Gilera Nexus 500 Instruction manual

WORKSHOP MANUAL
633309
Nexus 500

WORKSHOP
MANUAL
Nexus 500
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.
"©Copyright2005-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
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
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-
Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a
basic knowledge of mechanics principles and of vehicle fixing techniques and procedures. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing 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 specific tools, along
with the specific 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 Sectionsmarked with this symbol indicatethe correct use of thevehicle
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 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 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. Sul-
phuricacidis highly corrosive; in the event of contact with your eyesorskin, 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. Non-
original 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. Lubri-
cate 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.
•Forremoval, overhaul and reassemblyoperations use only tools provided with metric meas-
ures. 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 elec-
trical connections - especially earth and battery connections - have been implemented
properly.
Characteristics Nexus 500
CHAR - 2

Vehicle identification
Characteristic
Engine prefix:
M351M
Characteristic
Chassis prefix:
ZAPM35100
Dimensions and mass
WEIGHT
Specification Desc./Quantity
Dry weight 199 kg
Width 765 mm
Length 2090 mm
Wheel base 1515 mm
Saddle height 780 mm
Height 1045 mm
Engine
ENGINE
Specification Desc./Quantity
Engine single-cylinder four stroke
Bore 92 mm
Stroke 69 mm
Cubic capacity 460 cm³
Compression ratio 10.5: 1
Nexus 500 Characteristics
CHAR - 3

Specification Desc./Quantity
Timing system Single overhead camshaft with integrated tone
wheel, control from flywheel side chain, 4 valves
and automatic start-up valve lifting device.
Valve clearance: intake: 0.15 mm (when cold)
Valve clearance: exhaust 0.15 mm (when cold)
Valve clearance adjustment By threaded adjuster on the rockers
Engine idle speed 1500 ± 50 rpm
Air filter Dry paper filter.
CO % value (measured at the intake manifold) 1 ÷ 1.5%
Starting system Electric starter system with freewheel.
Lubrication By trochoidal pump (inside the crankcase), pres-
sure adjustment by-pass and oil filter.
Lubrication pressure 4 bar
Minimum allowed (at 100° C) 0.8 bar
Fuel supply Electronicinjection system with electric fuelpump,
Ø 38 mm throttle body and single injector.
Max. power (at crankshaft) 29.5 kW at 7500 rpm
Max. torque (at crankshaft) 43 Nm at 5500 rpm
Cooling system Fluid circulation through a motor-driven pump, 3-
way thermostat and electric fan.
Transmission
TRANSMISSIONS
Specification Desc./Quantity
Transmission Withautomaticexpandablepulleyvariatorwithtor-
que server, V belt, automatic clutch, gear reduc-
tion unit and transmission housing with forced air
circulation cooling.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil (dry) ~ 1.7 litres
Engine oil (at oil and filter change) approx. 1.5 litres
Fuel tank (including reserve approx. 2 litres) approx. 14.5 litres
Rear hub approx. 250 cc.
Cooling system approx. 1.8 litres
Front fork approx. 242 ± 3 cc (in each fork leg)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Electronic ignition inductive, high efficiency integrated with the injec-
tion system, with variable timing and separate HV
coil.
Spark plug NGK CR7EKB
Characteristics Nexus 500
CHAR - 4