Gilera 2008 MSS Nexus, 2008 MSS Nexus 300 i.e. E3 User Manual

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MANUALE STAZIONE DI SERVIZIO

XXXXXX IT- EN-FR-DE-ES-PT-NL-EL

MSS Nexus 300 i.e. E3 ( 2008)

MANUALE

STAZIONE DI

SERVIZIO

MSS Nexus 300 i.e. E3 ( 2008)

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/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

MANUALE STAZIONE DI

SERVIZIO

MSS Nexus 300 i.e. E3 ( 2008)

Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli attrezzi specifici.

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

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

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

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; 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 it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English sizes. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 7

Vehicle identification

To read the chassis prefix, remove the lid «A» in the helmet compartment.

The engine prefix «B» is stamped near the left shock absorber lower support.

VEHICLE IDENTIFICATION

Specification

Desc./Quantity

Chassis prefix ZAPM35600123456789

Engine prefix M356M

Dimensions and mass

WEIGHTS AND DIMENSIONS

Specification

Desc./Quantity

Kerb weight 174 ± 5 kg

Maximum weight allowed 370 Kg

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 8

Engine

ENGINE TECHNICAL DATA

Specification

Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 278 cm³

Bore x Stroke 75x63 mm

Compression ratio 11 ± 0.5 : 1

Idle speed 1700 ± 100 rpm

Timing system 4 valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.10 mm Outlet: 0.15 mm

Max. power 16.1 kW at 7,250 rpm Max. torque 23 Nm at 6,000 rpm

Main drive Automatic expandable pulley variator with torque server, V-

belt, automatic self-ventilating centrifugal dry clutch

Final reduction

Gear reduction unit in oil bath.

Lubrication Engine lubrication with lobe pump (inside crankcase) controlled

by a chain with double filter: mesh and paper.

Cooling Forced-circulation coolant system.

Electric start-up Oil-coated freewheel and torque limiter.

Ignition Electronic inductive discharge ignition, high efficiency, with

separate HV coil.

Ignition advance α/N three-dimensional map managed by control unit

Spark plug NGK CR8EKB

Fuel supply Electronic injection with electric fuel pump

Fuel Unleaded petrol (95 RON)

Exhaust muffler absorption-type exhaust muffler with catalytic converter.

Emission regulations EURO 3

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 9

Transmission

TRANSMISSION

Specification Desc./Quantity

Main drive Automatic expandable pulley variator with torque server, V-

belt, automatic self-ventilating centrifugal dry clutch

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 1.3 l

Transmission oil 250 cm³

Cooling system fluid ~ 1.8 l

Fuel tank (reserve) approx.15.00 l (approx. 2.80 l)

Electrical system

ELECTRICAL COMPONENTS

Specification

Desc./Quantity

Start-up Electric

Ignition Electronic inductive discharge ignition, high efficiency, with

separate HV coil.

Ignition advance α/N three-dimensional map managed by control unit

Spark plug NGK CR8EKB

Battery 12V/14 Ah, sealed battery

Frame and suspensions

FRAME AND SUSPENSIONS

Specification

Desc./Quantity

Chassis Tubular and sheet steel. Front suspension Hydraulic telescopic fork with Ø 35 mm stem Rear suspension Two double-acting shock absorbers, adjustable to four posi-

tions at preloading.

Brakes

BRAKES

Specification

Desc./Quantity

Front brake Ø 260-mm disc brake with hydraulic control activated by han-

dlebar right-side lever.

Rear brake Ø 240-mm disc brake with hydraulic control activated by the

handlebar left-side lever.

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 10

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front tyre Tubeless, 120/70 - 15'' 56P Rear tyre Tubeless, 140/60 - 14'' 64P

Front rim 15'' x 3.00 Rear rim 14'' x 3.50

TYRE PRESSURE

Specification Desc./Quantity

Front tyre pressure (with passenger) 2.3 bar (2.3) Rear tyre pressure (with passenger) 2.3 bar (2.5)

N.B.

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

Tightening Torques

STEERING

Name

Torque in Nm

Steering tube upper ring nut 40 ÷ 45 Steering tube lower ring nut 14 ÷ 17

Handlebar fixing screw 50 ÷ 55

Fixing screws for handlebar control assembly U-bolts 7 ÷ 10

CHASSIS

Name

Torque in Nm

Centre stand bolt 25 ÷ 30 Centre stand bolt 32 ÷ 40

Engine and vehicle side swinging arm junction bolt 33 ÷ 41

Body shell - Swinging arm pin 76 ÷ 83

Screw fixing the silent-block support plate to the body 42 ÷ 52

Engine-swinging arm bolt 64 - 72

FRONT SUSPENSION

Name

Torque in Nm

Fork leg screw 6 ÷ 7

Front wheel axle 45 ÷ 50

Hydraulic rod fixing screw 25 ÷ 35*

Fork locking screws cap 15 ÷ 30

Stem support clamp tightening screws 20 ÷ 25

Recommended products

Loctite 243 Medium strength threadlock

Loctite 243 medium-strength threadlock

REAR SUSPENSION

Name

Torque in Nm

Upper shock absorber clamp 33 ÷ 41 Lower shock absorber clamp 33 ÷ 41

Shock absorber-crankcase attachment bracket 20 ÷ 25

Rear wheel axle 104 ÷ 126

Muffler arm clamping screws 27 ÷ 30

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 11

FRONT BRAKE

Name Torque in Nm

Screw tightening calliper to the support 24 ÷ 27

Pad fastening pin 19.6 ÷ 24.5

Calliper support plate - fork fixing screws 41 ÷ 51

Brake disc screws 8 ÷ 10

Brake fluid pump-hose fitting 16 ÷ 20

Fixing screws for handlebar control assembly U-bolts 7 ÷ 10

Recommended products

Loctite 243 Medium strength threadlock

Loctite 243 medium-strength threadlock

REAR BRAKE

Name Torque in Nm

Rear brake calliper fixing screws 20 ÷ 25

Engine- calliper support plate fixing screws 48 ÷ 52

Brake disc screws 8 ÷ 10

Screw tightening calliper to the support 24 ÷ 27

Pad fastening pin 19.6 ÷ 24.5

Circuit bleed calliper fitting 12 - 16

Recommended products

Loctite 243 Medium strength threadlock

Loctite 243 medium-strength threadlock

MUFFLER

Name

Torque in Nm

Muffler heat guard fixing screw 4 ÷ 5 Screw for fixing muffler to the support arm 20 ÷ 25 Lambda probe clamp on exhaust manifold 40 ÷ 50

Exhaust manifold-muffler joint clamp 12 ÷ 13

Manifold - muffler diaphragm tightening clamp 16 ÷ 18

LUBRICATION

Name

Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 33

Engine oil drainage plug/mesh filter 24 ÷ 30

Oil filter 4 ÷ 6

Oil pump cover screws 7 ÷ 9

Screws fixing oil pump to crankcase 5 - 6

Oil pump control crown screw 10 ÷ 14

Oil pump cover plate screws 4 ÷ 6

Oil sump screws 10 ÷ 14

Minimum oil pressure sensor 12 ÷ 14

CYLINDER HEAD

Name

Torque in Nm

Spark plug 12 ÷ 14

Head cover screws 6 ÷ 7

Nuts fixing head to cylinder 7±1 + 10±1 + 270°

Head fixing side screws 11 ÷ 12

Starter ground screw 7 ÷ 8.5

Tappet set screw lock nut 6 ÷ 8

Inlet manifold screws 11 ÷ 13

Timing chain tensioner slider screw 10 ÷ 14

Starter ground support screw 11 ÷ 15

Timing chain tensioner support screw 11 ÷ 13

Timing chain tensioner central screw 5 - 6

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 12

Name Torque in Nm

Camshaft retention plate screw 4 ÷ 6

TRANSMISSION

Name Torque in Nm

Belt support roller screw 11 ÷ 13

Clutch unit nut on driven pulley 45 ÷ 50

Drive pulley nut 75 ÷ 83

Transmission cover screws 11 ÷ 13

Driven pulley shaft nut 54 ÷ 60

Rear hub cap screws 24 ÷ 27

FLYWHEEL

Name Torque in Nm

Flywheel cover screw 11 ÷ 13

Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength threadlock)

Flywheel nut 94 ÷ 102

Pick-Up clamping screws 3 ÷ 4

Screw fixing freewheel to flywheel 13 ÷ 15

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Internal engine crankcase bulkhead (transmission-side half

shaft) screws

4 ÷ 6

Engine-crankcase coupling screws 11 ÷ 13

Starter motor screws 11 ÷ 13

Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE 242 medium-strength threadlock)

COOLING

Name

Torque in Nm

Water pump rotor cover 3 ÷ 4

Thermostat cover screws 3 ÷ 4

Bleed screw 3

Overhaul data

Assembly clearances

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 13

Cylinder - piston assy.

CYLINDER - PISTON

Specification

Desc./Quantity

Plunger diameter 74.967 +0.014 -0.014 mm

Cylinder diameter 75 +0.038 +0.01 mm

COUPLING CATEGORIES

Name

Initials Cylinder Piston Play on fitting

cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064 cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064 cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064 cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064

N.B.

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.

- Measure the outside diameter of the gudgeon pin.

Characteristic

Pin outside diameter

16 +0 -0.004 mm

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 14

- Measure the diameter of the bearings on the piston.

Characteristic

Standard diameter

16 +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

Standard clearance:

0.001 ÷ 0.010 mm

- Carefully clean the sealing ring housings.

- Measure the coupling clearance between the sealing 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.

Fitting clearance

Top piston ring - standard coupling clearance

0.015 - 0.06 mm Top piston ring - maximum clear-

ance allowed after use 0.07 mm Middle piston ring - standard coupling clearance 0.015 - 0.06 mm Middle piston ring - maximum clearance allowed after use 0.07 mm oil scraper ring - standard coupling clearance 0.015 - 0.06 mm oil scraper ring - maximum clearance allowed after use

0.07 mm

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 15

- Check that the head coupling surface is not worn or misshapen.

- Pistons and cylinders are classified according to diameter. The coupling must be made with those of the same type (M-M, N-N, O-O, P-P).

Characteristic

Maximum allowable run-out:

0.05 mm

Crankcase - crankshaft - connecting rod

CRANKSHAFT

Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine

Crankshaft Crankshaft to crankcase axial

clearance

Crankshaft to crankcase axial clearance

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Description Dimensions Initials Quantity

Half-shaft, transmission

side

16.6 +0-0.05 A D = 0.20 - 0.50

Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50

Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50

Spacer tool 51.4 +0.05 E D = 0.20 - 0.50

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 16

CRANKSHAFT

Specification

Desc./Quantity

Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 17

MAX. ADMISSIBLE DISPLACEMENT

Specification

Desc./Quantity

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

Characteristics MSS Nexus 300 i.e. E3 ( 2008)

CHAR - 18

Characteristic

Crankshaft-crankcase axial clearance (H)

0.15 ÷ 0.43 mm

- Using a bore gauge, measure the connecting rod small end diameter.

N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX-

CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.

Characteristic

Standard diameter

16 +0.025 +0.015 mm

- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure 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 half-bearings, 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.

- 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.

- There are three crankcase versions: with BLUE bushings, with YELLOW bushings and with GREEN bushings.

- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter after driving is variable on the basis of a coupling selection.

- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft.

- The main bushings are available in three thickness categories, identified by colour markings, as shown in the table below.

BUSHINGS

TYPE

IDENTIFICATION CRANKSHAFT HALF-BEARING

B BLUE 1.973 ÷ 1.976 C YELLOW 1.976 ÷ 1.979 E GREEN 1.979 ÷ 1.982

MSS Nexus 300 i.e. E3 ( 2008) Characteristics

CHAR - 19

COUPLINGS

BUSHING CATEGORY CRANKCASE

HALVES CATEGORY

BUSHING INSIDE DIAMETER AFTER FITTING

B 2 29.024 ÷ 29.054 C 1 29.024 ÷ 29.054

2 29.018 ÷ 29.048

E 1 29.018 ÷ 29.048

Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare crankshaft has half-shafts of the same category.

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

Locking torques (N*m)

Hub oil drainage screw 15 ÷ 17 Nm

MSS Nexus 300 i.e. E3 ( 2008) Maintenance

MAIN - 43

Air filter

Proceed as follows:

1. Unscrew the 9 fixing screws «A»;

2. Remove the air filter«B»

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NECESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

1. Wash the sponge with water and neutral soap.

2. Dry it with a clean cloth and small blasts of compressed air.

3. Impregnate the sponge with a mixture of 50% petrol and 50% specified oil.

4. Gently squeeze the filter element, let it drip and then refit it.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS, IT IS NECESSARY TO SERVICE THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

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".

Maintenance MSS Nexus 300 i.e. E3 ( 2008)

MAIN - 44

Replacement

Change oil and replace filter as indicated in the scheduled maintenance table. Empty the engine by draining the oil through drainage plug «B».

To facilitate oil drainage, loosen the cap/dipstick «A».

Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ».

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil. Since a certain quantity of oil still remains in the circuit, engine oil must be added through plug «A». Then start the scooter, leave it running for a

MSS Nexus 300 i.e. E3 ( 2008) Maintenance

MAIN - 45

few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.

N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Locking torques (N*m)

Oil filter 4 ÷ 6 Engine oil drainage plug 24 ÷ 30

Check

This operation must be carried out with the engine cold and following the procedure below:

- Place the vehicle on its centre stand and on flat ground.

- Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it all the way down.

- Remove the cap/dipstick again and check that the level is between the min and max reference marks; top-up, if required. 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, wait at least 10 minutes after the engine has been stopped so as to get the correct level.

Maintenance MSS Nexus 300 i.e. E3 ( 2008)

MAIN - 46

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. Restoring the level from the MIN to the MAX marks requires approx. 400 m³ of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes. Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the mesh filter and oil drainage plug, screwing them up to the specified torque. Refit the new cartridge filter being careful to lubricate the O-ring before fitting it. Change the engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

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

MSS Nexus 300 i.e. E3 ( 2008) Maintenance

MAIN - 47

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the flywheel cover as shown in the figure (TDC). Make sure that the 4V reference point on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure. If the reference is opposite the indicator on the head, turn the crankshaft once more. For the use of this reference mark, remove the spark plug and turn the engine in the direction that is the reverse of the normal direction using a calliper spanner applied to the camshaft command pulley casing.

Cooling system

If noise or liquid leaks through the drain bore of the water pump is detected, it will be necessary to replace the pump as described in the «Flywheel cover» Chapter. Proceed to carry out a few preliminary operations as described below:

- Place the vehicle on its centre stand and on flat ground.

- 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 3 fixing 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

Maintenance MSS Nexus 300 i.e. E3 ( 2008)

MAIN - 48

Cooling system

approx. 1.8 litres

Level check

Check coolant level when the engine is cold and as indicated in the scheduled maintenance table, following the steps below:

- Place the vehicle on its centre stand and on flat ground.

- Remove the expansion tank cap.

- To check the level, it is necessary to look inside the expansion tank: Reference «C» shows the adequate coolant level.

-The coolant consists of an ethylene glycol and corrosion inhibitor based 50% de-ionised water- antifreeze solution mix.

CAUTION

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 - 40°C. THE MIXTURE IN COMBINATION WITH THE PRESSURE OF 0.9 BAR RAISES THE BOILING POINT TO APPROX. 125°C. 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.

MSS Nexus 300 i.e. E3 ( 2008) Maintenance

MAIN - 49

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.

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.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.

N.B.

Maintenance MSS Nexus 300 i.e. E3 ( 2008)

MAIN - 50

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.

- 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 EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE vehicle IS USED.

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INDEX OF TOPICS

TROUBLESHOOTING TROUBL

This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given.

Engine

Poor performance

POOR PERFORMANCE

Possible Cause Operation

Fuel pump Check the injection load relay

Excess of encrustations in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Transmission belt worn Replace

Inefficient automatic transmission Check the rollers, the pulley movement and make sure the

drive belt is in good conditions; replace the damaged parts and

lubricate the moveable driven pulley with specific grease.

Clutch slipping Check the clutch system and/or the bell and replace if neces-

sary

Overheated valves Remove the head and the valves, grind or replace the valves

Wrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head assembly

Starting difficulties

DIFFICULT STARTING

Possible Cause

Operation

Rpm too low at start-up or engine and start-up system dam-

aged

Check the starter motor, the system and the torque limiter

Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance

- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make

the motor turn so as to expel the fuel excess taking care to

connect the cap to the spark plug, and this in turn to the ground.

If the fuel tank is empty, refuel and start up.

Air filter blocked or dirty. Remove the sponge, wash with water and car shampoo, then

soak it in a mixture of 50% petrol and 50% specific oil. Press

with your hand without squeezing, allow it to drip dry and refit.

Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components

Battery flat Check the charge of the battery, if there are any sulphur marks,

replace and use the new battery following the instructions

shown in the chapter

Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-

ened

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause

Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

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Possible Cause Operation

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause

Operation

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass contact surface with the casing is mainly in the centre with equivalent characteristics on the three masses.

Check that the clutch casing is not scored or worn in an anom-

alous way

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause

Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shift

of the disc with a dial gauge and with wheel mounted on the

scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause

Operation

Defective sliding of pistons Replace the calliper.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and

a wheel mounted on the vehicle to measure the axial shift of

the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or stuck rubber gaskets Replace the calliper.

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Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the

above adjustments, check the rotation seats and the steering

fifth wheels.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the

above adjustments, check the rotation seats and the steering

fifth wheels.

Noisy suspension

NOISY SUSPENSION

Possible Cause

Operation

Malfunctions in the suspension system

If the front suspension is noisy, check: locking tor-

ques, headstock components, inspect forks.

Suspension oil leakage

OIL LEAKAGE FROM SUSPENSION

Possible Cause

Operation

Seal fault or breakage Replace the shock absorber

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Components arrangement

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1. Remote controls

Remove the legshield to reach it.

A. Electric fan remote control B. High-beam light remote control C. Injection load remote control

2. Electric control management device

Remove the legshield to reach it.

3. Main fuses

To reach them, remove the battery cover placed in the helmet compartment.

4. Injection ECU

To reach it, remove the inspection compartment placed in the helmet compartment.

5. Auxiliary fuses

Located in the helmet compartment.

6. Starter motor

To reach it, remove the helmet compartment.

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7. Start-up remote control

To reach it, remove the central chassis cover.

8. Stand button

Remove the left footrest to reach them.

9. Horn

To reach it, remove the lower cover.

10-11. Key switch/Immobilizer aerial

Remove the shield back plate to reach them.

12. Battery

To reach it, remove the battery cover placed in the helmet compartment.

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13. HV coil

Remove the right side fairing to reach them.

14. Magneto flywheel

The connector is located near the fuel pump. To reach it, remove the central chassis cover.

15. Oil pressure sensor

On the engine, on the right-hand side of the vehicle.

16. Fuel level transmitter

To reach it, remove the central chassis cover. The transmitter is integrated to the fuel pump.

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17. Voltage regulator

To reach it, remove the lower cover.

18.Wheel turning sensor

In the front wheel, on the right-hand side.

Ground points

A. Ground points on the chassis

To reach them, remove the right footrest.

B. Ground point on the engine

To reach it, remove the inspection compartment placed in the helmet compartment.

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Checks and inspections

This section is devoted to the checks on the electrical system components.

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 vehicle to be operated only when it is started with coded keys recognised by the control unit. The code is integrated in a transponder in the key block. This allows the driver clear operation without having to do anything other than just turning the key. The Immobilizer system consists of the following components:

- electronic control unit

- immobilizer aerial

- master key with incorporated transponder (red key)

- service key with incorporated transponder (black key)

- HV coil

- diagnosis LED The diagnosis LED also works as a theft-deterrent blinker. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the theft-deterrent blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit If the LED is off regardless of the position of the ignition-key switch and/or the instrument panel is not initiated, check if:

•

there is battery voltage

•

fuses 1,5,7,8 are in working order

•

there is power to the control unit as specified below:

Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions:

With the key switch set to OFF:

•

if there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power supply). If there is no voltage check that fuse 1 and its cable are in working order.

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With the key switch in the OFF position:

•

there is battery voltage between terminals 5-26 and terminal 5-frame earth (fixed power supply). If there is no voltage, check the key switch contacts, that fuses No. 5 and 7 plus their cables are in working order.

•

There is continuity between terminals 12-18 and the emergency cut-out switch is set to "RUN" and the side stand folded up. If there is no continuity check the contacts of the latter.

After removing the shield back plate, remove the electrical connection from the aerial as shown in the photograph.

Remove the protective base from the connector.

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With the ignition key switch set to ON, check if there is battery voltage between the White-Black and Black cables.

With MIU connector disconnected, check the continuity between the Orange-White cable and pin 7 of the interface wiring .

Specific tooling

020481Y Control unit interface wiring 020331Y Digital multimeter

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 if the control unit has been programmed properly. The data storage procedure for a previously not programmed control unit provides for the recognition of the master as the first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service

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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 (limit values 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, the master key transponder is strictly matched with the control unit. 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 thoroughly inspected: In any case it is advisable to use resistive spark plugs.

Characteristic

MASTER key:

RED KEY

SERVICE key.

BLACK KEY

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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. Previously unused control unit - 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. Previously unused control unit - transponder absent or cannot be used: The LED is per-

manently ON; in this condition, no operations are possible, including starting of the vehicle.

3. Programmed control unit - the service key in (normal condition of use): a single 0.7-second

flash is displayed, after which the LED remains off steadily. The engine can be started.

4. Programmed control unit - Master key in: 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 completed, the LED remains permanently OFF. The engine can be started.

5. Programmed control unit - 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:

•

Code 1 flash

•

2-flash code

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•

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 two-flash code shows a system where the control unit does not show 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. If this is not the case, replace the defective key and/or reprogram the control unit. Replace the control unit if the problem continues.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the control unit 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 control unit. If this is not the case, perform a reprogramming.

Ignition circuit

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No spark plug

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

HV coil primary resistance value:

Disconnect the connector of the HV coil and measure the resistance between the two terminals.

Characteristic

HV coil resistance primary value:

~ 0.9 Ω

HV coil secondary resistance value:

1) Disconnect the HV cable from the spark plug

and measure the resistance between the spark plug cap and the HV coil negative terminal.

2)Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable end and the HV coil negative terminal (see figure).

3) Measure the resistance between the 2 ends of the spark plug cap.

Characteristic

HV coil secondary resistance value with spark plug cap

~ 8.4 kΩ

HV coil secondary resistance value:

~ 3.4 kΩ

Spark plug cap resistance value

~ 5 kΩ

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. The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability.

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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 Ω

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

Look for any leakage

1) Access the battery by removing its cover under the saddle.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.

4) With ignition key still at OFF, the reading detected by the ammeter must be ≤ 0.5 mA.

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) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm. Maximum current output check.

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- With the engine off and the panel at «ON» with the lights on, allow the battery voltage to stop at 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Start the engine and rev it up to a high engine speed while reading the value on the pincer. With an efficient battery a value must be detected: > 20A

VOLTAGE REGULATOR/RECTIFIER

Specification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 ÷ 15V at 5000 rpm with lights off

Starter motor

KEY

1. Battery

2. Fuse No. 3

3. Key switch contacts

4. Fuse No. 10

5. Stop buttons

6. Starter button

7. Starter motor

8. Start-up remote control A. To injection ECU

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

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1) Check fuses No. 3 and 10, and the key switch contacts.

2) Check the contacts of the stop buttons and the starter button.

3) Check the start-up remote control switch.

4) Check wiring continuity between the Green-Blue cable that connects the starter remote control to

the injection electronic control unit (pin 24).

5) Check the starter motor ground connection.

Horn control

KEY

1. Battery

2. Fuse No. 3

3. Key switch contacts

4. Fuse No. 10

5. Horn button

6. Horn

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check fuses No. 3 and 10, and the key switch contacts.

2) Check the horn button contacts.

3) Check wiring continuity.

4) Check the horn ground connection.

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Turn signals system check

KEY

1. Battery

2. Fuse No. 5

3. Key switch contacts

4. Fuse No. 7

5. Fuse No. 8

6. Turn indicator control device

7. Electric control management device

8. Turn indicator switch

9. Turn indicator bulbs

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

1) Check that bulbs operate properly.

2) Check fuses No. 5; 7; 8 and the key switch contacts.

3) Check if there is voltage between the Red-Black cable and the Black cable of the turn indicator control

device or check wiring continuity.

3) With the key switch set to «ON», check again between the White-Black and the Black cables.

4) Check the turn indicator switch contacts.

5) Check continuity between the Red- Black cable (pin 3) and the White-Blue cable (pin 2) of the electric

control device.

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6) Repeat the check between the Blue cable (pin 5) and the Pink cable (pin 4).

7) Use the turn indicator control device to check bulb wiring continuity .

level indicators

WARNING

ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.

If faults are detected:

1) With a multimeter, check resistance values between the White-Green cable and the Black cable of the fuel level transmitter under different conditions.

2) If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted.

Electric characteristic

Resistance value when the tank is full

<= 7 Ω

Resistance value when the tank is empty

90 +13/-3 Ω

Lights list

BULBS

Specification

Desc./Quantity

1 High/low beam light bulb

Type: Halogen (H7)

Power: 12V - 55W

Quantity: 2

2 Front headlights bulb

Type: Incandescent (W2.1 x 9.5 D)

Power: 12V - 5W

Quantity: 2

3 Rear turn indicator bulbs

Type: Incandescent (BAU 155 )

Power: 12V-10W

Quantity: 2

4 Front turn indicator bulbs

Type: Incandescent (BAU 155 )

Power: 12V-10W

Quantity: 2

5 Tail light and stop light bulb

Type: Incandescent (W2.1 x 9.5 D)

Power: 12V - 21/5W

Quantity: 1

6 License plate light bulb

Type: Incandescent (W2.1 x 9.5 D)

Power: 12V - 5W

Quantity: 1

7 Helmet compartment light bulb

Type: Incandescent (SV 8.5)

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Specification Desc./Quantity

Power: 12V - 5W

Quantity: 1

Fuses

The electric system is fitted with 2 fuse boxes:

1. Fuse box «A» 6 fuses located in the helmet compartment near the battery.

2. Fuse box «B» 6 fuses located in the helmet compartment near the plug socket.

Replace fuses using adequate pliers supplied in the tool kit. The chart shows the position and characteristics of the fuses in the vehicle.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

FUSE BOX A

Specification

Desc./Quantity

1 Fuse No. 1

Capacity:7.5 A

Protected circuits: Injection ECU supply

2 Fuse No. 2

Capacity:10 A

Protected circuits:HV coil - Fuel injector -

Fuel pump

3 Fuse No. 3

Capacity: 15A

Protected circuits: Lines protected by fuses

No. 9; 10; 11; 12.

4 Fuse No. 4

Capacity:15A

Protected circuits: Radiator electric fan

5 Fuse No. 5

Capacity:15A

Protected circuits: Lines protected by fuses

No. 7 and 8; 12V 180W Socket, Helmet com-

partment bulb

6 Fuse No. 6

Capacity:30 A

Protected circuits:Recharge circuit

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CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

FUSE BOX B

Specification

Desc./Quantity

1 Fuse No. 7

Capacity:7.5 A

Protected circuits: Digital instrument panel,

Turn indicator bulbs, Radiator electric fan re-

mote control, ECU remote control, Immobil-

izer, Antitheft device pre-installation

2 Fuse No. 8

Capacity:7.5 A

Protected circuits: Digital instrument panel,

Antitheft device pre-installation

3 Fuse No. 9

Capacity:7.5 A

Protected circuits:Analogue rpm indicator

and digital instrument panel, tail lights, instru-

ment panel lights

4 Fuse No. 10

Capacity:7.5 A

Protected circuits: Stop bulb, Engine start-

up circuit, Horn

5 Fuse No. 11

Capacity: 7.5 A

Protected circuits: High-beam light bulb,

High-beam remote control, High-beam warn-

ing light

6 Fuse No. 12

Capacity:7.5 A

Protected circuits: Low-beam light bulb

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Dashboard

The digital display has two service symbols:

SERVICE:

The lamp should come on after reaching 1000 km, then every 10,000 km or 1 year after the last activation.

BELT:

This lamp should come on and flash every 10,000 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 and analogue speedometer, analogue rev counter and warning light group.

• Warning light group

The warning light group includes:

- Warning light preparation

- Tail light and low-beam warning light (green)

- High-beam warning light (blue)

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- Warning light preparation

• 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.

4. Momentary consumption The fuel symbol and km/h or mph appear.

5. Range The fuel icon appears.

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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 10,000 km.

SERVICE: 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 10,000 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". 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".

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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

-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

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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

COMMISSIONING A NEW DRY-CHARGED BATTERY

- Remove the battery air pipe stop cap and each single cell cap.

- Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an ambient temperature not below 15°C, until it reaches the upper level indicated on the block.

- Tilt the battery slightly to remove any air bubbles formed during filling.

- Place the caps on each single cell filling hole without screwing them and leave the battery to rest. During this stage, the battery is subjected to a gasification phenomenon and temperature increases.

- Let it rest until it reaches ambient temperature (this stage can take up to 60 minutes).

- Tilt the battery slightly to facilitate the elimination of any gas bubbles present inside; restore the level using the same filling electrolyte Note: This is the last time that electrolyte can be added. Future top-ups should be done only with distilled water;

- Before 24 hours elapse, recharge the battery following these steps:

- Connect the battery charger terminals observing the correct polarity;

- Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity;

- Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge. Note: Batteries that have been stored for a long time may take a longer charging time. The battery chargers drw. 020333Y and drw. 020334Y have an automatic protection which interrupts the recharge after 12 hours to avoid battery harmful heating. In this case, a green LED turns on to indicate the activation of the safety system and not the end of the charge.

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- Let the open circuit battery rest for approximately 4-6 hours; then check the off-load voltage using a standard tester.

- If the open-circuit voltage is higher or equal to 12.6V, the battery is charged adequately. Slightly shake or tilt the battery to eliminate any air bubbles formed during recharging.

- Check the electrolyte levels again, fill them with distilled water up to the upper level line if necessary, clean battery properly, close each single cell cap tightly and install it on the vehicle.

- If the voltage indicated is low, charge the battery another 4-6 hours in the way described above.

Note: With the battery charger drw. 020334Y, it is possible to check the battery charge level with the Check function. The value indicated on the display must be higher than the value indicated on the chart;

otherwise, recharge the battery again in the same way indicated above.

Battery installation

To access the battery, proceed as follows:

1. Place the scooter on its centre stand;

2. Open the saddle following above instructions, see «Saddle» section;

3. Remove the piston ring «A» and take off the battery cover. The battery is the electrical device that requires the most frequent inspections and diligent maintenance. The most relevant maintenance rules to be observed are as follows:

Electric characteristic

Battery

12V-14Ah

- Insert the battery by connecting the battery breather tube as shown in the photograph.

N.B.

IN ORDER TO FIT THE CABLES ON THE BATTERY TERMINALS CORRECTLY, REST THE LOWER END OF THE TERMINAL SIDE OF THE BATTERY ON THE EDGE OF THE BATTERY WELL.

- Using the screwdriver, tighten up the battery terminal cables as far as they will go, placing the special Grover washer between the screw head and the cable terminal.

N.B.

DO NOT USE WRENCHES TO TIGHTEN UP THE SCREWS FOR FIXING THE TERMINALS TO THE BATTERY TERMINALS

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- Refit the battery cover

Make sure that the terminals are connected correctly. When a new battery is installed, the correct time and date must be reset on the digital instrument panel («Clock» and «MODE button» section).

CAUTION

DO NOT REVERSE THE POLARITY: RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELECTRICAL SYSTEM.

The electrolyte level, which should be checked regularly, must always be at the maximum level. To top it up to this level, use only distilled water. Should it become necessary to top up the battery with water too frequently, check the scooter's electrical system because the battery is being overloaded, causing it to lose power quickly.

NEVER DISCONNECT THE BATTERY CABLES WHILE THE ENGINE IS RUNNING; THIS CAN CAUSE PERMANENT DAMAGE TO THE VEHICLE ELECTRONIC CONTROL UNIT.

CAUTION

ELECTROLYTE CONTAINS SULPHURIC ACID: AVOID CONTACT WITH EYES, SKIN AND CLOTHES. IN THE CASE OF ACCIDENTAL CONTACT, RINSE WITH ABUNDANT OF WATER AND CONSULT A DOCTOR.

WARNING

SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT REGULATIONS.

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

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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 BAT-

TERY 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.

Remote controls check

To check the operation of a remote control:

1) Check that, given regular conditions, there is no continuity between terminals 87 and 30.

2) Apply a 12V voltage to power terminals 86 and 85 of the remote control.

3) With the remote control fed, check that there is continuity between terminals 87 and 30.

4) If these conditions are not met, the remote control is surely damaged and, therefore, it should be replaced.

Switches check

To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts.

KEY 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

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ENGINE STOP SWITCH

STARTER BUTTON

LIGHT SWITCH

TURN INDICATOR SWITCH

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HORN BUTTON

HELMET COMPARTMENT LIGHT SWITCH

Connectors

INJECTION ELECTRONIC CONTROL UNIT

1. Injection telltale light (Brown-Black)

2. Rpm indicator (Green)

3. Not connected 4 Lambda probe negative terminal (Sky blue-

Black)

5 Live supply (White-Black)

6. Battery powered (White-Red)

7. Immobilizer aerial (Orange-White)

8. Electric fan remote control negative terminal (Green-White)

9. Engine temperature (Yellow-Pink)

10. Not connected

11. Lambda probe positive (Sky blue-Yellow)

12. Engine stop switch (Orange)

13. Pick-up positive terminal (Red)

14. Injector negative terminal (Red-Yellow)

15. Pick-up negative terminal (White)

16. K line (Orange-Black)

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17. Immobilizer warning light (Grey-Yellow)

18. Stand button (Brown-Red)

19. Not connected

20. Injection load remote control negative terminal

(Black-Purple)

21. Not connected

22. HV coil negative terminal (Pink-Black)

23. Not connected

24. Start-up enabling switch (Green-Blue)

25. Not connected

26. Ground (Black)

IMMOBILIZER AERIAL CONNECTOR

1. Live supply (White-Black)

2. Ground (Black)

3. Injection ECU (Orange-White)

ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR

1. LHS Turn indicator bulbs (Pink)

2. RHS Turn indicator bulbs (White-Blue)

3. Ground (Black)

4. Battery powered (Red-Black)

5 Live supply (White-Black)

6. Helmet compartment light bulb (Blue-Yellow)

7. Not connected

8. Not connected

LAMBDA PROBE CONNECTOR

1. Positive from injection ECU (Sky blue-Yellow)

2. Negative from injection ECU (Sky blue-Black)

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PICK-UP CONNECTOR

1. Positive from injection ECU (Red)

2. Negative from injection ECU (White)

3. Not connected

CONNECTOR FOR ELECTRICAL CONTROL MANAGEMENT DEVICE

1. Live supply (White-Black)

2. Right turn indicator switch (White-Blue)

3. LHS turn indicator signal (Blue)

4. LHS turn indicator switch (Pink)

5. RHS turn indicator signal (Pink-Black)

6. MODE button remote (Sky blue-Red)

7. MODE button remote signal (Grey)

8. Oil pressure sensor (Pink-White)

9. Oil pressure sensor signal (White)

10. Not connected

11. Not connected

12. Not connected FUEL INJECTOR CONNECTOR

1. Positive from remote control (Black-Green)

2. Negative from injection ECU (Red-Yellow)

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ENGINE TEMPERATURE SENSOR CONNECTOR

1. Injection ECU temperature signal (Yellow-Pink)

2. Indicator temperature signal (Orange)

3. Ground (Sky blue-Green)

4. Indicator temperature signal (Sky blue-Black)

ELECTRIC FAN CONNECTOR

1. Ground (Black)

2. Positive from remote control (Red-Black)

STAND BUTTON CONNECTOR

1. Ground (Sky blue-Green)

2. Injection ECU signal (Brown-Red)

HV COIL CONNECTOR

1. Positive from remote control (Black-Green)

2. Negative from injection ECU (Pink-Black)

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FUEL PUMP CONNECTOR AND FUEL LEVEL TRANSMITTER

1. Not connected

2. Ground (Black)

3. Ground (Black)

4. Fuel level indicator (White-Green)

5. Positive from remote control (Black-Green)

DIAGNOSIS CONNECTOR

1. Not connected

2. Ground (Black)

3. K line (Orange-Black)

VOLTAGE REGULATOR CONNECTOR

1. Battery positive terminal (Red-White)

2. Ground (Black)

3. Battery positive terminal (Red-White)

4. Ground (Black)

WHEEL TURNING SENSOR CONNECTOR

1. Indicator signal (Sky blue)

2. Indicator signal (Grey-Black)

3. Indicator signal (Red)

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INSTRUMENT PANEL CONNECTOR

1. Wheel turning sensor signal (Red)

2. Wheel turning sensor signal (Sky blue)

3. Wheel turning sensor signal (Grey-Black)

4. Instrument panel lighting (Yellow-Black)

5. Rpm indicator (Green)

6. Engine temperature signal (Orange)

7. Engine temperature signal (Sky blue-Black)

8. Oil pressure sensor signal (White)

9. RHS Turn indicator bulbs (White-Blue)

10. LHS Turn indicator bulbs (Pink)

11. Battery powered (Red-Black)

12. Immobilizer warning light (Grey-Yellow)

13. Live supply (White-Black)

14. MODE button remote signal (Grey)

15. Fuel level indicator (White-Green)

16. Ground (Black)

17. Injection telltale light (Brown-Black)

18. LHS turn indicator signal (Blue)

19. RHS turn indicator signal (Pink-Black)

20. Not connected

WARNING LIGHT UNIT CONNECTOR

1. Not connected

2. Not connected

3. High-beam warning light (Purple)

4. Ground (Black)

5. Headlight warning light (Yellow-Black)

6. Not connected

7. Not connected

8. Not connected

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo.

Exhaust assy. Removal

- Remove the Lambda probe from its support and

disconnect it.

- Remove the retainer clamp.

- Undo the two exhaust manifold fixings on the

head. To unscrew the nuts that fix the muffler flange to the head properly, use a jointed wrench that allows, according to the travel direction, to get also at the right nut. That is difficult to do with a traditional straight wrench.

- Undo the three screws that fix the muffler to the

support arm.

- Remove the full muffler unit.

Remove the lambda probe from the manifold.

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ENG VE - 92

CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP.

Removal of the engine from the vehicle

CAUTION

SUPPORT THE SCOOTER ADEQUATELY.

Disconnect the battery.

- Remove the side fairings.

- Remove the helmet compartment. Remove the full muffler unit.

- Remove the air filter.

- Release the blow-by return pipe from the clamp and disconnect it from the head.

CAUTION

THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

- Remove the rear brake calliper and release the rear brake piping from the four clamps of the engine.

- Get a + 2 l container in order to collect the coolant and place it under the vehicle.

- Remove the pipe that feeds coolant into the pump as shown in the photograph and then empty the system.

- Remove the engine coolant outlet pipe as indicated.

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- Disconnect:

- fuel piping and retainer clamp.

- injector connector.

- control unit connector.

- Remove the coolant outlet pipe from the motor

as indicated.

- Remove the spark plug cap.

- Remove the coolant temperature sensor con-

nector indicated in the photograph.

- Remove the throttle cables from the throttle body

by undoing the nuts indicated in the photograph.

- Remove the throttle cable retainer clamp on the

manifold.

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ENG VE - 94

- Remove the positive and negative wiring from the starter motor as shown in the photograph.

- Disconnect the flywheel wiring connector.

- Remove the clamp indicated.

- Remove the cables from the retainer clamps on the flywheel cover.

- Remove the lower screws of the right and left shock absorber.

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ENG VE - 95

When refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter.

- Check the engine oil level and if necessary, top

it up with the recommended type.

- Fill and bleed the cooling circuit.

- Check accelerator and electric devices for correct

functioning.

CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE

THROTTLE CONTROL TRANSMISSION PROPERLY.

Upon refitting the engine onto the scooter, carry out the removal operations but in reverse order and respect the tightening torques shown in the «Specifications» Chapter.

- 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.

- Fill and bleed the cooling circuit.

- Check accelerator and electrical devices func-

tioning.

- Pay particular attention to the sleeve, be careful

to position the throttle body reference marks as indicated in the photograph.

CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE

THROTTLE CONTROL TRANSMISSION PROPERLY.

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INDEX OF TOPICS

ENGINE ENG

This section describes the operations to be carried out on the engine and the tools to be used.

Automatic transmission

Transmission cover

- To remove the transmission cover it is necessary

to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.

Specific tooling

020423Y driven pulley lock wrench

- Remove the cap/dipstick from the engine oil filling

hole.

- Remove the ten screws.

- Remove the transmission cover.

N.B. WHEN YOU ARE REMOVING THE TRANSMISSION COVER

YOU MUST BE CAREFUL NOT TO DROP THE CLUTCH BELL.

Air duct

- Remove the transmission compartment air intake

cover shown in the photograph.

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- Remove the five screws on two different levels as well as the small casing.

Removing the driven pulley shaft bearing

- Remove the clip from the inside of the cover.

- Remove the bearing from the crankcase by means of:

Specific tooling

020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020412Y 15 mm guide

Refitting the driven pulley shaft bearing

- Slightly heat the crankcase from the inside so as not to damage the painted surface.

- Insert the bearing in its seat.

- Refit the seeger ring.

CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM-

AGING THE COVER PAINT. N.B. ALWAYS REPLACE THE BEARING WITH A NEW ONE

UPON REFITTING.

Specific tooling

020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020412Y 15 mm guide

Baffle roller

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Plastic roller

- Check that the roller does not show signs of wear

and that it turns freely.

- Remove the special clamping screws as indica-

ted in the photograph

- Check the outside diameter of the roller does not

have defects that could jeopardise belt functioning

- For refitting, place the roller with the belt contain-

ment edge on the engine crankcase side

- Tighten the wrench to the prescribed torque.

Locking torques (N*m)

Anti-flapping roller 12 - 16

Removing the driven pulley

- Remove the clutch bell housing and the driven

pulley assembly.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING

PULLEY MOUNTED.

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Gilera 2008 MSS Nexus, 2008 MSS Nexus 300 i.e. E3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual