield back plate.
Page 345 Nexus 500 euro 3 Chassis - From the underside it is possible to loosen the 3 retaining screws and to release the 2 locking tabs to raise the mounting plate of the steering lock strut. - The latter has a retaining tab with cylindrical teeth that cannot be replaced.
Page 346 Nexus 500 euro 3 Chassis Taillight assy. - Remove the side fairings. - Remove the upper central screw. - Using a wrench offset by 10 mm between the under-saddle compartment and the tubes of the frame, loosen the 2 rear retaining bolts and then disconnect the retainers of the lights at the ends of the support. - Remove the light and disconnect the bulb holder by turning it through 30°...
Page 347 Nexus 500 euro 3 Chassis - Remove the complete footrest from the side fair- ing. - Remove the screw shown in the figure to remove the front footrest. Side fairings - Remove the rear central cover. - Remove the passenger handles. - Remove the lower cover.
Page 348 Nexus 500 euro 3 Chassis - Remove the lower side cover. - Remove the eight screws shown in the figure (four on each side). - Pull out the fairing. - Remove the three screws indicated in the figure. CHAS - 348...
Page 349 Nexus 500 euro 3 Chassis - Remove the 2 hex. socket head screws and then the passenger handgrips on the left and right. License plate holder - Remove the lower cover. - Remove the four retaining screws (2 per side) and disconnect the electrical connectors.
Page 350: Rear Mudguard
Nexus 500 euro 3 Chassis - Loosen the two screws shown in the figure. - Loosen the two retainers shown in the figure and remove the complete air filter. - Remove the general fuse. - Disconnect the battery housing from its metallic support and remove the complete filter housing.
Page 351 Nexus 500 euro 3 Chassis - Remove the retainer of the mudguard/strut rein- forcement plate to remove the complete mud- guard. Helmet bay - Remove the side panels - Remove the six upper clamping screws. - Remove the 2 lateral retaining screws with the central covers.
Page 352 Nexus 500 euro 3 Chassis - Remove the complete underseat compartment. Fuel tank Fuel tank flap - Open the fuel tank flap. - Remove the hex. socket head screw shown in the figure. - Remove the 3 hex. socket head screws shown in the figure.
Page 353 Nexus 500 euro 3 Chassis - Remove the central chassis cover. - Remove the lower cover. - Remove the fuel tank cap. - Remove the two upper tank retainers shown in the figure. - Remove the fuel pump retainers. N.B. PAY PARTICULAR ATTENTION WHEN UNSCREWING THE FUEL PIPES AS EXCESSIVE FORCE COULD DAMAGE THE PLASTIC INSERTS ON THE PUMP BODY.
Page 354: Front Mudguard
Nexus 500 euro 3 Chassis Front mudguard - Remove the 4 retaining screws and pull the mud- guard towards the front of the scooter. - Pay attention during assembly to the correct po- sitioning of the retaining straps of the hoses. Radiator fan - Remove the spoiler.
Page 355 Nexus 500 euro 3 Chassis Flyscreen - Remove the 3 hex. socket head screws (when reassembling, pay attention to insert the longest screw in the middle position) then remove the windshield complete from the rubber lips. - Remove the plugs and remove the seals on the 2 lateral windshield support arms.
Page 356: Lower Cover
Nexus 500 euro 3 Chassis Pilot lights kit - Remove the handlebar cover. - Remove the three screws shown in the figure, then pull the complete group from the front han- dlebar cover. Battery - Remove the elastic strap and the battery cover. Lower cover - Remove the two screws of the lower spoiler (long type).
Page 357 Nexus 500 euro 3 Chassis - Remove the 4 union screws with the front wheel housing cover. - Pull the spoiler from the lower part of the scooter. CHAS - 357...
Page 358 INDEX OF TOPICS PRE DE DELIVERY...
Page 359 Nexus 500 euro 3 Pre-delivery Carry out the listed tests before delivering the vehicle. WARNING BE VERY CAREFUL WHEN HANDLING FUEL. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks SAFETY LOCKS: Name...
Page 360 Nexus 500 euro 3 Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE. CAUTION WHEN INSTALLING THE BATTERY, CONNECT THE POSITIVE CABLE BEFORE CONNECTING THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
Page 361 Nexus 500 euro 3 Pre-delivery - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks - Operation of the radiator electric fan Functional inspection Operating test: - Hydraulic brake system - Lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and make sure there is no unusual noise - Other...
Page 362 INDEX OF TOPICS TIME...
Page 363 Nexus 500 euro 3 Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replacement TIME - 363...
Page 364 Nexus 500 euro 3 Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Replacement 001133 Engine crankcase- Replacement 001153 Crankcase half gasket - Replace- ment TIME - 364...
Page 365 Nexus 500 euro 3 Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 365...
Page 366 Nexus 500 euro 3 Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder piston - Replacement 001154 Pin-ring-piston assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 366...
Page 367 Nexus 500 euro 3 Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 001083 Thermistor - Replacement 005116 Rpm timing sensor - Replacement 007012 Coolant bleed valve - Replacement TIME - 367...
Page 368 Nexus 500 euro 3 Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Replacement TIME - 368...
Page 369: Cylinder Head Cover
Nexus 500 euro 3 Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement TIME - 369...
Page 370 Nexus 500 euro 3 Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001057 Thermostat - Replacement 001062 Water pump command shaft - Re- placement 001150 Flywheel cover gasket - Replace-...
Page 371: Driven Pulley
Nexus 500 euro 3 Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement TIME - 371...
Page 372 Nexus 500 euro 3 Time Oil pump OIL PUMP Code Action Duration 001042 Oil pump - Service 001051 Belt/ Timing chain - Replacement 001112 Oil pump - Replacement 001125 Chain guide sliders - Replacement 001071 Start-up pinion - Replacement 001020 Starter motor - Replacement 001102 Net oil filter - Replacement / Cleaning...
Page 373 Nexus 500 euro 3 Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Service 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear gear shaft - Replacement TIME - 373...
Page 374 Nexus 500 euro 3 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 rear-view belt - Replacement 001006 rear-view pulley - Service 001141 Belt anti-flapping roller - Replace- ment 001066 rear-view pulley - Replacement TIME - 374...
Page 375 Nexus 500 euro 3 Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Re- placement 001096 External transmission cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement 001170 Air manifold - replacement TIME - 375...
Page 376: Flywheel Magneto
Nexus 500 euro 3 Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Replacement 001058 Flywheel - Replacement 001104 Start-up freewheel - Replacement 001151 Start-up driven gearing - Replace- ment TIME - 376...
Page 377: Throttle Body
Nexus 500 euro 3 Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - Replacement 001047 Injector - Replacement 001166 Throttle body - Replacement 004122 Cleaner / Throttle body union - Re- placement 001171 Throttle body - Service/cleaning TIME - 377...
Page 378 Nexus 500 euro 3 Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 004169 Muffler guard - Replacement 005138 Lambda probe - Replacement TIME - 378...
Page 379: Air Cleaner
Nexus 500 euro 3 Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - change 001014 Air filter - Replacement/Cleaning 001074 Oil vapour recovery pipe - Replace- ment TIME - 379...
Page 380 Nexus 500 euro 3 Time Frame FRAME Code Action Duration 004001 Frame - replace 004146 Front frame - Replacement 001032 Engine support pin - Replacement TIME - 380...
Page 381 Nexus 500 euro 3 Time Centre-stand SIDE/CENTRAL STAND Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Side stand switch - Replacement 004171 Stand support plate - Replacement TIME - 381...
Page 382 Nexus 500 euro 3 Time Legshield spoiler FRONT SHIELD - SPOILER Code Action Duration 004066 Driving mirror - Replacement 005091 Turn indicator glass - Replacement 005067 Front direction indicator bulb - Re- placement 004064 Front shield - Replacement 004149 Shield central cover - Replacement 004065 Shield back plate - Replacement 005080...
Page 383 Nexus 500 euro 3 Time Central cover CENTRAL FRAME COVER Code Action Duration 004011 Central chassis cover - Replacement 004104 Left side cover - Replacement 004105 Right side cover - Replacement 004079 Rear footrest - Replacement 004143 Footrest support - replace TIME - 383...
Page 384 Nexus 500 euro 3 Time Mudguard MUDGUARDS Code Action Duration 004167 Grill / radiator cover - replace 004009 Rear mudguard - Replacement 004002 Front mudguard - change 003087 Wheel housing - Replacement TIME - 384...
Page 385 Nexus 500 euro 3 Time Fuel tank FUEL TANK Code Action Duration 004005 Fuel tank - replace 004170 Tank filler neck - Replacement 004168 Fuel filler flap - Replacement 004109 Fuel tank breather - replace TIME - 385...
Page 386 Nexus 500 euro 3 Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 005129 Warning light group - Replacement 004156 Glove-box flap - Replacement 005038 Instrument panel warning light bulbs - Replacement TIME - 386...
Page 387 Nexus 500 euro 3 Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002037 Brake or clutch lever - Replacement 002060 Complete gas command - Replace- ment 002059 Right hand grip - Replacement 003059 Counterweight - Replacement 002063...
Page 388 Nexus 500 euro 3 Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004150 Saddle shock absorber - Replace- ment TIME - 388...
Page 389 Nexus 500 euro 3 Time Locks LOCKS Code Action Duration 004010 Antitheft lock - Replacement 005099 Electric saddle opening device - Re- placement 002083 Saddle opening transmission - Re- placement 002092 Seat locking transmission - replace- ment 004054 Saddle lock catch - Replacement 005072 Immobilizer antenna - replacement 005126...
Page 390: Turn Signal Lights
Nexus 500 euro 3 Time Turn signal lights REAR LIGHTS Code Action Duration 005005 Taillight - change 005022 Rear turn indicators - Replacement 005068 Rear turn indicator bulb- Replace- ment 005091 Turn indicator glass - Replacement 005031 Licence plate light bulb - Replace- ment 004136 License plate holder support - Re-...
Page 391 Nexus 500 euro 3 Time FRONT LIGHTS Code Action Duration 005002 Front headlamp - replace 005008 Front headlamp bulbs - replace 005044 Front lights cable unit - replace TIME - 391...
Page 392: Front Wheel
Nexus 500 euro 3 Time Front wheel FRONT WHEEL Code Action Duration 005089 Tone wheel - Replacement 002041 Front brake disc - Replacement 003037 Front wheel rim- Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003063...
Page 393 Nexus 500 euro 3 Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001017 Rear wheel rim - replace 002070 Rear brake disc - Replacement 003063 Tyre pressure - Check 003077 Muffler / rear shock absorber support arm - Service 004126 Rear wheel tyre - Replacement...
Page 394: Fuel Pump
Nexus 500 euro 3 Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 394...
Page 395 Nexus 500 euro 3 Time Electric devices HANDLEBAR ELECTRICAL COMPONENTS Code Action Duration 004035 Instrument panel - Replacement 005014 Odometer assembly - replacement 005083 Board computer - replacement 003074 Handlebar right control - Replace- ment 003075 Handlebar left control - Replacement 005082 Instrument unit wiring - replacement TIME - 395...
Page 396 Nexus 500 euro 3 Time ELECTRIC DEVICES Code Action Duration 005127 Overturn sensor - replacement 001069 HV coil - Replacement 005007 Battery - Replacement 005046 Battery cover - Replacement 005073 Immobilizer decoder - Replacement 005011 Start-up remote control switch - Re- placement 005128 Diode group - replacement...
Page 397 Nexus 500 euro 3 Time ELECTRIC DEVICES Code Action Duration 001023 Injection ECU - Replacement 005009 Voltage regulator - Replacement 005117 Electric fan remote control - Replace- ment 005088 Emergency stop remote control - Re- placement 005096 Injection components remote control - Replacement 005003 Horn - Replacement...
Page 398 Nexus 500 euro 3 Time ELECTRIC DEVICES Code Action Duration 005001 Electrical system - Replacement 005054 Fuse holder - Replacement 005052 Fuse (1) - Replacement 005114 Electrical system - Service 005130 Electric control management device - Replacement TIME - 398...
Page 399: Helmet Compartment
Nexus 500 euro 3 Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - replace 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment light - Replace- ment 004142 Plug socket - Replacement 005027 Helmet compartment bulb support - Replacement TIME - 399...
Page 400 Nexus 500 euro 3 Time Rear side fairings REAR COVERS Code Action Duration 004053 Spoiler - Replacement 004085 Rear fairing - Replacement 004068 Passenger handgrip - Replacement 004159 Plates / Stickers - Replacement 004036 Lower chassis cover - Replacement 004012 Rear side panels (2) - Replacement 004075 Mat - Replacement...
Page 401 Nexus 500 euro 3 Time Front suspension FRONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - service 003076 Fork housing - replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003073 Steering clearance - Adjustment 003002 Steering fifth wheels - change 004119...
Page 402: Rear Suspension
Nexus 500 euro 3 Time Rear suspension REAR SUSPENSION Code Action Duration 003085 Suspension strut - Replacement 003007 Rear shock absorber - Replacement 004120 Rear suspension linkage - Replace- ment 003086 Suspension strut support - replace- ment TIME - 402...
Page 403 Nexus 500 euro 3 Time Cooling system COOLING SYSTEM Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan with support - Replacement 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007019 Coolant return pipe - replacement 007013 Expansion tank / radiator connecting hose - Replacement...
Page 404: Brake System
Nexus 500 euro 3 Time Braking system BRAKE SYSTEM Code Action Duration 002021 Front brake piping - Replacement 002047 Front brake fluid and air bleeding system - Replacement 002020 Rear brake disc piping - Replace- ment 002087 Rear integral braking system rigid hose - Replacement 002084 Integral break pump pipe, device -...
Page 405 Nexus 500 euro 3 Time Windscreen WINDSHIELD Code Action Duration 004028 Windshield glass - Replacement 004101 Windshield - Replacement 004117 Top fairing - Replacement TIME - 405...
Page 406 Air filter: 35, 349 Battery: 50, 60, 68, 69, 76, 356 Brake: 310, 313, 315, 317, 319, 320, 323, 324 Coolant: 260, 331 Engine oil: 36 Fuel: 13, 211, 224, 228, 352, 385, 394 Fuses: 62 Headlight: 41, 340 Hub oil: 33 Identification: 8 Immobilizer: Instrument panel: 339...
Page 407 Technical Data: Transmission: 9, 83, 99, 375 Turn indicators: 54 Tyres: 10...

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