Gilera Nexus 500 2005 2006 Full Service Repair Manual

WORKSHOP MANUAL 633721 - 633728

Nexus 500 euro 3

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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. "Š 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

CHAR

TOOLING

TOOL

MAINTENANCE

MAIN

ELECTRICAL SYSTEM

ELE SYS

ENGINE FROM VEHICLE

ENG VE

ENGINE

ENG

INJECTION

INJEC

SUSPENSIONS

SUSP

BRAKING SYSTEM

BRAK SYS

COOLING SYSTEM

COOL SYS

CHASSIS PRE-DELIVERY TIME

CHAS PRE DE TIME

INDEX OF TOPICS

CHARACTERISTICS

CHAR

Characteristics

Nexus 500 euro 3

This section describes the general specifications of the vehicle.

Rules This section describes general safety rules for any maintenance operations performed on the scooter.

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 reassembly.

•

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 - 2

Nexus 500 euro 3

Characteristics

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 - 3

Nexus 500 euro 3

Characteristics

Engine ENGINE Specification Engine Bore Stroke Cubic capacity Compression ratio Timing system

Valve clearance: intake: Valve clearance: exhaust 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

Desc./Quantity single-cylinder four stroke 92 mm 69 mm 460 cm³ 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, Ø 38 mm throttle body and single injector.

29 kW (39 CV) at 7250 rpm 40 N·m (4 kgm) at 5500 rpm Fluid circulation through a motor-driven pump, 3way thermostat and electric fan.

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 (dry) Engine oil (at oil and filter change) Fuel tank (including reserve approx. 2 litres) Rear hub Cooling system Front fork

CHAR - 4

Desc./Quantity ~ 1.7 litres approx. 1.5 litres approx. 14.5 litres approx. 250 cc. approx. 1.8 litres approx. 242 ± 3 cc (in each fork leg)

Nexus 500 euro 3

Characteristics

Electrical system ELECTRICAL SYSTEM Specification Electronic ignition

Spark plug Spark plug Battery Generator

Desc./Quantity inductive, high efficiency integrated with the injection system, with variable timing and separate HV coil.

NGK CR7EKB CHAMPION RG6YC Dry-cell lead-acid battery, 12V-14Ah Three-phase alternating current

Frame and suspensions CHASSIS AND SUSPENSIONS Specification Chassis Front suspension Max. front fork travel Rear suspension

Desc./Quantity Welded tubular steel chassis with stamped sheet reinforcements 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

Rear 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

Wheels and tyres WHEELS AND TYRES Specification Rims in light alloy: Front

Desc./Quantity 3.50 x 15" CHAR - 5

Nexus 500 euro 3

Characteristics

Specification Rims in light alloy: Rear Rear tyres Front tyres Tyre pressure (cold) front Tyre pressure (cold) rear

Desc./Quantity 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)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF THE 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.

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 clamp to crankcase Pipe joint / brake calliper 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

Torque in Nm 20 - 24 5÷6• 11 ÷ 13 20 ÷ 25 20 ÷ 25 20 ÷ 25 12 - 16 5-6 16 ÷ 20 20 ÷ 25 20 ÷ 25 20 ÷ 25

• Locking with Loctite threadlock medium 243

FRONT SUSPENSION Name Front wheel shaft Holding torque of lower ring nut Fork stem mounting to the plate Lower steering ring nut Upper steering ring nut Stem upper cap Screw securing handlebar to steering tube CHAR - 6

Torque in Nm 45 ÷ 50 20 ÷ 25 20 ÷ 25 10 - 13 ** 36 - 39 35 - 55 45 - 50

Nexus 500 euro 3

Characteristics

Name Pumping element fixing screw Safety screw on fork leg Wheel fastening screws

Torque in Nm 25 - 35 6÷7 33 - 37

* Tighten and loosen completely. ** Tighten and loosen by 90°

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

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

• Locking with Loctite threadlock medium 243

ENGINE ASSEMBLY Name Starter motor screws

Torque in Nm 11 ÷ 13

THERMAL UNIT AND TIMING SYSTEM Name Spark plug 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 12 ÷ 14 *** 10 - 12 10 - 12 5-7 10 - 12 10 - 12 3÷4 7 ÷ 8.5 10 - 14 3-4 30 - 35 11 ÷ 13 7-9 11 ÷ 13 10 - 12 4÷6 5-6 11 ÷ 13

*** Apply a preliminary torque of 7 N·m in a crossed sequence. - Tighten by 90° in a crossed sequence. - Tighten again by 90° in a crossed sequence.

CHAR - 7

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