Gilera Nexus 500 Euro 3 (EN)

WORKSHOP MANUAL
633721 - 633728
Nexus 500 euro 3
WORKSHOP MANUAL
Nexus 500 euro 3
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. Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. " Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com
WORKSHOP MANUAL
Nexus 500 euro 3
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera 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. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to special tools, along with the special tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS TOOLING MAINTENANCE ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE INJECTION SUSPENSIONS BRAKING SYSTEM COOLING SYSTEM CHASSIS PRE-DELIVERY TIME
CHAR TOOL MAIN ELE SYS ENG VE ENG INJEC SUSP BRAK SYS COOL SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
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. never let the engine run in an enclosed area. Exhaust fumes are toxic. The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. Fuel is highly flammable, and in some conditions it can be explosive. Do not smoke in the working area, and avoid open flames or sparks. Clean the brake pads in a well ventilated environment, directing the compressed air jet so as to not inhale the dust produced by the wear of the friction material. Even though the latter contains no asbestos, dust inhalation is harmful.
Maintenance rules
Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Nonoriginal or non-conforming spares may damage the vehicle. Use only the special tools designed for this scooter. Always use new gaskets, sealing rings and split pins upon reassembly. After removal, clean the components using non-flammable or low fire-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting. After reassembly, check that all components have been installed properly and that they are in good working order. For removal, overhaul and reassembly operations use only tools provided with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter. Should any interventions to the scooter electrical system be required, check that the electrical connections - especially earth and battery connections - have been implemented properly.
CHAR - 7
Characteristics
Nexus 500 euro 3
Vehicle identification
Characteristic
Engine prefix: M351M
Chassis prefix: ZAPM35200
Dimensions and mass

WEIGHT
Specification Dry weight Width Length Wheel base Saddle height Height Desc./Quantity 199 kg 765 mm 2090 mm 1515 mm 780 mm 1045 mm
CHAR - 8
Nexus 500 euro 3
Characteristics
Engine
ENGINE
Specification Engine Bore Stroke Cubic capacity Compression ratio Timing system Desc./Quantity Single-cylinder, four-stroke 92 mm 69 mm 460 cm 10.5: 1 Single overhead camshaft with integrated tone wheel, control from flywheel side chain, 4 valves and automatic start-up valve lifting device. 0.15 mm (when cold) 0.15 mm (when cold) By threaded adjuster on the rockers 1500 50 rpm sponge, impregnated with mixture (50% petrol and 50% oil) 1 - 1.5% Electric starter system with freewheel. By trochoidal pump (inside the crankcase), pressure adjustment by-pass and oil filter. 4 bar 0.8 bar Electronic injection system with electric fuel pump, 38 mm throttle body and single injector. 29 kW (39 CV) at 7250 rpm 40 Nm (4 kgm) at 5500 rpm Fluid circulation through a motor-driven pump, 3-way thermostat and electric fan.
Valve clearance: intake Valve clearance: discharge Valve clearance adjustment Engine idle speed Air filter CO % value (measured at the intake manifold) Starting system Lubrication Lubrication pressure Minimum allowed (at 100 C) Fuel supply Max. power (shaft) Max. torque (shaft) Cooling system
Transmission
TRANSMISSIONS
Specification Transmission Desc./Quantity With automatic expandable pulley variator with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling.
Capacities
CAPACITY
Specification Engine oil (empty) Engine oil (at oil and filter change) Fuel tank (including reserve approx. 2 litres) Rear hub Cooling system Front fork Desc./Quantity 1.7 lt. 1.5 lt. approx. 14.5 litres approx. 250 cc. approx. 1.8 litres approx. 242 3 cc (in each fork leg)
Electrical system
ELECTRICAL SYSTEM
Specification Electronic ignition Spark plug Spark plug Desc./Quantity inductive, high efficiency integrated with the injection system, with variable timing and separate HV coil. NGK CR7EKB CHAMPION RG6YC
CHAR - 9
Characteristics
Nexus 500 euro 3
Specification Battery Generator
Desc./Quantity Dry-cell lead-acid battery, 12V-14Ah Three-phase alternating current
Frame and suspensions

CHASSIS AND SUSPENSIONS
Specification Chassis Front suspension Front fork max. stroke Rear suspension Desc./Quantity Welded steel pipes with pressed sheet metal stiffening Hydraulic telescopic fork with diameter 41 mm stems 104 mm
Type "Power drive": Shock absorber (with doubleacting helicoidal spring and adjustment of the spring preload in 7 positions) mounted in horizontal position, connected to a connecting rod pivoted to a strut with variable length. By varying the length of the strut it is possible to modify the geometry and balance of the rear axle (15 positions). The motor has a fixed connection to the frame by means of a shaft (direct link).
Brakes
BRAKES
Specification Front brakes Desc./Quantity Twin discs of stainless steel, dia. 260 mm, with floating calliper and twin 28 mm diameter plungers (Brembo) at front right and twin 26 mm diameter plungers (Brembo) at front left. Disc of stainless steel, dia. 240 mm, with fixed calliper and two opposed 34 mm diameter plungers
Rear brakes
Wheels and tyres

WHEELS AND TYRES
Specification Rims in light alloy: Front Rims in light alloy: Rear Rear tyres Front tyres Tyre pressure (cold) front Tyre pressure (cold) rear N.B. Desc./Quantity 3.50 x 15" 4.50 x 14" Bridgestone 160/60-R14" Tubeless 65H Bridgestone 120/70-R15" Tubeless 56H 2.1 bar 2.3 bar (2.5 bar with passenger)
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.
CAUTION
IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE CORRECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES RECOMMENDED BY PIAGGIO.
CHAR - 10
Nexus 500 euro 3
Characteristics
Tightening Torques
FRAME
Name Electric pump locking ring nut Torque in Nm 20
BRAKE SYSTEM
Name Brake calliper coupling Front brake disc mounting Rear brake disc mounting Front brake calliper mounting on fork Rear calliper support on crankcase retainer Pipe / brake calliper coupling Circuit bleed calliper fitting Plastic protection retaining screw Coupling for oil on the integral braking system pump Coupling on the integral braking system device (from the pump) Front brake calliper - integral braking system device coupling Rear brake calliper - integral braking system device coupling Locking with Loctite threadlock medium 243 Torque in Nm 20 - 24 56 11 13 20 25 20 25 20 25 12 - 16 5-6 16 20 20 25 20 25 20 25
FRONT SUSPENSION
Name Front wheel axle Holding torque of lower ring nut Fork stem mounting to the plate Steering lower ring nut Upper steering ring nut Stem upper cap Fixing screw handlebar to steering tube Pumping element fixing screw Safety screw on fork leg Wheel fastening screws * tighten and loosen completely. ** tighten and loosen by 90. Torque in Nm 45 50 20 25 20 25 10 - 13 ** 36 - 39 35 - 55 45 50 25 - 35 67 33 - 37
REAR SUSPENSION
Name Engine - chassis fixing pin Central stand retainers Muffler heat guard retainers Side stand clamp Rear wheel axle Connection of rear shock absorber to support connecting rod Rear shock absorber retainer to the chassis Upper strut connection Clamping of connection rod supporting strut and shock absorber to frame Clamping of rear strut support to hub cover Lower strut clamping Rear strut support clamping to crankcase Assembly plate mounting on strut support Locking with Loctite threadlock medium 243 Torque in Nm 100 - 120 25 30 6-8 15 20 104 126 38 - 46 38 - 46 56 - 70 73 - 80 20 - 25 30 - 35 11 - 13 11 - 13
ENGINE ASSEMBLY
Name Starter motor screws Torque in Nm 11 13
THERMAL GROUP AND TIMING SYSTEM

Name Spark plug Torque in Nm 12 14
CHAR - 11
Characteristics
Nexus 500 euro 3
Name Head fixing stud bolts Head fixing nuts Exhaust / intake head fixing nuts Head lubrication control jet coolant temperature sensor: Lambda probe on exhaust manifold injector fixing screw Counterweight screw Tensioner sliding block fixing screw Rpm timing sensor fixing screw Valve lifter mass stop bell fixing screws Inlet manifold screws Tappet cover fixing screws Throttle body fixing screws Head fixing screws Camshaft retaining bracket screws: Tightener screw: Tightener fastening screws:
Torque in Nm *** 10 - 12 10 - 12 5-7 10 - 12 10 - 12 34 7 8.5 10 - 14 3-4 30 - 35 11 13 7-9 11 13 10 - 12 46 5-6 11 13
*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90 in a crossed sequence. - tighten again by 90 in a criss-crossed sequence.
CRANKCASE AND CRANKSHAFT

Name Countershaft fixing nut Engine oil filter Engine oil drainage plug Engine-crankcase coupling screws Oil pump screws Gear mounting on crankshaft screws Bulkhead screws for oil pump housing cover Torque in Nm 25 29 12 - 16 24 30 11 13 5-6 10 -12 8 - 10
FINAL REDUCTION
Name Rear hub cover screws Torque in Nm 24 27
TRANSMISSION COVER
Name Driven pulley nut Driving pulley nut Anti-vibration roller screw M8 retainers for transmission cover M6 retainer Anti-vibration roller retainer Clutch ring nut Air conveyor screws Water pump cover screws External transmission cover screws Flywheel cover screws Torque in Nm 92 - 100 160 - 175 16.7 19.6 23 26 11 13 17 - 19 65 - 75 11 12 34 79 11 - 13
FLYWHEEL COVER
Name Chain guide sliding block retain plate fastening screws Flywheel fixing nut Stator retainers Blow-by recovery duct fixing screws Screw fixing freewheel to flywheel Stator cable harness guide bracket screws Supporting screws with bulkhead Minimum oil pressure sensor Water pump impeller Torque in Nm 34 115 - 125 8 - 10 3-4 13 15 3-4 0.3 - 0.4 12 14 45
CHAR - 12
Nexus 500 euro 3
Characteristics
LUBRICATION
Name Oil pump cover screws Screws fixing oil pump to crankcase Torque in Nm 0.7 0.9 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.
(Values in mm)
HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Specification A: B: Desc./Quantity 10 mm 43 mm
CATEGORIES OF COUPLING
Name Cylinder Piston Cylinder Piston Cylinder Piston Cylinder Piston N.B. Initials A B C D Cylinder 91.990 - 91.997 91.997 - 92.004 92.004 - 92.011 92.011 - 92.018 Piston 91.954 - 91.961 91.961 - 91.968 91.968 - 91.975 91.975 - 91.982 Play on fitting 0.029 - 0.043 0.029 - 0.043 0.029 - 0.043 0.029 - 0.043
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS.
CHAR - 13
Characteristics
Nexus 500 euro 3
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 1st Compression ring Middle piston ring Oil scraper ring Initials A A A Cylinder 0.15 0.35 0.25 0.50 0.25 0.50 Piston 0.5 0.65 0.65 Play on fitting </> </> </>
Crankcase - crankshaft - connecting rod

Crankcase / countershaft coupling Besides considering it should match the crankshaft, the crankcase is chosen according to the centre to centre distance between the seat of the crankshaft and that of the contra-rotating shaft. Both the centre to centre distance and the pair of gears driving the contra-rotating shaft are divided into two types (A and B) to be matched (A with A and B with B). This selection is useful to keep the difference between the working distance of the gears and their distance without clearance at a given value in order to avoid abnormal noise.
TYPE A
Specification Centre to centre distance of the gears without clearance Centre to centre distance on the crankcase Desc./Quantity 76.937 76.867 77.022 76.992
TYPE B
Specification Centre to centre distance of the gears without clearance Centre to centre distance on the crankcase Desc./Quantity 76.907 76.837 76.992 76.962
The gears with centre to centre distance without clearance between 76.867 and 76.907 are considered universal and can be fitted to either crankcase type. Either the pair of gears or the crankcase is identified with the letter referring to the type (on the crankcase, this mark is found at the cylinder mouth, flywheel side).
CHAR - 14
Nexus 500 euro 3
Characteristics
Diameter of crankshaft bearings. Measure the capacity on both axes x-y.
CRANKSHAFT
Specification Cat. 1 Cat. 2 Desc./Quantity Standard diameter: 40.010 40.016 Standard diameter: 40.016 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT

Specification A= B= C= D= Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm
CHAR - 15
Characteristics
Nexus 500 euro 3
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Transmission-side shoulder Transmission-side halfshaft Connecting rod Flywheel-side shoulder Flywheel-side half-shaft Complete drive shaft Description Dimensions 0.8 0.025 19.6 + 0.050 22 0.10-0.15 13 0.025 19.6 +0.050 63.5+0.1-0.05 Initials A B C F E G Quantity D= 0.20 - 0.40 D= 0.20 - 0.40 D= 0.20 - 0.40 D= 0.20 - 0.40 D= 0.20 - 0.40 D= 0.20 - 0.40
Characteristic
Drive shaft / crankcase axial clearance: 0.1 - 0.5 mm (when cold)
Slot packing system

Shimming system for limiting the compression ratio Rc = 10.5 : 1 DISTANCE A IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE. DISTANCE A HELPS DETERMINE THE THICKNESS OF GASKET B THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE COMPRESSION RATIO. BASE GASKET B MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.
BASE GASKET THICKNESS

Name A MEASURE TAKEN A MEASURE TAKEN A MEASURE TAKEN N.B. Measure A - 0.185 - - 0.10 - 0.10 - + 0.10 + 0.10 + 0.185 Thickness 0.4 0.05 0.6 0.05 0.8 0.05
VALUES INDICATED WITH - REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE. CHAR - 16
Nexus 500 euro 3
Characteristics
N.B.
DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B
Products
PRODUCTS
Product AGIP ROTRA 80W-90 AGIP FILTER OIL AGIP CITY HI TEC 4T AGIP BRAKE 4 AGIP PERMANENT SPEZIAL AUTOSOL METAL POLISH AGIP GP 330 AGIP CITY TEC 2T Description Rear hub oil Oil for air filter sponge Engine oil Brake fluid coolant Muffler cleaning paste Grease for brake levers, throttle Mixer oil Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Mineral oil with specific additives for increased adhesiveness SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil FMVSS DOT 4 Synthetic fluid Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 special product for cleaning and polishing stainless steel muffler White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 synthetic oil for 2-stroke engines: JASO FC, ISO-L-EGD
CHAR - 17
INDEX OF TOPICS
TOOLING
TOOL
Nexus 500 euro 3
Tooling
GOOD
SPECIAL TOOLS
Stores code 001330Y
Description 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 bearings
001467Y014
Pliers to extract 15-mm bearings
TOOL - 19
Tooling
Nexus 500 euro 3
Stores code 001467Y031
Description Bell
001467Y034
Pliers to extract 15-mm bearings
001467Y035
Belle for OD 47-mm bearings
002465Y
Pliers for circlips
006029Y
Punch for fitting fifth wheel seat on steering tube
020004Y
Punch for removing fifth wheels from headstock
TOOL - 20
Nexus 500 euro 3
Tooling
Stores code 020055Y
Description Wrench for steering tube ring nut
020150Y
Air heater support
020151Y
Air heater
020193Y
Oil pressure gauge
020201Y 020262Y
Spacer bushing driving tube Crankcase splitting strip
020306Y
Punch for assembling valve seal rings
TOOL - 21
Tooling
Nexus 500 euro 3
Stores code 020329Y
Description MityVac vacuum-operated pump
020330Y
Stroboscopic light to check timing
020331Y
Digital multimeter
020333Y
Single battery charger
020334Y
Multiple battery charger
TOOL - 22
Nexus 500 euro 3
Tooling
Stores code 020335Y
Description Magnetic support for dial gauge
020357Y 020358Y 020359Y
32 x 35 mm adaptor 37x40-mm adaptor 42x47-mm adaptor
020360Y
Adaptor 52 x 55 mm
020364Y
25-mm guide
020376Y
Adaptor handle
020382Y012
bush (valve removing tool)
TOOL - 23
Tooling
Nexus 500 euro 3
Stores code 020412Y
Description 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
Nexus 500 euro 3
Tooling
Stores code 020444Y
Description Tool for fitting/ removing the driven pulley clutch
020456Y
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
Tooling
Nexus 500 euro 3
Stores code 020468Y
Description 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
Nexus 500 euro 3
Tooling
Stores code 020474Y
Description 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
Tooling
Nexus 500 euro 3
Stores code 020481Y
Description Control unit interface wiring
020482Y
Engine support
020483Y
30 mm guide
020512Y
Piston fitting fork
020527Y
Engine support base
020604Y011 020565Y
Fitting adapter Flywheel lock calliper spanner
TOOL - 28
Nexus 500 euro 3
Tooling
Stores code 020623Y
Description Pre-service gas extraction set
020625Y
Kit for sampling gas from the exhaust manifold
020640y
software euro3
TOOL - 29
INDEX OF TOPICS
MAINTENANCE
MAIN
Nexus 500 euro 3
Maintenance
Maintenance chart
EVERY 2 YEARS
60'
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 Brake pads - check condition and wear Tyre pressure and wear - check Vehicle and brake test - road test Hub oil - change Crankcase breather - empty Steering - adjustment Injection system pipework - visual check
AFTER 10,000 KM AFTER 30,000 KM AFTER 50,000 KM AND AFTER 70,000 KM

Action Safety locks - check Spark plug - replacement Driving belt - replacement Throttle lever - adjustment Air filter - check Air filter belt compartment - check Engine oil - change Valve clearance - check Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check Vehicle and brake test - road test Hub oil - check Stand control roller - replace Suspensions - check Steering - Check Injection system pipework - visual check
MAIN - 31
Maintenance
Nexus 500 euro 3
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 Engine oil - change Valve clearance - check Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check Vehicle and brake test - road test Hub oil - check Stand control roller - replace Crankcase breather - empty Suspensions - check Steering - Check Injection system pipework - visual check Fuel filter - check
Spark plug
Check and replacement
CAUTION THE SPARK PLUG MUST BE REMOVED WITH COLD ENGINE. THE SPARK PLUG SHOULD BE CHECKED EVERY 6,000 KM AND REPLACED EVERY 12,000 KM. THE USE OF NON-CONFORMING IGNITION CONTROL UNITS AND SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Characteristic
Recommended spark plugs: CHAMPION RG6YC - NGK CR 7 EKB
- Position the scooter on centre stand. - Remove the side cover on the left-hand side of the scooter, loosening the three screws shown in the figure. MAIN - 32
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 electrodes using the appropriate feeler gauge.
Characteristic
Electrode gap 0.7-0.8 mm Adjust the gap if necessary, carefully bending the earth electrode. In the event of irregularity, replace the spark plug with a recommended type. - Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it.
Locking torques (N*m)

Spark plug 12 14 - Insert the cap onto the spark plug and proceed with the reassembly operations.
Hub oil Check

Check the oil in the rear hub.
Characteristic
Rear hub oil Capacity approximately 250 cc
To check the rear hub oil level, proceed as follows: - Park the scooter on flat ground resting on its centre stand. - Set the strut that adjusts the level to its minimum height. - Unscrew the oil dipstick, dry it with a clean cloth and reinsert it, screwing it in thoroughly.
MAIN - 33
Maintenance
Nexus 500 euro 3
- 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, restore the proper amount of oil in the hub. -Retighten the oil dipstick again and make sure it is locked properly into place.
Replacement
- Prepare a suitable container. - Remove the oil filler plug shown in the figure.
- Unscrew the oil drainage plug and drain out all the oil. - Tighten the drainage plug with its gasket and refill. - Tighten the oil filler plug.
Characteristic
Rear hub oil Capacity approximately 250 cc Recommended oil: TUTELA ZC 90
MAIN - 34
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 figure.
- Loosen the mounting screw located under the intake manifold. - Replace the air filter and reassemble the various components, reversing the removal procedure.
- An inspection and possible cleaning (with compressed air) of the air filter is scheduled every 6000 km in any case. - The air jet must be directed from the inside to the outside of the filter (i.e. opposite the direction of the air flow during normal operation of the engine). - Any deposits of condensate out of the engine oil caused by blow-by can be removed via the pipe shown in the figure.
MAIN - 35
Maintenance
Nexus 500 euro 3
N.B. FAILURE TO OBSERVE THE RULES REGARDING CLEANING OF THE FILTER ELEMENT CAN LEAD TO IMPROPER LUBRICATION OF THE ELEMENT. POOR LUBRICATION AFFECTS THE FILTERING CAPACITY. EXCESSIVE LUBRICATION AS WITH A SOILED FILTER CAUSES AN EXCESSIVELY RICH FUEL/AIR MIXTURE. CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. WARNING DO NOT RUN THE ENGINE IF THE AIR FILTER IS NOT IN PLACE THIS WILL RESULT IN EXCESSIVE WEAR TO ALL THE PARTS OF THE COOLING SYSTEM.
Engine oil
In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".
Check
This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly. 3) Remove the cap/dipstick again and check that the level is between the max. and min levels; topup, if required. Topping up from the MIN to MAX. level requires around 1700 cc. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level. Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. MAIN - 36
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 DISPOSED OF ACCORDING TO THE REGULATIONS IN FORCE.
WARNING
AVOID TOUCHING PARTS OF THE ENGINE WHEN HOT, AS THIS MAY CAUSE BURNS. - Remove the muffler. - Remove the filler plug.
- Remove and clean the mesh pre-filter of the drain cap with compressed air.
- Use a belt spanner for filters to remove cartridge filter "C". - Make sure the pre-filter and drain cap O-rings are in good condition. - Lubricate them and refit the mesh filter and oil drain cap by tightening to the prescribed torque. - Refit a new cartridge filter making sure to lubricate the O-ring before fitting, then screw until it comes into contact with the seal and further tighten to the prescribed torque. - Refit the muffler. - Add recommended engine oil. - Start the engine and let it run for a few minutes and then turn it off. After 5 minutes check the level and top up, if necessary, never exceed the MAX. level.
N.B.
MAIN - 37
Maintenance
Nexus 500 euro 3
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 cm

Engine oil drainage plug 24 30 Engine oil filter 12 - 16
Oil pressure warning light

Warning light (low oil pressure) The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position. However, this light should switch off once the engine has been started. If the light comes on during braking, at idling speed or while turning, it is necessary to first switch off the engine and then to check the oil level and the lubrication system
Checking the valve clearance

- To check the clearance in the valves collimate the references between the cam shaft control pulley and head. - Use a feeler to make sure the clearance between the valve and register screw correspond to the indicated values. If the clearance does not correspond, adjust it by loosening the lock nut using a screwdriver on the set screw as shown in the figure.
Characteristic
Valve clearance: intake 0.15 mm (when cold) Valve clearance: discharge 0.15 mm (when cold)
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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. - Remove the right footrest as described in the Bodywork Chapter. - Remove the muffler to access the flywheel cover, as described in the Engine Chapter. - Empty the cooling system by removing the couplings on the pump cover and the filler plug on the expansion tank.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD. - Remove the water pump cover as indicated in the figure by loosening the 6 retaining screws. - Proceeding as described in chapter "Engine", partially drain the system and overhaul the pump. - Refill and drain the system again once after having repaired the damaged and reinstalled all the components.
N.B. FOR CHANGING THE COOLANT AND BLEEDING THE SYSTEM, SEE CHAPTER "COOLING SYSTEM".
Characteristic
Cooling system approx. 1.8 litres
Level check
The coolant level must checked every 6,000 kilometres with a cold engine, in the way shown below: - Place the scooter on its centre stand and on flat ground. - Remove the cap of the expansion tank. - To check the level, it is necessary to look inside the expansion tank: The reference mark in the figure shows the correct coolant level. -The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- antifreeze solution mix.
CAUTION
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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. THE MIXTURE THUS OBTAINED LOWERS THE FREEZING POINT OF THE COOLANT TO - 40C. THE MIXTURE IN COMBINATION WITH THE PRESSURE OF 0.9 BAR RAISES THE BOILING POINT TO APPROX. 125C. THE RECOMMENDED LIQUID ALSO PROVIDES PROTECTIVE FUNCTIONS FOR THE ALUMINIUM ALLOYS. THIS CHARACTERISTIC MAY DECREASE OVER THE COURSE OF TIME; THIS IS WHY A PERIODIC REPLACEMENT OF THE COOLANT IS INDISPENSABLE.
N.B.
FOR THE REPLACEMENT OF THE COOLANT AND THE FLUSHING OF THE SYSTEM, SEE CHAPTER COOLING SYSTEM.
Braking system Level check

- Position the vehicle on a flat surface and on the centre stand. - Check the brake fluid level via the special indicator located on the pump.
N.B.
THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF REQUIRED. TOP UP THE PUMP TANK, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL MUST ONLY BE OBTAINED WITH NEW PADS.
Top-up
CAUTION
ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. Proceed as follows: - Position the vehicle on a flat surface and on the centre stand. - Remove the tank cap by removing the two screws, remove the gasket and top up using only the liquid specified without exceeding the maximum level.
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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.
WARNING
THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING; FOR THIS REASON, NEVER USE BRAKING FLUID FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.
Characteristic
Prescribed fluid: TUTELA TOP 4 Under normal climatic conditions, the fluid must be changed every 20,000 km or anyway every two years.
N.B.
SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Headlight adjustment
- Place the scooter in use conditions, with tyres inflated to the prescribed pressure on flat ground at 10 m from a white screen placed in dim light. - Make sure that the scooter's axle is perpendicular to the screen. - Turn the headlight on and check that the limit of the light beam projected onto the screen does not exceed 9/10 of the headlight centre height from the ground and that it is not less than 7/10.
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- Otherwise, adjust the right headlight by the screw shown in the figure, which can be accessed by removing the front shield connecting member.
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.
Checking the end compression pressure

- Remove the spark plug cap with the engine cold. - Remove the spark plug. - Fit a compression test gauge into the spark plug seat using a 10 mm spark plug union at the proper tightening torque. - Turn the switch to "ON", wait a few seconds and the disconnect the connector of the revolution sensor to prevent the function of the injector and the spark plug. - Allow the engine to run using the starter and with the throttle body in fully open position as long as the gauge value is steady. - If the pressure is higher than specified, remove the tool and reassemble the scooter. - If the pressure is less than indicated, check the rpm at which the test is carried out; if it is less than 450 rpm, check the starter system. If the final compression pressure is less than specified, remove the pressure gauge connector and inject a few cc of oil into the combustion chamber, then turn the engine over (preferably by hand) to lubricate the cylinder. Repeat the compression test: If the new value is also too low, check the valve seating. Higher compressions on a new engine indicate poor seating of the segments.
Characteristic
Compression ratio 10.5: 1

Spark plug 12 14
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INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Nexus 500 euro 3
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. Overturn sensor 11. Injection load remote control 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 16. Horn button 17. Horn 18. Engine stop remote control 19. Diode ELE SYS - 44
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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. Saddle opener actuator 30. Saddle opener receiver 31. 12V 180W socket 32. Helmet compartment light switch 33. Helmet compartment light 34. Preparation for anti-theft device 35. Left rear turn indicator bulb 36. Twin filament bulb tail light / stop light 37. Licence plate bulb 38. Right rear turn indicator bulb 39. Left front turn indicator bulb 40. Front right light assembly A. Low beam light B. Tail light 41. Front left light assembly B. Tail light C. High beam light 42. Right front turn indicator bulb 43. Headlight remote control 44. High beam passing mode switch 45. Light switch 46. Turn indicator assembly 47. Handlebar warning lights A. Emergency lights B. Tail lights C. High beam light 48. Turn indicator switch 49. Electric control system 50. Mode button ELE SYS - 45
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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. Low fuel warning light G. Oil warning light 55. Immobilizer aerial 56. Fuel pump / fuel level transmitter 57. Immobilizer decoder 58. Fuel injector 59. Spark plug 60. Tone wheel 61. HV coil 62. Lambda probe 63. Diagnostic socket 64. Fuel injection electronic control unit Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black, Ro = Pink, Rs = Red, Ve = Green, Vi = Purple
Components arrangement
Diagnostic socket In order to access the diagnostic socket, remove the supports of the passenger footrest. Overturn sensor In order to access the overturn sensor, remove the central union.
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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, remove the upper shield back plate.
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In order to access the connector, remove the windshield 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.
Immobiliser decoder In order to access the immobilizer decoder, remove the upper shield back plate.
Relays and diode group In order to access the relays and the diode group, remove the upper shield back plate.
Voltage regulator In order to access the voltage regulator, remove the lower cover.
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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. Fuse box B 18. Engine stop remote control ELE SYS - 49
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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. Oil warning light 55. Immobilizer aerial 57. Immobilizer decoder 59. Spark plug 61. HV coil 64. Fuel injection electronic control unit
Battery recharge and starting
KEY: ELE SYS - 50
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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. Starter enable remote control 25. Engine stop switch 26. Centre stand switch 27. Rear brake stop button 28. Front brake stop button 36. Twin filament bulb position light / stop light
Level indicators and enable signals section
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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. Main fuse 15. Fuse box B 18. Engine stop remote control 19. Diode 20. Battery 52. Oil pressure sensor 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. Oil warning light 56. Fuel pump / fuel level transmitter 58. Fuel injector 60. Tone wheel 62. Lambda probe 64. Fuel injection electronic control unit
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Devices and accessories
KEY 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. Engine stop remote control 19. Diode 20. Battery 25. Engine stop switch 26. Centre stand switch 29. Saddle opener actuator 30. Saddle opener receiver 31. 12V 180W socket
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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. Batteria 34. Predisposizione antifurto 35. Lampada indicatore di direzione posteriore Sx 36. Lampada doppio filamento Luce di posizione/Luce stop 37. Lampada luce targa 38. Lampada indicatore di direzione posteriore Dx 39. Lampada indicatore di direzione anteriore Sx 40. Gruppo ottico anteriore Dx A. Lampada anabbagliante B. Luce di posizione ELE SYS - 54
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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 modalit Pass 45. Deviatore luci 46. Dispositivo lampeggiatori 47. Spie gruppo manubrio A. Lampeggiatori di emergenza B. Luci di posizione C. Luce abbagliante 48. Commutatore indicatori di direzione 49. Dispositivo gestione comandi elettrici 51. Interruttore lampeggiatori di emergenza 53. Quadro strumenti A. Contagiri B. Lampade illuminazione strumento 54. Quadro strumenti A. Lampade illuminazione strumento B. Led immobilizer C. Tachimetro D. Display digitale E. Spia Warning motore F. Spia Riservacarburante G. Spia olio H.
Checks and inspections Immobiliser

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the scooter to be operated only when it is started with coded keys recognised by the control unit. The code is integrated into a transponder inserted into the body of the key. This permits transparent operation for the rider who has to do no more than the normal turn of the key. The Immobilizer system consists of the following components: - Control unit - Decoder ELE SYS - 55
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- 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" or the emergency stop switch is turned to "OFF" and, in order not to prejudice the battery charge, remains active for 48 hours. When the key switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The time for which this lamp stays on depends on the programming of the control unit. In the event that the LED goes out irrespective of the position of the key switch and/or the instrument panel is not initialised, check: Battery voltage is "ON" That none of fuses 1, 3, 7 or 8 has blown Power supply to the control unit as specified below:
Disconnect the connector from the control unit. Check the following conditions: With the key switch in position "OFF": Battery voltage between terminals 17-23 and terminals 17-chassis ground (continuous power supply). In the event that there is no voltage, check that fuse 1 has not blown and check the corresponding wiring. With the key switch in position "ON" and the engine stop switch in "RUN": Battery voltage between terminals 26-23 and terminals 26-chassis ground (continuous power supply). In the event that there is no voltage, check: 1. The condition of fuse No. 1 and the corresponding wiring. 2. The function of the engine stop remote control. Check for voltage on the blue/grey cable at the exit from the engine stop remote control. In the event that there is no voltage, check: 1. The contacts of the key switch. 2. The function of the engine stop switch, then for the presence of earth on the green/blue cable and the engine stop switch with the stand raised and the engine stop switch in position RUN. 3. The function of the diode of the engine stop remote control. If no fault is found, replace the control unit.
N.B.
AN ACCIDENTAL LOSS OF THE SERVICE KEY PROGRAMMING CAN ARISE FROM GENERAL FAULTS OF THE IGNITION SYSTEM. IN THIS CASE, CHECK THE HV LINE SHIELDING. In any case it is advisable to use resistive spark plugs.
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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 recognition of the "master" key as the first key to be programmed: this is particularly important as it is the only key that allows the decoder to be reset and reprogrammed for programming the service keys. The master and service keys must be used to code the system as follows: - Insert the Master key, turn it to ON and keep this position for two seconds (lower and upper limits 1 to 3 seconds). - Insert the service key and turn it to ON for 2 seconds. - If you have copies of the key, repeat the operation with each key. - Insert the MASTER key again and turn it to ON for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using. If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thor-
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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 ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited: 1. New decoder - key inserted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs. 2. New decoder - transponder missing or illegible: The LED is permanently ON; in this condition, no operations are possible, including starting of the vehicle. 3. Decoder programmed - service key inserted (normal operating condition): a single 0.7-second flash is displayed, after which the LED remains off steadily. The engine can be started. 4. Decoder programmed - master key inserted: a 0.7-sec flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46-sec flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been comELE SYS - 58
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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 transmitted are: 1-flash code 2-flash code 3-flash code
Diagnostic code - 1 flash

The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessary.
Diagnostic code - 2 flashes

A 2-flash code indicates a system where the decoder does not recognise the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. Otherwise replace the faulty key and/or reprogram the decoder. If the problem persists, replace the decoder.
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Diagnostic code - 3 flashes

The 3-flash code indicates a system where the decoder does not recognise the key. Turn the switch to ON using several keys: If the error code is repeated even with the Master key, replace the decoder. If this is not the case, reprogram the decoder.
Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability.
Stator check
Stator winding check-up
WARNING
THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Remove the central chassis cover. 2) Disconnect the connectors between stator and regulator with the three yellow cables. 3) Measure the resistance between each of the yellow terminals and the other two.
Electric characteristic
Resistance: 0.2 - 1
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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 Type Voltage Desc./Quantity Non-adjustable three-phase transistor 14 15V at 5000 rpm with lights off
Maximum current output check. - With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V. - Connect ammeter pliers to the 2 recharge positive poles in output from the regulator. - Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter. With an efficient battery a value must be detected: > 20A
Check the charging current

WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER. 1) Place the vehicle on its centre stand 2) With the battery correctly connected to the circuit, place the tester terminals between the battery terminals.. 3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time measure the voltage.
Voltage ranging between 14.0 and 15.0V at 5000 rpm. Look for any leakage 1) Check that the battery does not show signs of leaking fluid before checking the output voltage. 2) Turn the ignition key to OFF and connect the multimeter leads between the battery negative pole (-) and the Black cable. 3) With the multimeter leads connected, disconnect the Black cable from the battery negative pole (-). 4) With the ignition key always at OFF, the reading indicated by the ammeter must be 0.5 mA. ELE SYS - 61
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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. Check the function of the turn signal indicator switch 3. Without disconnecting the instrument panel, with the key switch in position ON and with the engine stop switch in position RUN, check for intermittent voltage between terminals 9-ground and 10-ground of the large 20-pin connector. If there is no voltage, check the wiring and the correct function of the electrical control units. If the fault persists, replace the instrument panel.
Lights list
LIST OF BULBS
1 2 3 4 5 6 Specification High-beam / low-beam headlights Position light / front headlight Turn indicator bulb Tail light bulb and light Licence plate bulb Helmet compartment bulb Desc./Quantity 2 12V-55W, halogen (H7) 2 12V-5W, all-glass 4 12V-10W, spherical 1 12V-21/5W, spherical, twin-filament 1 12V-5W, all-glass 1 12V-5W, cylindrical
Fuses
The electrical system is equipped with: 1. Six fuses "A" located on the shield back plate 2. Five fuses "B" located in the helmet compartment 3. One fuse of 30A "D" (main fuse), located near the battery on the left-hand side, under which is also a replacement fuse. The rating of the various fuses are stamped on the fuse holders "C". To replace the fuse, use the gripper provided in the tool bag. The table shows the position and characteristics of the fuses installed in the scooter.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
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TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).
FUSIBILE PRINCIPALE
1 Specification Generale Desc./Quantity
Nominazione: Fuse 1 Soglia di intervento: 30A Collocazione: Vano batteria
PORTAFUSIBILI B
1 Specification Non utilizzato Desc./Quantity
License plate bulb - position lights - instrument panel lights Instrument panel power supply
Seat opener receiver power supply - anti-theft device preparation Horn - emergency stop warning light - instrument panel permanent power supply - light controller Helmet compartment light - socket 12V-180W - anti-theft device preparation
Nominazione: Soglia di intervento: Collocazione: Vano portacasco Designation:Fuse 2 Threshold of operation: 3 A Location: Helmet compartment Designation:Fuse 3 Threshold of operation: 7.5 A Location: Helmet compartment Designation:Fuse 4 Threshold of operation: 7.5 A Location: Helmet compartment Designation:Fuse 5 Threshold of operation: 7.5 A Location: Helmet compartment Designation:Fuse 6 Threshold of operation: 15 A Location: Helmet compartment
FUSE HOLDER "B"

1 Specification Immobilizer decoder power supply - ignition ECU power supply Ignition ECU - immobilizer decoder (+ permanent power supply) Stop light - starter remote control coil Desc./Quantity
High-beam lamp with warning light
Low beam lamp
Designation:Fuse 7 Threshold of operation: 3 A Location: Shield back plate Designation:Fuse 8 Threshold of operation: 5A Location: Shield back plate Designation:Fuse 9 Threshold of operation: 7.5 A Location: Shield back plate Designation:Fuse 10 Threshold of operation: 7.5 A Location: Shield back plate Designation:Fuse 11 Threshold of operation: 7.5 A ELE SYS - 63
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Specification 6 HV coil - fuel injector - fuel pump - remote control injection load
Desc./Quantity
Location: Shield back plate Designation:Fuse 12 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. In order to access the remote control switches: Remove the front shield. - Remove the front knee guard.
The following table shows the functions of each remote control switch:
Remote control switch Description
A B C D E
Immobiliser remote control switch Electric fan remote control switch Light remote control switch Engine stop remote control switch Electronic control unit remote control switch
Starter remote control switch
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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.
Press buttons "MODE" and "ODO/SET" simultaneously at the moment you turn the key to "ON" for more than 3 seconds: The "BELT" symbol starts to flash. Pressing the button "MODE" for less than 1 second displays the symbols in turn. The selected symbol remains lit. Pressing button "MODE" for longer than 3 seconds resets the kilometre reading for the symbol selected, in "SERVICE" mode the date is also reset.
N.B.
AT THE MOMENT THE DATE IS RESET, THE "SERVICE" SYMBOL IS ACTIVATED AGAIN. PERFORM THE RESET PROCEDURE ONLY AT THE MOMENT OF DELIVERY OF THE SCOOTER TO THE CUSTOMER IN ORDER THAT THIS SYMBOL SIGNALS THE NEED FOR THE FIRST SERVICE IN RELATION TO THE DISTANCE TRAVELLED AND THE TIME SINCE THE ACTIVATION.
The scooter has an instrument panel subdivided into 3 sections: Digital instrument with LCD display and analogue speedometer, analogue rpm indicator and warning light group. Warning light group The warning light group includes: - Emergency light warning light (red) - Position light and low-beam warning light (green) - High beam warning light (blue)
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- 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) - Oil pressure warning light (red) - Turn signal warning light (green) - Immobilizer LED (red)
The digital section of the instrument panel is completed by a liquid crystal display and 3 control buttons (MODE - CLOCK - ODO/SET).
- The LCD panel provides a 5-digit display for the visualisation of: Total kilometres Trip kilometres Clock
N.B.
IT IS POSSIBLE TO CHANGE THE DISPLAY TO KM OR MILES BY PRESSING THE BUTTONS "MODE" AND "CLOCK" SIMULTANEOUSLY FOR LONGER THAN 3 SECONDS AT THE MOMENT YOU TURN THE KEY TO POSITION "ON". THE WORD "SET" WILL BE DISPLAYED. - Pushing the "MODE" button for less than a second displays the following function sequence: 1. Average speed The word "MEAN" appears together with km/h or mph. The value is calculated on the basis of the trip kilometre reading. 2. Maximum speed The word "MAX" appears together with km/h or mph. The value is calculated on the basis of the trip kilometre reading. 3. Average consumption The fuel symbol, the word "MEAN" and km/h or mph appear. The value is calculated on the basis of the trip kilometre reading. ELE SYS - 66
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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. Battery voltage The battery symbol appears Pressing button "MODE" for longer than 3 seconds returns you to function "1" of the sequence (average speed). - The display also contains the symbols:
BELT: Indicates the need to replace the transmission belt This lamp should come on and flash every 12000 km.
SERVICE (Service coupon): Indicates the need to carry out the scheduled maintenance operations. 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.
WARNING
THE SCOOTER SHOULD BE SERVICED IN ANY CASE AT THE KILOMETRE INTERVALS INDICATED IN THE OPERATING AND MAINTENANCE MANUAL; DO NOT RELY ON THE SERVICE DISPLAY THAT APPEARS ON THE INSTRUMENT PANEL.
Data check function

Setting the clock. To set the clock, press the button "CLOCK" for more than 3 seconds. The figures showing the hours start to flash. Set the hours with the button "ODO/SET". ELE SYS - 67
Electrical system
Nexus 500 euro 3
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. Setting the date. Set the "DATE" using the "CLOCK". If the button "CLOCK" is pressed for longer than 3 seconds, the figures showing the days start to flash. Set the day with the ODO/SET button. Press the "CLOCK" button again; the numbers showing the months start to flash. Set the month with the "ODO/SET" button. Press the "CLOCK" button again; the numbers showing the years start to flash. Set the year 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 date.
Sealed battery
Commissioning sealed batteries If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a regular tester. - If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode - Constant voltage charge equal to 14.40 14.70V -Initial charge voltage equal to 0.3 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode ELE SYS - 68
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.
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.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the negative clamp while the other two red wires marked (+) must be connected to the clamp marked with the + positive sign.
Dry-charge battery
- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of 1.26, corresponding to 30 B at a minimum temperature of 15C until the upper level is reached. - Allow to stand for at least 2 hours, then top up the level with sulphuric acid. - Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of about 1/10 of the battery nominal capacity and until the acid gravity is about 1.27, corresponding to 31 B and such values become steady. - After charging, top up the acid (adding distilled water). Close and clean carefully.
ELE SYS - 69
Electrical system
Nexus 500 euro 3
- After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery recharge".
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 Checking the electrolyte level The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear. Charging status check After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged, you should detect a density of 30 to 32 B corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15 C. A density reading of less than 20 B indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal. Battery recharge
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING. Remove the battery from the vehicle removing the negative clamp first. Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).
Specific tooling
020333Y Single battery charger 020334Y Multiple battery charger ELE SYS - 70
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
CAUTION
ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.
CAUTION
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY.
Phonic wheel
- Ensure that the tone wheel is correctly installed on the scooter and connected to the electrical system. - Turn the key switch to "ON". - Access the tone wheel connector on the system side. - Carry out the following measurements using the special tool.
Specific tooling
020331Y Digital multimeter Check the supply voltage. Keeping the connector in the position shown in the photo, check for battery voltage (12 V) with the polarity shown. If incorrect values are measured, check the electrical system and the digital instrument.
N.B. A DROP IN VOLTAGE OF 1 V IN RELATION TO THE BATTERY VOLTAGE CAN BE CONSIDERED NORMAL.
Check the signal Move the positive rod to the position shown in the photo. Turn the front wheel very slowly and check that the measured voltage is 0 V or battery voltage, depending on the position taken up. This condition should be repeated 16 times during a complete revolution of the wheel.
N.B. THE DIGITAL MULTIMETER IS NOT ABLE TO DISPLAY THE VOLTAGE WHEN THE WHEEL IS ROTATED FAST.
If other voltages are measured or there is no alternation, replace the tone wheel.
ELE SYS - 71
Electrical system
Nexus 500 euro 3
Connectors ECU
Layout of the system-side connectors and the connectors on the electronic control unit.
ECU
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Specification Throttle potentiometer power supply Oxygen sensor Rpm indicator / consumption counter Engine temperature 86 electric fan remote control switch Stepper motor Engine rpm sensor Oxygen sensor EMS diagnostic connector EMS diagnostic connector Throttle potentiometer signal Engine rpm sensor Injector control Stepper motor Injection telltale light Decoder (serial) Battery powered Air temperature sensor Fuel pump H.V. coil Stepper motor Sensor power supply Control unit negative Stepper motor Turn indicator control device Continuous power supply Desc./Quantity +5 V (-) (+) Stepper motor (+)
(negative) Stepper motor (-) Overturn sensor (+) (+) (-) (negative control) Stepper motor (-) Stepper motor (positive)
ELE SYS - 72
Nexus 500 euro 3
Electrical system
Seat opening receiver
RECEIVER CONTROL UNIT FOR SADDLE OPENER

1 2 3 4 5 6 7 8 9 10 11 12 Specification 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 Desc./Quantity
Immobiliser decoder
IMMOBILIZER DECODER
1 2 3 4 5 6 7 8 Specification Immobilizer LED control Base power supply Negative Electronic control unit EMS Continuous power supply (positive) Desc./Quantity (negative) (positive)
(serial) Immobilizer aerial
ELE SYS - 73
Electrical system
Nexus 500 euro 3
Engine rev. sensor

REV SENSOR
1 2 3 Specification M: F: S: Desc./Quantity Male Female Shielding
Dashboard
The instrument panel is provided with two connectors ("A" with 20 pins and "B" with 12 pins) shown in the figure.
Connector "A" KEY: 1. Wheel sensor (+) 2. Wheel sensor signal 3. Wheel sensor (-) 4. Lights 5. Engine rpm signal 6.Water temperature 7.Water temperature (-) 8. Oil pressure 9. Right turn indicator
ELE SYS - 74
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. Left turn indicator warning light 20. Emergency warning flashers Connector "B" KEY: 1. Rpm indicator (D) 2. Rpm indicator (B) 3. 4. 5. ICP/ID "NEXUS 500" 6. ICP/ID "NEXUS 250" 7. Rpm indicator (C) 8. Rpm indicator (A) 9. 10. 11. 12. ICP/ID "COMAND ID"
Analogue odometer
ANALOGUE RPM INDICATOR
Specification 1 2 3 4 Desc./Quantity STEPPER MOTOR A STEPPER MOTOR B STEPPER MOTOR C STEPPER MOTOR D
Remote seat opening

The vehicle is equipped with a remote control to open the saddle. ELE SYS - 75
Electrical system
Nexus 500 euro 3
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.
Battery replacement
The remote control for the black key is powered by inner batteries that get discharged after extended used. You may need to replace the batteries if the remote control fails or if its range of operation is reduced. To replace the batteries remove the three screws and uncouple the two half-shells.
Batteries used: CR1616
Zeroing
- Remove the front shield to gain access to the receiver control unit / seat opener controller. - Within the electrical wiring harness there are two cables, one black (ground) and one black/blue coming from pin 3 of the control unit. - Connect the two cables for at least 10 seconds to cancel all the remote control commands stored in the control unit.
Programming
- Follow these steps to program the remote controls: 1. Insert the remote control key to be programmed in the steering lock key block.
ELE SYS - 76
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. Repeat steps 2 and 3 for 4 times without removing the key. The control unit confirms the programming has been successful by opening the saddle.
N.B.
THE CONTROL UNIT CAN PROGRAMME UP TO 7 REMOTE CONTROLS.
ELE SYS - 77
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Nexus 500 euro 3
Engine from vehicle
Exhaust assy. Removal

- Loosen the two mountings of the exhaust manifold 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.
ENG VE - 79
Engine from vehicle
Nexus 500 euro 3
N.B. DUE TO MUFFLER DIMENSIONS IT IS NOT POSSIBLE TO ACTUATE ON THE SCREW PERPENDICULARLY TO REMOVE IT; USE A COMMERCIALLY AVAILABLE BONDUS 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 Specifications Chapter.
CAUTION
PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY. Check that there is a small clearance when the valve is in abutment against the set screw. -Check the engine oil level and if necessary top it up with the recommended type. - Top-up the cooling circuit. - Check the functioning of the accelerator and the electrical devices. Removal of engine
WARNING
CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD. - Disconnect the battery - Remove the underseat compartment. - Drain the coolant. - Remove the complete muffler assembly. - Remove the rear wheel. - Remove the swinging arm. - Remove the throttle control transmission. ENG VE - 80
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). - Disconnect the HV cable from the spark plug. - Disconnect the alternator cable from the electrical system of the scooter.
WARNING
BE VERY CAREFUL WHEN HANDLING FUEL.

CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
ENG VE - 81
INDEX OF TOPICS
ENGINE
ENG
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. - Remove the nut and the two washers.
N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFERENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.
- Remove the six M6 screws.
ENG - 83
Engine
Nexus 500 euro 3
- 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. - Unscrew the two screws shown in the figure to remove the air conveyor.

Air conveyor screws 11 12
- Remove the external transmission cover. - Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.
ENG - 84
Nexus 500 euro 3
Engine
Air duct filter

- Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter.
Removing the driven pulley shaft bearing

- Remove the transmission cover. - Remove the Seeger ring.
- Place transmission cover on a wood surface and use the special tool so that it is adequately supported. - Pull out the bearing using the special tool.
N.B. BELL MUST BE PLACED INTO THE TRANSMISSION COVER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.
Specific tooling
001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020439Y 17 mm guide
ENG - 85
Engine
Nexus 500 euro 3
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. - Install the new bearing using the special tool.
N.B. PROPERLY SUPPORT THE OUTSIDE COVER TO PREVENT DAMAGING THE PAINTED SURFACE.
Specific tooling
020376Y Adaptor handle 020358Y 37x40-mm adaptor 020439Y 17 mm guide
Baffle roller Plastic roller

Installation of belt anti-vibration roller - Install the anti-flapping roller with the lip facing the engine crankcase. - Tighten the central screw to the prescribed torque.
N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED.

Anti-vibration roller screw 16.7 19.6
ENG - 86
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.
Removing the driven pulley

- Remove the driven pulley assembly with the belt.
Inspecting the clutch drum

- Remove the clutch bell.
- Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter.
N.B. CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX.
Characteristic
Max. value: 160.5 mm Standard value: 160.2 mm ENG - 87
Engine
Nexus 500 euro 3
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; - Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure.
CAUTION
THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD CAUSE AN IRREVERSIBLE TOOL DEFORMATION. USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT. LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING WITH SHEATH.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch
Pin retaining collar

- Extract the collar using 2 screwdrivers.
- Remove the 4 guide pins. - Extract the moving driven half-pulley.
ENG - 88
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 halfpulley. - Remove the lock ring using pliers.
- Using the special tool inserted through the roller bearing, pull out the ball bearing.
N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAMAGING THE THREADING.
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020363Y 20 mm guide
N.B.
IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL
Specific tooling
001467Y002 Driver for OD 73 mm bearing - Remove the roller bearing using the special tool, supporting the fixed half-pulley with the bell.
Specific tooling
020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020364Y 25-mm guide 001467Y002 Driver for OD 73 mm bearing
ENG - 89
Engine
Nexus 500 euro 3
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. - Remove the 2 inside sealing rings and the 2 outside O-rings. - Measure the movable half-pulley bushing inside diameter.
Characteristic
Maximum admissible diameter: 50.05 mm Standard diameter: 50.00 +0.035 0.00 mm
Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.
N.B.
PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS. - Properly support the half-pulley to prevent damaging the threading. If you are working on the driven pulley unit fully assembled, use the special tool.
ENG - 90
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.
Refitting the driven pulley

- Insert the new oil guards - Insert the new O-rings
N.B.
O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, AT THE BASE OF THE HALF-PULLEY. - Install the half-pulley on the bushing being careful not to damage the top sealing ring during the introduction. - Make sure the pins and collar are not worn, reassemble the pins and collar.
- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.
Recommended products
AGIP GREASE SM 2 Grease for the tone wheel revolving ring
ENG - 91
Engine
Nexus 500 euro 3
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 relaxed.
Characteristic
Standard length: 125.5 mm Admissible limit after use: 120 mm
- Check the thickness of the clutch mass friction material.
Characteristic
Minimum thickness permitted: 1 mm - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. - Do not open the masses using tools to prevent a variation in the return spring load.
ENG - 92
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.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch - Compress the spring and insert the clutch on the driven pulley bushing.
N.B.
BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END. - Tighten the ring nut by hand and complete the tightening using the special wrench to the prescribed torque.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch

Clutch ring nut 65 - 75 - To facilitate reassembly on the engine, turn the moving driven pulley and insert the belt onto the smaller diameter.
ENG - 93
Engine
Nexus 500 euro 3
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 to horizontally align the central inside holes and install the special tool.
Specific tooling
020474Y Driving pulley lock wrench
ENG - 94
Nexus 500 euro 3
Engine
- First install the lock ring of the special tool onto the pulley so that the splines are completely engaged. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself. - Tighten the two tool fastening nuts, also by hand. - Loosen the central nut. - Remove the spring washer and the flat washer. - Remove the fixed driving half-pulley. - Remove the bushing connection washer. - Move the belt downwards. - Suitable support the roller contrast and extract the mobile driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out.
Inspecting the rollers case

- Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter.
CAUTION
DO NOT LUBRICATE OR CLEAN THE BUSHINGS
Characteristic
Maximum admissible diameter: 30.12 mm Standard diameter: 30.021 mm
ENG - 95
Engine
Nexus 500 euro 3
- Measure the pulley sliding bushing outside diameter shown in the figure.
Characteristic
Minimum admissible diameter 29.95 mm Standard diameter: 29.959 mm - Check that the rollers are not damaged or worn.
Characteristic
Minimum admissible diameter 24.5 mm Standard diameter: 24.9 mm - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves.
ENG - 96
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.
- Insert the nut in the original position (nut side in contact with the belleville washer).
ENG - 97
Engine
Nexus 500 euro 3
- 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 INSERTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE.
Specific tooling
020474Y Driving pulley lock wrench
- Install the lock ring from the rear so that the splines are completely engaged. - Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly. - Tighten the driving pulley fastening nut to the prescribed torque - Remove the special tool.

Driving pulley nut 160 - 175 Installing the roller container - Install the spacer with the internal chamfer facing towards the inside.
- Position the rollers on the half-pulley as shown in the figure. - The closed side must rest on the inside thrust face of the roller container.
ENG - 98
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.
N.B.
ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE. - Install the outside plastic transmission cover. - Tighten the 4 fastening screws to the prescribed torque.

External transmission cover screws 7 9
ENG - 99
Engine
Nexus 500 euro 3
- 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.

M8 retainers for transmission cover 23 26
- Lock the 7 M6 retainers.

M6 retainer 11 13
- Insert the washers on the driven pulley shaft.

N.B.
INSERT THE SMALLER WASHER FIRST, THEN THE LARGER ONE. - Insert the flanged nut. - Prepare the torque wrench for LHS locking using a machine hexagon wrench. - Tighten the driven pulley shaft fastening nut using an offset wrench.
N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFERENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

Driven pulley nut 92 - 100
ENG - 100
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. Remove the hub cover and the relevant gasket.
Removing the wheel axle

- Remove the countershaft. - Remove the wheel axis complete with gear.
Removing the hub bearings

- Support the hub cover using the column kit. - Pull out the bearing using the special tool.
Specific tooling
020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings
ENG - 101
Engine
Nexus 500 euro 3
- 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 15-mm bearings 001467Y034 Pliers to extract 15-mm bearings 001467Y031 Bell - Use the special extractor to disassemble the bearing on the engine chassis of the countershaft.
Specific tooling
001467Y006 Pliers to extract 20 mm bearings 001467Y035 Belle for OD 47-mm bearings
Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox cover.
- Support the hub cover using the column kit. - Pull out the bearing using the special tool.
Specific tooling
020476Y Stud bolt set 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide
ENG - 102
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 described in the Automatic transmission chapter. - Extract the driven pulley shaft from its bearing. - Remove the oil guard using a screwdriver into the hub gear box. - Remove the Seeger ring shown in the figure. - Pull out the driven pulley shaft bearing from the engine crankcase using the special tool.
Specific tooling
020376Y Adaptor handle 020358Y 37x40-mm adaptor 020364Y 25-mm guide
Inspecting the hub shaft

- Check that the 3 shafts exhibit no wear or deformation on the grooved surfaces, at the bearings and at the oil guards. - In case of faults, replace the damaged parts.
Characteristic
ENG - 103
Engine
Nexus 500 euro 3
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
Inspecting the hub cover

- Check that the mounting surface is not damaged or deformed. - Check the bearing bearings. In case of faults, replace the hub cover.
Refitting the driven pulley shaft bearing

- Heat the crankcase using the heat gun.
Specific tooling
020151Y Air heater
- Insert the driven pulley shaft bearing until it abuts against the bottom of the seat using the special tool.
N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE).
Specific tooling
020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020364Y 25-mm guide
ENG - 104
Nexus 500 euro 3
Engine
- Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor 020363Y 20 mm guide - Heat the gear shaft bearing seat on the crankcase. - Insert the gear shaft bearing in the upper crankcase seat using the special tool.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide - Place the safety lock Seeger ring of the driven pulley shaft bearing.
N.B. PLACE IT IN THE POSITION SHOWN IN THE FIGURE.
- Insert the pulley shaft oil guard on the transmission side.
ENG - 105
Engine
Nexus 500 euro 3
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.
Specific tooling
020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide - Heat the gear shaft bearing seat from the cover outside. - Insert the gear shaft bearing on the cover using the special punch until abutment.
Specific tooling
020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020483Y 30 mm guide - Replace the snap ring
ENG - 106
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 020476Y Stud bolt set
Refitting the hub bearings

- Place the 3 shafts as shown in the figure.
Refitting the ub cover

- Check the proper position of the centring dowels. - Install a new gasket. - Fit the gearbox cover, making sure the breather pipe is in the correct position.
- Position the 7 set screws, tighten them to the prescribed torque, being careful of the position of the bands holding the vent tube, and the position of the 3 shortest screws as indicated in the figure. - Refill with the prescribed oil to the Max. level.
AGIP ROTRA 80W-90 rear oil hub SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Characteristic
Quantity: approx. 250 cc ENG - 107
Engine
Nexus 500 euro 3

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.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM, OPEN WITH A SCREWDRIVER OR CUT THEM. BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.
Removing the hub cover

- Drain the engine oil by removing the drainage cap. - Prepare a suitable container to collect the oil.
- Remove the pre-filter.
ENG - 108
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 gasket and the cooling system sleeve support.
N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE THE RELEVANT POSITIONS.
CAUTION
REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.
CAUTION
BE CAREFUL TO PREVENT SLIPPAGE OF THE BY-PASS VALVE AND OF THE RELEVANT SPRING.
Removing the flywheel cover components

- Loosen the six mounting screws and remove the water pump cover.
ENG - 109
Engine
Nexus 500 euro 3
- 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 stator and its wiring.
- Loosen the two retaining screws and remove the reed valve support with bulkhead.
ENG - 110
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. THE THREADING IS CLOCKWISE. IT IS ADVISABLE TO PREVENT THE SHAFT ROTATION BY INSERTING A 12-MM WRENCH INTO THE DRIVE.
- Extract the shaft with the relevant abutment washer.
ENG - 111
Engine
Nexus 500 euro 3
- Remove the sealing ring.
- Remove the ceramic ring and the relevant gasket.
- Remove the sealing ring for the pump shaft lubrication using a suitably shaped tool.
- Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing. - Remove the minimum oil pressure sensor.
ENG - 112
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.

Engine oil filter 12 - 16
- Install the supply hose to the cylinder and connect the return hose to the pump cover using 3 new clamps.
N.B. TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS, PAYING ATTENTION NOT TO CONSTRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUFFICIENTLY.
- Install the pre-filter again and insert the engine oil drain plug, tightening to the prescribed torque. - Refill the engine with the prescribed type of oil.
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

Engine oil drainage plug 24 30 - Check the condition of the stator and of the respective cable harness.
ENG - 113
Engine
Nexus 500 euro 3
- Check the continuity between the 3 phases.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
Resistance: 0.2 - 1
- Check the ground insulation of each phase. - If a fault is found, carry out a thorough check of the cable harness that contains two types of cable: Rigid cables close to the stator and flexible cables close to the connector.
- Check that the winding is positioned so as not to interfere with the heads of the retaining screws.
- Check that the mounting surface of the crankcase is not worn or deformed. - Check that the by-pass valve seat, the torque limiter and the water pump shaft are free from wear.
Characteristic
By-pass housing hole diameter: 13.9 mm Connection diameter for start-up gear shaft: 12 mm Connection diameter for pump shaft: 8 mm
ENG - 114
Nexus 500 euro 3
Engine
- Check that the oil filter union and matching surface exhibit no deformations or wear.
Refitting the stator

- Install the stator assembly together with the wiring harness, tightening the 3 screws to the prescribed torque.
N.B. INSERT THE RUBBER WIRING SEALING GASKET INTO THE SPECIAL SEAT ON THE CRANKCASE.

Stator retainers 8 - 10
- Install the wiring guide bracket tightening the 2 screws to the prescribed torque.

Stator cable harness guide bracket screws 3 - 4
- Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar. - Insert the blow-by recovery duct using a new Oring. - Tighten the screws to the prescribed torque.

Blow-by recovery duct fixing screws 3 - 4
ENG - 115
Engine
Nexus 500 euro 3
- 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 channels, in particular: - The 3 by-pass channels.
- Oil feeding duct at the water pump shaft connection.
- Pump drainage duct.
ENG - 116
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.

Supporting screws with bulkhead 0.3 - 0.4
- Install a new sealing ring for the pump shaft using the special tool - Install the oil minimum pressure sensor and tighten to the prescribed torque.
Specific tooling
020376Y Adaptor handle 020412Y 15 mm guide

Minimum oil pressure sensor 12 14
ENG - 117
Engine
Nexus 500 euro 3
- Pre-assemble the ceramic seal and the relevant gasket.

N.B. PLACE THE CHAMFERING TOWARDS THE GASKET BEING 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.
ASSEMBLE BY HAND TO PREVENT DAMAGES TO THE CERAMIC SEAL. - Insert the water pump shaft after lubricating the flywheel cover seat. - Insert the mechanical seal on the shaft up to the impeller abutment surface.
N.B. THE FINAL INTRODUCTION DEPTH WILL BE DETERMINED BY THE IMPELLER.
- Screw the impeller and tighten to the prescribed torque.

Water pump impeller 4 5
Refitting the flywheel cover

- Lubricate the intermediate gear seat with torque limiter on the flywheel cover. - Align the water pump movement sensor with a reference and install the flywheel cover as described in the Flywheel cover chapter.
ENG - 118
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 countershaft movement sensor with a reference point on the crankcase (see figure).
- Repeat the alignment for the water pump crankshaft using the same reference point on the engine.
N.B. THIS PREPARATION IS USEFUL PARTICULARLY IN THE EVENT OF REPAIRS WITH THE WATER PUMP COVER INSTALLED.
- Install the flywheel cover on the engine, paying attention to avoid interference between the stator and rotor.
WARNING
FAILURE TO OBSERVE THIS INSTRUCTION MAY RESULT IN DESTRUCTION OF THE CERAMIC MAGNETS. - Tighten the 14 retaining bolts of the cover to the prescribed torque.
N.B.
THE BOLTS HAVE FOUR LENGTHS: - THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE. - THE LONGEST IS INSERTED UNDER THE ENGINE OIL FILLER PLUG.
ENG - 119
Engine
Nexus 500 euro 3
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.

Flywheel cover screws 11 - 13
Flywheel and starting

The starter is sold as a complete part. Before deciding to replace it, carry out the following tests: 1 - Battery Check the voltage after not running (a few hours): Voltage >12.5V Check the density of the electrolyte of each cell: B = 30 32 Specific weight: 1.25 - 1.26 YES go to 2 NO go to 3 2 - Make sure the negative terminals (battery negative and starter negative) are correctly connected to each other and to the frame. YES go to 4 NO go to 5 3 - Recharge and if necessary replace the battery. 4 - Connect the diagnostic tester (see chapter "Injection system"). Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor. Remove the 10A fuse no. 12 (see "fuses" chapter). Switch in position "ON" with interrupt switch in position "RUN" and side stand raised. Select the "PARAMETERS" function. Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption.
N.B.
THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Specific tooling
020460Y Scooter diagnosis and tester
Absorption at trailing speed: ENG - 120
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. Remove the starter motor (see the flywheel and starter system). Reconnect the earth and positive and perform the test.
Current consumption at idle speed: <40 A YES go to 10 NO go to 11 7- Low trailing speed High electrical absorption Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies are found, replace the starter motor. 8- Low trailing speed Low electrical absorption Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing them. Check the new values. YES go to 12 NO go to 13 9 - High trailing speed Low electrical absorption The engine turns too freely, check the compression end pressure. If the values are not correct proceed as follows. 10 - The starter motor works properly. 11 - Check the rotation of the armature. 12 - Replace the starter remote control switch. 13 - Test the battery again and if necessary replace the starter motor. ENG - 121
Engine
Nexus 500 euro 3
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 Type Power Desc./Quantity Mitsuba sm13d 0.9 kW
BATTERY
Specification Capacity Starting current Desc./Quantity 14 Ah 125 A
START-UP REMOTE CONTROL SWITCH

Specification Type Maximum load Desc./Quantity SEALED 150 A continuous
STARTER TRANSMISSION
Specification Ring gear and freewheel coaxial to the flywheel. Desc./Quantity Intermediate gear with built-in torque limiter.
The starter system has a transmission between the motor armature and engine shaft equipped with freewheel coaxial to the flywheel and torque limiter on the intermediate shaft. The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting. The starter control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions. The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the starter system, check the consensus of the immobilizer. In order to check the enabling switches circuit, see the Electrical system chapter, whereas to check the engine shaft control transmission, follow what is described in the Flywheel and starter system chapter.
- 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.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE THEM, OPEN WITH A SCREWDRIVER OR CUT THEM. BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.
ENG - 122
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. - Unscrew the 3 fastening screws and remove the chain guide sliding block retain plate and the startup rim.
- Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool.
ENG - 123
Engine
Nexus 500 euro 3
- 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 into the previously aligned holes and that it is perfectly abutted and almost flush with the flywheel.
Specific tooling
020472Y Flywheel lock wrench
- Loosen the magneto flywheel fastening nut. - Remove the special tool and the fastening nut.
- Remove the washer.
ENG - 124
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.
- Insert the special removing tool. - Using a 27-mm wrench and a 19-mm bushing, release the flywheel.
Specific tooling
020467Y Flywheel extractor
- Remove the extractor. - Remove the nut and extract the flywheel with the start-up rim. - Remove the crankshaft key.
- To remove the start-up rim from the freewheel it is necessary to turn it clockwise and pull it out.
ENG - 125
Engine
Nexus 500 euro 3
- Remove the freewheel from the flywheel by loosening the 6 fastening screws.
SINCE THE FREEWHEEL MUST BE REMOVED, IT IS ADVISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.
- The freewheel is coupled to the flywheel with high precision; if removal is difficult, use 2 screws as gripping points and as removing tools, if required.
- Extract the intermediate gear provided with torque limiter.
Inspecting the flywheel components

- Check the integrity of the magnets. - Check that the magnet support cage is free from deformation or cracks. - Check that the flywheel splines exhibit no loosening.
ENG - 126
Nexus 500 euro 3
Engine
Starter gear rim

- Check that there is no wear or abnormal impressions 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
- Check the inside diameter of the bushing of the starter gearing. - Check that the toothing is not worn.
Characteristic
Inside diameter of the bushing: Diameter 27 + 0.020 +0.041 mm
N.B.
IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND FREEWHEEL. IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE STARTUP RIM. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANKSHAFT.
Intermediate gear
- Check that the toothing is not worn. - Check the diameter of the two bearings.
Characteristic
Gear bearing diameter: 12 - 0 0.011 mm
ENG - 127
Engine
Nexus 500 euro 3
Also check the shaft diameter on the flywheel cover 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.
THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH DRIVE PLATES. Driven plates consist of 4 Belleville springs provided with grooved profiles; this assembly allows transmitting torque lower than 10 kgm. In case of incorrect start-up manoeuvres, the limiter prevents any kicks, with consequent reversal of direction of the crankshaft which would impair the engine structure.
The limiter assembly cannot be overhauled. In case of irregularities on the toothed discs, replace the assembly.
Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition. - Thoroughly clean the free wheel to remove LOCTITE residue. - Degrease the threading of the holes in the free wheel and the clamping screws. - Apply the recommended product to the end of the screws.
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock
ENG - 128
Nexus 500 euro 3
Engine
- Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the flywheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fashion to the prescribed torque.

Screw fixing freewheel to flywheel 13 15
- Oil the free wheel "rollers".
Refitting the intermediate gear

- Lubricate the gear housing on the engine crankcase.
- Insert the intermediate gear with torque limiter
ENG - 129
Engine
Nexus 500 euro 3
- 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.
- Insert washer and nut on the crankshaft.
ENG - 130
Nexus 500 euro 3
Engine
- Tighten thoroughly the guide bushing of the flywheel lock tool and loosen by 1/4 turn.
N.B. FAILURE TO OBSERVE THIS RULE CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL.
Specific tooling
- Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
- Insert the special tool checking that the pins are perfectly introduced into the seat.
Specific tooling
- Tighten the flywheel lock nut to the prescribed torque.

Flywheel fixing nut 115 - 125
ENG - 131
Engine
Nexus 500 euro 3
- Install the chain guide retain plate tightening the 3 screws to the prescribed torque.
N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE STARTUP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIRECTION.

Chain guide sliding block retain plate fastening screws 3 4
Refitting the starter motor

- Check that the O-ring is in good working order and lubricate it. - Insert the starter motor. - Tighten the 2 fastening screws to the prescribed torque.

Starter motor screws 11 13
Cylinder assy. and timing system

- Remove the external and internal transmission cover.
- Remove the flywheel cover, the flywheel and the torque limiter.
ENG - 132
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, as shown in the figure.
ENG - 133
Engine
Nexus 500 euro 3
- 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. BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COMPARTMENT.
- Align the references located on the tone wheel and on the head.
- Loosen the central screw on the tensioner first. - Unscrew the 2 fastening screws and remove the tensioner with relevant gasket.
ENG - 134
Nexus 500 euro 3
Engine
Remove the inside hexagon screw and the counterweight 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.
N.B. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER.
ENG - 135
Engine
Nexus 500 euro 3
Removing the cam shaft

- Unscrew the 3 fastening screws and remove camshaft retaining bracket.
N.B. REMOVING THE FASTENING SCREWS MAY BE DIFFICULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEXAGON. IF NECESSARY, SEPARATE THE THREADS IN ADVANCE.
- Remove the cam shaft.
- Remove pins and rocking levers by the transmission side holes.
Removing the cylinder head

- Remove the spark plug. - Remove the cooling system outlet sleeve with thermostat.
ENG - 136
Nexus 500 euro 3
Engine
- Remove the coolant temperature sensor.

N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE ANALOGUE 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.
- Remove the two M6 screws into the distribution channel and the M6 screw on the spark plug side with the thermostat support.
N.B.
THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY. - Loosen the 4 head-cylinder fastening nuts in 2 or 3 times and in a crossed sequence. - Remove the head, the 2 centring dowels, the gasket and the lower chain guide sliding block.
N.B. DO NOT REMOVE THE DOWELS IF THEY ARE FORCED INTO THEIR SEAT.
CAUTION
WHEN YOU HAVE TO REMOVE THE HEAD, PREPARE A SUITABLE CONTAINER SINCE THE THERMAL GROUP CONTAINS COOLANT.
ENG - 137
Engine
Nexus 500 euro 3
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 (FLYWHEEL SIDE AND TRANSMISSION SIDE). - Remove the oil guards using the special tool.
Specific tooling
020431Y Valve oil seal extractor
- Remove the spring supports.

N.B. BLOW THE SEATS WITH COMPRESSED AIR TO FACILITATE THE SPRING SUPPORT REMOVAL.
ENG - 138
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 ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
- Extract the cylinder with the relevant gasket and the centring dowel.
N.B. THE SECOND CENTRING IS ENSURED BY A PIN SET INTO THE CYLINDER. CAUTION TO PREVENT DAMAGES TO THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER.
- Remove the 2 piston pin locking rings by the specific housings. - Extract the pin and remove the piston.
N.B. USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE.
- Remove the piston sealing rings and the oil scraper.

CAUTION NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSITION IN CASE OF REUSE. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL.
ENG - 139
Engine
Nexus 500 euro 3
Inspecting the small end

- Using a bore gauge, measure the connecting rod small end diameter.
N.B. IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Characteristic
Standard diameter: 22 + 0.025 +0.015 mm
Inspecting the wrist pin

- Check the pin outside diameter using a micrometer.
Characteristic
Standard diameter: 22 0 -0.004 mm - Calculate the coupling clearance between pin and connecting rod end.
Characteristic
Standard clearance: 0.015 0.029 mm
- Measure the diameter of the bearings on the piston.
Characteristic
Standard diameter: 22 + 0.006 + 0.001 mm - Calculate the piston pin coupling clearance.
N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
ENG - 140
Nexus 500 euro 3
Engine
Inspecting the piston

- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Take the measurement in the position shown in the figure.
Characteristic
A= 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.
Characteristic
- Check that coating is free from flakes. - Check that the head matching surface exhibits no deformations or wear.
Characteristic
Maximum allowable run-out: 0.05 mm - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
- Carefully clean the seal housings. - Measure the coupling clearance between the seal rings and the grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE.
ENG - 141
Engine
Nexus 500 euro 3
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 </> </> Maximum permissible clearance after use </> 1.25 + 0.03 mm </> </> Standard coupling clearance </> 2.5 - 0.005 mm </> </> Maximum permissible clearance after use </> 2.5 + 0.03 mm </> </>
Inspecting the piston rings

- Alternately insert the three sealing rings into the cylinder, in the area where it retains its original diameter. Using the piston, insert the rings perpendicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge. - If higher values than those prescribed are measured, replace the linings.
N.B.
BEFORE REPLACING ONLY THE PISTON RINGS, ENSURE THAT THE CLEARANCE BETWEEN THE PISTON RINGS AND THE PISTON RING GROOVES, AND BETWEEN THE PISTON AND THE CYLINDER, IS AS SPECIFIED. IN ANY CASE, NEW PISTON RINGS USED IN COMBINATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD.
Fitting clearance (Cylindrin/Pison)

Compression ring 0.15 0.35 mm Max. value. 0.5 mm </> Oil scraper ring 0.25 0.50 mm Max. value. 0.65 mm </> Oil scraper ring 0.25 0.50 mm Max. value. 0.65 mm </>
Removing the piston

- Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards the exhaust.
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- 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.
Specific tooling
020470Y Pin retainers installation tool
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING.
Choosing the gasket

- Provisionally fit the piston into the cylinder, without any base gasket. - Install a comparator on the special tool using the short union, as shown in the figure.
Specific tooling
020475Y Piston position checking tool
ENG - 143
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- 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. - Lock the tool using the original head fixing nuts. - Rotate the crankshaft up to the TDC (the inversion point of the dial gauge rotation) - Measure the deviation from the reset value.
- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Correctly identify the cylinder base gasket thickness to keep the correct compression ratio. - Remove the special tool and the cylinder.
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION.
Characteristic
Recess / Projection measured 1 - 0.185 - - 0.10 Gasket thickness 1 0.4 0.05 Recess / Projection measured 2 - 0.10 - + 0.10 Gasket thickness 2 0.6 0.05 Recess / Projection measured 3 + 0.10 + 0.185 Gasket thickness 3 0.8 0.05
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Refitting the piston rings

- Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening opposed 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. - Fit the second lining with the identification letter or the writing "top" facing the piston crown. In any case, the step must be facing opposite the piston top. - Install the first compression lining in the direction imposed by the housing. - It is advisable to use a fitter to facilitate the installation of the linings.
N.B. THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO ACHIEVE A BETTER BEDDING.
- Misalign the lining openings at 120 as shown in the figure. - Lubricate the components with engine oil. - The engine uses the first compression lining with an L section.
Refitting the cylinder

- Insert the cylinder base gasket with the thickness determined above. - Using the fork and the ring clamp, fit the cylinder as shown in the figure.
N.B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW THE LUBRICATION DUCT AND LUBRICATE THE CYLINDER LINER. CHECK THE PRESENCE OF THE TWO REFERENCE DOWELS.
Specific tooling
020468Y Piston fitting band 020512Y Piston fitting fork
Inspecting the cylinder head

- Using a trued bar and a feeler thickness gauge check that the cylinder head surface is not worn or distorted. ENG - 145
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Characteristic
Maximum allowable run-out: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the intake and exhaust manifold. - Check that the bearings of the camshaft and the rocker pins exhibit no wear. - Check that the head cover surface is not worn. - Check that the coolant sealing pad exhibits no oxidation.
STANDARD DIAMETER
Specification A B C Desc./Quantity 13 + 0.018 0 20 + 0.021 0 42 + 0.025 0
- If wear is discovered, replace the head and check also the corresponding component.
Inspecting the timing system components

- Check that the guide shoe and the tensioner shoe are not worn out. - Check that the crankshaft pinion and the camshaft timing gear and crankshaft pinion exhibit no wear. In case of wear of the sliding blocks, replace them. In case of wear of the chain or rim, replace the entire unit.
N.B.
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT. - Remove the centre screw with the washer and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole assembly.
ENG - 146
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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.
- Visually inspect the valve sealing surface.

CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT). - If the sealing surface of the valve is found to be interrupted at one or more points or is not flat, replace the valve.
Inspecting the valve housings

- Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V". - Measure the inside diameter of each valve guide. - Measure according to the rocking lever thrust direction at three different heights.
Characteristic
Standard value: 1 - 1.3 mm Admissible limit: 1.6 mm - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45 mill and then grind. - In case of excessive wear or damages, replace the head. ENG - 147
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Nexus 500 euro 3
Inspecting the valves

- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification Inlet: Outlet: Desc./Quantity 4.987 - 4.972 mm 4.975 - 4.960 mm
MINIMUM ADMISSIBLE DIAMETER

Specification Inlet: Outlet: Desc./Quantity 4.96 mm 4.945 mm
- Calculate the clearance between valve and valve guide.
- Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation with a comparator.
Characteristic
Limit values admitted: 0.1 mm
- Check the concentricity of the valve head by arranging a comparator at right angle relative to the valve head and rotate it on a "V" shaped abutment.
Characteristic
Admissible limit: 0.03 mm
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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 Standard clearance: Admissible limit: Desc./Quantity 0.013 - 0.04 mm 0.08 mm
OUTLET
Specification Standard clearance: Admissible limit: Desc./Quantity 0.025 0.052 mm 0.09 mm
STANDARD VALVE LENGTH

Specification Inlet: Outlet: Desc./Quantity 95.0 0.3 mm 94.2 0.3 mm
- Check that there are no signs of wear on the surface of contact with the articulated register terminal.
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- If the checks above give no failures, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
Inspecting the springs and half-cones

- Check that the upper spring caps and the cotter halves show no signs of abnormal wear.
- Measure the unloaded spring length.
Characteristic
Standard length: 44.4 mm Admissible limit after use: 42.4 mm
ENG - 150
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Refitting the valves

- Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the special 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. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool)
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH).
Inspecting the cam shaft

- Check that the camshaft bearings exhibit no scores or abnormal wear. - Using a micrometer, measure the camshaft bearings.
STANDARD DIAMETER
Specification Bearing A : Bearing B diameter: Desc./Quantity 42 - 0.060 -0.085 mm 20 - 0.020 -0.041 mm
MINIMUM ADMISSIBLE DIAMETER

Specification Bearing A : Bearing B diameter: Desc./Quantity 41.910 mm 19.940 mm
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-Using a gauge, measure the cam height.
STANDARD HEIGHT
Specification Intake Exhaust: Desc./Quantity 33.988 mm 33.417 mm
ADMISSIBLE LIMITS
Specification Intake Exhaust: Standard axial clearance: Maximum admissible axial clearance: Desc./Quantity 33.740 mm 33.170 mm 0 - 0.22 mm 0.3 mm
- If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones. - Check that the retaining plate seat shown in the figure exhibits no wear. - Check that the automatic valve lifting device cam, the travel end roller and the rubber abutment on the containment bell are free from wear. - Check that the valve lifting spring has not yielded. - Replace any defective or worn components. - Check that the rocking lever pins exhibit no scores or wear.
Characteristic
Standard diameter: 13 - 0.010 -0.018 mm - Measure the inside diameter of each rocking lever.
Characteristic
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- 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. - Install the head gasket.
N.B.
THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER. THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS. - The head gasket is made of steel and has a standard thickness.
- Check that the head lubrication channel is perfectly clean. Clean with compressed air jets, if required. - Insert the head. - Lubricate the stud bolts and the 4 fixing stud bolts.
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- 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.

Head fixing stud bolts *** - Tighten the fastening nuts on the exhaust and on the intake side to the prescribed torque.

Exhaust / intake head fixing nuts 10 - 12
- Tighten the 3 side screws to the prescribed torque.

Head fixing screws 10 - 12
- Install the coolant temperature sensor with the washer and tighten to the prescribed torque.
CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR.

coolant temperature sensor: 10 - 12
- Install the spark plug and tighten to the prescribed torque.

Spark plug 12 14
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- Insert the timing control belt on the crankshaft according to the initial direction of rotation. - Install the tensioner shoe with its spacer, tightening the bolt to the prescribed torque, using the recommended product.

Tensioner sliding block fixing screw 10 - 14 - Insert pins and rocking levers on the flywheel side. - Lubricate the two rocking levers through the holes at the top.
- Clean the camshaft by blowing with little compressed air jets, especially the retaining plate housing. - Lubricate the 2 shafts. - Insert the camshaft into the head with the cams opposite the rocking levers.
- Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush. - Apply the recommended product to the fixing screws and tighten the screws after wiping off any threadlock deposits.
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- 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.

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.
- Insert the wheel speed sensor on the camshaft keeping the stroke reference visible.
- Install the engine revolution timing sensor using a new O-Ring, orientating it as shown in the figure. Tighten the 2 fastening screws to the prescribed torque.
N.B. TO CHECK THIS COMPONENT, SEE CHAPTER "INJECTION".

Rpm timing sensor fixing screw 3 - 4
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- 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.
- Align the wheel speed sensor references with the head as shown in the figure.
- Keeping the belt slightly pulled, turn the crankshaft using the driving pulley to make the reference on the magnet support collimate with that on the flywheel cover.
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- 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 TENSIONED BY PRESSING ON THE TIGHTENER COMPARTMENT SIDE.
- Install the counterweight mass. - Centre using the bell fastening screw. - Lock the mass fixing screws to the prescribed torque, using the recommended product.

Counterweight screw 7 8.5 - Remove the central screw. - Install the valve lifting mass being careful to the proper positioning of the travel end ring. - Lubricate the mass and de-compressor control pin.
- Install the return spring and load it by about 3/4 turn.
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- 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.
THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD.
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock - Check that the decompression mass is free and that it is pulled by the spring.

Valve lifter mass stop bell fixing screws 30 - 35
- Place the engine with the valve clearance adjustment timing references aligned with the head. - Check the clearance between valve and rocking lever using a thickness gauge.
PRESCRIBED CLEARANCE
Specification Inlet drainage Desc./Quantity 0.15 mm (engine cold) 0.15 mm (engine cold)
- In case different values are found, adjust by loosening the lock nut and use a screwdriver for the set screw as shown in the figure.
ENG - 159
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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. It is possible to check whether the ignition advance determined by the injection system matches the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020460Y Scooter diagnosis and tester 020330Y Stroboscopic light to check timing Proceed as follows: - Remove the outside transmission cover as described in the automatic transmission chapter.
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the flywheel cover chapter.
- By the driving pulley, turn the engine to find the alignment of the references to identify the TDC.
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- 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 traditional four-stroke engine position (1 spark 2 revs). - Check that the real values of rpm and ignition advance match those measured using the diagnostic tester.
Specific tooling
020460Y Scooter diagnosis and tester If the values do not match, check: - distribution timing - rpm-timing sensor - injection control unit
Inspecting the radial air gap

- Align a tooth of the tone wheel with the revolution timing sensor. - Check the air gap using a probe.
Characteristic
Standard air gap: from 0.20 to 0.70 mm
ENG - 161
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- 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 prescribed torque.

Tightener fastening screws: 11 13
- Insert the spring with the central screw and the washer. - Tighten the central screw to the prescribed torque.

Tightener screw: 5 - 6
ENG - 162
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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 sequence (3, 4, 5, 6).
N.B. CHECK THE PROPER POSITION OF THE GASKET.

Tappet cover fixing screws 7 - 9 - Install the transmission cover and the relevant net filter and the outside transmission cover as described in the "Automatic transmission" chapter.
- Install the cooling system sleeves using new bands, as described in the "Flywheel cover" chapter.
ENG - 163
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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.

Inlet manifold screws 11 13
Crankcase - crankshaft
- Remove the outside and inside transmission cover and the complete driving pulley as described in "Automatic transmission".
- Remove the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover" chapter.
- Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting system".
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- Remove the thermal group (cylinder, head, piston) as described in the Thermal group and timing system chapter.
- Before opening the crankcase, check the crankshaft axial clearance. For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.
Specific tooling
020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge
Characteristic
Standard clearance: 0.10 - 0.50 mm Admissible increase limit after use: 0.60 mm - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support. - To carry out an accurate measurement, measure the clearance in both directions between crankcase and crankshaft.
ENG - 165
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Nexus 500 euro 3
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. - Remove the coupling gasket.
N.B. THE BUSHING SUPPORT CAN BE LEFT IN THE FLYWHEEL SIDE HALF-CRANKCASE.
Removing the crankshaft

- Before removing the crankshaft, check the timing with the countershaft. To carry out this check, turn the crankshaft to align the two holes obtained on the crankshaft with the hole on the countershaft control gear. This is an optimal position also to remove the crankshaft.
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- 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.
Removing the oil pump and countershaft control gear. - To remove the control gear, loosen the 4 fastening screws. Remove the gear only if actually required.
CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE. BE CAREFUL NOT TO DAMAGE THE CONTROL HEXAGON. TO OBTAIN BETTER RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH.
Removing the countershaft

- Place the special tool as shown in the figure.
Specific tooling
020479Y Countershaft lock wrench
- Remove the fastening nut with relevant washer.
ENG - 167
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- Remove the special tool and extract the countershaft 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.
- Upturn the half-crankcase. - Remove the bearing from the flywheel side halfcrankcase using the special tool and a mallet.
Specific tooling
020376Y Adaptor handle 020358Y 37x40-mm adaptor 020439Y 17 mm guide - Remove the bearing from the transmission side half-crankcase using the special tool.
Specific tooling
001467Y008 Pliers to extract 17 mm bearings 001467Y007 Driver for OD 54-mm bearings
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- 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. - Install the new bearing on the half-crankcase using the special tool.
N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor 020439Y 17 mm guide - Fit the Seeger ring.
- Before installing the new bearing on the transmission side crankcase, heat the seat using the special tool.
Specific tooling
020151Y Air heater
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- 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.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm adaptor 020439Y 17 mm guide
Inspecting the crankshaft components

- Check the axial clearance on the connecting rod.
Characteristic
- Check the connecting rod diametrical clearance.
Characteristic
Standard clearance: 0.046 0.076 mm -Check the surfaces that limit the axial free-play are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram.
N.B. BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard dimensions: 63.6 - 63.45 mm
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CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VALUES AND THE SURFACES ARE FREE FROM SCRATCHES.
Shimming - Check the overall height of the crankshaft - shoulders - gear assembly.
Characteristic
Standard thickness: 71.804 - 72.000 mm - Check that shim adjustment is free from scratches.
N.B.
IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION.
Specific tooling
020074Y Support base for checking crankshaft alignment - If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. Half-shafts are classified into two categories, Cat. 1 and Cat. 2.
STANDARD DIAMETER
Specification Cat. 1 Cat. 2 Desc./Quantity 40.010 40.016 40.016 40.022
Inspecting the crankshaft alignment

- Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure.
Specific tooling
020074Y Support base for checking crankshaft alignment ENG - 171
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MAX ADMISSIBLE DISPLACEMENT:

Specification A B C D 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. - In case of failures, replace the crankshaft.
N.B.
MAIN BEARINGS CANNOT BE MODIFIED. The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter "Thermal group and timing system". - When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication hole.
N.B.
IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF-SHAFTS OF DIFFERENT CATEGORY, REPLACE THE TWO HALF-CRANKCASES AS WELL, COUPLING THE TWO COMPONENTS (SHAFT AND CRANKCASE) WITH THE SAME CATEGORY. - To check the gearing of the crankshaft, see section "Thermal group and timing system".
See also
Cylinder assy. and timing system
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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.
N.B. THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
- For the flywheel side half-crankcase, special attention should be given to the lubrication channels for the main bearings and to the compartment and the channels for the oil pump, as well as to the duct for the by-pass located on the flywheel cover.
N.B. AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAPTER, IT IS ESPECIALLY IMPORTANT THAT THE BY-PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON. THE HEAD LUBRICATION CHANNEL IS EQUIPPED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION. THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP.
The jet clogging impairs the head lubrication and the timing mechanisms. A jet failure causes a decrease in the main bearing and connecting rod lubrication pressure. - Check that the surfaces exhibit no dents or deformations, with special attention to the crankcase coupling and the crankcase-cylinder surfaces. - Any defects in the crankcase gasket or matching surfaces (see Flywheel cover coupling) can cause pressurised oil leaks, thereby affecting the connecting rod and main bearing lubrication pressure. - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. For the dimensional check, refer to the instructions about checking the axial clearance and the dimensions on the crankshaft ENG - 173
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Inspecting the crankshaft plain bearings

- To obtain a good bushing lubrication it is necessary 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. - The main bushings are comprised of two halfbearings, one with holes and channels for lubrication whereas the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent obstructions in the oil feeding channels, the matching surface of the two half-bearings must be perfectly perpendicular to the cylinder axis, as shown in the figure. - The oil feeding channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES. - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram.
N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALFSHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
- The standard bushing diameter after driving is variable on the basis of a coupling selection. - The bushing seats into the crankcases are classified into 2 categories as for the drive shaft Cat. 1 and Cat. 2. - Bushings are divided into 3 categories according to their thickness. See the table below:
CHECK THE BENCH BUSH

Name Type A - Red Type B - Blue Type C - Yellow Description Dimensions 1.982 - 1.987 1.987 - 1.992 1.992 - 1.997 Initials Quantity
ENG - 174
Nexus 500 euro 3
Engine
Coupling chart
COUPLING THE SEMI-SHAFTS WITH THE SEMI-CHASSIS AND BUSHES
Name Half-shaft category 1 Bushing category B Half-shaft category 2 Bushing category C Half-shaft category 1 Bushing category A Half-shaft category 2 Bushing category B N.B. Description Dimensions Initials Spare crankcase set-up FC1 - Dis. CM1033015001 Spare crankcase set-up FC1 - Dis. CM1033015001 Spare crankcase set-up FC2 - Dis. CM1033015002 Spare crankcase set-up FC2 - Dis. CM1033015002 Quantity
FOR SERVICING WITH SPARE PARTS, MATCH THE SHAFT WITH TWO SHOULDERS OF CATEGORY 1 TO CRANKCASE FC1 (OR CATEGORY 2 TO CRANKCASE FC2). A spare crankcase cannot be combined with a driving shaft with mixed categories. Spare shafts have half-shafts of the same category.
N.B.
TO REPLACE THE HALF-SHAFTS, REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED ABOVE. REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI-FLAPPING ROLLER FROM THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS DESCRIBED IN CHAPTER "FINAL REDUCTION".
Countershaft
- Using a micrometer, measure the 2 bearings of the countershaft as shown in the figure.
Characteristic
Standard diameter: 17 - 0.01 - 0.02 mm
- Check that the water pump drive is not worn.
Refitting the crankshaft

- Check that the oil pump and countershaft control gear are free from deformations or dents. Replace, if required.
N.B.
IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NECESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL.
ENG - 175
Engine
Nexus 500 euro 3
- Before installing the gear on the crankshaft, carefully 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. Apply the recommended product to the holes again.
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock - Repeat the same procedure for the 4 fastening screws. - Insert the control gear on the crankshaft with the hole countersink visible. - Tighten the 4 fastening screws to the prescribed torque.
N.B.
TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH.

Gear mounting on crankshaft screws 10 -12 - Lubricate the main bearing on the flywheel side half-crankcase. - Lubricate the shim adjustment washer. - Insert the shim adjustment washer on the crankshaft in its original position. - Insert the special timing tool in the hole on the countershaft.
Specific tooling
020471Y Pin for countershaft timing
ENG - 176
Nexus 500 euro 3
Engine
- Insert the crankshaft on the pin and into the bushing. - 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 TIMING CONTROL TOOTHED PINION. - Install the oil pump closing plate. - Tighten the 2 flanged fastening screws to the prescribed torque.

Bulkhead screws for oil pump housing cover 8
- 10
Refitting the crankcase halves

- Remove the oil guard from the transmission side half-crankcase using a screwdriver.
- Install a new oil guard after lubricating it, using the special tool, arranging it at a 0.5 mm recess from the crankcase plane.
CAUTION A WRONG POSITIONING OF THE OIL GUARD AFFECTS THE LUBRICATION OIL CIRCULATION.
Specific tooling
020360Y Adaptor 52 x 55 mm 020376Y Adaptor handle ENG - 177
Engine
Nexus 500 euro 3
- Insert the gasket on the flywheel side half-crankcase.
- Lubricate the main bearing on the transmission side half-crankcase. - Couple the 2 half-crankcases being careful not to damage the bushing on the transmission side half-crankcase with the threaded tang of the crankshaft. - Insert the engine support retain screw on the flywheel side half-crankcase without tightening. - Insert the 14 fastening screws by arranging the single shorter screw A and the single longer screw B as shown in the figure. - Tighten the screws thoroughly and tighten to the prescribed torque. - Check that the crankshaft rotates freely.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER PLANE, TO ENSURE BETTER SEALING PERFORMANCE.

Engine-crankcase coupling screws 11 13 - Install the thermal group (cylinder, head, piston) as described in section Thermal group and timing system.
ENG - 178
Nexus 500 euro 3
Engine
- Install the flywheel with start-up control as described in the "Flywheel and start-up" chapter.
- Install the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover chapter".
- Install the complete driving pulley, the transmission cover and the relevant mesh filter and the outside transmission cover as described in the section "Automatic transmission".
See also
Cylinder assy. and timing system Flywheel cover
Lubrication
TECHNICAL SPECIFICATIONS
SUMP CAPACITY
Specification Overhaul Oil and filter replacement Desc./Quantity 1.7 l 1.5 l
RECOMMENDED ENGINE OIL

Product AGIP CITY HI TEC 4T Description Engine oil Specifications SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil
ENG - 179
Engine
Nexus 500 euro 3
OIL PUMP
Specification Type Rotor washers Assembly clearances External rotor radial clearance Rotor axial clearance Desc./Quantity Trochoidal 8 mm Lobe ends 0.05-0.008 mm 0.05- 0.12 mm 0.025 - 0.065 mm
BY-PASS
Specification Type Plunger diameter Spring free length Calibration pressure Desc./Quantity with piston 13.9 - 0.039 -0.057 mm 62.5 mm 4 bar
PRE-FILTER
Specification Type Desc./Quantity mesh, plastic
OIL FILTER
Specification Type Desc./Quantity Paper with pressure relief and anti-drain back by-pass valves
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

Specification Calibration Desc./Quantity 0.3 - 0.6 bar
HEAD LUBRICATION CONTROL JET

Specification Diameter * Tightening torque 57 Nm Desc./Quantity 1 0.05 mm *
PISTON COOLING NOZZLE

Specification Diameter Desc./Quantity 0.8 0.05 mm
CRANKCASE VENTILATION CHECK

Specification Device Desc./Quantity metal reed valve and decantation chamber
ENG - 180
Nexus 500 euro 3
Engine
Conceptual diagrams
PRINCIPLE DIAGRAM
Specification A B C D E F G H L M N O 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 The high pressure section includes all components located on the engine crankcase whereas the low pressure section only refers to the thermal group. The trochoidal pump is installed in the sump and is controlled by a pair of gears. To guarantee the integrity of the pump, a pre-filter is fitted. This is a screw-in type pre-filter and the relevant plug serves at the same time as an engine oil drain plug. ENG - 181
Engine
Nexus 500 euro 3
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. The by-pass located before the cartridge filter improves the operating conditions for the filter, particularly with cold oil. The filter is equipped with an anti-drain back valve and a pressure relief valve; the latter intervenes when the filtering mass causes a pressure drop above 1 0.2 bar. These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged. The filtered oil is used to lubricate the water pump shaft and once at the engine crankcase, to lubricate the main bearings, the connecting rod head and the piston cooling nozzle, on the transmission-side bearing. The main bearing on the transmission side is fitted with an oil seal and the respective drain line. The supply line for the timing system comes from the flywheel-side bearing; the supply to the head is controlled by the respective spray jets in the engine crankcase. The components of the timing system function with low-pressure oil lubrication. The camshaft bearings are installed directly on the aluminium of the head; the camshaft axial clearance is partially compensated by the oil supplied to the smaller diameter bearing. The camshaft supplies the lubricant to the rocking levers via the holes provided; these are installed in a position to ensure that the lubrication is maintained even after the scooter has stopped. This is achieved when the camshaft reaches its most usual and likely position when the engine is shut off. The oil used to lubricate the head returns to the sump via the chain casing channel and therefore it also provides lubrication for the chain. A one-way valve and a decantation chamber are used so that gases from the crankcase do not carry any oil. The one-way valve is a metal reed valve; the decantation chamber has a drainage hole. A failure in these components implies oil getting into the line supplying air to the engine. Excessive oil vapours may result in clogged ducts on the throttle body. In order to signal low oil pressure in the system, a pressure switch is used, located immediately after the oil filter outlet. The lubrication circuit does not include the countershaft. The countershaft is lubricated by the oil transported by the gears or by the centrifugal effect of the crankshaft The same applies to the piston or the pin, but in this case the cooling nozzle is particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine. AHEAD - go to 2 2 - Remove the minimum pressure switch electric connector. Check that the warning light turns off. YES - go to 3 NO go to 11 ENG - 182
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. Insert the probe to feel contact with the crankcase bottom and pull back a few millimetres.
Specific tooling
020331Y Digital multimeter AHEAD - go to 5
5 - Measure the pressure with cold and idling engine.
STANDARD VALUES
Specification 20C Temperature 1400 rpm approx. 4.5 bar N.B. Desc./Quantity
RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC TESTER
Specific tooling
020460Y Scooter diagnosis and tester YES go to 6 NO go to 12 6 - Let the engine warm up and repeat the check with hot oil.
STANDARD VALUES
Specification 80C Temperature 1400 rpm approx. 1.5 bar Desc./Quantity
YES go to 7 NO go to 8 7 - Replace the oil minimum pressure switch. ENG - 183
Engine
Nexus 500 euro 3
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 80C. YES go to 10 NO go to 13 10 - The failure was fixed. It is recommended to respect the suggested number of kilometres covered. 11 - Check and restore the electrical system. 12 - If pressure lower than 4 bar is measured. AHEAD go to 9 13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket efficiency towards the case internal side, as described in the "Flywheel cover" chapter. YES go to 14 NO go to 15 14 - Check whether there is an irregular clearance on the crankshaft: - axial clearance (see the "Crankcase and crankshaft" chapter) - radial clearance, especially in the direction of the cylinder axis - clearance according to the direction of rotation with the connecting rod in quadrature YES go to 16 NO go to 17 15 - Replace the faulty components ("Flywheel cover" chapter). 16 - Overhaul the engine ("Crankcase and crankshaft" chapter). 17 - Open the engine crankcase and remove the oil pump as described in the "Crankcase and crankshaft" chapter. - Check the oil pump as described in the following pages. - Check that the cooling nozzle and the timing system feeding jet are properly installed. - Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter).
N.B.
POTENTIAL IRREGULARITIES IN COUPLINGS AND THE TIMING SYSTEM COMPONENTS CANNOT BE DETECTED WHEN INSPECTING THE LUBRICATION PRESSURE. THEY MAY BECOME EVIDENT BY AN INCREASE IN NOISE.
N.B.
IN CASE OF IRREGULAR PRESSURE ON THE CRANKCASE, CARRY OUT A VISUAL AND DIMENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS (SEE "THERMAL GROUP AND TIMING SYSTEM" CHAPTER).
Oil pressure check

1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket, check the lubrication pressure. AHEAD go to 2 2 - Install the special tool.
Specific tooling
020193Y Oil pressure gauge ENG - 184
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. 5 - Check the working order of the adjustment by-pass (see "flywheel cover" chapter) and restore proper sliding.
N.B.
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE. 1 - If oil consumption is above 250 g/1000 km on a run-in engine, proceed as follows. AHEAD go to 2 2 - Check the presence of oil at the scavenge duct on the filter box. YES go to 3 NO go to 4 3 - Check the one-way reed valve and the decantation chamber drainage hole. YES go to 5 NO go to 4 4 - Check the thermal group seals (piston rings, valve guides and oil guards), see "Thermal group and Timing system" chapter. 5 - Restore the valve or the drainage hole efficiency.
Oil pump Removal

- Remove the closing plate of the oil pump housing by loosening the 2 retaining screws with their washers.
ENG - 185
Engine
Nexus 500 euro 3
- 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 turning it to move the opening at the shaft face.
ENG - 186
Nexus 500 euro 3
Engine
- Remove and wash the rotors thoroughly with petrol 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, keeping the two reference marks visible - Insert the shaft with the gear and install the lock ring; then, turn it with the opening opposed to the shaft face. - Check any irregular clearance between shaft and pump body.
- Using a thickness gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Admissible limit clearance: 0.012 mm
- Check the distance between external rotor and pump body; see figure.
Characteristic
Admissible limit clearance: 0.25 mm
ENG - 187
Engine
Nexus 500 euro 3
- 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.
Refitting
- Make sure the gasket is in the correct position.
N.B. THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
- Insert the oil pump with gear - Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque.
N.B.
THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS.
ENG - 188
Nexus 500 euro 3
Engine
Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body.

Screws fixing oil pump to crankcase 5 - 6
- Insert the countershaft with gearing into the flywheel-side half-crankcase. - Install the special tool in the position shown in the figure.
Specific tooling
020479Y Countershaft lock wrench
- Keep the countershaft in position and insert the washer with the nut. - Tighten the nut to the prescribed torque, using the recommended product. - Remove the special tool.

Countershaft fixing nut 25 29 - Lubricate the internal rotors. - Check there are no signs of scoring or wear on the oil pump cover. - If non-conforming values or signs of wear are found, replace the pump. - Fit the pump cover in the position that permits the crankcase fixing screws to be aligned. - Tighten the two fastening screws to the prescribed torque.

ENG - 189
Engine
Nexus 500 euro 3
Oil pump cover screws 0.7 0.9
ENG - 190
INDEX OF TOPICS
INJECTION
INJEC
Injection
Nexus 500 euro 3
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. Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further corrections are made according to the following parameters: - Coolant temperature. - Intake air temperature - Ambient pressure The system implements an idle feeding correction with cold engine through a Stepper motor on a bypass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time, thereby ensuring the idle steadiness and the proper combustion. In all conditions of use, mixture preparation is managed by modifying the injector opening time. The fuel supply pressure is kept constant based on the ambient pressure. The fuel supply circuit consists of: - Fuel pump - Fuel filter - Injector - Pressure regulator The pump, the filter and the regulator are placed inside the fuel tank on a single support. The injector is connected by two pipes provided with quick couplings. This allows obtaining a continuous circulation, thereby avoiding the risk of fuel boiling. The pressure regulator is situated at the end of the circuit. The fuel pump is controlled by the EMS control unit; this ensures the scooter safety The ignition circuit consists of: - HV coil - HV cable - Shielded cap - EMS control unit - Spark plug The EMS control unit manages the ignition with optimum timing, ensuring the timing on the 4-stroke cycle (ignition only during compression). The EMS injection/ignition system manages the engine function according to a pre-set program. Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to reach a service station. Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the control circuits: INJEC - 192
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 instrument panel.
Failures are detected and restored by the diagnostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop). The diagnostic tester is also required to adjust the idle mixture.
Specific tooling
020460Y Scooter diagnosis and tester The EMS injection-ignition system has a control function over the rpm indicator and the radiator cooling electric fan. The EMS is connected to the anti-theft immobilizer system decoder. In turn, the decoder is connected to a flashing diagnostic LED that also serves as deterrent.
The EMS control unit power supply is further controlled by the emergency switch and by the side stand switch, that is to provide further safety for the scooter.
INJEC - 193
Injection
Nexus 500 euro 3
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. Do not smoke. Act with caution to prevent spraying in the eyes. 3. When fixing electric components, operate with the battery connected only when actually required. 4. When functional checks are performed, check that the battery voltage is over 12V. 5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump. 6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the level. This will ensure the pump will be covered by fuel. 7. When washing the vehicle, be careful with the electric components and wiring. 8. When an ignition fault is detected, start the checks from the battery and the injection system connections. 9. Before disconnecting the EMS control unit connector, perform the following operations in the following order: - Set the switch to OFF - Disconnect the battery Failure to respect this norm may damage the control unit. 10. Do not invert the polarity when fitting the battery. 11. In order to prevent damages, disconnect and reconnect the EMS connectors only if actually required. Before reconnecting, check that the connectors are dry. 12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not take measurements not specifically foreseen by the manual. 13. At the end of every check performed with the diagnostic tester, protect the system connector with its cap. Failure to respect this norm may damage the EMS control unit. 14. Before reconnecting the quick couplers of the power supply system, check that the terminals are perfectly clean.
Terminals setup
Layout of the system-side connectors and the connectors on the electronic control unit.
INJEC - 194
Nexus 500 euro 3
Injection
ELECTRONIC CONTROL UNIT SIDE
SYSTEM SIDE
ECU
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Specification Throttle potentiometer power supply Oxygen sensor Rpm indicator / consumption counter Engine temperature 86 electric fan remote control switch Stepper motor Engine rpm sensor Oxygen sensor EMS diagnostic connector EMS diagnostic connector Throttle potentiometer signal Engine rpm sensor Injector control Stepper motor Injection telltale light Decoder (serial) Battery powered Air temperature sensor Fuel pump H.V. coil Stepper motor Sensor power supply Control unit negative Stepper motor Turn indicator control device Continuous power supply Desc./Quantity +5 V (-) (+) Stepper motor (+)
(negative) Stepper motor (-) Overturn sensor (+) (+) (-) (negative control) Stepper motor (-) Stepper motor (positive)
INJEC - 195
Injection
Nexus 500 euro 3
IMMOBILIZER DECODER
1 2 3 4 5 6 7 8 Specification Immobilizer LED control Base power supply Negative Electronic control unit EMS Continuous power supply (positive) Desc./Quantity (negative) (positive)
(serial) Immobilizer aerial
EMS circuit diagram
KEY: 3. Engine rev sensor 4. Throttle valve position sensor INJEC - 196
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. Diode 20. Battery 25. Engine stop switch 26. Centre stand switch 52. Oil pressure sensor 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. Oil warning light 55. Immobilizer aerial 56. Fuel pump / fuel level transmitter 58. Fuel injector 60. Tone wheel 62. Lambda probe 63. Diagnostic socket 64. Fuel injection electronic control unit
Troubleshooting procedure
This section makes it possible to find what solutions to apply when troubleshooting.
Engine does not start

ENGINE DOES NOT START IF ONLY PULLED
Possible Cause Immobiliser enabling signal Operation
System not encoded INJEC - 197
Injection
Nexus 500 euro 3
Possible Cause
Operation
Presence of faults detected by the self diagnosis
Fuel supply
System not efficient, repair according to the indications of the self-diagnosis Pump relay HV coil Injector revolution timing sensor Fuel in the tank Fuel pump activation Fuel pressure (low) Injector capacity (low)
Shielded spark-plug cap HV coil (secondary insulation)
Power to the spark plug Parameter reliability
Coolant temperature Distribution timing - injection ignition Intake air temperature

End of compression pressure
Starting difficulties
ENGINE START-UP PROBLEMS
Possible Cause Presence of faults detected by the self diagnosis Operation
Start up engine speed
Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure Starter motor and remote control Battery Ground connections
End of compression pressure Power to the spark plug
Fuel supply
Correctness of the parameters
Spark plug Shielded cap HV coil Rpm-timing sensor Ignition advance Fuel pressure (low) Injector capacity (low) Injector seal (poor) Coolant temperature Stepper throttle valve position intake air temperature (steps and actual opening) Cleaning of the auxiliary air pipe and throttle valve; air filter efficiency
Engine stops at idle

ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW
Pump relay H.V. coil Injector revolution timing sensor
INJEC - 198
Nexus 500 euro 3
Injection
Possible Cause
Operation
Ignition efficiency Correctness of the parameters
Intake system cleaning
Intake system sealing (infiltrations)
Fuel feed (low pressure)
Air temperature Coolant temperature. Atmospheric pressure Spark plug Ignition timing Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity
Trimmer value adjustment (CO % adjustment)
Analysis of exhaust fumes before the catalytic converter
Engine does not rev down

ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH
Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure
Ignition timing
Ignition efficiency Correctness of the parameters
Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity
Exhaust backfires in deceleration

EXHAUST BACKFIRES WHEN DECELERATING
Pump relay INJEC - 199
Injection
Nexus 500 euro 3
Possible Cause
Operation
Correctness of the parameters
Exhaust system sealing (infiltrations)
H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel pump Pressure regulator Fuel filter Injector capacity Manifold - head Manifold - muffler Analyser socket Muffler welding
Engine revs irregularly

IRREGULAR PROGRESS OF THE ENGINE WITH VALVE SLIGHTLY OPEN
Intake system cleaning
Intake system seal Ignition system Parameter reliability
Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake sleeve Filter box
Spark plug wear check
Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance
TPS reset successful Trimmer value adjustment (CO % adjustment)
TPS reset successful Analysis of exhaust fumes before the catalytic converter
INJEC - 200
Nexus 500 euro 3
Injection
Poor performance at full throttle

POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS ON PICKUP
Spark plug power supply
Intake system
Parameter reliability
Fuel supply
Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure Spark plug Shielded cap HV cable HV coil Air filter Filter box (sealing) Intake sleeve (sealing) Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Fuel level in the tank Fuel pressure Fuel filter Injector capacity
Engine knocking
PRESENCE OF KNOCKING (OVERHEAD KNOCKING)
Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature. Atmospheric pressure
Spark plug
Ignition efficiency Parameter reliability
Intake system seal TPS reset successful Fuel supply
Throttle valve position signal Coolant temperature indicator Intake air temperature indicator Ignition advance Intake sleeve Filter box
TPS reset successful
Fuel pressure Fuel filter Injector capacity Fuel quality

Selection of the cylinder base gasket thickness
Selection of the cylinder base gasket thickness
INJEC - 201
Injection
Nexus 500 euro 3
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. A power supply failure disables both ignition and injection. In case of power supply faults, the diagnostic tester gives the information "NO REPLY FROM THE CONTROL UNIT". To carry out the check, proceed as follows:
Specific tooling
020460Y Scooter diagnosis and tester 1 - Check whether the immobiliser system LED indicates that the switch is in position "ON" and that the deterrent flashing is on. YES go to 2 NO go to 7 2 - The decoder is properly programmed. YES go to 3 3 - Switch set to "ON" with side stand raised and emergency switch set to "OFF". The injection telltale light turns on for about 3 seconds. YES go to 5 NO go to 4 4 - Check the instrument unit and its power supply. YES go to 3 5 - Set the emergency switch to "RUN". The injection telltale light comes on for about 5 seconds. YES go to 6 NO go to 7 6 - The injection control unit is certainly powered. 7 - Check that fuses 3 and 7 are in working order. YES go to 10 NO go to 8
INJEC - 202
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. Disconnect the main decoder connector and check the following conditions: Terminal no. 3= battery positive Terminal no. 4= battery negative YES go to 11 NO go to 13
Specific tooling
020481Y Control unit interface wiring 11 - Decoder with proper base power supply. Use the special tool to check the control unit power supply: Pin 17 = battery positive Pin 23 = battery negative YES go to 12 NO go to 13
12 - Control unit with proper base power supply. 13 - If the battery negative is not present, check continuity between Pin 23 of the special tool and earth. Detect the presence of the battery positive on Pin 17 of the special tool and on pin 3 of the decoder connector. YES go to 12 NO go to 14 YES go to 11 14 - Fix the cable harness.
Key-switch power supply circuit check

A failure of the constant power supply disables both ignition and injection functions. In case of power supply faults, the diagnostic tester gives the information "NO REPLY FROM THE CONTROL UNIT". INJEC - 203
Injection
Nexus 500 euro 3
Specific tooling
020460Y Scooter diagnosis and tester 1 - Check whether the immobilizer system LED indicates switching to "ON" YES go to 2 NO go to 4 2 - Raise the side stand. Set the emergency switch to "OFF". Turn the key switch to "ON". Set the emergency switch to "RUN". Check whether the injection telltale light turns on for 5 seconds YES go to 3 NO go to 4 3 - Continuous power supplies are regular 4 - Check the function of fuse No. 8, check the function of the engine stop remote control. YES go to 5 NO go to 6 5 - Place the special tool between control unit and injection system. YES go to 7
Specific tooling
020481Y Control unit interface wiring 6 - Fix any short circuits and replace the fuse. Check decoder and control unit, if necessary YES go to 1 7 - Disconnect the main decoder connector and check the following conditions: switch set to "ON", switch to "RUN" and side stand raised Terminal no. 8 = battery positive Terminal no. 4= battery negative YES go to 8 NO go to 10 8 - Decoder with proper continuous power supply. Use the special tool to check the control unit continuous power supply. Switch set to "ON", switch to "RUN" and side stand raised. Pin 26 = battery positive Pin 23 = battery negative YES go to 9 NO go to 10
Specific tooling
020481Y Control unit interface wiring
INJEC - 204
Nexus 500 euro 3
Injection
9 - Control unit with proper continuous power supply. 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. Pin 26 electronic control unit - Pin 87 engine stop remote control switch = continuity Pin 8 decoder - Pin 87 engine stop remote control switch = continuity YES go to 12 NO go to 11
11 - Fix the wiring or the connection YES go to 10 12 - Proper continuous power supply YES go to 13 13 - Check the connector and the continuity of the key switch set to "ON" Pin B - F = Continuity YES go to 14 14 - Check the engine stop remote control switch connector and the switch efficiency. The connector can be recognised by its larger section white lead. 85 - 86 = approx. 70W YES go to 15
N.B.
CHECK THE COIL RESISTANCE 15 - Check the signal circuit: - emergency switch and connector - side stand switch and connector YES go to 16 16 - Check the cable harness continuity. Check the utility control main remote control switch. Disconnect the master remote control switch. Check the diode installed on the earth connection of the main remote control switch pickup. 86 - earth = continuity with high resistance (connect the tester: positive with 86; negative with earth). When the polarity is inverted there should be no continuity. INJEC - 205
Injection
Nexus 500 euro 3
Diagnostic circuit
* CONNECTOR FOR DIAGNOSTIC TESTER A = INJECTION CONTROL UNIT Connect the diagnostic tester.
Specific tooling
If the diagnostic tester displays No reply from the control unit, disconnect the continuous power supply for 10 seconds and switch to ON again; if the message is still displayed, proceed as follows: 1 - Check the diagnostic tester connections. YES go to 2 NO go to 3
2 - Check the control unit base and continuous power supplies. YES go to 4 3 - Restore 4 - Place the special tool between control unit and system. Keep the control unit disconnected. YES go to 5
Specific tooling
INJEC - 206
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 = continuity 10 - 23 = insulation (>1 M) 9 - 23 = insulation (>1 M) YES go to 6 NO go to 7 6 - The circuit is in good working order. Check the control unit. 7 - Fix the interruption or short-circuit.
Injection warning light circuit
KEY: 12. Key switch 13. Fuse box A 14. Main fuse 15. Fuse box B 18. Engine stop remote control INJEC - 207
Injection
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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. Oil warning light 64. Fuel injection electronic control unit
REFERENCE VALUES
1 Specification TERMINAL: 15 - 23 Desc./Quantity
CONDITIONS: DURING THE CHECK - Switch set to "ON" - Side stand raised - Switch to "RUN"
STANDARD VALUES : O V
TERMINAL: 15 - 23
CONDITIONS: AFTER THE CHECK - Switch set to "ON" - Side stand raised - Switch to "RUN"
STANDARD VALUES : Battery voltage
The injection telltale light is controlled upon every switching to "ON" by the 3-second timing generated by the digital instrument. This step is normally interrupted by the injection control unit control. The timing lasts 5 seconds. The diagnostic tester is not programmed to check this circuit. Proceed as follows:
Specific tooling
020460Y Scooter diagnosis and tester 1 - Turn the switch to the "ON" position Turn the emergency switch to position "RUN". Keep the side stand raised. Make sure the light goes on for 5 seconds. YES go to 2 NO go to 3 2 - The system is working. 3 - Put the special tool between the control unit and system. YES go to 4
Specific tooling
INJEC - 208
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. 6 - Check the continuity between pin 15 of the ECU and pin 17 of the connector 20 input connector of the instrument panel.
The injection ECU manages the negative of the light. The light must go off after the initial check. The light goes on again when the ECU self-diagnosis detects a fault. When the fault disappears the light goes back off, however, the related operating tests need to be carried out. The light can go on whether the engine is able to run or not.
Self-diagnosis system
The injection control unit is provided with an auto-diagnosis function. When a failure is detected, the control unit: - turns on the injection telltale light (only when it is current). - enables the engine management check according to the data entered in the control unit (where possible). - stores the failure (always). In the event of intermittent failures, the indicator follows the failure trend and storage remains active. Stored data are automatically deleted when the failure does not occur for over 16 usage cycles of the scooter (heating - use - cooling). The battery disconnection does not delete stored data.
INJEC - 209
Injection
Nexus 500 euro 3
Checking stored failures Connect the diagnostic tester to the scooter system. Select the function "ERROR" in the menu.
Specific tooling
The tester pages display the list of errors detectable by the auto-diagnosis. Errors detected by the auto-diagnosis are marked by one or two reference dots. They are arranged on two lines: Line A = current failures (present) Line M = stored failures
Errors detectable by the auto-diagnosis may refer to the following system circuits or sectors of the control unit: - Throttle valve position signal - ambient pressure signal - coolant temperature signal - intake air temperature signal - wrong battery voltage - Injector and relevant circuit - HV coil and relevant circuit - Stepper and relevant circuit - Pump relay circuit - Electric fan relay circuit - RAM memory - ROM memory - EEPROM - Microprocessor - Signals panel (stroke - revolution signal - unsteady cycle) Underlined failures cause the engine to stop. In the other cases, the engine works managed by the basic data.
INJEC - 210
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.
Specific tooling
020460Y Scooter diagnosis and tester For troubleshooting for any faults see the related chapter sections.
Fuel supply system

Fuel is fed to the injector by a pump, a filter and a pressure regulator integrated with the fuel level indicator inside the tank.
The pump unit is connected to the injector by: 2 semi-flexible pipes 4 quick unions 1 T union with O-ring and retain bracket for the injector The pipes are crossed and fixed to the intake manifold to prevent wear of the quick unions connected to the T union for the injector.
N.B.
BEFORE WORKING ON THE FUEL SUPPLY SYSTEM, CAREFULLY CLEAN THE PARTS TO PREVENT DAMAGING THE FAST-RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING INTO THE DUCTS.
CAUTION
THE SYSTEM IS UNDER PRESSURE. DO NOT SMOKE DURING ANY OPERATION. PREVENT ANY FUEL SPRAYING.
WARNING
- BEFORE STARTING THE ENGINE, CHECK WHETHER THERE IS FUEL IN THE TANK. - DO NOT USE THE SCOOTER IN RESERVE FOR A LONG TIME, UP TO THE POSSIBILITY OF RUNNING OUT OF FUEL. - IF THE SCOOTER IS EXPECTED TO REMAIN UNUSED FOR A LONG TIME, REFILL THE TANK AT LEAST TO HALF THE LEVEL. FAILURE TO OBSERVE THESE RULES CAN DAMAGE THE PUMP. INJEC - 211
Injection
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Circuit diagram
KEY 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. Fuel pump / fuel level transmitter 58. Fuel injector 59. Spark plug 61. HV coil 64. Fuel injection electronic control unit
INJEC - 212
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" shunt acting as a support for the injector.
- Remove the injector from the manifold.
- Once the engine is repaired check the CO% value again 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 "Carburetion adjustment" chapter.
Refitting the injector

Carefully check to make sure the components are clean. - Fit new O-rings and grease them. - Apply the recommended product to the set screws and tighten to the prescribed torque.

injector fixing screw 3 4
N.B.
INJEC - 213
Injection
Nexus 500 euro 3
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.
THE THROTTLE BODY IS A PART WHICH INCLUDES VARIOUS COMPONENTS AND IS USUALLY SUPPLIED COMPLETE. TO TEST THESE COMPONENTS SEE THE "INJECTION" CHAPTER. - Remove the 3 retaining screws indicated in the figure.
CAUTION
THE THROTTLE BODY COMES PRE-CALIBRATED. TAMPERING WITH THE THROTTLE STOP REGISTER IS TO BE ABSOLUTELY AVOIDED. THIS REGISTER HAS BEEN SEALED FOR THIS PURPOSE. FOR PROBLEMS WITH IDLING SEE THE "INJECTION" CHAPTER.
N.B.
REMOVAL OF THE THROTTLE BODY CAN BE EFFECTED WITH THE MANIFOLD ON OR OFF THE ENGINE. - Make sure the seal rims on the coupling surfaces between the manifold-throttle body and manifoldhead are in good condition.
CAUTION IF AIR GETS IN IT CAN JEOPARDISE THE OPERATION OF THE INJECTION SYSTEM, ESPECIALLY WHEN THE ENGINE IS IDLING.
- Make sure the throttle valve and related conduit are clean. - Make sure the supplementary air channel managed by the Stepper motor is clean.
N.B.
IF THE THROTTLE BODY IS REPLACED RESET THE T.P.S. AND ADJUST THE CO%.
INJEC - 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 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. Dirt deposited on that valve, mainly on the inlet manifold side, can be easily removed. Once clean, the throttle body guarantees an air flow exactly the same as the original. Throttle valve fouling is phenomenon that happens at different times depending on how the scooter is used, weather conditions and idle speed adjustment. This phenomenon can be easily detected as a gradual poor idle signals it. Carry out a thorough check with a scooter diagnostic tester, drw. 020460y. With engine temperature of at least 90, the parameters may be as follows:
Standard Engine revs Ignition advance Throttle valve opening Dirty throttle body
15005 57 5.24
< 1400 10 5.24
The error menu displays the signals stored in the "RPM sensor". This takes place only when the engine stops with the key switch set to "on." An exhaust fumes analysis will show a very rich and non adjustable idle carburetion (CO > 4% - CO2 < 12%). Measure with the tool in drw. 020625y. It is evident that, except for cases of early fouling, cleaning should not be carried out when still covered by the warranty. After cleaning the throttle body, check and, if necessary, adjust C0. If these indications occur when the injection warning light turns on or further errors or wrong parameters are present, it is necessary to carry out the relevant controls indicated in the manual. In such a case, there is a real fault evidently.
Refitting the butterfly valve

- Carry out the removal operations but in reverse order, tighten the 3 fixing screws to the prescribed torque.

Throttle body fixing screws 11 13
Pump supply circuit

The control unit starts the pump in the following conditions: - by setting the switch to ON with the emergency switch to RUN and side stand raised. The pump does not supply. INJEC - 215
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- 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.
Circuit check
Proceed as follows: 1 - Set the switch to "ON" with emergency switch to "RUN" and side stand raised. The pump rotates for 2 seconds. YES go to 2 NO go to 3 2 - Try to start up. Check that the engine speed matches the pump rotation. YES go to 4 NO go to 5 3 - The pump does not rotate, or it rotates uninterruptedly. YES go to 5 4 - The pump power supply is conforming. 5 - Connect the diagnostic tester to the scooter system. YES go to 6
Specific tooling
020460Y Scooter diagnosis and tester 6 - Try to start up. Select the function "ERRORS" in the menu. Check whether there are any failures. YES go to 7 YES go to 8 NO go to 28 7 - Pump control relay circuit failure. YES go to 9
8 - Failure of: - injector - H.V. coil - Signals panel YES go to 18
9 - The control unit has detected a failure on the line of pin 19 YES go to 10 YES go to 11 INJEC - 216
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. YES go to 14 13 - Install the special tool between control unit and the injection system. YES go to 15
Specific tooling
020481Y Control unit interface wiring 14 - Delete the code and check from the beginning. 15 - Set the switch to "ON" with switch to "RUN" and side stand raised. Wait more than two seconds and check the following conditions: 19 - 23 = battery voltage YES go to 16 NO go to 17
16 - Replace the control unit. 17 - Check the presence of voltage (+ batt.) between pin 86 of the pump remote control switch and pin 23 of the control unit. Fix the wiring, if required. Check the relay coil continuity. 85 - 86 = 100 50
18 - Check that fuse 12 is in working order YES go to 20 NO go to 19
INJEC - 217
Injection
Nexus 500 euro 3
19 - Disconnect the following connectors: fuel pump, H.V. coil, injector YES go to 22 20 - Check the efficiency of the pump remote control switch. Check the wiring continuity between remote control switch and pump. 87 (remote control switch) - green/black (pump) = continuity NO go to 21 21 - Fix the wiring and repeat the check from the beginning. 22 - Check the earth insulation of wiring 87 (pump remote control switch) - 23 = insulation (>1 M) YES go to 24 NO go to 23
23 - Restore the wiring insulation and replace the fuse. 24 - Check the ground insulation of the primary winding of the HV coil and of the injector coil. YES, go to 25 25 - Check the pump winding resistance: approx. 1.5 YES go to 26 NO go to 27 26 - Replace the fuse and check the pump. 27 - Check the absorbed current. 28 - Select the diagnostic tester menu on the "ACTIVE DIAGNOSIS" function. Select the fuel pump simulation function. Enable the function with continuous power supply on and engine off. YES go to 29
Specific tooling
020460Y Scooter diagnosis and tester 29 - The tester prompts the control unit to start the pump for 30 seconds YES go to 30 30 - Acoustically check the following conditions: INJEC - 218
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. 34 - Restore The injection CPU manages the negative of the light. The light must go off after the initial check. The light goes on again when the CPU autodiagnosis detects a fault. When the fault disappears the light goes back off, however, the related operating tests need to be carried out. The light can go on whether the engine is able to run or not.
The ignition system control unit is programmed to ensure optimal carburetion while riding along streets. The idle carburetion needs to be adjusted to compensate for the production tolerances and engine settlement. This adjustment is done by modifying the injector opening time with the engine running at idle. To adjust, proceed as follows: 1 - Idle carburetion adjustment must be performed on an engine ready for precision adjustment. Check in advance: - spark plug - that air filter is clean - that throttle body is clean - intake system for sealing - exhaust system for sealing - valve clearance - fuel filter - Fuel pressure
N.B.
IDLE SPEED IS OBTAINED BY PRE-CALIBRATING THE THROTTLE BODY AND THE ACTIVITY OF THE STEPPER.
Characteristic
Engine idle speed 1500 50 rpm
INJEC - 219
Injection
Nexus 500 euro 3
Check that the throttle body is not tampered. YES go to 2 2 - Preheat and check the zero setting of the exhaust fumes analyser. Remove the exhaust manifold cover and connect the extension to the coupling clamp for the analyser pipe. YES go to 3 3 - Connect the diagnostic tester. Set the switch to "ON" with switch to "RUN" and side stand raised. YES go to 4 4 - Select the menu on the "ERRORS" function. Check whether there are any failures. YES go to 6 NO go to 5 5 - Select the menu on the "PARAMETERS" function. YES go to 7 6 - Repair according to indications supplied. YES go to 4 7 - Start the engine and let it warm up until the following conditions are present: - coolant temperature = over 80C - intake air temperature = 25 30C YES go to 8 8 - Activate the exhaust fumes analyser and check the following conditions are present: - CO = 1.250.25% - CO2 = 14.501% YES go to 9 NO go to 10 9 - The adjustment is correct. 10 - If a different CO value is read, adjust the idle injection timing. YES go to 11 11 - Select the diagnostic tester menu on the CO CALIBRATION option. Activate the adjustment function.
INJEC - 220
Nexus 500 euro 3
Injection
YES point 12 12 - TRIMMER VALUE is displayed. The numbers displayed can be positive or negative. YES go to 13 13 To increase the CO the injection time needs to be increased. To decrease the CO the injection time needs to be decreased. Adjust the trimmer value according to the indications in the table: YES go to 14 TRIMMER VALUE +100 + 50 + 10 0 - 10 - 50 -100
N.B.
INJECTION TIME HIGH LOW MEDIUM
CO INCREASE DECREASE
THE TRIMMER VALUE 0 CORRESPONDS TO THE AVERAGE INJECTION TIMING. AFTER ADJUSTMENT ENGINES CAN HAVE CARBURETION WITH BOTH POSITIVE AND NEGATIVE TRIMMER VALUES. THIS IS DUE TO NORMAL PRODUCTION TOLERANCES. 14 - After having modifying a trimmer value, wait until the CO value becomes steady. In case of incorrect adjustment, press OK to store the value in the control unit memory. YES go to 15
15 - Select PARAMETERS and ECU DATA to confirm the new trimmer change has been stored.
N.B.
INJEC - 221
Injection
Nexus 500 euro 3
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, CAREFULLY 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 - timing system phase - outlet valves for sealing When the control unit is replaced, reset TPS and pre-program the trimmer value of the original control unit (if available) preventively. In any case, check the CO value again.
N.B.
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, carefully 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 - timing system phase - outlet valves for sealing When the control unit is replaced, reset TPS and pre-program the trimmer value of the original control unit (if available) preventively. In any case, check the CO value again.
Circuit leak test

Before performing the checks concerning the system pressure, it is necessary to carefully clean all feeding system components. To perform the inspections it is necessary to use the special tooling kit for fuel pressure check.
Specific tooling
020480Y Petrol pressure check set Before disconnecting any fastener, reduce the system pressure. Detach the electrical connector from the pump support with the engine running, and wait for the shutdown. The engine stops at approximately 1.5 bar.
CAUTION
CAREFULLY DETACH THE HOSE TERMINAL PREVENT ANY POSSIBLE SPRAYING INTO THE EYES. INJEC - 222
Nexus 500 euro 3
Injection
The special tool is equipped with fast-release fittings, similar to those provided for the circuit. In order to disconnect the female terminals (injector side), it is necessary to press the two extensions and draw them.
CAUTION DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME LOOSE; EVENTUALLY, TRY TWISTING IT. THE TERMINAL IS DESIGNED SO THAT AN INCREASE IN TENSION INCREASES THE LOCKING FORCE.
To detach male type terminals (pump side) it is necessary to press the coaxial rings towards the pump, and extract the terminals.
CAUTION DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME LOOSE; EVENTUALLY, TRY TWISTING IT. THE TERMINAL IS DESIGNED SO THAT AN INCREASE IN TENSION INCREASES THE LOCKING FORCE.
The system pressure check must be carried out, for practical reasons, by connecting on the pump side. Connect the manometer to the outlet duct (RHS) and the extension tube to the inlet duct (LHS).
CAUTION BEFORE REASSEMBLING CHECK THE TOOL DUCTS ARE CLEAN.
Pressure regulator check

1 - Connect the diagnostic tester.
Specific tooling
INJEC - 223
Injection
Nexus 500 euro 3
Select the menu on the "ACTIVE DIAGNOSIS" function. Select the "PUMP DIAGNOSIS" function. YES go to 2 2 - Enable the function with continuous power supply 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. Make sure that there are no external leaks. Check the regulation pressure with pump power supply voltage higher than 12 V. Regulation pressure = 300 - 320 kPa (3 - 3.2 BAR) YES go to 4 NO go to 5 4 - The pressure regulator is efficient. 5 - Pressure too high Check that the return duct is not clogged or squashed YES go to 6 NO go to 7 6 - Replace the pressure regulator. 7 - Pressure regulation too low Start the pump rotation again. Using pliers with flat and long tips, temporarily clamp the return duct by the extension of the specific tool (the serial pipe does not allow this operation). fuel pressure = over 300 kPa (3 BAR) YES go to 8 NO go to 9 8 - Replace the pressure regulator. 9 - Replace the fuel pump.
Fuel pump and filter check

This procedure is useful during maintenance to check the filter efficiency in delivery. Connect the diagnostic tester. Connect the fuel pressure check kit.
Specific tooling
020460Y Scooter diagnosis and tester 020480Y Petrol pressure check set INJEC - 224
Nexus 500 euro 3
Injection
1 - Select the diagnostic tester menu on the ACTIVE 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. Using pliers with flat and long tips, temporarily clamp the return duct by the extension of the special tool with pump power supply voltage higher than 12 V, check the system maximum pressure. Maximum pressure = > 600 kPa (6 BAR) YES go to 3 NO go to 4
Specific tooling
020480Y Petrol pressure check set 3 - Check the system seal. Start the pump for 30 seconds using the diagnostic tester. When the pump stops, wait 3 minutes. Check the system pressure. Fuel pressure = over 200 kPa (2 BAR) YES go to 5 NO go to 6
Specific tooling
020460Y Scooter diagnosis and tester 4 - If pressure is lower, carefully check the voltage with pump under stress. If voltage is higher than 12 V, replace the pump. 5 - The system seal is efficient. Check the free flow rate. AHEAD go to 16 6 - Repeat the test. When the pump stops, use pliers with flat and long tips to temporarily clamp the return duct by the extension of the special tool. This causes an increase of the fuel pressure. AHEAD go to 7 INJEC - 225
Injection
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7 - Check whether the pressure decreases with the same trend as the system when free from bottlenecks AHEAD go to 8 8 - Pressure decreases much more slowly YES go to 9 NO go to 10 9 - Replace the pressure regulator. Check the system seal again. 10 - There occur trend variations YES go to 11 NO go to 13 11 - Repeat the test clamping the pipe of the special tool in the portion between the branch and the injector. Check whether the pressure decreases with the same trend as the system when free. Pressure decreases much more slowly YES go to 12 NO go to 13
Specific tooling
020480Y Petrol pressure check set 12 - Check and replace the injector, if required, due to an insufficient seal. (see "THERMAL GROUP AND TIMING SYSTEM ") 13 - There are no trend variations Repeat the test clamping the pipe of the special tool in the portion between the branch and the pump. Check whether pressure decreases much more slowly. YES go to 14 NO go to 15
Specific tooling
020480Y Petrol pressure check set 14 - The pump unidirectional valve is faulty. Replace the pump. (see Pump bracket overhaul) 15 - Check the pipe and the injector union seals more carefully. Check the component seals again, if necessary. A POOR SYSTEM SEAL ONLY AFFECTS THE START-UP VELOCITY.
INJEC - 226
Nexus 500 euro 3
Injection
16 - Disconnect the pump connector, start the engine, wait until it stops and connect the connector again. Disconnect the fuel return pipe from the pump support (left pipe). AHEAD go to 17
17 - Introduce the return pipe into a graduated container. Using the diagnostic tester, start the fuel pump for 10 seconds. Make sure that the power supply voltage is more than 12V. Measure the amount of fuel delivered. Pump free flow rate = 300 - 320 cc. YES go to 18 NO go to 19
Specific tooling
020460Y Scooter diagnosis and tester 18 - The fuel filter is not clogged. The scooter can be used respecting the limit of 48000 km. 19 - The flow rate is less than 250 cc. The fuel filter is dirty. Replace the pump support.
Pump electrics check

This section describes the operations to be carried out to perform electric checks on the pump.
Resistor check
Disconnect the connector from the pump support. Using a tester, measure the pump winding resistance. Connect the tester probes to the pump support pins as shown in the figure.
Resistance: approx. 1.5 In case of infinite resistance, replace the pump. INJEC - 227
Injection
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With infinite resistance, the pump does not rotate. With resistance close to 0 , 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 to: - Power supply voltage - Pump running-in - Regulation pressure - Delivery filter cleaning To check the current consumption, proceed as follows - Disconnect the pump remote control switch connector. - With key switch set to "OFF", connect the jumpers 30-87 on the connector using the tester probes in ammeter function (see figure). - Check the pump rotation and power consumption
N.B.
THIS CONSUMPTION REFERS TO: - POWER SUPPLY VOLTAGE = approx. 12 V - PUMP RUN IN - SYSTEM PRESSURE = 300 kPa (3 BAR) - FUEL FILTER CLEAN
Current consumption: approx. 3.5 - 4.2 A A dirty filter causes an increase of input. If the pressure-relief valve opens, the pump absorbs approx. 6-7A. In case of excessive input (5A), replace the filter. See pump support overhaul. If the fault continues, replace the pump.
Fuel filter check

To check the fuel filter inspect the following: - Free flow - Current consumed by the pump. A clogged filter causes: - Poor performance especially at full power - Pump input increase INJEC - 228
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, proceed as follows: - Disconnect the electric connector. - Start the engine and wait for the spontaneous stop. - Clean the tank and the pump support (wash and blow with compressed air, if necessary). - Disconnect the delivery and return pipes by the fast-release fittings.
CAUTION PREVENT ANY FUEL SPRAYING.
- Loosen the pump support mounting ring nut (RH threading).
- Remove the pump support and the sealing gasket.

N.B. UPON EXTRACTING IT, BE CAREFUL NOT TO DEFORM THE FLOATING ARM.
INJEC - 229
Injection
Nexus 500 euro 3
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 filter and pressure regulator. - Disconnect and extract the wires - Using a screwdriver on the retain tab as shown in the figure, extract the level indicator from the support
- Level indicator check The check may also be carried out before removing it from the support. Measure the resistance between the two level indicator wires. Moving the float arm, check that the resistance is subject to gradual variations according to the arm motion.
LIMIT VALUES
1 2 Specification Empty tank position: Full tank position: Desc./Quantity 95 - 105 0-9
- To refit, repeat the removal operations but in reverse order. (2) Pressure regulator: - Remove the locking spring - Extract the pressure regulator with sealing rings.
N.B.
INJEC - 230
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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) - Disconnect the power supply cables
- Cut the delivery pipe fastening clamp on the support.
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- Remove the pump mounting washer
- Remove the filter coupling pipe - Remove the pump with annular support and prefilter.
- 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.
N.B.
TO CLEAN THE PRE-FILTER, USE PETROL AND COMPRESSED AIR. Orientate the pump properly.
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(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 given above.
Pump bracket installation

- Before reassembling, carefully check that the tank is clean. In case of dirt or water, remove the tank. - Install the sealing gasket on the pump support. - Introduce the pump into the tank being careful not to deform the level indicator arm.
- Place the sealing gasket on the tank. - Install the pump support onto the seat aligning the connector with the scooter longitudinal axle.
N.B. AN INCORRECT ORIENTATION MAY IMPAIR THE LEVEL INDICATOR PERFORMANCE.
- Screw the mounting ring nut and tighten thoroughly.

Electric pump locking ring nut 20 - Connect the feeding circuit pipes again and check the proper introduction by pulling and turning upwards. - Reconnect the electric connector. - Recharge the system with at least 45 timings (key switch OFF-ON)
N.B.
DO NOT START THE PUMP BEFORE REFILLING THE TANK. FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE PUMP. - Check that the fuel feeding system fast-release fitting seal is efficient.
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Inspecting the injector circuit
KEY 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. Fuel pump / fuel level transmitter 58. Fuel injector 59. Spark plug 61. HV coil 64. Fuel injection electronic control unit
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1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Select the "INJECTOR" function. YES go to 2
Specific tooling
2 - Enable the function with continuous power supply on and engine off. The control unit controls the fuel pump continuously and at the same time starts the injector opening. The injector openings are repeated for a few seconds. YES go to 3 3 - Acoustically check the injector openings and wait for the tester results YES go to 4 NO go to 5 4 - 5 injector openings detected. The injection tester displays test successful. YES go to 7 5 - No injector openings detected. The injection tester displays test failed. YES go to 9 NO go to 6 6 - No injector openings detected. The injection tester displays test successful. YES go to 8 7 - The injector control circuit is efficient. Perform the injector hydraulic check. 8 - The injector control circuit is efficient. Repeat the acoustic check and perform the injector hydraulic check for safety reasons. 9 - Select the menu on the "ERRORS" function. Check whether the injector failure message only is displayed. YES go to 14 NO go to 10
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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. 13 - Check the pump relay control circuit 14 - Install the special tool between the injection system and the control unit. YES go to 15
Specific tooling
020481Y Control unit interface wiring 15 - Arrange a multimeter with positive prod on pin 13 and negative prod on pin 23. Set the switch to "ON" with switch to "RUN" and side stand raised. Check the presence of battery voltage during the fuel pump timing. 13 - 23 = battery voltage for 2 seconds. YES go to 16 NO go to 17
16 - The injector electric circuit is steady Repeat the checks. If the fault continues, check the control unit connector. If necessary, replace the electronic control unit. 17 - Repeat the test using the resistance multimeter. Check the resistance between pin 13 and pin 87 (black/green cable) of the pump remote control switch. 13 - black/green = 14.5 5% (resistance of the injector) YES go to 19 NO go to 18
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18 - No continuity. Disconnect the connector and repeat the resistive check directly at the injector terminals. Resistance = 14.5 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. 13 - 23 = infinity NO go to 20 20 - Repair or replace the cable harness. 21 - Check the continuity between the injector power supply connector (red - yellow) and pin 13. Restore the continuity, if required, or replace the wiring 22 - Replace the injector.
Inspecting the injector hydraulics

To check the injector it is advisable to remove the intake manifold along with throttle body and injector. The injector should be removed from the manifold only if necessary. For these operations, see the "thermal group and timing system" chapter 1 - Connect the diagnostic tester. Use the socket in the under-saddle compartment. Install the fuel pressure check kit special tool. In this case, the injector can be connected directly to the tool quick couplings. AHEAD go to 2
Specific tooling
020460Y Scooter diagnosis and tester 020480Y Petrol pressure check set
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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. Prepare an auxiliary battery. Set the switch to "ON" with switch to "RUN" and stand raised. Select the "active diagnosis" function. Start the pump diagnosis. During the first 30 seconds of pump diagnosis, power the injector by the wire and the auxiliary battery for 15 seconds. Collect the fuel delivered by the injector into the graduated container. Power supply pressure = 300 kPa (3 BAR) Quantity delivered = approx. 40 cm3 YES go to 3 NO go to 4 3 - Perform the injector sealing test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal. Value limit = 1 drop per minute YES go to 5 NO go to 6
4 - Higher quantities are not expected. For lower quantities, replace the injector (THERMAL GROUP AND TIMING SYSTEM). 5 - The injector is conforming. 6 - Repeat the test. If the fault continues, replace the injector (THERMAL GROUP AND TIMING SYSTEM) The injector atomisation cannot be checked by simple methods. The injector is provided with 5 holes whose angulation forms a jet with a taper of
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about 80. The jet thus formed impinges both intake valves.
N.B.
- AN INJECTOR WITH LOW FLOW RATE AFFECTS THE MAXIMUM PERFORMANCE. - AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND THE START-UP FEATURES AFTER A SHORT STOP WITH HOT ENGINE. - IN CASE OF CLOGGING OF THE INJECTOR, IT IS NECESSARY TO REPLACE IT, ALONG WITH THE FUEL FILTER CONTAINED IN THE TANK. CAREFULLY CLEAN THE SYSTEM AND THE TANK.
Troubleshooting
1 - A failure of the EMS system is more likely to be due to the connections than to the components. Before searching the EMS system for failures, perform the following checks:
SUGGESTION FOR TROUBLESHOOTING

1 Specification 1. Power supply Desc./Quantity
- Battery voltage - Burnt fuse - Remote control switches - Connectors - Faulty fuel pump - Dirty fuel filter - Faulty spark plug - Faulty coil - Faulty screened cap - Dirty air filter - Dirty by-pass circuit - Faulty stepper motor - Wrong distribution timing - Wrong idle speed carburetion - Wrong reset of the throttle valve position sensor
2 3 4
2. Chassis earth 3. Fuel supply 4. Ignition system
5. Intake circuit
6. Other
2 - Failures to the EMS system may depend on loosened connectors. Make sure that all connections are properly implemented. Check the connectors being careful of the following: 1. check that terminals are not bent. check that connectors are properly engaged. Check whether the failure changes if the connector is slightly vibrating. 3 - Before replacing the EMS control unit, check the whole system carefully. If the fault is fixed by replacing the EMS control unit, install the original control unit again and check whether the fault occurs again. 4 - For troubleshooting, use a multimeter with an internal resistance of more than 10K/V. Improper instruments may damage the EMS control unit.
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The instruments to be preferred have a definition of more than 0.1V and 0.5 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. - Deterrent flashing.
System components
The system consists of: -EMS system control unit - Decoder - Aerial - Master key (red) - Service key (black) - Deterrent and diagnosis LED
Virgin circuit
When control unit (ECU) and decoder are not programmed, the following conditions occur: - Key switch set to "OFF". Deterrent flashing inactive. - Key switch set to "ON". Ignition and injection disabled and LED on with solid light. When the key switch is set to "ON", the LED switches on as shown in the figure. The LED is turned on by the decoder. The control unit data can be checked by the diagnostic tester.
Specific tooling
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To connect the diagnostic tester, open the spark plug inspection port and pull out the EMS Diagnosis socket. Remove the protection cap and connect the tester terminal.
Power the diagnostic tester by connecting the terminals to the battery poles, or the specific connector to the socket inside the gloves compartment.
Set the switch to "ON" and select the diagnostic tester menu to the immobiliser function. Scroll the pages to display the control unit data.
N.B.
AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY. The information will be as follows: Unprogrammed control unit ON Start-up disabled ON Key number Zero 250
Setting the circuit

The electronic ignition system is controlled by the control unit with the integrated Immobilizer system. The immobilizer is an anti-theft system that allows the scooter to be operated only when it is started with coded keys recognised by the control unit. The code is integrated into a transponder inserted into the body of the key. This permits transparent operation for the rider who has to do no more than the normal turn of the key. The Immobilizer system consists of the following components: INJEC - 241
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- 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" or the emergency stop switch is turned to "OFF" and, in order not to prejudice the battery charge, remains active for 48 hours. When the key switch is turned to "ON", it interrupts the function of the immobiliser lamp and a start enable lamp comes "ON". The time for which this lamp stays on depends on the programming of the control unit. In the event that the LED goes out irrespective of the position of the key switch and/or the instrument panel is not initialised, check: Battery voltage is "ON" That none of fuses 1, 3, 7 or 8 has blown Power supply to the control unit as specified below:
Disconnect the connector from the control unit. Check the following conditions: With the key switch in position "OFF": Battery voltage between terminals 17-23 and terminals 17-chassis ground (continuous power supply). In the event that there is no voltage, check that fuse 1 has not blown and check the corresponding wiring. With the key switch in position "ON" and the engine stop switch in "RUN": Battery voltage between terminals 26-23 and terminals 26-chassis ground (continuous power supply). In the event that there is no voltage, check: 1. The condition of fuse No. 1 and the corresponding wiring. 2. The function of the engine stop remote control. Check for voltage on the blue/grey cable at the exit from the engine stop remote control. In the event that there is no voltage, check: 1. The contacts of the key switch. 2. The function of the engine stop switch, then for the presence of earth on the green/blue cable and the engine stop switch with the stand raised and the engine stop switch in position RUN. 3. The function of the diode of the engine stop remote control. If no fault is found, replace the control unit.
N.B.
AN ACCIDENTAL LOSS OF THE SERVICE KEY PROGRAMMING CAN ARISE FROM GENERAL FAULTS OF THE IGNITION SYSTEM. IN THIS CASE, CHECK THE HV LINE SHIELDING. In any case it is advisable to use resistive spark plugs. INJEC - 242
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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 recognition of the "master" key as the first key to be programmed: this is particularly important as it is the only key that allows the decoder to be reset and reprogrammed for programming the service keys. The master and service keys must be used to code the system as follows: - Insert the Master key, turn it to ON and keep this position for two seconds (lower and upper limits 1 to 3 seconds). - Insert the service key and turn it to ON for 2 seconds. - If you have copies of the key, repeat the operation with each key. - Insert the MASTER key again and turn it to ON for 2 seconds. The maximum time to change keys is 10 seconds. A maximum of 7 service keys can be programmed at one time. It is essential to adhere to the times and the procedure. If you do not, start again from the beginning. Once the system has been programmed, master key transponder, decoder and control unit are strictly matched. With this link established, it is now possible to encode new service keys, in the event of losses, replacements, etc. Each new programming deletes the previous one so, in order to add or eliminate keys, you must repeat the procedure using all the keys you intend to keep using.
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If a service key becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs.
Characteristic
MASTER key: BROWN KEY SERVICE key. BLACK KEY
Checking master-box data

Connect the diagnostic tester. Set to ON and select the immobilizer function. Scroll the pages the find the data.
Specific tooling
The information will be as follows: - Unprogrammed control unit OFF - Start-up disabled OFF - Number of keys 2* *The number denotes how many keys have been used for programming, master key included.
Resetting the circuit

1 Replacing the small cylinder - Remove the original master key transponder and install it on the master key of the new cylinder. - Program the system again as described above. 2 Decoder replacement When the decoder is replaced it is necessary to program the system again. Programming is indispensable for the engine start-up. (see System programming). 3 Control unit replacement Programming is indispensable when the control unit is replaced to enable the engine start-up. In this case it is sufficient to switch to "ON" using the master key.
N.B.
- THE SERVICE KEY (BLACK-COLOURED) IS NOT USED FOR PROGRAMMING. INJEC - 244
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- 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).
N.B.
THE CODE CARD CAN ONLY BE USED WHEN THE ORIGINAL MASTER KEY IS AVAILABLE.
Diagnostic codes
The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the led remains on permanently, it means the ignition is inhibited: 1. New decoder - key inserted: a single 2 second flash is displayed, after which the LED remains off permanently. The keys can be stored to memory, the vehicle can be started but with a limitation imposed on the number of revs. 2. New decoder - transponder missing or illegible: The LED is permanently ON; in this condition, no operations are possible, including starting of the vehicle. 3. Decoder programmed - service key inserted (normal operating condition): a single 0.7-second flash is displayed, after which the LED remains off steadily. The engine can be started. 4. Decoder programmed - master key inserted: a 0.7-sec flash is displayed followed by the LED remaining off for 2 sec. and then by short 0.46-sec flashes the same number of times as there are keys stored in the memory including the Master key. When the diagnosis has been com-
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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 transmitted are: 1-flash code 2-flash code 3-flash code
Code 1
Code 1 indicates a non-programmed system. If the code is still displayed after having carried out the programming procedure, repeat the procedure carefully observing the "ON" times of each key.
If the code is still displayed, proceed as follows: - Disconnect the battery negative. - Remove the control unit connector. - Connect the special tool between the injection system and the control unit. - Remove the main decoder connector.
N.B.
TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER.
Specific tooling
020481Y Control unit interface wiring 1 - Using a multimeter, check the continuity between pin 16 of the control unit and pin 6 of the decoder connector. YES go to 3 NO go to 2
2 - Repair or replace the wiring. 3 - Check the connections carefully YES go to 5 NO go to 4 4 - Restore INJEC - 246
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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 decoder does not recognise the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary. Otherwise replace the faulty key and/or reprogram the decoder. If the problem persists, replace the decoder.
Code 3
The 3-flash code indicates a system where the decoder does not recognise the key. Turn the switch to ON using several keys: If the error code is repeated even with the Master key, replace the decoder. If this is not the case, reprogram the decoder.
Tachometer
TERMINAL: 7 - 12 CONDITIONS : Start-up speed STANDARD: approx. 0.8 - 4.5 V
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CIRCUIT LAYOUT
1 2 Specification Electronic control unit Engine rpm sensor Desc./Quantity
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. Such solution allows controlling the injector and the spark plug every two revolutions of the crankshaft. The sensor is of the reluctance variation type and is therefore comparable to an alternate current generator that powers the control unit. The signal frequency is interrupted by the vacuum generated by the two missing teeth on the wheel speed sensor.
The sensor signal is fundamental for obtaining starting of the engine. The ECU self-diagnosis is enabled on this circuit in 2 different ways based on use conditions. Right after turning to ON (Power under the panel present in the CPU), the continuity and isolation of the sensor and related circuit are checked. Any faults discovered in this phase are signalled via the injection telltale light. INJEC - 248
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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). If a signal panel is detected which is not perfectly synchronised, corrective interventions are applied used to reconstruct the cycle. In this case the self-diagnosis records the number of lost synchronisations and signals the fault via the injection telltale light. The light remains on during the period the cycle is reconstructed. If the rpm-timing signal is completely missing due to mechanical faults or lack of magnetic activity, it will be impossible to start the engine (or it will stop while driving) and the self-diagnosis will not be able to record any faults. To check the sensor and related circuit, proceed as follows: 1 - Connect the scooter tester. Select the function "ERRORS" in the menu. Check for any faults on the Signal panel. YES go to 2 NO go to 3
Specific tooling
020460Y Scooter diagnosis and tester 2 THE FAULT HAS BEEN RECORDED IN MEMORISED STATUS: The signal panel may be synchronised with possibility of starting. The fault is probably occasional.
N.B.
A NON-CONFORMING SIGNAL PANEL FAULT MAY ALSO BE DETECTED IF THE ENGINE STOPS AFTER A FAULT INVOLVING IDLING.
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THE FAULT HAS BEEN RECORDED IN CURRENT 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 > 1 TOOTH YES go to 4 NO go to 5 4 THE INDICATION INCREASES PROGRESSIVELY OVER TIME WITH THE ROTATION OF THE ENGINE. AHEAD go to 8 5 INDICATION = 1-3 THE RPM-TIMING CIRCUIT IS IN COMPLIANCE. Make an attempt to start and use the parameters function to check for the engine revs indication. YES go to 6 NO go to 7 6 The signal panel is in conformance. 7 CHECK THE AIR GAP AND MAGNETIC ACTIVITY OF THE SENSOR. See engine mechanics. 8 Check the sensor and related connection circuit with the control unit. AHEAD go to 9 9 Install the connection wiring between the control unit and injection system. Do not make the connection with the control unit. CONTINUE at 10
Specific tooling
020481Y Control unit interface wiring 10 Install the connection connector between the rpm timing sensor and injection system. Measure the sensor resistance by connecting a multimeter between the terminals marked + and - (see the "Electrical system" chapter).
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RESISTANCE OF THE RPM TIMING SENSOR: (AT 25C)

1 2 Specification Model with 1 clamp: Model with 2 clamps: Desc./Quantity 860 130 680 100
YES go to 11 NO go to 12
11 - Check the earth isolation between a pole and the shielding. (see the Electrical system chapter).
S-+= infinite (>M) YES go to 13 NO go to 12
12 - Replace the revolution sensor. 13 - Reconnect the rpm-timing sensor connector. Repeat the resistance check through the injection wiring pin 7, pin 12.
7-12 = 680 100 (Model with 2 clamps) 7-12 = 890 130 (Model with 1 clamp) The value should be very close to that detected directly by the sensor. YES go to 17 NO go to 14 14 - Higher or infinite resistance. YES go to 15 NO go to 16 INJEC - 251
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15 - Check the connectors carefully. Disconnect and check the continuity between connector and pin 7-12
Connector - 7 = Continuity Connector - 12 = Continuity Fix the connectors or replace the cable harness. 16
Resistance 0 Repair or replace the injection wiring (short circuit) 17 - Check the earth insulation again.
7-23 = infinite (>1M) YES go to 19 NO go to 18 18 - Check the sensor and control unit connectors. Repair or replace the injection wiring 19 - Measure the alternated voltage between pins 7 and 12 with engine at start-up speed.
7-12 = approx. 0.8 - 4.5 V eff Revolution speed = approx. 300-400 rpm YES go to 20 NO go to 21 20 The sensor circuit is in conformance. Use the parameter function to check if the engine rpm indication is present when trying to start. If not, carefully check the ECU connection connector and replace it if necessary. 21 Check the air gap and magnetic activity of the sensor. See the "Combustion unit and distribution" chapter. If there is no magnetic activity replace the sensor.
N.B.
-THE SENSOR CABLE MUST BE PROPERLY INSTALLED FOR SERVICING. -DO NOT FORCE THE CABLE. INJEC - 252
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-A POOR CABLE SHIELDING CAN IMPAIR THE ENGINE PERFORMANCE AT HIGH SPEED.
HT coil
This section describes the ignition system operation.
Circuit diagram
TERMINALS: 20 - 23 CONDITIONS : During the pump timing with engine off. STANDARD: Battery voltage
KEY 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 INJEC - 253
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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 parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 50 R/1'. - Magnetisation time The coil magnetisation time is controlled by the control unit. The ignition power is increased during the engine start-up. The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during compression. To check the ignition circuit, proceed as follows: 1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Start the HV coil check with switch set to ON, switch to RUN and side stand raised. Wait for the tester to display: "TEST SUCCESSFUL" YES go to 3 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester 2 - The tester displays: "TEST FAILED". Repeat the test and wait for the tester to display: "TEST SUCCESSFUL" YES go to 3 NO go to 4 3 - Select the menu on the "ERRORS" function. Check the presence of current or stored errors relating to the H.V. coil.
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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. Measure voltage between pins 20 and 23 of the specific Specific during the timing phase of the fuel pump. To start the timing, set the switch to "ON" with switch to "RUN" and side stand raised.
20-23 = Battery voltage (coupled to the pump rotation -2 seconds). If you want to increase the test time, enable the "pump relay diagnosis" function (30 seconds) YES go to 7 NO go to 8
7 - The coil primary control circuit is efficient. Carefully check the connectors to the control unit and to the coil. Replace the control unit, if necessary. 8 - Disconnect the connector to the HV coil primary. Repeat the voltage check between the black-green wire and earth.
Black-green-23 = battery voltage (coupled to the pump rotation-2 seconds). YES go to 10 NO go to 9
9 - Check the black-green wire continuity. INJEC - 255
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Repair or replace the cable harness.

N.B.
A FAILURE OF THE REMOTE CONTROL SWITCH WOULD CAUSE THE PUMP ROTATION FAILURE 10 - The positive power supply is conforming. Check the continuity between the pink-black wire of the connector and pin 20.
Pink-black-20 = Continuity YES go to 12 NO go to 11
11 - Check the continuity of the pink-black wire in the two systems.
Pink-black (coil connector)-20 = Continuity YES go to 12 NO go to 13
12 - Check the earth insulation of the negative line.
20-23 = infinite (>1M)
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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" H.V. coil control simulation. Delete the errors stored in memory. 15 - Check the continuity of the H.V. coil primary. See figure.
Primary resistance = 0.5 8% YES go to 16 NO go to 19
16 - Check the earth insulation of the primary circuit Measure between one of the primary terminals and earth.
Primary-earth = infinite (>1M)
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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
Primary HV cable output = 3.1 K 9% YES go to 18 NO go to 19
18 - The coil is conforming. 19 - Replace the coil
Inspecting the spark plug shielded cap

Measure the shielded cap resistance.
Resistance: 5 K
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If different values are measured (<1; >20K), replace 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 MAINTENANCE CHAPTERS.
Spark advance
The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to declare the reference values based on the engine rpm. The ignition timing value is detectable any time using the diagnostic tester. It is possible to check whether the ignition advance determined by the system does in fact correspond with the value actually activated on the engine, by means of the stroboscopic light.
Specific tooling
020460Y Scooter diagnosis and tester 020330Y Stroboscopic light to check timing Proceed as follows: - Remove the transmission compartment cover as described in the "automatic transmission" chapter.
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the "flywheel cover" chapter
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- 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. - Start the engine. - Select the parameter function in this menu. - Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2 revs). - Check that the real values of rpm and ignition advance match those measured using the diagnostic tester. If the values do not match, check: - distribution timing - rpm-timing sensor - Injection control unit
Coolant temperature sensor

TERMINALS: 4 - 22 CONDITIONS : coolant temperature STANDARD: With connected sensor: 20 = 2500 100 INJEC - 260
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Injection
80 = 308 6
KEY 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. It is realised with two electrically different sections. The injection section is realised with an NTC sensor connected to a 5V powered circuit. The resistance variation causes a variation of the circuit voltage. Such voltage is combined with a temperature value. By this value, the control unit can manage the engine operation, optimising it for all temperatures. A failure of this circuit causes the switching on of the injection telltale light and the tripping of the safeties (among which the electric fan continuous start). In these conditions, the engine works, even though not in an optimum way, always safeguarding the catalytic converter integrity. A false temperature value that falls within the range of possible temperatures is a failure very difficult to manage. This can cause a failure of the safeties and an improper management of the ignition. Such failure is more easily detected upon the engine start-up. To check the sensor and related circuit, proceed as follows: INJEC - 261
Injection
Nexus 500 euro 3
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 temperatures. If you suspect a wrong temperature indication, proceed to perform the following check.
N.B.
A WRONG TEMPERATURE SIGNAL CAN BE DETECTED BY COUPLING THE ANALOGUE INSTRUMENT INDICATION WITH THE ELECTRIC FAN START. IN ANY CASE, BEFORE CHECKING THE SENSOR, CHECK THE FILLING AND BLEEDING OF THE COOLING SYSTEM 3 - Before checking the sensor and the relevant circuit, wait until the engine has cooled down and the scooter has set to the working area temperature. YES go to 4 4 - Set the switch to "ON" with switch to "RUN" and side stand raised. Select the menu on the "parameters" function. Do not start the engine. YES go to 5 5 - Check the following values: coolant temperature intake air temperature ambient temperature The three indications are equal or they are slightly different (e.g. 1 C). YES go to 6 NO go to 7 6 - The temperature sensor is providing probably correct information. Check at approx. 80 C. 7 - Install the special tool.
WARNING
DO NOT CONNECT THE CONTROL UNIT CONNECTOR.
Specific tooling
020481Y Control unit interface wiring YES go to 8 8 - Disconnect the coolant temperature sensor connector. Measure the sensor resistance between the terminals shown in the figure. Check that the resistance matches the values declared according to the temperature.
TEMPERATURE RESISTANCE 9.6KW -10 C
INJEC - 262
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;
4-22 = 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. If infinite resistance is detected (>1MW), check the continuity between the two lines with disconnected connectors.
Blue-white-4 = 0W (continuity) Light blue/green-22 = 0 ohm. (Continuity) YES point 12
12 - Repair or replace the cable harness. YES go to 10 13 - Check that the sensor circuit is earth insulated.
INJEC - 263
Injection
Nexus 500 euro 3
4-23 = infinite (>1M) 22-23 = infinite (>1M) 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. Set the switch to "ON" with switch to "RUN" and side stand raised. YES go to 16
Specific tooling
020481Y Control unit interface wiring 16 - Measure voltage at terminals 4 and 22;
TEMPERATURE VOLTAGE
1 2 3 4 5 6 Specification XV XV XV XV XV XV Desc./Quantity -10 C 0 +10 C +20 C +30 C +80 C
17 INJEC - 264
Nexus 500 euro 3
Injection
Measured value = 50.2 V Repeat the wiring and sensor continuity checks. YES go to 18 18
Measured value = 0V Repeat the sensor and circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary. 20 - Repair or replace the cable harness. 21 - Start the engine and check that voltage decreases gradually according to the temperature increase as per table. YES go to 22 NO go to 23 22 - The temperature signal is conforming. 23 - Replace the temperature sensor.
N.B.
FOR A MORE ACCURATE CHECK OF THE SENSOR, REMOVE IT FROM THE ENGINE AND CHECK ITS RESISTANCE AT CONTROLLED TEMPERATURE. USING A SUITABLE CONTAINER, IMMERSE THE METAL PORTION OF THE SENSOR IN WATER, HEAT GRADUALLY AND READ THE TEMPERATURE AND RESISTANCE VALUES. CHECK THE MATCHING AS PER TABLE
Intake air temperature sensor

TERMINALS: 18 - 22 CONDITIONS: Intake air temperature 20 STANDARD: With connected sensor: 3750 200
INJEC - 265
Injection
Nexus 500 euro 3
KEY 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. The sensor is an NTC and has the same functional layout as the coolant temperature sensor. This signal is used to optimise the engine performance. Anyway, this data is less important than the coolant temperature signal. A failure of this circuit causes the control unit to turn on the injection warning light and activate the safety control, thereby ensuring the engine operation.
INJEC - 266
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 2 - The EMS system has received no indications of temperatures out of the range of possible values. If you suspect a wrong temperature indication, proceed to perform the following check. 3 - Before checking the sensor and the relevant circuit, wait until the engine has cooled down and the scooter has set to the working area temperature. YES go to 4 4 - Set the switch to "ON" with switch to "RUN" and side stand raised. On the diagnostic tester, select the PARAMETERS menu. YES go to 5 5 - Check the following values: coolant temperature intake air temperature ambient temperature indicated by the digital instrument. The three indications are equal or they are slightly different (e.g. 1 C). YES go to 6 NO go to 7 6 - The intake air temperature sensor is providing an incorrect information. 7 - Install the special tool. Do not connect the control unit connector. YES go to 8
Specific tooling
020481Y Control unit interface wiring 8 - Disconnect the intake air temperature sensor connector. Measure the resistance between the sensor terminals. Check that the resistance matches the values declared according to the temperature.
TEMPERATURE RESISTANCE
1 2 3 4 5 Specification 9,6 K 5,975 K 3,81 K 2,5 K 1,68 K Desc./Quantity -10 C 0 +10 C +20 C +30 C
INJEC - 267
Injection
Nexus 500 euro 3
9 - Replace the sensor. 10 - Connect the sensor connector and repeat the resistive check at terminals 18 and 22.
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. If infinite resistance is detected (>1M), check the continuity of the two lines with disconnected connectors.
Grey-white-18 = 0 (continuity) Light blue/green-22 = 0 (continuity) YES point 12
INJEC - 268
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.
18-23 = infinite (>1M) 22-23 = infinite (>1M) YES go to 15 NO go to 14
14 - Repair or replace the wiring. Check the valve position and the fluid temp. lines. YES go to 13 15 - Connect the special tool to the control unit. Set the switch to "ON" with switch in "RUN" and side stand raised. YES go to 16
Specific tooling
020481Y Control unit interface wiring 16 - Measure voltage at terminals 18 and 22.
18-22 = V as in the table.
TEMPERATURE VOLTAGE
1 2 3 4 5 6 Specification XV XV XV XV XV XV Desc./Quantity -10 C 0 +10 C +20 C +30 C +80 C
INJEC - 269
Injection
Nexus 500 euro 3
17
Measured value = 50.2 V Repeat the wiring and sensor continuity checks. YES go to 18 18
Measured value = 0V Repeat the sensor circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary. 20 - Repair or replace the cable harness. 21 - Start the engine and check that voltage decreases gradually according to the air filter box temperature increase.
N.B.
WITH MILD WEATHER, 30 C CAN BE EASILY REACHED AFTER A FEW MINUTES OF STOP WITH IDLE ENGINE.
INJEC - 270
Nexus 500 euro 3
Injection
Pressure sensor
This sensor does not have a system since it is directly installed into the control unit. The sensor allows the control unit to optimise the engine performance based on altimetric variations. To check the sensor, proceed as follows: 1 - Connect the diagnostic tester. Select the function "ERRORS" in the menu. Check whether there are any indications regarding the pressure sensor. YES go to 2 NO go to 3
Specific tooling
020460Y Scooter diagnosis and tester 2 - Replace the injection control unit. 3 - Select the menu on the "PARAMETERS" function. Check that the pressure value in mm/Hg matches that of another scooter or of an external barometer.
Max error: 20 mmHg YES go to 4 NO go to 5
4 - The ambient pressure signal is correct. 5 - Replace the injection control unit.
Throttle valve opening sensor

Throttle position sensor (t.p.s.)
TERMINALS: 1 - 22 CONDITIONS: Switch set to "ON" INJEC - 271
Injection
Nexus 500 euro 3
STANDARD: 5 V TERMINALS: 11 - 22 CONDITIONS: Opening the throttle gradually STANDARD: Volt= Progressive increase
CIRCUIT LAYOUT
1 2 3 4 Specification Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor Desc./Quantity
The throttle valve position sensor is not removable and is installed on the throttle body. This sensor receives a 5-V power supply from the control unit and transmit a gradually increasing voltage to the same, with an increase of the throttle valve opening. The control unit converts this voltage at an angular position of the valve. The engine rpm and the throttle valve position are the two basic signals for the engine management. A failure of this circuit causes the switching on of the injection telltale light and the tripping of the safeties. In these conditions, the engine works,
INJEC - 272
Nexus 500 euro 3
Injection
even though not in an optimum way, always safeguarding the catalytic converter integrity. The throttle valve position signal is especially important 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. To check the sensor and related circuit, proceed as follows: 1 - Connect the diagnostic tester. Set the switch to "ON" with switch to "RUN" and side stand raised. Select the tester menu on the ERRORS function. Check whether the control unit has detected any failures relating to the throttle valve position signal. YES go to 6 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester 2 - Select the diagnostic tester menu on the "PARAMETERS" function. Check whether the control unit recognises the extreme positions: Throttle valve to minimum Throttle valve to maximum YES go to 4 NO go to 3
3 - Check the adjustment of the throttle valve control flexible transmissions. Fix or replace, if required. YES go to 2 4 - Gradually open the throttle valve, check that the mV value increases progressively and proportionally with the opening variation. YES go to 5 NO go to 6 5 - The throttle valve position signal is conforming. 6 - Connect the special tool to the injection system. Do not connect the tool to the control unit. Disconnect the throttle valve position sensor connector. Check the continuity between the connector's terminals and the relevant pins on the control unit.
Specific tooling
INJEC - 273
Injection
Nexus 500 euro 3
Light blue/green-22 = 0 (continuity) Brown-yellow-1 = 0 (continuity) Orange-light blue-11 = 0 (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.
22-23 = infinite (>1M) 1-23 = infinite (>1M) 11-23 = infinite (>1M) YES go to 10 NO go to 9
9 - Repair or replace the injection wiring YES go to 8 10 - Connect the special tool to the control unit. Set the switch to "ON" with switch to "RUN" and side stand raised. INJEC - 274
Nexus 500 euro 3
Injection
Measure voltage between terminals 1 and 22 of the special tool.
Specific tooling
1-22 = 50.2 V YES go to 12 NO go to 11
11 - Check the control unit connector. Replace the control unit, if necessary. YES go to 10 12 - Connect the throttle valve position sensor connector. Repeat the voltage measurement between terminals 1 and 22 of the special tool.
1-22 = 50.2 V YES go to 13 NO go to 14
13 - Measure voltage between terminals 11 and 22. Gradually open the throttle valve and check that the voltage value increases progressively.
N.B.
BY WAY OF AN INDICATION, VOLTAGE MAY VARY FROM APPROX. 700MV AT MINIMUM, AND ABOVE 4V AT MAXIMUM.
11-22 = V (progressive variation) INJEC - 275
Injection
Nexus 500 euro 3
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". YES go to 16 NO go to 17 16 - The throttle valve position sensor and relevant circuit are conforming. 17 - Replace the control unit.
Zeroing the throttle

Resetting the throttle valve position signal (TPS reset) The throttle body is supplied with throttle valve position sensor and is pre-calibrated. Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of air under pre-set reference conditions. Pre-calibration ensures optimal air flow to control idling. This regulation must not be tampered with in any way whatsoever. The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance. The throttle body after the pre-calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also assume various fitting positions. For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another. To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to match the throttle body with the control unit following the procedure known as TPS resetting. With this operation we inform the control unit, as the starting point, of the mV value corresponding to the pre-calibrated position. The control unit will recognise such value as angle 5.24. To reset, proceed as follows:
INJEC - 276
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.
Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Select the "PARAMETERS" function and check that the TPS reset "YES" is displayed.
Reset should be performed in the following cases: - on first fitting. - in case of replacement of the throttle body - if the injection control unit is replaced.
N.B.
INJEC - 277
Injection
Nexus 500 euro 3
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
1 2 Specification Electronic control unit Stepper motor Desc./Quantity Stepper motor
The throttle body is provided with an auxiliary air circuit. This is enabled by a piston valve controlled by a Stepper motor. The Stepper is powered by the control unit only when the opening must be changed. The revolution is divided into portions called "steps". By changing the opening "steps" it is possible to properly feed the engine to facilitate the start-up procedure and adjust the air feeding with cold engine. When the engine reaches the working temperature, the Stepper partly closes again.
INJEC - 278
Nexus 500 euro 3
Injection
To prevent wear of the adjustment piston, operation at full speed is obtained with a minimum opening 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). When the control unit changes the Stepper opening "steps" it also changes the injection time to ensure proper ignition. The engine idle speed is practically stabilised at 1550-50 rpm. After a hot start-up step you can perceive the first increase in the revolutions and the subsequent closing of the Stepper to stabilise the speed. In case of irregular speed, before carrying out electric checks inspect the throttle valve and the auxiliary air circuit cleaning. To check the Stepper and the relevant circuit, proceed as follows: 1 - Connect the diagnostic tester. Set the switch to "ON" with switch to "RUN" and side stand raised. Lift the scooter on the central stand. Select the function "ERRORS" in the menu. Check whether the control unit has detected any failures relating to the Stepper circuit. YES go to 8 NO go to 2
Specific tooling
020460Y Scooter diagnosis and tester 2 - Select the menu on the "PARAMETERS" function. Check the number of "steps" programmed by the control unit to obtain start-up. This setting is a function of the engine temperature.
20 C = approx. 135 - 140 steps
INJEC - 279
Injection
Nexus 500 euro 3
3 - Start the engine and let it warm up. With a coolant temperature of more than 70C, the control unit must control the Stepper with about 45 steps. YES go to 5 NO go to 4
4 - Check the coolant temperature sensor signal. Check the control unit, if necessary. 5 - Select the menu on the ACTIVE DIAGNOSIS function. Select STEPPER diagnosis. Start the diagnosis with idle engine at the working temperature. Check whether the Stepper controls some revolution variations and wait for the diagnostic tester response.
N.B.
THE ECU ENABLES THE DIAGNOSIS ONLY WHEN THE IDLE SPEED IS WITHIN THE SPECIFICATIONS. YES go to 6 NO go to 8
6 - Test successful. Variations of revolutions perceived. YES go to 7 NO go to 9 7 - Stepper and relevant circuit efficient. 8- Test failed. No variations of revolutions. Check the Stepper circuit. Disconnect the Stepper connector. Check the resistance of the Stepper circuits by connecting the tester as indicated in the figure. The two measurements must have the same value.
INJEC - 280
Nexus 500 euro 3
Injection
Resistance = approx. 51 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 whether the piston valve moves. If the valve does not move, replace the throttle body.
10 - Replace the throttle body 11 - Connect the special tool. For these checks, do not connect the special tool to the control unit. Check the continuity of the 4 power supply lines of the Stepper.
Specific tooling
A Light blue-red-14 = 0 (continuity) B Orange-blue-6 = 0 (continuity) C Light blue-yellow-21 = 0 (continuity) D Light blue-black-24 = 0 (continuity)
INJEC - 281
Injection
Nexus 500 euro 3
12 - Check the earth insulation of the 4 Stepper lines.
14-23 = >1 M (infinite) 6-23 = >1 M (infinite) 21-23 = >1 M (infinite) 24-23 = >1 M (infinite) YES go to 14 NO go to 13
13 - Repair or replace the wiring. YES go to 11 14 - Connect the Stepper connector. Repeat the continuity check with the tool pins.
14-24 = approx. 51 6-21 = approx. 51
INJEC - 282
Nexus 500 euro 3
Injection
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. Check the presence of voltage pulses on the Stepper command lines. Set-up for direct voltage measurements.
N.B.
PULSES ARE USED TO CHANGE THE STEPPER POSITION.
14-24 = V (pulses for a few seconds) 6-21 = V (pulses for a few seconds) After reaching the optimum position, the power supply voltage becomes null. YES go to 17 NO go to 18
17 - The Stepper circuit is efficient. 18 - Check the control unit connector. Replace the control unit, if necessary.
Lambda probe
SIGNAL CHECK
INJEC - 283
Injection
Nexus 500 euro 3
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 With the throttle valve completely open, the voltage is approx. 1V. During the closing phase, the voltage is approx. 0V. If the voltage remains constant, the sensor may be damaged. Remove the sensor and check that there are no oil or carbon deposits inside it..
Impianto elettroventilatore
TERMINALS 5 - 23 CONDITIONS Switch in position "ON" Switch on "RUN" Side stand raised Electric fan off STANDARD Battery voltage
INJEC - 284
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. Engine stop remote control 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 INJEC - 285
Injection
Nexus 500 euro 3
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. The electronic control unit of the injection system controls the electric fan in relation to the measured engine temperature. If prolonged running of the electric fan is noticed, check the following carefully before starting to check the electrical system: - Coolant level in the expansion tank - bleeding of the inlet hose to the engine - Bleeding of the outlet from the head - Function of the thermostat - Function of the pump For these checks, see chapter "Cooling system". To check the circuit, proceed as follows: 1 - Connect the diagnostic tester. Set the switch to "ON" with switch to "RUN" and side stand raised. Select the "ERRORS" function. Check whether the control unit has detected any failures relating to the electric fan control circuit. YES go to 8 NO go to 2 2 - Select the menu on the "ACTIVE DIAGNOSIS" function. Activate the electric fan diagnostic function. Check acoustically for rotation of the electric fan. Wait for the exit from the diagnostic tester. YES go to 3 NO go to 4
INJEC - 286
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. The fan is not functioning YES go to 7 7 - The remote control switch circuit is OK. Check the connections to the electric fan, the function of the contacts of the remote control switch, the positive lines, the negative line and the motor of the electric fan. 8 - Disconnect the remote control unit of the electric fan. Check the continuity of the excitation coil. 85 - 86 = 100 50 YES go to 10 NO go to 9 9 - Replace the remote control switch YES go to 8 10 - Connect the special tool between the control unit and the system. Do not connect the electronic control unit YES go to 11 11 - Check for positive battery voltage at pin 85 of the remote control switch connector. 85 (blue/grey) - 23 = Battery voltage with switch in position "ON" YES go to 13 NO go to12 12 - Repair or replace the wiring. 13 - Leaving the remote control switch disconnected, check for continuity between pin 86 of the remote control switch connector and pin 5 of the electronic control unit. 86 (green/white) - 5 = 0 (continuity) YES go to 14 NO go to15
INJEC - 287
Injection
Nexus 500 euro 3
14 - Check the earth insulation. 5 - 23 >1 M (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". 5 - 23 = Battery voltage with panel in position "ON" YES go to 17
17 - Repeat the check with the electronic control unit connected and the engine cold. 5 - 23 = Battery voltage with panel in position "ON" If the fault continues, replace the electronic control unit.
INJEC - 288
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
Nexus 500 euro 3
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.
Front wheel hub overhaul

Check that the wheel bearings do not show signs of wear. If you have to replace the wheel bearings, proceed as follows: - Remove the two bearings on the brake disc side using pliers 14 and the special bell 9. - Remove the internal spacer.
SUSP - 290
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.
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15 mm guide - Heat the bearing seat on the side opposite the brake disc with the heat gun.
- Insert the bearing using the punch consisting of adaptor handle, 40x37 mm adaptor and 15 mm guide, and take it to the stop.
SUSP - 291
Suspensions
Nexus 500 euro 3
- 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.
- Turn over the wheel and insert the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side.
SUSP - 292
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 020412Y 15 mm guide
Refitting the front wheel

- When refitting, pay attention in repositioning the odometer drive correctly.

Wheel axle nut 45 50 Wheel axle clamp screws 6 - 7 Nm
Front fork Removal

- Remove the front wheel. - Remove the front mudguard - Remove the front brake calliper - Remove the front and rear handlebar covers. - Remove the pin mounting the handlebar to the steering tube. - Remove the handlebar and rest it on the shield back plate. SUSP - 293
Suspensions
Nexus 500 euro 3
Using the special tool, loosen and remove the upper ring nut, the spacer washer and the counterring 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
Overhaul
Check pump unit - Check that the oil holes on the pumping are free from clogging. - Check that the sealing snap ring is not damaged.
Check the spring length - Check the length "A" of the spring.
Characteristic
Standard spring length: 291.6 mm
Servicing tapered bearing seats - Check that the seats and the tapered bearings exhibit no scratches or wear.
N.B.
THE TAPERED BEARING SEATS SHOULD BE REMOVED ONLY IF STRICTLY NECESSARY.
SUSP - 294
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 bearing inserting the punch from the top of the headstock.
Specific tooling
020004Y Punch for removing fifth wheels from headstock Servicing fork stems - Using an inside 17 mm hexagonal spanner, loosen the top stem closing cap.
- Loosen the stem support clamp and remove fork leg and stem.
- Remove the spring. - Drain the oil. - Remove the screw with copper washer shown in the figure. To prevent the pumping member rotation, insert an inside 22 mm hexagon spanner into the stem. - Remove the pumping member.
SUSP - 295
Suspensions
Nexus 500 euro 3
- 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 screwdriver. - Repeatedly actuate the stem to remove it from the fork leg.
- Extract the oil guard "D", the abutment washer "C" and the top bushing "B". - Widen and remove the bottom bushing "A".
Refitting
Refitting stems on fork legs Preassemble the stem as indicated: - Install the bushing from the bottom of the stem
SUSP - 296
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. - Move the oil guard in abutment using a tube.
TUBE SIZE
Specification Inside: Outside: Height: Desc./Quantity 44 mm 51 mm approx. 105 mm
SUSP - 297
Suspensions
Nexus 500 euro 3
- Insert the contrast spring into the pumping member. - 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.
CAUTION TO PREVENT THE PUMPING MEMBER ROTATION, INSERT AN INSIDE 22 MM HEXAGON WRENCH INTO THE STEM.

Pumping element fixing screw 25 - 35 - Pour recommended oil into the stem.
AGIP FORK 7,5W Oil for front fork Hydraulic oil SAE 7,5W
Characteristic
Amount oil: 195 3 cc - Insert the spring with the thickest turns at the bottom. - Insert the stem into the fork clamp. - Tighten the clamp to screw the top stem closing cap. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.

Stem upper cap 35 - 55
SUSP - 298
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 torque.

Fork clamp screws 20 25
- Grease the tapered bearing using the specified product.
AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. - Insert the fork into the headstock. - Insert the tapered bearing after applying the specified product.
AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. - Using the special tool, tighten the first ring-nut on the steering tube to a holding torque, then tighten completely.

Holding torque of lower ring nut 20 25 - Tighten to the prescribed torque.

Steering lower ring nut 10 - 13 ** - Install the space washer. - Using the special tool, tighten the second locking ring nut on the steering tube to the prescribed torque.

Upper steering ring nut 36 - 39
SUSP - 299
Suspensions
Nexus 500 euro 3
- Install the handlebars on the steering tube, paying 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". - Install the front mudguard - Install the front wheel. - Install the front brake callipers. - Tighten the retaining screws of the brake calliper to the support.
Specific tooling
020055Y Wrench for steering tube ring nut

Fixing screw handlebar to steering tube 45 50 Holding torque of lower ring nut 20 25 Upper steering ring nut 36 - 39 Steering lower ring nut 10 - 13 ** Front brake calliper mounting on fork 20 25 Front brake disc mounting 11 13 Plastic protection retaining screw 5 - 6
Steering bearing Removal

Service of tapered bearing on fork - Check that the tapered bearing on the fork exhibits no deformations or wear. THE BEARING SHOULD BE REMOVED ONLY IF STRICTLY NECESSARY. In case of replacement, proceed as follows: - Support the fork in a vice. - Insert the contrast plate in the upper end of the steering tube
SUSP - 300
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 tube - Insert the a new plate and a new dust guard in the steering tube - Insert the a new tapered bearing in the steering tube - Using the special tool and a mallet to move the dust guard and the bearing in abutment.
Specific tooling
006029Y Punch for fitting fifth wheel seat on steering tube SUSP - 301
Suspensions
Nexus 500 euro 3
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. - Using two 24 mm wrenches, tighten the screw to move the two seats in abutment.
N.B. ALWAYS USE A NEW BEARING AND A NEW SEAT.
Specific tooling
001330Y Tool for fitting steering seats
Rear
A= Connection of rear shock absorber to support connecting rod: 38 - 46 B = Strut upper connection: 56 - 70 C = Connection of front support strut and shock absorber to frame: 73 - 80
A = Connection of rear support strut to hub cover: 20-25 Nm B = Strut lower connection: 30 - 35 Nm* * Lock using the recommended product C = Rear support connection to crankcase: 11-13 Nm D= Assembly plate mounting on strut support: 11-13 Nm
Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock SUSP - 302
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. If is thus possible by turning the ring nut on the lower part of the strut to raise or lower the rear section of the scooter. It is possible to adjust the geometry of the rear end to the preference of the rider and thus to adjust the road bolding of the scooter: - Lowers the rear section for improved stability at higher speeds.
- Preference for a higher rear section to improve handling and reduced speeds.
Removing the rear wheel

- Remove the muffler assembly. - Remove the plastic plug from the wheel locking nut
SUSP - 303
Suspensions
Nexus 500 euro 3
- 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.
- Remove the 5 bolts of the wheel and remove
SUSP - 304
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.

Muffler arm clamping screws 27 30 Rear wheel axle nut 104 126 Shock absorber-crankcase attachment bracket 20 25 Lower shock absorber clamping screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm
Swing-arm
The scooter features a rigid engine-chassis retainer called Direct-link. The system comprises the following components: A= Left spacer B= RHS engine support bearing C= Central spacer D= Right spacer E= LHS engine support bearing F = Chassis Removal - Support the engine adequately. - Remove the pin anchoring the engine to the chassis. - Move the engine backwards to take out spacers - Remove the left spacer highlighted in the figure.
SUSP - 305
Suspensions
Nexus 500 euro 3
- Remove the central and the right spacer.
- To refit, follow the removal operations but in reverse order, being careful to observe the original torque and to lubricate the sliding area A of the right spacer on the engine bearing.

Engine - chassis fixing pin 100 - 120
Two types of engine fixing pins, without distinction, have been fitted on the scooter: - 17-mm flanged-head pin. - 22-mm head pin and washer.
Shock absorbers Removal

- To remove the rear shock absorber, remove the two retaining screws shown in the figure.
Refitting
- To refit perform the operation in reverse order carefully respecting the locking torques.

Rear shock absorber retainer to the chassis 38 - 46 SUSP - 306
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.

Central stand retainers 25 30
Centre stand We wish to inform you that from Chassis No. ZAPM3510000007012, a new centre stand has been introduced to improve the function. The new stand differs from the old stand in having a 5 mm longer stand arms, increasing the height of the scooter from the ground. The modification also requires the introduction of a new stand stop buffer.
Side stand
- Unhook the springs. - Loosen the nut. - Pull out the screw. Fitting Carry out the previous operations but in reverse order.

Side stand clamp 15 20
SUSP - 307
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
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. The correct splitting of the braking force is also obtained via the dimensioning of the diameters of the discs and of the plungers of the callipers. The integral brake system is also designed to meet higher standards of safety. To this end, simple deceleration is obtained only with the rear brake. When the pump pressure exceeds 8 bar, front and rear brake operate simultaneously. In this phase the increases in the pump pressure are detected by both the callipers. When the front brake pressure reaches 23 bar, a new phase of limitation starts. Any increments in the pump pressure will be detected in linear mode by the rear calliper. The front calliper only detects slight increases, for example 80 bar rear corresponding to 31.7 bar front. Any demands for excessive braking force will always result in a loss of rear wheel traction. This condition helps to avoid dangerous locking of the front wheel. When the traction conditions, load and speed permit the use of the full braking force, this is obtained by combining the function of the integral brake with that of the single front brake.
BRAK SYS - 309
Braking system
Nexus 500 euro 3
[P]
Specification A: B: 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.
- Remove the screws fixing the brake calliper to the bracket, then remove the brake calliper complete with pipe.
- Complete the extraction of the pad retention pin, the spring and the pads.
N.B.
IF BRAKE CALLIPER REPLACEMENT OR SERVICE IS NEEDED, BEFORE REMOVING THE CALLIPER CLAMPS TO THE SUPPORT BRACKET, LOOSEN THE OIL JOINT FITTING.
BRAK SYS - 310
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. - Remove the dust ring and the O-ring of each half calliper. - Remove the two O-rings in the right half-calliper.
N.B. WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER SEATS
- Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully. - Fit new sealing rings and dust guards. - Refit the plungers in their seats being careful to lubricate with brake fluid
- Couple the half-calliper and tighten the two screws to the prescribed torque.
N.B.
TO AVOID DAMAGING THE GASKETS, WASH THE PLIERS COMPONENTS ONLY WITH ALCOHOL. DO NOT USE FUEL OR DERIVATIVES.

Brake calliper coupling 20 - 24
BRAK SYS - 311
Braking system
Nexus 500 euro 3
Refitting
- The rear break calliper can be recognised by its 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.
- Insert the pad fixing pin and the retention spring being careful to position its ends pointing towards the bleed screw as shown in the photograph.
- Insert the circlips on the pad fixing pin.

N.B.
FAILURE TO RESPECT THE PAD POSITIONING REQUIREMENTS WITH RESPECT TO THE DIRECTION OF ROTATION COULD COMPROMISE PROPER BRAKE FUNCTIONING AND NOISELESSNESS.
BRAK SYS - 312
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.
- Fasten the brake pipe union to the calliper and tighten to the prescribed torque - Bleed the system and replace the rear wheel
N.B.
IF THE REAR BREAK CALLIPER SUPPORT PLATE HAS BEEN REMOVED, UPON REFITTING IT IS NECESSARY TO FOLD THE EDGES OF THE WASHER ON THE HEAD OF THE SCREWS FIXING THE PLATE TO THE CRANKCASE.

Pipe / brake calliper coupling 20 25 Rear calliper support on crankcase retainer 20 25
Front brake calliper Removal

- Check the good condition of the brake hoses, of the seals and of the respective fittings. If any loss of brake fluid is discovered at the brake callipers, the callipers must be replaced. - Remove the two retaining screws of the front brake calliper at the fork as indicated in the photo.
N.B. BEFORE STARTING TO SERVICE OR REPLACE THE CALLIPER, LOOSEN THE CONNECTION OF THE PRESSURE HOSE AT THE BRAKE CALLIPER AFTER HAVING DEPRESSURISED THE CIRCUIT AS A WHOLE.
BRAK SYS - 313
Braking system
Nexus 500 euro 3
Overhaul
- Remove the front brake calliper and the corresponding 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 compressor gun.
N.B. PAY ATTENTION WHEN THE PISTONS COME OUT AS THE STRONG BLASTS OF COMPRESSED AIR CAN MAKE THE PISTONS COME OUT OF THE PUMP BODY VIOLENTLY
- Remove the dust-cover ring A and the sealing ring B of each piston.
N.B. DO NOT SCRATCH THE SEATS WHILE REMOVING THE RINGS.
- Check that the pistons and relevant seats exhibit no scratches. - Wash only with alcohol and blow all the components carefully. - Fit new sealing rings and dust guards. - Assembly the pistons into the appropriate seats being careful to lubricate the sealing ring B with brake fluid. The dust guard ring A has an internal groove with specific grease.
BRAK SYS - 314
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. LUBRICATE THE SLIDING PINS WITH SPECIFIC GREASE (APPROPRIATE FOR RUBBER GASKETS).
- Once the cleaning and replacement operations have been performed, reassemble all the parts in the reverse order followed during the removal.
N.B.
TO AVOID DAMAGING THE GASKETS, WASH THE PLIERS COMPONENTS ONLY WITH ALCOHOL. DO NOT USE FUEL OR DERIVATIVES.
Refitting
- Attach the sliding plate of the front brake calliper to the fork using the two screws with lock washers tightened to the specified torque. - Connect the brake pipe to the calliper and tighten it to the prescribed torque, turning the fitting towards the front and parallel to the scooter axis as shown in the photo.

Pipe / brake calliper coupling 20 25
Rear brake disc Removal

- Remove the rear brake calliper - Remove the brake disc with hub from the wheel axle. - To remove the brake disc from the hub, support the unit in a vice and tighten the 5 fastening bolts with self-locking nuts.
BRAK SYS - 315
Braking system
Nexus 500 euro 3
Refitting
- To reassemble the brake disc on the hub, carry out the removal operations in the reverse order arranging the brake disc on the hub on the side opposed the wheel keying - Follow the direction of rotation shown by the arrow and tighten to the prescribed torque. - Lubricate the seat of the wheel bearing shaft on the manifold support with the recommended grease.
N.B. APPLYING AN EXCESSIVE QUANTITY OF GREASE MAY IMPAIR THE BRAKE PERFORMANCE
AGIP GREASE PV2 Grease for the steering bearings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; NLGI 2; ISO-L-XBCIB2. - Insert the hub - disc assembly in the wheel axle.

Rear brake disc mounting 11 13
Disc Inspection
- Remove the rear brake calliper - Use a micrometer to check the disc thickness as shown in the photograph.
Characteristic
Standard thickness: 5 +0.2-0.1 mm Minimum thickness allowed after use: 4 mm
BRAK SYS - 316
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. - Suitably fix the flange to the wheel axle with the original nut and spacer and a 17-mm bearing
N.B.
SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN IN ORDER TO ROTATE THE DISC.
Specific tooling
Characteristic
Max. deviation allowed: 0.1 mm - If you detect incorrect values, replace the disc. If the anomaly persists, replace the hub.
Front brake disc Removal

- Remove the front wheel. - Undo the five clamping screws shown in the photograph
Refitting
For fitting, position the disc correctly using the arrow stamped on it as reference. - Do up the screws to the prescribed torque and apply the recommended product
N.B.
THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE.
BRAK SYS - 317
Braking system
Nexus 500 euro 3

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.

Brake disc screws: 6 +0.5 -1 Nm
Disc Inspection
Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring.
Characteristic
New rear disc thickness 4.0 mm Disc thickness at wear limit (front) 3.5 mm Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm. If a value is measured other than the specified value, remove the front wheel (Front/Rear Suspension chapter) and check the protrusion of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, replace the disc and repeat the check. If the problem persists, check and replace the wheel hub if necessary.
Specific tooling
BRAK SYS - 318
Nexus 500 euro 3
Braking system
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.
- Using a calliper, remove the 2 retaining pins of the pad sliding pin. - Unscrew the retaining pin and the pads too.
- Check that the thickness of the friction material is more than 1.5 mm. - Otherwise, replace it.
BRAK SYS - 319
Braking system
Nexus 500 euro 3
Refitting
- Assemble the brake pads into the calliper inserting 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.
- Insert the 2 locking split pins of the pin orientating the heads towards the calliper body as shown in the figure.
Rear brake pads
BRAK SYS - 320
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. Otherwise, replace it.
Refitting
- Insert the brake pads according to the direction of rotation of the brake disc, as indicated by the arrow on the anti-vibration pad.
- Insert the pad mounting pin and the retaining spring with its ends facing the bleed screw as shown in the figure.
- Insert the retaining ring on the pin - Fasten the rear brake calliper to the bracket and tighten the 2 screws to the prescribed torque.

Fill
BRAK SYS - 321
Braking system
Nexus 500 euro 3
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. - Keeping the left-hand brake lever pulled, loosen the bleed screw to purge the air. Then tighten the bleed screw.
- Repeat the operation until only brake fluid comes out of the rubber pipe. - Then repeat the bleed operations for both the regulating valve and the front left calliper.
- To access the regulating valve, it is necessary to remove the front shield. - Top up the brake fluid to the right level in the tank.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM If necessary, bleeding can be done using a special vacuum pump
Specific tooling
020329Y MityVac vacuum-operated pump

BRAK SYS - 322
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. - Keeping the right-hand brake lever pulled, loosen the bleed screw to purge the air. Then tighten the bleed screw. - Repeat the operation until only brake fluid comes out of the rubber pipe. - Remove the fluid recovery pipe and refit the rubber cap over the bleed screw. - Top up the brake fluid to the right level in the reservoir.
N.B.
DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKING SYSTEM If necessary, bleeding can be done using a special vacuum pump
Specific tooling
020329Y MityVac vacuum-operated pump

Circuit bleed calliper fitting 12 - 16
Front brake pump
BRAK SYS - 323
Braking system
Nexus 500 euro 3
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 photograph.
- Remove the oil pipe fitting from the pump undoing the screw indicated in the figure. - Remove the stop light switch connector
BRAKE PUMP TECHNICAL DATA

Specification Pump right piston diameter: Pump left piston diameter: Desc./Quantity 12 15
Refitting
To refit, carry out the removal operations but in reverse order, respecting the prescribed locking torques.

Rear brake pump - combined
BRAK SYS - 324
Nexus 500 euro 3
Braking system
Removal
Replace the pressure distribution valve If problems are discovered in the brake force distribution 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 engages but the front brake does not operate or vice versa, or the brakes function in completely different modes, or the distribution valve does not function correctly), proceed as described below: - Bleed the brakes of the combined system. - Remove the front knee guard. - Loosen fitting 1 shown in the figure for the rear brake calliper.
N.B. INSERT A CLOTH UNDER THE DISTRIBUTION VALVE TO AVOID BRAKE FLUID DRIPPING ONTO THE PLASTIC OR OTHER COMPONENTS OF THE SCOOTER.
- Remove fitting 2 of the front brake calliper. - Remove fluid inlet fitting 3 from the pump to the valve. - Remove the 2 TCEI socket head retaining screws of the holding the valve to the frame in the 2 bores shown in the figure.
- Remove the valve and replace with a new valve.
Refitting
To refit carry out the disassembly steps but in reverse order.
N.B. USE NEW COPPER GASKETS ON THE JOINTS.
BRAK SYS - 325
Braking system
Nexus 500 euro 3
- Tighten the screws fixing the valve to the chassis, but above all tighten the brake piping to the prescribed locking torques. - Fill and purge the braking system as described in the relevant section.

Coupling for oil on the integral braking system pump 16 20 Coupling on the integral braking system device (from the pump) 20 25 Front brake calliper - integral braking system device coupling 20 25 Rear brake calliper - integral braking system device coupling 20 25
BRAK SYS - 326
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
Nexus 500 euro 3
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. One way is connected to the pump and the other to the radiator (of the horizontal circulation type). The radiator output is directly connected to the pump. The expansion tank is connected in parallel to the radiator. The radiator hot box is connected to the upper side of the expansion tank (in air). The radiator cold box is connected to the lower side of the expansion tank (in the fluid). When the engine is cold, the thermostat output to the radiator is closed, even though there is still a little flow for de-aeration obtained by a hole into the closing plate. In this case, the circulation into the thermal group is active to ensure an even heating. Once the working temperature has been reached, the main circulation on radiator and expansion tank starts. With the small openings in the thermostat there is a flow overlapping (recirculation and main one). When the temperature is higher, the thermostat allows excluding the recirculation to favour the main circulation. In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic venting.
COOL SYS - 328
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.
TECHNICAL SPECIFICATIONS
Specification Cooling system capacity Prescribed fluid Sealing pressure Desc./Quantity 1.7 l Mixture of 50% water and fluid for sealed circuits (PARAFLU MOTO RIDER) Cap calibrated at 0.9 bar
THERMOSTAT
Specification Type Starts opening Desc./Quantity Wax-type, with deviator 82 2C
ELECTRIC VENTILATION
Specification Type Electric ventilation starts at Electric ventilation stops at Desc./Quantity With piston 107C 103C
WATER PUMP
Specification Type Control Desc./Quantity Centrifugal Coaxial at the countershaft
RADIATOR
Specification Type Desc./Quantity Aluminium, with horizontal circulation
EXPANSION TANK
Specification Calibration Desc./Quantity Automatic bleeding, in parallel with the radiator
Electric fan check

- Connect the injection diagnostic tester and select the ERRORS function in this menu. - Check any failures in the electric fan control circuit (see Injectionchapter)
Specific tooling
COOL SYS - 329
Cooling system
Nexus 500 euro 3
- Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simulation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and stop temperatures.
- Select the PARAMETERS function in this menu to display the coolant temperature. Electric fan starts: 107C Electric fan stops: 103C - If non-conforming values are detected, replace the injection control unit (see Injection Chapter). - If the analogue instrument temperature is close to the red zone, but the degrees indicated by the diagnostic tester are below the electric fan start temperature, check the temperature sensor on the head and the relevant injection circuit (see Injection chapter);
N.B.
THE ELECTRIC FAN TEMPERATURE AT 107 C CAN ONLY BE MANAGED BY A SYSTEM SUPPLIED WITH A 50% MIXTURE AND PRESSURISED AT 0.9 BAR. AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOILING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING. IN CASE OF AN INCREASE OF THE ELECTRIC FAN START TIME, CHECK THE THERMOSTAT OPENING TEMPERATURE AND CHECK THAT THE COOLANT DENSITY IS CORRECT. THE OPTIMUM DENSITY IS OBTAINED WITH A 50% WATER / 50% COOLING CIRCUIT FLUID MIXTURE.
System sealing check

- Check the proper circuit sealing when it is under pressure and at the temperature. - For a more accurate check, wait until the system has cooled down since small leaks may not be visible due to evaporation - The water pump is provided with a drainage hole in case of leaks from the cooling system mechanical seal, or from the shaft sealing oil guard. - If coolant or oil leaks are detected, inspect the pump (see Flywheel cover chapter).
N.B.
COOL SYS - 330
Nexus 500 euro 3
Cooling system
DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OBSERVE THIS REGULATION CAN CAUSE IRREVERSIBLE DEFORMATION TO THE SEALING GASKETS.
Coolant replacement
System top-up instructions - Prepare the mixture of 50% water and 50% coolant. - Fill the system to reach a level ranging between the MIX and MAX levels indicated in the expansion tank filler. - Do not close the expansion tank with the cap.
- Use a transparent hose to connect the venting union with the expansion tank filler. - Loosen the vent and start the engine.
- Keep it open until the air has been fully vented. - Close the bleed screw. - Stop the engine. - Restore the level into the expansion tank and tighten the cap. - Start the engine and let it warm up to reach the electric ventilation temperature. - Stop the engine. - Restore the level with cold engine.
CAUTION
ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD. THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COMPLETED. VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES.
Water pump - overhaul

- Carefully position a new O-Ring, avoiding contact with grease or oil.
CAUTION
FAILURE TO OBSERVE THIS ADVICE CAN IRRETRIEVABLY DEFORM THE O-RING.
COOL SYS - 331
Cooling system
Nexus 500 euro 3
- Refit the water pump cover, tightening the 6 fixing screws to the prescribed torque.

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. This component is intended to guarantee the leak tightness of the coolant in relation to the pump shaft. The seal achieved via two special ceramics, a static one and a spinning one, kept in contact by the thrust of a spring, coaxially mounted onto the pump shaft. The efficiency of this system is guaranteed by the accurate machining and cleaning of the components as they are fitted; in any case, ceramic seals are subjected to a running in period. During this period (1,000 1,500 km), there may be small leaks through draining holes, which remain visible on the aluminium crankcase. This phenomenon is particularly visible there where the hole is more exposed (Quasar and Master). In such cases we recommend cleaning the casing in order to be able to check again for leaks after a distance of more than 1500 km. If leaks continue or in the event of real losses, the ceramic seal should be replaced. For these operations, observe the tools and instructions given in the relevant service station manuals. Note: The ceramic seal may be overhauled according to the following couplings: Coupling "A": seal ring no. 485084 with ceramic seal no. 486216 Coupling "B": seal ring no. 841329 with ceramic seal no. 841330
The couplings above may be selected according to their availability, as they are interchangeable.
- Check that the reed valve of blow-by circuit closes adequately.
COOL SYS - 332
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 condition
- Check that the rotor does not show deformations or dents. - Check that the plastic rotor forms an integral unit with the metal part.
- Check that the water pump shaft does not show signs of wear and tear on the bearings in contact with the crankcase, in the oil seal area and on the motion sensor. - Check that the ceramic seal surfaces are not scratched or worn.
- Check that there are no damages or dents on the outside diameter of the bypass.
Characteristic
Outside diameter: 10.5 mm
COOL SYS - 333
Cooling system
Nexus 500 euro 3
- 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 PARAMETERS function (see Injection chapter). - Start the cold engine and let it warm up. - Manually check the moment when there is a sudden increase in temperature at the output of the radiator cold box.
N.B. THERE SHOULD BE A SLIGHT AND GRADUAL HEATING CAUSED BY A SMALL PASSAGE ON THE THERMOSTAT TO THE OFF POSITION.
Specific tooling
020460Y Scooter diagnosis and tester - Check the temperature read by the diagnostic tester. Thermostat opening starts: approx. 80C - If opening occurs at different temperatures, check the thermostat. - Remove the thermostat as described in the flywheel cover paragraph.
COOL SYS - 334
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. - Warm up the container using the heat gun. - Heat the water and periodically pull the thermostat out until its opening becomes visible. - Insert a thin copper wire between the seat and the thermostat closing plate. - Keep the wire into position until locking up is perceived. - Let water and thermostat cool down. - Progressively heat the water keeping the thermostat immersed by the wire. - Check the opening temperature when the thermostat is released from the wire. Opening starts temperature approx. 82 C
Specific tooling
020331Y Digital multimeter 020151Y Air heater - Heat up until the thermostat is completely open:
N.B.
HEATING SHOULD BE GRADUAL.

N.B.
AVOID CONTACT BETWEEN THERMOSTAT AND CONTAINER FOR A CORRECT TEST PERFORMANCE. - If incorrect values are detected, replace the thermostat. - Repeat the filling and bleeding procedure.
diagnosis Excessive system pressure

1 - Check the expansion tank cap efficiency. COOL SYS - 335
Cooling system
Nexus 500 euro 3
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 chapter) 3 - Replace the cap.
Cooling fluid consumption

1 - Check the system outside seals as described above. YES go to 2 NO go to 3 2 - Check the head gasket seal (see Thermal group and timing system chapter) - If water leaks are detected in the engine oil, inspect the pad on the head cooling circuit. 3 - Fix any damaged seals.
Oil in the fluid

1 - Presence of oil in the coolant. YES go to 2 2 - Check the head gasket seal (see Thermal group and timing system chapter)
COOL SYS - 336
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Nexus 500 euro 3
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. - Remove the control button of the undersaddle light.
Rear handlebar cover

- Release the 3 locking tabs of the rear handlebar cover shown in the figure using a screwdriver and paying attention not to damage the paintwork.
- Remove the 5 mounting screws of the rear handlebar cover.

N.B. WHEN INSTALLING, THE CENTRE SCREW IS A METAL SCREW, THE OTHER 4 ARE PLASTIC.
CHAS - 338
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 handlebar 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. - Loosen the 5 nuts of 10 mm holding the instrument panel.
CHAS - 339
Chassis
Nexus 500 euro 3
Headlight assy.
- Remove the centre cover of the shield. - Remove the 4 front retainers of the front light assemblies.
- To remove the right-hand light assembly, remove the screw located near the cover of the expansion tank.
- To remove the left-hand light assembly, remove the screw located in the left-hand storage compartment.
Remove the light, disconnecting the electric connector from the light and the complete lamp holder of the position light.
N.B. THE TWO REAR ADJUSTMENT SCREWS SHOWN IN THE FIGURE ARE ADJUSTED DURING ASSEMBLY OF THE LIGHT AND MUST NOT BE ALTERED.
CHAS - 340
Nexus 500 euro 3
Chassis
Frame central cover

- Remove the saddle. - Remove the two screws in the battery compartment 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 OBJECTS ACCIDENTALLY FALLING INTO THE TANK.
- Remove the lateral air conveyors and loosen the two screws shown in the figure. - Remove the cover, unscrewing it from its retainers.
- Remove the two screws indicated in the figure.
CHAS - 341
Chassis
Nexus 500 euro 3
- Remove the seven screws indicated in the figure. - Remove the central cover from its retainers.
Legshield
- Remove the windscreen complete with support. - Remove the front light assembly. - Remove the upper shield back plate. - Remove the lower shield back plate. - Remove the front deflectors. - Remove the 2 screws located under the front deflectors. - Remove the centre screw (without slotted head) located behind the front light. - Remove the 4 screws (2 per side) accessible from the footrest and located to the sides of the radiator.
- 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
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) indicated in the figure.
- Press the shield back plate forward to allow access to the socket on the frame of the key switch. - Turn the frame in anticlockwise direction (it may be necessary to use pliers), disengaging the locking teeth shown in the figure.
- Remove the front fuse holder, levering out using a flat screwdriver on the tab located on the side (on the side of the key switch).
- Remove the 2 screws located inside the storage compartment and the coolant top-up compartment (in order not to have to remove the front headlight).
CHAS - 343
Chassis
Nexus 500 euro 3
- 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. - Remove the cap of the expansion tank and the rubber gasket using a screwdriver or pliers. - Disconnect the complete upper shield back plate from the lower section paying particular attention to the tab located under the glove-box (left-hand side). Once raised, remove the 3 connectors of the instrument panel and the connector on the wiring of the instrument lighting.
Removing the ignition key-switch when on *off*

- Remove the lower shield back plate. - Unscrew the seat opening transmission from the side. - Remove in advance the ring of the immobiliser antenna. - Loosen the 2 hex. socket head screws and remove the complete switch.
CHAS - 344
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.
Front wheel housing

- Remove the spoiler. - Remove the front fork. - Remove the plate supporting bracket for the horn and voltage regulator by loosening the two retaining screws shown in the figure in order to release the two lower retainer of the wheel housing.
- Remove the upper fixing screw of the wheel housing to permit movement.
- In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and combination with the splitter.
CHAS - 345
Chassis
Nexus 500 euro 3
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 in anticlockwise direction.
Footrest
- Remove the centre union. - Remove the side fairings. - Remove the mat of the footrest. - Remove the screws indicated in the figure.
CHAS - 346
Nexus 500 euro 3
Chassis
- Remove the complete footrest from the side fairing.
- 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.
CHAS - 347
Chassis
Nexus 500 euro 3
- 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
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.
- In order to access the licence plate bulb it is sufficient to remove the two retaining screws of the rear cover from the support and to pull out the complete bulb holder.
Air filter
- Remove the helmet compartment. - Remove the straps of the oil vapour recovery hose and the air bellows shown in the figure.
CHAS - 349
Chassis
Nexus 500 euro 3
- 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.
Fuse 30A
Rear mudguard
- Remove the two clamps shown in the figure.
CHAS - 350
Nexus 500 euro 3
Chassis
- Remove the retainer of the mudguard/strut reinforcement plate to remove the complete mudguard.
Helmet bay
- Remove the side panels - Remove the six upper clamping screws.
- Remove the 2 lateral retaining screws with the central covers.
- Remove the 3 screws located inside the compartment in the rear part providing the mounting for the electrical system of the saddle opening device and for the support of the transmission.
- Disconnect the connectors of the power socket and the under-saddle light. - Remove in turn the complete power socket due to the interference with the frame. - Remove the fuse holder assembly, disconnecting the lateral retaining tab. CHAS - 351
Chassis
Nexus 500 euro 3
- 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.

N.B. THE OTHER 3 SCREWS HAVE ONLY AN AESTHETIC FUNCTION
Remove the flap, the gasket, the second flap and the second gasket.
Fuel tank filler neck - Remove the fuel tank flap. - Remove the central chassis cover. - Remove the 2 retaining straps of the filler neck to the tank. - Remove the 2 upper hoses (the left-hand hose and the "too short" hose; the hose on the right is the tank breather).
N.B.
THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.
CHAS - 352
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. IT IS NECESSARY, HOWEVER, DURING REMOVAL TO PRESS LIGHTLY ONTO THE LINES AND TO PUSH THE CROWN TOWARDS THE PUMP, AND THEN TO MAINTAIN PRESSURE ON THE CROWN AND TO PULL THE LINES UPWARDS. - Remove the plate supporting bracket for the horn and voltage regulator by loosening the two retaining screws shown in the figure in order to release the two lower retainers of the wheel housing.
- Remove the tank through the front lower part of the scooter. - For reassembly, perform the previous operations in the reverse order.
Rear central cover

- Raise the saddle. - Remove the two fixing screws shown in the figure.
CHAS - 353
Chassis
Nexus 500 euro 3
Front mudguard
- Remove the 4 retaining screws and pull the mudguard towards the front of the scooter. - Pay attention during assembly to the correct positioning of the retaining straps of the hoses.
Radiator fan
- Remove the spoiler. - Remove the front fork. - Remove the plate supporting bracket for the horn and voltage regulator by loosening the two fixing screws shown in the figure in order to release the two lower retainers of the wheel housing.
- Remove the upper fixing screw of the wheel housing to permit movement.
- Prepare a container to collect the coolant. - Remove the feed and return hoses from the expansion tank. - Remove the coolant feed and return hoses from the radiator. - Remove the retaining screws of the radiator to the frame shown in the figure. - Disengage the complete radiator and the electric fan.
CHAS - 354
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.
- Remove the plastic cover from the windshield support, loosening the 5 screws shown in the figure.
- Disengage the 7 retaining tabs (3 with the shield back plate, 4 with the shield). Once the 4 lateral tabs have been released it is sufficient to separate the upper part from the lower part and to pull it carefully upwards.
CHAS - 355
Chassis
Nexus 500 euro 3
Pilot lights kit

- Remove the handlebar cover. - Remove the three screws shown in the figure, then pull the complete group from the front handlebar cover.
Battery
- Remove the elastic strap and the battery cover.
Lower cover
- Remove the two screws of the lower spoiler (long type). - Remove the 2 screws located under the footrests.
CHAS - 356
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
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
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 Rear shock absorber retainer to the chassis Front wheel axle Rear wheel axle Rear brake disc mounting Engine - chassis fixing pin Fixing screw handlebar to steering tube Upper steering ring nut Steering lower ring nut ** tighten and loosen by 90 Torque in Nm 38 - 46 45 50 104 126 11 13 100 - 120 45 50 36 - 39 10 - 13 **
- Cover retaining screws
Electrical system
Electrical System: - Main switch - Headlamps: high beams, low beams, side/taillights (front and rear) and relevant warning lights - Adjusting the headlights according to the regulations currently in force - Front and rear stop light buttons and bulb - Turn indicators and their warning lights - Instrument lighting - Instrument panel: fuel and temperature indicator - Instrument panel warning lights - Horn - Electric start-up - Engine stop by emergency stop switch and side stand - Saddle electric opening button PRE DE - 359
Pre-delivery
Nexus 500 euro 3
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.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
CAUTION
Levels check
Level check: - Hydraulic brake system liquid level. - Rear hub oil level - Engine coolant level - Engine oil level
Road test
Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise
Static test
Static test after test ride: - Restarting when warmed up PRE DE - 360
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 - Check documents: - Check the frame and engine numbers - Check tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 361
INDEX OF TOPICS
TIME
TIME
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 001001
Action Engine to chassis - Replacement
Duration
TIME - 363
Time
Nexus 500 euro 3
Crankcase
CRANKCASE
1 2 3 Code 001100 001133 001153 Action Oil seal, clutch side - Replacement Engine crankcase- Replacement Crankcase half gasket - Replacement Duration
TIME - 364
Nexus 500 euro 3
Time
Crankshaft
CRANKSHAFT
1 2 Code 001117 001098 Action Crankshaft - Replacement Countershaft - Replacement Duration
TIME - 365
Time
Nexus 500 euro 3
Cylinder assy.
CYLINDER GROUP
1 2 3 Code 001002 001154 001129 Action Cylinder piston - Replacement Pin-ring-piston assembly - Service Chain tensioner - Service and Replacement Duration
TIME - 366
Nexus 500 euro 3
Time
Cylinder head assy.
HEAD UNIT
1 2 3 4 5 6 7 Code 001045 001049 001056 001126 001083 005116 007012 Action Valves - Replacement Valves - Adjustments Head gasket - Replacement Head - Replacement Thermistor - Replacement Rpm timing sensor - Replacement Coolant bleed valve - Replacement Duration
TIME - 367
Time
Nexus 500 euro 3
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT

1 2 Code 001044 001148 Action Camshaft - Replacement Rocking lever valve - Replacement Duration
TIME - 368
Nexus 500 euro 3
Time
Cylinder head cover
HEAD COVER
1 2 3 Code 001089 001093 001088 Action Head cover - Replacement Spark plug - Replacement Head cover gasket - Replacement Duration
TIME - 369
Time
Nexus 500 euro 3
Flywheel cover
FLYWHEEL COVER
1 2 3 4 5 6 7 8 9 Code 001087 001113 001123 001124 001057 001062 001150 001160 007011 Action Flywheel cover - Replacement Water pump - Replacement Oil filter -Replacement By-pass valve - Replacement Thermostat - Replacement Water pump command shaft - Replacement Flywheel cover gasket - Replacement Minimum oil pressure sensor - Replacement By-pass manifold - thermostat - drain valve - Replacement Duration
TIME - 370
Nexus 500 euro 3
Time
Driven pulley
DRIVEN PULLEY
1 2 3 4 Code 001022 001012 001110 001155 Action Clutch - Replacement Driven pulley - Overhaul Driven pulley - Replacement Clutch bell housing - Replacement Duration
TIME - 371
Time
Nexus 500 euro 3
Oil pump
OIL PUMP
1 2 3 4 5 6 7 8 Code 001042 001051 001112 001125 001071 001020 001102 003064 Action Oil pump - Service Belt/ Timing chain - Replacement Oil pump - Replacement Chain guide sliders - Replacement Start-up pinion - Replacement Starter motor - Replacement Net oil filter - Replacement / Cleaning Engine oil - Change Duration
TIME - 372
Nexus 500 euro 3
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY

1 2 3 4 Code 001010 001156 003065 004125 Action Geared reduction unit - Service Gear reduction unit cover - Replacement Gear box oil - Replacement Rear gear shaft - Replacement Duration
TIME - 373
Time
Nexus 500 euro 3
Driving pulley
DRIVING PULLEY
1 2 3 4 5 Code 001086 001011 001006 001141 001066 Action Driving half-pulley - Replacement rear-view belt - Replacement rear-view pulley - Service Belt anti-flapping roller - Replacement rear-view pulley - Replacement Duration
TIME - 374
Nexus 500 euro 3
Time
Transmission cover
TRANSMISSION COVER
1 2 3 4 5 Code 001065 001096 001131 001135 001170 Action Internal transmission cover - Replacement External transmission cover - Replacement Transmission air intake - Replacement Transmission cover bearing - Replacement Air manifold - replacement Duration
TIME - 375
Time
Nexus 500 euro 3
Flywheel magneto
MAGNETO FLYWHEEL
1 2 3 4 5 Code 001173 001067 001058 001104 001151 Action Rotor - Replacement Stator - Replacement Flywheel - Replacement Start-up freewheel - Replacement Start-up driven gearing - Replacement Duration
TIME - 376
Nexus 500 euro 3
Time
Butterfly valve
THROTTLE BODY
1 2 3 4 5 Code 001013 001047 001166 004122 001171 Action Intake manifold - Replacement Injector - Replacement Throttle body - Replacement Cleaner / Throttle body union - Replacement Throttle body - Service/cleaning Duration
TIME - 377
Time
Nexus 500 euro 3
Exhaust pipe
MUFFLER
1 2 3 4 5 Code 001009 001092 001095 004169 005138 Action Muffler - Replacement Exhaust manifold - Replacement Muffler guard - Replacement Muffler guard - Replacement Lambda probe - Replacement Duration
TIME - 378
Nexus 500 euro 3
Time
Air cleaner
AIR CLEANER
1 2 3 Code 001015 001014 001074 Action Air filter box - change Air filter - Replacement/Cleaning Oil vapour recovery pipe - Replacement Duration
TIME - 379
Time
Nexus 500 euro 3
Frame
FRAME
1 2 3 Code 004001 004146 001032 Action Frame - replace Front frame - Replacement Engine support pin - Replacement Duration
TIME - 380
Nexus 500 euro 3
Time
Centre-stand
SIDE/CENTRAL STAND
1 2 3 4 Code 004004 004102 005079 004171 Action Stand - Replacement Side stand - Replacement Side stand switch - Replacement Stand support plate - Replacement Duration
TIME - 381
Time
Nexus 500 euro 3
Legshield spoiler
FRONT SHIELD - SPOILER

1 2 3 4 5 6 7 Code 004066 005091 005067 004064 004149 004065 005080 Action Driving mirror - Replacement Turn indicator glass - Replacement Front direction indicator bulb - Replacement Front shield - Replacement Shield central cover - Replacement Shield back plate - Replacement Front fuse-holder - Replacement Duration
TIME - 382
Nexus 500 euro 3
Time
Central cover
CENTRAL FRAME COVER

1 2 3 4 5 Code 004011 004104 004105 004079 004143 Action Central chassis cover - Replacement Left side cover - Replacement Right side cover - Replacement Rear footrest - Replacement Footrest support - replace Duration
TIME - 383
Time
Nexus 500 euro 3
Mudguard
MUDGUARDS
1 2 3 4 Code 004167 004009 004002 003087 Action Grill / radiator cover - replace Rear mudguard - Replacement Front mudguard - change Wheel housing - Replacement Duration
TIME - 384
Nexus 500 euro 3
Time
Fuel tank
FUEL TANK
1 2 3 4 Code 004005 004170 004168 004109 Action Fuel tank - replace Tank filler neck - Replacement Fuel filler flap - Replacement Fuel tank breather - replace Duration
TIME - 385
Time
Nexus 500 euro 3
Handlebar covers
HANDLEBAR COVERS
1 2 3 4 5 Code 004018 004019 005129 004156 005038 Action Handlebar front section - Replacement Handlebar rear section - Replacement Warning light group - Replacement Glove-box flap - Replacement Instrument panel warning light bulbs - Replacement Duration
TIME - 386
Nexus 500 euro 3
Time
Handlebar components
HANDLEBAR COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 Code 003001 005017 002037 002060 002059 003059 002063 003061 002024 002071 002088 Action Handlebar - Replacement Stop switch - Replacement Brake or clutch lever - Replacement Complete gas command - Replacement Right hand grip - Replacement Counterweight - Replacement Throttle control transmission - Replacement Accelerator transmission - Adjustment Front brake pump - replace Left hand grip - Replacement Integral brake pump - Replacement Duration
TIME - 387
Time
Nexus 500 euro 3
Seat
SADDLE
1 2 Code 004003 004150 Action Saddle - Replacement Saddle shock absorber - Replacement Duration
TIME - 388
Nexus 500 euro 3
Time
Locks
LOCKS
1 2 3 4 5 6 7 Code 004010 005099 002083 002092 004054 005072 005126 Action Antitheft lock - Replacement Electric saddle opening device - Replacement Saddle opening transmission - Replacement Seat locking transmission - replacement Saddle lock catch - Replacement Immobilizer antenna - replacement Saddle opener receiver - replacement Duration
TIME - 389
Time
Nexus 500 euro 3
Turn signal lights
REAR LIGHTS
1 2 3 4 5 6 7 8 9 10 11 Code 005005 005022 005068 005091 005031 004136 005030 005048 005032 005028 005066 Action Taillight - change Rear turn indicators - Replacement Rear turn indicator bulb- Replacement Turn indicator glass - Replacement Licence plate light bulb - Replacement License plate holder support - Replacement Rear headlight cable unit- Replacement Licence plate holder - Replacement Transparent licence plate cover - replace Rear light assembly glass - Replacement Rear light bulbs - Replacement Duration
TIME - 390
Nexus 500 euro 3
Time
FRONT LIGHTS
1 2 3 Code 005002 005008 005044 Action Front headlamp - replace Front headlamp bulbs - replace Front lights cable unit - replace Duration
TIME - 391
Time
Nexus 500 euro 3
Front wheel
FRONT WHEEL
1 2 3 4 5 6 7 8 Code 005089 002041 003037 003038 003040 003047 003063 004123 Action Tone wheel - Replacement Front brake disc - Replacement Front wheel rim- Replacement Front wheel axle - Replacement Front wheel bearings - Replacement Front tyre - Replacement Tyre pressure - Check Front wheel - Replacement Duration
Grease tone wheel or drive Please take note that the code has been introduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide). In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 392
Nexus 500 euro 3
Time
Rear wheel
REAR WHEEL
1 2 3 4 5 6 7 8 Code 001016 001017 002070 003063 003077 004126 002028 004052 Action Rear wheel - Replacement Rear wheel rim - replace Rear brake disc - Replacement Tyre pressure - Check Muffler / rear shock absorber support arm - Service Rear wheel tyre - Replacement Rear wheel hub - Replacement Bumper - Replacement Duration
TIME - 393
Time
Nexus 500 euro 3
Fuel pump
FUEL PUMP
1 2 Code 004073 004137 Action Fuel pump - Replacement Injector pump pipe - Replacement Duration
TIME - 394
Nexus 500 euro 3
Time
Electric devices
HANDLEBAR ELECTRICAL COMPONENTS

1 2 3 4 5 6 Code 004035 005014 005083 003074 003075 005082 Action Instrument panel - Replacement Odometer assembly - replacement Board computer - replacement Handlebar right control - Replacement Handlebar left control - Replacement Instrument unit wiring - replacement Duration
TIME - 395
Time
Nexus 500 euro 3
ELECTRIC DEVICES
1 2 3 4 5 6 7 8 9 Code 005127 001069 005007 005046 005073 005011 005128 001094 005024 Action Overturn sensor - replacement HV coil - Replacement Battery - Replacement Battery cover - Replacement Immobilizer decoder - Replacement Start-up remote control switch - Replacement Diode group - replacement Spark plug cap - Replacement Main fuse - replacement Duration
TIME - 396
Nexus 500 euro 3
Time
ELECTRIC DEVICES
1 2 3 4 5 6 Code 001023 005009 005117 005088 005096 005003 Action Injection ECU - Replacement Voltage regulator - Replacement Electric fan remote control - Replacement Emergency stop remote control - Replacement Injection components remote control - Replacement Horn - Replacement Duration
TIME - 397
Time
Nexus 500 euro 3
ELECTRIC DEVICES
1 2 3 4 5 Code 005001 005054 005052 005114 005130 Action Electrical system - Replacement Fuse holder - Replacement Fuse (1) - Replacement Electrical system - Service Electric control management device - Replacement Duration
TIME - 398
Nexus 500 euro 3
Time
Helmet bay
HELMET COMPARTMENT
1 2 3 4 5 Code 004016 005033 005026 004142 005027 Action Helmet compartment - replace Glove-box light switch - Replacement Helmet compartment light - Replacement Plug socket - Replacement Helmet compartment bulb support Replacement Duration
TIME - 399
Time
Nexus 500 euro 3
Rear side fairings
REAR COVERS
1 2 3 4 5 6 7 8 9 Code 004053 004085 004068 004159 004036 004012 004075 004015 004056 Action Spoiler - Replacement Rear fairing - Replacement Passenger handgrip - Replacement Plates / Stickers - Replacement Lower chassis cover - Replacement Rear side panels (2) - Replacement Mat - Replacement Footrest - Replacement Upper rear light cover - Replacement Duration
TIME - 400
Nexus 500 euro 3
Time
Front suspension
FRONT SUSPENSION
1 2 3 4 5 6 7 8 Code 003051 003010 003076 003079 003048 003073 003002 004119 Action Complete fork - Replacement Front suspension - service Fork housing - replacement Fork stem - Replacement Fork oil seal - Replacement Steering clearance - Adjustment Steering fifth wheels - change Upper steering bearing - replacement Duration
TIME - 401
Time
Nexus 500 euro 3
Rear suspension
REAR SUSPENSION
1 2 3 4 Code 003085 003007 004120 003086 Action Suspension strut - Replacement Rear shock absorber - Replacement Rear suspension linkage - Replacement Suspension strut support - replacement Duration
TIME - 402
Nexus 500 euro 3
Time
Cooling system
COOLING SYSTEM
1 2 3 4 5 6 7 8 Code 007002 007016 007001 007024 007019 007013 001052 007022 Action Water cooling radiator - Replacement Fan with support - Replacement Expansion tank - Replacement Expansion tank cap - Replacement Coolant return pipe - replacement Expansion tank / radiator connecting hose - Replacement Coolant and air bleed - replacement Coolant delivery pipe - Replacement Duration
TIME - 403
Time
Nexus 500 euro 3
Braking system
BRAKE SYSTEM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Code 002021 002047 002020 002087 002084 002085 002089 002090 002039 002040 002007 003070 002002 003071 002048 002068 Action Front brake piping - Replacement Front brake fluid and air bleeding system - Replacement Rear brake disc piping - Replacement Rear integral braking system rigid hose - Replacement Integral break pump pipe, device Replacement Integral front brake pipes Integral breaking device - Replacement Integral brake fluid and bleeding system - Replacement Front brake calliper - Replacement Front brake calliper - Service Front brake pads - Replacement Front brake pads - Wear check Rear brake pads - Replacement Rear brake pads - Wear check Rear calliper - Replacement Rear calliper - Service Duration
TIME - 404
Nexus 500 euro 3
Time
Windscreen
WINDSHIELD
1 2 3 Code 004028 004101 004117 Action Windshield glass - Replacement Windshield - Replacement Top fairing - Replacement Duration
TIME - 405
A
Air filter: 35, 349
B
Battery: 50, 60, 68, 69, 76, 356 Brake: 310, 313, 315, 317, 319, 320, 323, 324
C
Coolant: 260, 331
E
Engine oil: 36
F
Fuel: 13, 211, 224, 228, 352, 385, 394 Fuses: 62
H
Headlight: 41, 340 Hub oil: 33
I
Identification: 8 Immobilizer: Instrument panel: 339
L
Light switch:
M
Maintenance: 7, 31
O
Odometer: 75 Oil filter: 37
S
Saddle: Shock absorbers: 306 Spark plug: 32, 258 Stand: 307 Start-up:
T
Tank: 13, 352, 385
Technical Data: Transmission: 9, 83, 99, 375 Turn indicators: 54 Tyres: 10

Gilera Nexus 500 Euro 3 (EN)

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Gilera Nexus 500 Euro 3 (EN)

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What is the manual about?

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WORKSHOP MANUAL

Nexus 500 euro 3

Nexus 500 euro 3

Nexus 500 euro 3

This section describes the general specifications of the vehicle.

Nexus 500 euro 3

Chassis prefix: ZAPM35200

Dimensions and mass

Nexus 500 euro 3

Nexus 500 euro 3

Specification Battery Generator

Desc./Quantity Dry-cell lead-acid battery, 12V-14Ah Three-phase alternating current

Frame and suspensions

Wheels and tyres

Nexus 500 euro 3

THERMAL GROUP AND TIMING SYSTEM

Nexus 500 euro 3

Torque in Nm *** 10 - 12 10 - 12 5-7 10 - 12 10 - 12 34 7 8.5 10 - 14 3-4 30 - 35 11 13 7-9 11 13 10 - 12 46 5-6 11 13

CRANKCASE AND CRANKSHAFT

Nexus 500 euro 3

Assembly clearances Cylinder - piston assy.

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Nexus 500 euro 3

Crankcase - crankshaft - connecting rod

Nexus 500 euro 3

Diameter of crankshaft bearings. Measure the capacity on both axes x-y.

MAX. ADMISSIBLE DISPLACEMENT

Nexus 500 euro 3

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Slot packing system

BASE GASKET THICKNESS

Nexus 500 euro 3

DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B

Nexus 500 euro 3

Stores code 001330Y

Description Tool for fitting steering seats

Driver for OD 73 mm bearing

Pliers to extract 20 mm bearings

Driver for OD 54-mm bearings

Pliers to extract 17 mm bearings

Pliers to extract 15-mm bearings

Nexus 500 euro 3

Stores code 001467Y031

Pliers to extract 15-mm bearings

Belle for OD 47-mm bearings

Pliers for circlips

Punch for fitting fifth wheel seat on steering tube

Punch for removing fifth wheels from headstock

Nexus 500 euro 3

Stores code 020055Y

Description Wrench for steering tube ring nut

Air heater support

Oil pressure gauge

Spacer bushing driving tube Crankcase splitting strip

Punch for assembling valve seal rings

Nexus 500 euro 3