Gilera 2008 MSS Nexus Operation & User’s Manual

Operation & User’s Manual for Gilera 2008 MSS Nexus Scooter (315 pages)

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749/749633-2008_mss_nexus.pdf file (13 Mar 2024)
  • Manufacturer: Gilera
  • Category of Device: Scooter
  • Document: 2008 MSS Nexus, File Type: PDF Operation & User’s Manual
  • Updated: 13-03-2024
  • Count of Pages: 315
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Compatible devices: Runner PureJet 50, 633721, Runner RST 50 SP, NEXUS 300 i.e., Runner 125VX, Fuoco 500ie, GP 800 i.e., Runner Purejet 2007.

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  • Page 1:

    MANUALE STAZIONE DI SERVIZIO

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

    MSS Nexus 300 i.e. E3 ( 2008)

  • Page 2:

    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.

    "© Copyright 2007 - 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. - After-Sales

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

  • Page 3:

    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.

  • Page 4:

  • Page 5:

    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

  • Page 6:

    INDEX OF TOPICS

    CHARACTERISTICS CHAR

  • Page 7:

    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 well-

    ventilated, 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

  • Page 8:

    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

  • Page 9:

    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

  • Page 10:

    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

  • Page 11:

    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. REGU-

    LATE 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

  • Page 12:

    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

  • Page 13:

    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

  • Page 14:

    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

  • Page 15:

    - Measure the diameter of the bearings on the pis-

    ton.

    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 sen-

    sors, 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 al-

    lowed after use 0.07 mm oil scraper ring - stand-

    ard 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

  • Page 16:

    - 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

  • Page 17:

    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

  • Page 18:

    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

  • Page 19:

    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 CRANK-

    SHAFT 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

  • Page 20:

    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.

    CATEGORIES

    CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING

    Cat. 1 Cat. 1 E

    Cat. 2 Cat. 2 B

    Cat. 1 Cat. 2 C

    Cat. 2 Cat. 1 C

    N.B.

    DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-

    SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-

    LIEVED TO ALLOW BENDING DURING THE DRIVING

    OPERATION.

    N.B.

    CRANKCASES FOR REPLACEMENTS ARE SELECTED

    WITH CRANKCASE HALVES OF THE SAME CATEGORY

    AND ARE FITTED WITH CATEGORY C BUSHINGS (YEL-

    LOW)

    Characteristic

    Crankshaft-bushing maximum clearance ad-

    mitted:

    0.08 mm

    Diameter of crankcase without bushing

    CAT. 1: 32.959 ÷ 32.965 mm

    CAT. 2: 32.953 ÷ 32.959 mm

    Cylinder Head

    Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of

    the springs and the valves so as not to change the original position during refitting

    - Using a trued bar and a feeler thickness gauge

    check that the cylinder head surface is not worn or

    distorted.

    Characteristic

    Maximum allowable run-out:

    0.1 mm

    - In case of irregularities, replace the head.

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

    CHAR - 20

  • Page 21:

    - Check the sealing surfaces for the intake and exhaust manifold.

    - Check that the bearings of the camshaft and the rocker pins exhibit no wear.

    - Check that the head cover surface is not worn.

    - Check that the coolant sealing pad exhibits no oxidation.

    - Insert the valves into the cylinder head.

    - Alternatively check the intake and exhaust

    valves.

    - The test is carried out by filling the manifold with

    petrol and checking that the head does not ooze

    through the valves when these are just pressed

    with the fingers.

    Measure the camshaft bearing seats and rocking

    lever support pins with a bore meter

    HEAD BEARINGS

    Specification

    Desc./Quantity

    bearing «A» Ø 12.000 - 12.018 mm

    bearing «B» Ø 20.000 ÷ 20.021 mm

    bearing «C» Ø 37.000 - 37.025 mm

    Measure the unloaded spring length

    Characteristic

    Standard length

    40.2 mm

    Allowable limit after use:

    38.2 mm

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

    CHAR - 21

  • Page 22:

    - Clean the valve seats of any carbon residues.

    - Using the Prussian blue, check the width of the

    impression on the valve seat "V".

    Characteristic

    Standard value:

    1 - 1.3 mm

    Admissible limit:

    1.6 mm

    - If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45°

    mill and then grind.

    - In case of excessive wear or damages, replace the head.

    STANDARD VALVE LENGTH

    Specification Desc./Quantity

    Valve check standard length Inlet: 94.6 mm

    Valve check standard length Outlet: 94.4 mm

    - Measure the diameter of the valve stems in the

    three positions indicated in the diagram.

    STANDARD DIAMETER

    Specification

    Desc./Quantity

    Inlet: 4.987 - 4.972 mm

    Outlet: 4.975 - 4.960 mm

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

    CHAR - 22

  • Page 23:

    MINIMUM ADMISSIBLE DIAMETER

    Specification Desc./Quantity

    Inlet: 4.96 mm

    Outlet: 4.945 mm

    - Calculate the clearance between valve and valve guide.

    - Check the deviation of the valve stem by resting

    it on a "V" shaped abutment and measuring the

    extent of the deformation with a comparator.

    Characteristic

    Limit values admitted:

    0.1 mm

    - Check the concentricity of the valve head by ar-

    ranging a comparator at right angle relative to the

    valve head and rotate it on a "V" shaped abutment.

    Characteristic

    Admissible limit:

    0.03 mm

    Measure the valve guide.

    Characteristic

    Valve guide:

    5 +0.012 mm

    - After measuring the valve guide diameter and the

    valve stem diameter, check the clearance be-

    tween guide and stem.

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

    CHAR - 23

  • Page 24:

    INLET

    Specification Desc./Quantity

    Standard clearance: 0.013 - 0.04 mm

    Admissible limit: 0.08 mm

    OUTLET

    Specification Desc./Quantity

    Standard clearance: 0.025 ÷ 0.052 mm

    Admissible limit: 0.09 mm

    - Check that there are no signs of wear on the surface of contact with the articulated register terminal.

    - If the checks above give no failures, you can use

    the same valves. To obtain better sealing perform-

    ance, grind the valve seats. Grind the valves gently

    with a fine-grained lapping compound. During the

    grinding, keep the cylinder head with the valve ax-

    es in a horizontal position. This will prevent the

    lapping compound residues from penetrating be-

    tween the valve stem and the guide (see figure).

    CAUTION

    TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO

    LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES

    WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.

    CAUTION

    DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

    - Check that the camshaft bearings exhibit no scores or abnormal wear.

    - Using a micrometer, measure the camshaft bearings.

    STANDARD DIAMETER

    Specification

    Desc./Quantity

    Cam shaft check: Standard diameter Bearing A Ø: 36.95 ÷ 36.975 mm

    Cam shaft check: Standard diameter Bearing B diameter: 19.959 ÷ 19.98 mm

    MINIMUM DIAMETER PERMITTED

    Specification

    Desc./Quantity

    Cam shaft check: Minimum admissible diameter Bearing A Ø: 36.94 mm

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

    CHAR - 24

  • Page 25:

    Specification Desc./Quantity

    Cam shaft check: Minimum admissible diameter Bearing B diameter: 19.950 mm

    -Using a gauge, measure the cam height.

    STANDARD HEIGHT

    Specification Desc./Quantity

    Cam shaft check: Standard height Inlet: 30.285 mm

    Cam shaft check: Standard height Outlet: 29.209 mm

    Check the axial clearance of the camshaft

    CAMSHAFT AXIAL CLEARANCE

    Specification

    Desc./Quantity

    Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm

    Cam shaft check: Maximum admissible axial clearance 0.42 mm

    - Measure the outside diameter of the rocking lever pins

    - Check the rocking lever pins do not show signs of wear or scoring.

    - Measure the inside diameter of each rocking lever.

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

    CHAR - 25

  • Page 26:

    Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment

    plate.

    ROCKING LEVERS AND PIN DIAMETER:

    Specification Desc./Quantity

    Internal rocker arm diameter: Standard diameter Diameter 12.000 - 12.011 mm

    Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm

    Slot packing system

    Characteristic

    Compression ratio

    10.5 ÷ 11.5 : 1

    Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed

    by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls

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

    CHAR - 26

  • Page 27:

    inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice

    versa.

    N.B.

    MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK-

    CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON

    A GROUND PLANE

    ENGINE 300 SHIMMING

    Name Measure A Thickness

    shimming 3.70 - 3.60 0.4 ± 0.05

    shimming 3.60 - 3.40 0.6 ± 0.05

    shimming 3.40 - 3.30 0.8 ± 0.05

    Products

    RECOMMENDED PRODUCTS TABLE

    Product Description Specifications

    AGIP GEAR 80W-90 Oil for speed gearbox SAE 80W-90, API GL-4 mineral multi-

    grade oil

    AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions

    (throttle control)

    Oil for 4-stroke engines

    AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-based

    spray grease with NLGI 2; ISO-L-XBCIB2

    AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA

    Synthetic oil

    AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

    AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze

    fluid, CUNA NC 956-16

    AUTOSOL METAL POLISH Muffler cleaning paste special product for cleaning and polishing

    stainless steel muffler

    AGIP GREASE PV2 Grease for the steering bearings, pin

    seats and swinging arm

    Soap-based lithium and zinc oxide

    grease containing NLGI 2; ISO-L-

    XBCIB2 of the swinging arm

    AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap-based lithium grease containing

    NLGI 2 Molybdenum disulphide; ISO-L-

    XBCHB2, DIN KF2K-20

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

    CHAR - 27

  • Page 28:

    INDEX OF TOPICS

    TOOLING TOOL

  • Page 29:

    SPECIFIC TOOLS

    Stores code Description

    001330Y Tool for fitting steering seats

    001467Y014 Pliers to extract ø 15-mm bearings

    005095Y Engine support

    002465Y Pliers for circlips

    020459Y Punch for fitting bearing on steering tube

    020004Y Punch for removing fifth wheels from

    headstock

    020055Y Wrench for steering tube ring nut

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

    TOOL - 29

  • Page 30:

    Stores code Description

    020074Y Support base for checking crankshaft

    alignment

    020150Y Air heater support

    020151Y Air heater

    020193Y Oil pressure gauge

    020262Y Crankcase splitting strip

    020263Y Sheath for driven pulley fitting

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

    TOOL - 30

  • Page 31:

    Stores code Description

    020306Y Punch for assembling valve seal rings

    020329Y MityVac vacuum-operated pump

    020330Y Stroboscopic light to check timing

    020331Y Digital multimeter

    020332Y Digital rev counter

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

    TOOL - 31

  • Page 32:

    Stores code Description

    020648Y Single battery charger

    020335Y Magnetic support for dial gauge

    020357Y 32 x 35 mm adaptor

    020359Y 42x47-mm adaptor

    020360Y Adaptor 52 x 55 mm

    020363Y 20 mm guide

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

    TOOL - 32

  • Page 33:

    Stores code Description

    020375Y Adaptor 28 x 30 mm

    020376Y Adaptor handle

    020382Y Valve cotters equipped with part 012 re-

    moval tool

    020382Y011 adapter for valve removal tool

    020393Y Piston fitting band

    020412Y 15 mm guide

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

    TOOL - 33

  • Page 34:

    Stores code Description

    020423Y driven pulley lock wrench

    020424Y Driven pulley roller casing fitting punch

    020426Y Piston fitting fork

    020431Y Valve oil seal extractor

    020434Y Oil pressure control fitting

    020444Y Tool for fitting/ removing the driven pulley

    clutch

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

    TOOL - 34

  • Page 35:

    Stores code Description

    020456Y Ø 24 mm adaptor

    020477Y Adaptor 37 mm

    020483Y 30 mm guide

    020489Y Hub cover support stud bolt set

    020428Y Piston position check support

    020460Y Scooter diagnosis and tester

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

    TOOL - 35

  • Page 36:

    Stores code Description

    020621Y HV cable extraction adaptor

    020481Y Control unit interface wiring

    001467Y035 Belle for OD 47-mm bearings

    020626Y Driving pulley lock wrench

    001467Y013 Pliers to extract ø 15-mm bearings

    020627Y Flywheel lock wrench

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

    TOOL - 36

  • Page 37:

    Stores code Description

    020454Y Pin lock fitting tool

    020467Y Flywheel extractor

    020622Y Transmission-side oil guard punch

    020480Y Petrol pressure check set

    020244Y 15 mm diameter punch

    020115Y Ø 18 punch

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

    TOOL - 37

  • Page 38:

    Stores code Description

    020271Y Tool for removing-fitting silent bloc

    020469Y Reprogramming kit for scooter diagnosis

    tester

    020487Y Fork oil seal extractor

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

    TOOL - 38

  • Page 39:

    INDEX OF TOPICS

    MAINTENANCE MAIN

  • Page 40:

    Maintenance chart

    SCHEDULED MAINTENANCE TABLE

    I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.

    C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE

    Clean the SAS air filter every 2 years

    * Replace every 2 years

    km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60

    Safety locks I I I I I

    Spark plug R R R R R R

    Driving belt R R R R

    Throttle control A A A A A A A

    Air filter C C C C C C

    Belt compartment air filter I I I I I I

    Oil filter R R R R R R R

    Oil filter (mesh) C

    Valve clearance A A A

    Electrical system and battery I I I I I I I

    Brake fluid * I I I I I I I

    Coolant * I I I I I I I

    Engine oil R I R I R I R I R I R I R

    Hub oil R I R I R I R

    Brake pads I I I I I I I I I I I I I

    Sliding blocks / variable speed rollers R R R R R R

    Tyre pressure and wear I I I I I I I

    Vehicle road test I I I I I I I

    Suspensions I I I I I I

    Steering A A A A A A A

    Centre stand L L

    Checking the spark advance

    The ignition advance is determined electronically

    on the basis of parameters known by the control

    unit. For this reason it is not possible to declare the

    reference values based on the engine rpm. The

    ignition timing value is detectable any time using

    the diagnostic tester. It is possible to check wheth-

    er the ignition advance determined by the system

    does in fact correspond with the value actually ac-

    tivated on the engine, by means of the strobo-

    scopic light.

    Proceed as follows:

    - Remove the spark plug.

    - Remove the transmission crankcase.

    - Rotate the driving pulley fan until the reference

    marks between the flywheel and flywheel cover

    coincide as shown in the photograph.

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

    MAIN - 40

  • Page 41:

    - Bring the reference mark onto the transmission

    side between the fan and the transmission cover

    as shown in the photograph.

    - Refit the spark plug.

    - Refit the plastic cap on the flywheel cover.

    - Adjust the spark gap to the contact position (no

    reference mark visible) and install it on engine be-

    tween the spark plug and spark plug cap

    - Connect the induction calliper on the spark gap

    cable respecting the proper polarity (the arrow on

    the calliper must be pointing at the spark plug).

    - Connect the diagnostic tester.

    - Start the engine.

    - Select the «parameter» function in this menu.

    - Select the stroboscopic light command in the tra-

    ditional four-stroke engine position (1 spark 2

    revs).

    - Check that the real values of rpm and ignition

    advance match those measured using the diag-

    nostic tester.

    If the values do not correspond, check:

    - distribution timing

    - revolution-timing sensor

    - Injection control unit

    Specific tooling

    020460Y Scooter diagnosis and tester

    020330Y Stroboscopic light to check timing

    020621Y HV cable extraction adaptor

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

    MAIN - 41

  • Page 42:

    Spark plug

    Proceed as follows:

    1. Remove the right side cover unscrewing the 3

    «A» screws;

    2. Disconnect the spark plug HV wire hood «B» ;

    3. Unscrew the spark plug using the wrench sup-

    plied. ;

    4. When refitting, place the spark plug in the hole

    at the due inclination and tighten it by hand until it

    is finger tight;

    5. Only use the wrench to lock it in place;

    6. Push hood «B» fully over the spark plug.

    WARNING

    THE USE OF SPARK PLUGS OTHER THAN THOSE REC-

    OMMENDED OR A SHIELDLESS SPARK PLUG CAP

    COULD CAUSE DISTURBANCES TO THE SYSTEM.

    WARNING

    THE SPARK PLUG MUST BE REMOVED WHEN THE EN-

    GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-

    TED IN THE SCHEDULED MAINTENANCE TABLE. THE

    USE OF ELECTRONIC CENTRAL UNITS AND OF NON-

    COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS

    OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY

    DAMAGE THE ENGINE.

    Characteristic

    Spark plug

    NGK CR8EKB

    Electric characteristic

    Electrode gap

    0.7 ÷ 0.8 mm

    Locking torques (N*m)

    Spark plug 12 ÷ 14

    Hub oil

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

    MAIN - 42

  • Page 43:

    Check

    -Park the vehicle on its centre stand on flat ground;

    - Remove the oil dipstick «A», dry it with a clean

    cloth and put it back into its hole tightening it

    completely;

    Remove the dipstick and check that the oil level is

    slightly over the second notch starting from the

    lower end; if the level is under the MAX. mark, it

    needs to be filled with the right amount of hub oil.

    -Screw up the oil dipstick again and make sure it

    is locked properly into place.

    Replacement

    -Remove the oil filler cap «A».

    - Unscrew the oil drainage cap "B" and drain out

    all the oil.

    - Screw in the drainage cap again and fill the hub

    with the prescribed oil.

    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

  • Page 44:

    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 NEC-

    ESSARY 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 con-

    sidered 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

  • Page 45:

    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 lubri-

    cate 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

  • Page 46:

    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 require-

    ments of API SL, ACEA A3, JASO MA specifica-

    tions

    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 cor-

    rect check, wait at least 10 minutes after the en-

    gine has been stopped so as to get the correct

    level.

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

    MAIN - 46

  • Page 47:

    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 star-

    ted.

    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

  • Page 48:

    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 fly-

    wheel 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 ref-

    erence 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 cal-

    liper 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 hav-

    ing 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

  • Page 49:

    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- anti-

    freeze 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 PROTEC-

    TIVE 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 indi-

    cator located on the pump.

    N.B.

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

    MAIN - 49

  • Page 50:

    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 RE-

    QUIRED. 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 maxi-

    mum 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 SUR-

    ROUNDING 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

  • Page 51:

    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 re-

    moving the front shield connecting member.

    N.B.

    THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

    PEAN STANDARDS REGARDING MAXIMUM AND MINI-

    MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-

    TORY REGULATIONS IN FORCE IN EVERY COUNTRY

    WHERE THE vehicle IS USED.

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

    MAIN - 51

  • Page 52:

    INDEX OF TOPICS

    TROUBLESHOOTING TROUBL

  • Page 53:

    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

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

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  • Page 54:

    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.

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

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  • Page 55:

    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

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

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  • Page 56:

    INDEX OF TOPICS

    ELECTRICAL SYSTEM ELE SYS

  • Page 57:

    Components arrangement

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 58:

    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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 60:

    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 vehi-

    cle.

    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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 62:

    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 ter-

    minals 6-26 and terminal 6-chassis

    ground (fixed power supply). If there is

    no voltage check that fuse 1 and its ca-

    ble are in working order.

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    With the key switch in the OFF position:

    there is battery voltage between termi-

    nals 5-26 and terminal 5-frame earth

    (fixed power supply). If there is no volt-

    age, 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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 64:

    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 con-

    tinuity 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 pro-

    cedure 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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  • Page 65:

    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 pro-

    cedure. If you do not, start again from the begin-

    ning. 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 program-

    ming deletes the previous one so, in order to add

    or eliminate keys, you must repeat the procedure

    using all the keys you intend to keep using. If a

    service key becomes uncoded, the efficiency of

    the high voltage circuit shielding must be thor-

    oughly inspected: In any case it is advisable to use

    resistive spark plugs.

    Characteristic

    MASTER key:

    RED KEY

    SERVICE key.

    BLACK KEY

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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    Diagnostic codes

    The immobiliser system is tested each time the ig-

    nition-key switch is turned from OFF to ON. During

    this diagnosis phase a number of control unit sta-

    tuses can be seen and various light codes dis-

    played. Regardless of the code transmitted, if at

    the end of the diagnosis the led remains off per-

    manently, the ignition is enabled. If, however, the

    led remains on permanently, it means the ignition

    is inhibited:

    1. Previously unused control unit - key inser-

    ted: 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 star-

    ted but with a limitation imposed on the number of

    revs.

    2. Previously unused control unit - transpond-

    er 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 re-

    maining 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 trans-

    mitted are:

    Code 1 flash

    2-flash code

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

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  • Page 67:

    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 nec-

    essary.

    Diagnostic code - 2 flashes

    A two-flash code shows a system where the con-

    trol 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 re-

    programming.

    Ignition circuit

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 68:

    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 meas-

    ure 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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  • Page 69:

    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 WORK-

    ING 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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 70:

    - 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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  • Page 71:

    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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 72:

    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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  • Page 73:

    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 be-

    tween the White-Green cable and the Black cable

    of the fuel level transmitter under different condi-

    tions.

    2) If the transmitter operates correctly but the in-

    dication 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)

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 74:

    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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  • Page 75:

    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

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

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  • Page 76:

    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 acti-

    vation.

    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 se-

    lected 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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  • Page 77:

    - 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 com-

    pleted 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.

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 77

  • Page 78:

    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 OPER-

    ATING AND MAINTENANCE MANUAL; DO NOT RELY ON

    THE SERVICE DISPLAY THAT APPEARS ON THE INSTRU-

    MENT 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".

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

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  • Page 79:

    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

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 79

  • Page 80:

    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 con-

    nected 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 am-

    bient 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.

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

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  • Page 81:

    - 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 mainte-

    nance. 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 LOW-

    ER 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

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 81

  • Page 82:

    - 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 ELEC-

    TRICAL 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

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

    ELE SYS - 82

  • Page 83:

    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 elec-

    trical 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 con-

    trol 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

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 83

  • Page 84:

    ENGINE STOP SWITCH

    STARTER BUTTON

    LIGHT SWITCH

    TURN INDICATOR SWITCH

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

    ELE SYS - 84

  • Page 85:

    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)

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 85

  • Page 86:

    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)

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

    ELE SYS - 86

  • Page 87:

    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)

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 87

  • Page 88:

    ENGINE TEMPERATURE SENSOR CONNEC-

    TOR

    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)

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

    ELE SYS - 88

  • Page 89:

    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)

    MSS Nexus 300 i.e. E3 ( 2008) Electrical system

    ELE SYS - 89

  • Page 90:

    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

    Electrical system MSS Nexus 300 i.e. E3 ( 2008)

    ELE SYS - 90

  • Page 91:

    INDEX OF TOPICS

    ENGINE FROM VEHICLE ENG VE

  • Page 92:

    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.

    Engine from vehicle MSS Nexus 300 i.e. E3 ( 2008)

    ENG VE - 92

  • Page 93:

    CAUTION: SHOULD IT BE NECESSARY TO REMOVE ONLY THE MUFFLER TIP, ALWAYS RE-

    PLACE 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 en-

    gine.

    - 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 indi-

    cated.

    MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle

    ENG VE - 93

  • Page 94:

    - 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.

    Engine from vehicle MSS Nexus 300 i.e. E3 ( 2008)

    ENG VE - 94

  • Page 95:

    - 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.

    MSS Nexus 300 i.e. E3 ( 2008) Engine from vehicle

    ENG VE - 95

  • Page 96:

    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 in-

    dicated in the photograph.

    CAUTION

    PAY PARTICULAR ATTENTION TO POSITIONING THE

    THROTTLE CONTROL TRANSMISSION PROPERLY.

    Engine from vehicle MSS Nexus 300 i.e. E3 ( 2008)

    ENG VE - 96

  • Page 97:

    INDEX OF TOPICS

    ENGINE ENG

  • Page 98:

    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.

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

    ENG - 98

  • Page 99:

    - 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

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

    ENG - 99

  • Page 100:

    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.

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

    ENG - 100

  • Page 101:

    Inspecting the clutch drum

    - Check that the clutch bell is not worn or damaged.

    - Measure the clutch bell inside diameter.

    Characteristic

    Max. value clutch bell

    Max. value: Ø 134.5 mm

    Clutch bell standard value

    Standard value: Ø 134 - 134.2 mm

    Checking the bell working surface eccentricity

    - Install the bell on a driven pulley shaft using 2

    bearings (inner diameter 15 and 17 mm).

    - Lock with the original spacer and nut.

    - Place the bell/shaft assembly on the support to

    check the crankshaft alignment.

    - Using a feeler pin gauge and the magnetic base,

    measure the bell eccentricity.

    - Repeat the measurement in 3 positions (Central,

    internal, external).

    - If faults are found, replace the bell.

    Specific tooling

    020074Y Support base for checking crankshaft

    alignment

    020335Y Magnetic support for dial gauge

    Characteristic

    clutch bell inspection: Limit eccentricity.

    Admissible limit eccentricity: 0.15 mm

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

    ENG - 101

  • Page 102:

    Removing the clutch

    Fit the driven pulley spring compressor specific

    tool with medium length pins screwed in position

    «C» on the tool internal side.

    - Introduce the adapter ring No. 11 with the cham-

    fering facing the inside of the tool.

    - Fit the driven pulley unit on the tool with the in-

    sertion of the 3 pins in the ventilation holes in the

    mass holder support.

    - Make sure that the clutch is perfectly inserted into

    the adapter ring before proceeding to loosen/tight-

    en the clutch nut.

    - Use the special 46x55 wrench component No. 9

    to remove the nut fixing the clutch in place.

    - Dismantle the driven pulley components (Clutch

    and spring with its plastic holder)

    CAUTION

    THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND

    THE CENTRAL SCREW MUST BE BROUGHT INTO CON-

    TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE

    THE SPECIFIC TOOL TO BUCKLE.

    Specific tooling

    020444Y011 adapter ring

    020444Y009 46x55 Wrench

    020444Y Tool for fitting/ removing the driven

    pulley clutch

    Inspecting the clutch

    - Check the thickness of the clutch mass friction

    material.

    - The masses must not show traces of lubricants;

    otherwise, check the driven pulley unit seals.

    N.B.

    UPON RUNNING-IN, THE MASSES MUST EX-

    HIBIT A CENTRAL CONTACT SURFACE AND

    MUST NOT BE DIFFERENT FROM ONE AN-

    OTHER.

    VARIOUS CONDITIONS CAN CAUSE THE

    CLUTCH TO TEAR.

    CAUTION

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

    ENG - 102

  • Page 103:

    DO NOT OPEN THE MASSES USING TOOLS TO PREVENT

    A VARIATION IN THE RETURN SPRING LOAD.

    Characteristic

    Check minimum thickness

    1 mm

    Pin retaining collar

    - Simultaneously turn and pull the collar manually

    to remove it.

    N.B.

    USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY.

    N.B.

    BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN

    TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER

    THE O-RING SEAL.

    - Remove the four torque server pins and pull the

    pulley halves apart.

    Removing the driven half-pulley bearing

    - Check there are no signs of wear and/or noisi-

    ness; - Replace with a new one if there are.

    - Remove the retaining ring using two flat blade

    screwdrivers.

    - Support the pulley bushing adequately from the

    threaded side using a wooden surface.

    - Using a hammer and pin, knock the ball bearing

    out as shown in the figure.

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

    ENG - 103

  • Page 104:

    - Support the pulley properly using the bell as

    shown in the figure.

    Specific tooling

    001467Y035 Belle for OD 47-mm bearings

    - Remove the roller bearing using the modular punch.

    Specific tooling

    020376Y Adaptor handle

    020456Y Ø 24 mm adaptor

    020363Y 20 mm guide

    Inspecting the driven fixed half-pulley

    - Measure the outside diameter of the pulley bush-

    ing.

    - Check the contact surface with the belt to make

    sure there are no flaws.

    - Check the riveted joints are functional.

    - Check the evenness of the belt contact surface.

    Characteristic

    Half-pulley minimum diameter

    Minimum admissible diameter Ø 40.96 mm

    Half-pulley standard diameter

    Standard diameter: Ø 40.985 mm

    Wear limit

    0.3 mm

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

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  • Page 105:

    Inspecting the driven sliding half-pulley

    - Remove the two internal grommets and the two

    O-rings.

    - Measure the movable half-pulley bushing inside

    diameter.

    - Check the contact surface with the belt to make

    sure there are no flaws.

    - Check the riveted joints are functional.

    - Check the evenness of the belt faying surface.

    MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

    Specification

    Desc./Quantity

    Wear limit 0.3 mm

    standard diameter Diameter 41.000 - 41.035 mm

    maximum allowable diameter Ø 41.08 mm

    Refitting the driven half-pulley bearing

    - Support the pulley bushing adequately from the

    threaded side using a wooden surface.

    - Fit a new roller sleeve as in the figure.

    - For the fitting of the new ball bearing, follow the

    example in the figure using a modular punch.

    Fit the snap ring

    WARNING

    N.B.

    FIT THE BALL BEARING WITH THE VISIBLE SHIELD

    Specific tooling

    020376Y Adaptor handle

    020375Y Adaptor 28 x 30 mm

    020424Y Driven pulley roller casing fitting

    punch

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

    ENG - 105

  • Page 106:

    Refitting the driven pulley

    - Insert the new oil guards and O-rings on the mov-

    able half-pulley.

    - Lightly grease the O-rings «A» shown in the fig-

    ure.

    - Fit the half-pulley over the bushing using the spe-

    cific tool.

    - Check that the pins are not worn and proceed to

    refitting them in their slots.

    - Refit the torque server closure collar.

    - Using a curved-spout grease gun, lubricate the

    driven pulley unit with approximately 6 gr. of

    grease. Apply the grease through one of the holes

    in the bushing until it comes out through the hole

    on the opposite side. This operation is necessary

    to avoid the presence of grease beyond the O-

    rings.

    N.B.

    THE TORQUE SERVER CAN BE GREASED WHETHER

    WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-

    PLACED; UNDERTAKING THE OPERATION WHEN THE

    BEARINGS ARE BEING SERVICED MIGHT BE EASIER.

    Specific tooling

    020263Y Sheath for driven pulley fitting

    Recommended products

    AGIP GREASE SM 2 Grease for the tone wheel

    revolving ring

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

    ENG - 106

  • Page 107:

    Soap-based lithium grease containing NLGI 2 Mo-

    lybdenum disulphide; ISO-L-XBCHB2, DIN

    KF2K-20

    Inspecting the clutch spring

    - Measure the length of the spring, while it is re-

    laxed.

    Characteristic

    Standard length

    123 mm

    acceptable limit after use:

    118 mm

    Refitting the clutch

    - Support the driven pulley spring compressor ap-

    propriate tool with the control screw in vertical axis.

    - Arrange the tool with the medium length pins

    screwed in position "C" on the inside.

    - Introduce the adapter ring No. 11 with the cham-

    fering facing upwards.

    - Insert the clutch on the adapter ring.

    - Lubricate the end of the spring that abuts against

    the servo-system closing collar.

    - Insert the spring with its plastic holder in contact

    with the clutch.

    - Insert the driving belt into the pulley unit accord-

    ing to their direction of rotation.

    - Insert the pulley unit with the belt into the tool.

    - Slightly preload the spring.

    - Make sure that the clutch is perfectly inserted into

    the adapter ring before proceeding to tighten the

    clutch nut.

    - Place the tool in the clamp with the control screw

    on the horizontal axis.

    - Fully preload the spring.

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

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  • Page 108:

    - Apply the clutch fixing nut and tighten it to the

    prescribed torque using the special 46x55 wrench.

    - Loosen the tool clamp and insert the belt accord-

    ing to its direction of rotation.

    - Lock the driven pulley again using the specific

    tool.

    - Preload the clutch return spring with a traction/

    rotation combined action and place the belt in the

    smaller diameter rolling position.

    - Remove the driven pulley /belt unit from the tool.

    N.B.

    DURING THE SPRING PRELOADING PHASE, BE CARE-

    FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND

    THE BUSHING THREADING.

    N.B.

    FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-

    METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-

    TED IN CONTACT WITH THE CLUTCH.

    Specific tooling

    020444Y Tool for fitting/ removing the driven

    pulley clutch

    020444Y011 adapter ring

    020444Y009 46x55 Wrench

    Locking torques (N*m)

    Clutch unit nut on driven pulley 45 ÷ 50

    Refitting the driven pulley

    - Refit the clutch bell.

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

    ENG - 108

  • Page 109:

    Drive-belt

    - Check that the driving belt is not damaged.

    - Check the width of the belt.

    Characteristic

    Driving belt - minimum width

    19.5 mm

    Driving belt - standard width

    21.3 ± 0.2 mm

    During the wear checks in the scheduled servicing

    programme, you are advised to check the rim bot-

    tom of the toothing does not show signs of inci-

    sions or cracking (see figure): The rim bottom of

    the tooth must not have incisions or cracking; if it

    does, replace the belt.

    Removing the driving pulley

    - Turn the crankshaft until the ropes of the pulley

    are on a horizontal axis

    - Insert the adaptor sleeve of the appropriate tool

    in the hole shown in the photograph

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

    ENG - 109

  • Page 110:

    - Insert the tool in the hollows and apply the reten-

    tion ring

    - Bring in the ring's clamping screws while keeping

    the tool to support the pulley

    Specific tooling

    020626Y Driving pulley lock wrench

    - Remove the fixing nut and the washer

    - Remove the stationary drive pulley half.

    Inspecting the rollers case

    - Check that the internal bushing shown in the fig-

    ure is not abnormally worn and measure its inside

    diameter.

    - Measure outside diameter B of the pulley sliding

    bushing shown in the figure.

    - Check that the rollers are not damaged or worn.

    - Check the guide shoes for the variator back-plate

    are not worn.

    - Check the wear of the roller housings and of the

    belt contact surfaces on both pulley halves.

    - Check that stationary driving pulley does not

    show signs of abnormal wear on the grooved edge

    and on the surface in contact with the belt.

    - Check that the O-ring is not pushed out of shape.

    CAUTION

    DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

    Characteristic

    Movable driving half-pulley bushing: Standard

    Diameter

    26.000 - 26.021 mm

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

    ENG - 110

  • Page 111:

    Movable driving half-pulley bushing: Maxi-

    mum allowable diameter

    Ø 26.12 mm

    Sliding bushing: Standard Diameter

    Ø 25.959 ÷ 25.98 mm

    Sliding bushing: Minimum admissible diame-

    ter

    Ø 25.95 mm

    Roller: Standard Diameter

    Diameter 20.5 - 20.7 mm

    Roller: Minimum diameter permitted

    Ø 20 mm

    Refitting the driving pulley

    - Preassemble the movable half-pulley with the

    roller contrast plate by putting the rollers in their

    housings with the larger support surface touching

    the pulley according to the direction of rotation.

    - Check that the roller contact plate does not have

    flaws and is not damaged on the grooved edge.

    - Mount the complete bushing unit on the driving

    shaft.

    - Fit the driven pulley/Clutch/belt unit on the en-

    gine.

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

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  • Page 112:

    - Fit the steel shim in contact with the bushing and

    the stationary drive pulley.

    - Install the appropriate tool as described in the re-

    moval phase.

    -Tighten the nut with washer to the prescribed tor-

    que.

    Specific tooling

    020626Y Driving pulley lock wrench

    Locking torques (N*m)

    Drive pulley nut 75 ÷ 83

    Refitting the transmission cover

    - Check the presence of the 2 centring dowels and

    the correct installation of the sealing gasket for the

    oil sump on the transmission cover.

    - Replace the cover tightening the 10 screws at the

    specified torque.

    - Refit the oil loading cap/bar.

    - refit the steel washer and the driven pulley nut.

    - Tighten the nut to the prescribed torque using the

    lock wrench and the torque wrench tools.

    - Replace the plastic cover.

    Specific tooling

    020423Y driven pulley lock wrench

    Locking torques (N*m)

    Transmission cover screws 11 ÷ 13 Driven pul-

    ley shaft nut 54 ÷ 60

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

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  • Page 113:

    End gear

    Removing the hub cover

    - Empty the rear hub through the oil drainage plug.

    - Remove the 7 flanged screws indicated in the

    figure.

    - Remove the hub cover and its gasket.

    Removing the wheel axle

    - Remove the wheel axis complete with gear.

    - Remove the intermediate gear.

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

    ENG - 113

  • Page 114:

    Removing the hub bearings

    - Check the state of the bearings being examined

    (wear, clearance and noisiness). If faults are de-

    tected, do the following.

    - Use the specific bearing extractor to remove the

    three 15 mm bearings (2 in the crankcase and 1 in

    the hub cover).

    Specific tooling

    001467Y013 Pliers to extract ø 15-mm bearings

    Removing the wheel axle bearings

    - Take out the clip on the outside of the gearbox

    cover.

    - Support the hub cover and expel the bearing.

    By means of the appropriate tools, remove the oil

    guard as in the figure.

    Specific tooling

    020376Y Adaptor handle

    020477Y Adaptor 37 mm

    020483Y 30 mm guide

    020359Y 42x47-mm adaptor

    020489Y Hub cover support stud bolt set

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

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  • Page 115:

    Removing the driven pulley shaft bearing

    - As you need to remove the driven pulley shaft, its

    bearing and oil guard, remove the transmission

    cover as described above.

    - Extract the driven pulley shaft from its bearing.

    - Remove the oil guard using a screwdriver, work-

    ing from inside the bearing and being careful not

    to damage the housing, make it come out of the

    belt transmission side.

    - Remove the seeger ring shown in the figure

    Remove the driven pulley shaft bearing using the

    modular punch.

    Specific tooling

    020376Y Adaptor handle

    020375Y Adaptor 28 x 30 mm

    020363Y 20 mm guide

    Inspecting the hub shaft

    - Check the three shafts for wear or distortion of

    the toothed surfaces, the bearing housings, and

    the oil seal housings.

    - In case of anomalies, replace the damaged com-

    ponents.

    Inspecting the hub cover

    - Check that the fitting surface is not dented or distorted.

    - Check the bearing bearings.

    - In case of anomalies, replace the damaged components.

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

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  • Page 116:

    Refitting the wheel axle bearing

    - Support the hub cover on a wooden surface.

    - Heat the crankcase cover with the specific heat

    gun.

    - Fit the wheel shaft bearing with a modular punch

    as shown in the figure.

    - Fit the seeger ring.

    - Fit the oil guard with seal lip towards the inside

    of the hub and place it flush with the internal sur-

    face by means of the appropriate tool used from

    the 52 mm side.

    The 52 mm side of the adapter must be turned to-

    wards the bearing.

    Specific tooling

    020376Y Adaptor handle

    020360Y Adaptor 52 x 55 mm

    020483Y 30 mm guide

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

    ENG - 116

  • Page 117:

    Refitting the hub cover bearings

    For the fitting of the hub box bearings the engine

    crankcase and the cover must be heated with the

    special heat gun.

    - The three 15 mm bearings must be fitted using

    the appropriate tools.

    - The 42-mm side of the adapter must be turned

    towards the bearing.

    Specific tooling

    020150Y Air heater support

    020151Y Air heater

    020376Y Adaptor handle

    020359Y 42x47-mm adaptor

    020412Y 15 mm guide

    N.B.

    TO FIT THE BEARING ON THE COVER, SUPPORT THE COVER WITH THE STUD BOLT SET.

    - Refit the driven pulley shaft bearing with a mod-

    ular punch as shown in the figure.

    N.B.

    IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-

    ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM

    THE HUB INNER SIDE.

    Specific tooling

    020376Y Adaptor handle

    020359Y 42x47-mm adaptor

    020363Y 20 mm guide

    N.B.

    WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE, SUPPORT THE CRANKCASE

    PREFERABLY ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN VERTICALLY.

    - Refit the seeger ring with the opening facing the bearing and fit a new oil guard flush with the crankcase

    from the pulley side.

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

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  • Page 118:

    Refitting the hub bearings

    - Install the three shafts in the engine crankcase

    as shown in the figure.

    Refitting the ub cover

    - Fit a new gasket together with the centring dow-

    els.

    - Seal the gasket of the breather pipe using black

    silicone sealant.

    - Fit the gearbox cover, making sure the breather

    pipe is in the correct position.

    - Position the shorter screw that can also be rec-

    ognised from the different colour as shown in the

    figure.

    - Fix the breather tube support by means of the

    lower screw.

    - Fit the remaining screws and tighten the seven

    screws to the prescribed torque.

    Flywheel cover

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

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  • Page 119:

    Removing the hub cover

    - Remove the clip fixing the hose to the cylinder.

    - Remove the 10 fixings

    - Remove the flywheel cover.

    Removing the stator

    - Remove the two pickup screws and the screw

    holding the wiring support and the three stator

    clamping screws shown in the figure.

    - Remove the stator and its wiring.

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

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  • Page 120:

    Refitting the stator

    - Refit the stator and flywheel carrying out the re-

    moval procedure in reverse, tightening the retain-

    ers to the specified torque.

    Locking torques (N*m)

    Stator assembly screws (°) 3 ÷ 4

    Refitting the flywheel cover

    - Position the spline clip on the crankshaft and ori-

    ent the end as shown in the figure.

    - Orient the water pump shaft with reference to the

    transmission gear seat as shown in the photo.

    - Refit the cover over the engine and tighten the screws to the prescribed torque.

    - Carry out the steps in the reverse order from the dismantling procedure.

    CAUTION

    TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-

    TRING DOWELS ARE PRESENT.

    Locking torques (N*m)

    Flywheel cover screws 11 - 13

    Flywheel and starting

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

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  • Page 121:

    Removing the starter motor

    - Remove the two screws indicated in the figure.

    - Take the starter motor out of its seat

    Removing the flywheel magneto

    - Remove the water pump shaft and crankshaft

    spline clip

    - Line up the two holes in the flywheel as shown in

    the photo

    - Screw in the guide bushing that is part of the

    special flywheel stop tool on the flywheel as shown

    in the photo.

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

    ENG - 121

  • Page 122:

    - Insert the special flywheel stop tool on the fly-

    wheel as shown in the photo

    Specific tooling

    020627Y Flywheel lock wrench

    - Remove the plate indicated in the photo.

    - Remove the flywheel nut with its washer

    - Do up the flywheel nut by three or four threads

    so that the flywheel does not fall accidentally on

    extraction

    - Screw the extractor onto the flywheel and extract

    it as shown in the photograph

    Specific tooling

    020467Y Flywheel extractor

    Inspecting the flywheel components

    - Check the integrity of the internal plastic parts of the flywheel and the Pick-Up control plate.

    Refitting the free wheel

    - Make sure the freewheel faying surfaces are in good condition.

    - Thoroughly clean the free wheel to remove LOCTITE residue.

    - Degrease the threading of the holes in the free wheel and the clamping screws.

    - Apply the recommended product to the end of the screws.

    Recommended products

    Loctite 243 Medium strength threadlock

    Loctite 243 medium-strength threadlock

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

    ENG - 122

  • Page 123:

    - Fit the freewheel on the magneto flywheel making

    sure that the ground side is in contact with the fly-

    wheel itself, i.e. with wheel seeger ring visible.

    - Lock the six clamping screws in criss-cross fash-

    ion to the prescribed torque.

    Locking torques (N*m)

    Screw fixing freewheel to flywheel 13 ÷ 15

    - Oil the free wheel "rollers".

    Refitting the flywheel magneto

    - Remove the freewheel retaining plate indicated

    in the photograph

    - Remove the transmission gear and the freewheel

    - Insert the free wheel on the flywheel as shown in

    the photo

    - Then refit the flywheel with free wheel and trans-

    mission gear

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

    ENG - 123

  • Page 124:

    - Using the special flywheel stop tool, tighten up

    the flywheel fixing nut to the prescribed torque

    -Refit the retention plate

    Specific tooling

    020627Y Flywheel lock wrench

    Locking torques (N*m)

    Flywheel nut 94 ÷ 102

    Refitting the starter motor

    - Fit a new O-ring on the starter motor and lubricate

    it.

    - Fit the starter on the crankcase, locking the two

    screws to the prescribed torque.

    Locking torques (N*m)

    Starter motor screws 11 ÷ 13

    Cylinder assy. and timing system

    Removing the intake manifold

    Loosen the three screws and remove the air intake manifold.

    - When refitting, secure to the specified torque.

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

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  • Page 125:

    Removing the rocker-arms cover

    - Remove the 5 screws indicated in the figure

    Removing the timing system drive

    - Remove the parts listed below first: transmission

    cover, drive pulley with belt, oil sump with spring

    and by-pass piston, oil pump pulley cover, O-ring

    on the crankshaft and the sprocket wheel separa-

    tion washer.

    - Remove the tappet cover.

    - Remove the central screw fastener and the au-

    tomatic valve-lifter retaining cover, as shown in the

    figure.

    - Remove the return spring of the automatic valve

    lifter unit and the automatic valve lifter unit and its

    end of stroke washer.

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

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  • Page 126:

    - Loosen the central screw on the tensioner first.

    - Remove the two fixings shown in the figure.

    - Remove the tensioner with its gasket.

    - Remove the internal hex screw and the counter-

    weight shown in the figure.

    - Remove the camshaft control pulley with its

    washer.

    - Remove the command sprocket wheel and the

    timing chain.

    - Remove the screws indicated in the figure, the

    spacer bar and the tensioner slider.

    The chain tensioning pad must be removed from

    the transmission side. As regards the lower chain

    guide pad, it may only be removed after the head

    has been removed.

    N.B.

    IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-

    SURE THAT THE INITIAL DIRECTION OF ROTATION IS

    MAINTAINED.

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

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  • Page 127:

    Removing the cam shaft

    - Remove the two screws and the cam shaft re-

    tainer shown in the diagram.

    - Remove the cam shaft.

    - Remove the pins and the rocker arms from the

    flywheel side holes.

    N.B.

    IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH

    THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING

    BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-

    OUT REMOVING THE CHAIN AND THE DRIVING SHAFT

    CHAIN TIGHTENER.

    Removing the cylinder head

    - Remove the spark plug.

    - Remove the 2 side fixings shown in the figure.

    - Loosen the 4 head-cylinder fastening nuts in two

    or three stages and in criss-cross fashion.

    - Remove the head, the two centring dowels and

    the gasket.

    N.B.

    IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH

    THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING

    BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-

    OUT REMOVING THE CHAIN AND THE DRIVING SHAFT

    CHAIN TIGHTENER.

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

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  • Page 128:

    Removing the valves

    - Using the appropriate tool fitted with an adaptor,

    remove the cotters, caps, springs and valves.

    - Remove the oil guards with the appropriate tool.

    - Remove the lower spring supports.

    CAUTION

    REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-

    NISE THEIR ORIGINAL POSITION ON THE HEAD.

    Specific tooling

    020382Y011 adapter for valve removal tool

    020382Y Valve cotters equipped with part 012

    removal tool

    020431Y Valve oil seal extractor

    Removing the cylinder - piston assy.

    Removing cylinder and piston

    - Remove the chain guide pad.

    - Remove the 4 O-rings on the stud bolts.

    - Pull out the cylinder.

    - Remove the cylinder base gasket.

    - Remove the two stop rings, the wrist pin and the

    piston.

    - Remove the piston seals.

    CAUTION

    TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE

    REMOVING THE CYLINDER.

    N.B.

    BE CAREFUL NOT TO DAMAGE THE SEALING RINGS

    DURING REMOVAL.

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

    ENG - 128

  • Page 129:

    Inspecting the small end

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Crankcase - crankshaft - connecting rod

    Inspecting the wrist pin

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder - piston assy.

    Inspecting the piston

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder - piston assy.

    Inspecting the cylinder

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder - piston assy.

    Inspecting the piston rings

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Piston rings

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

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  • Page 130:

    Removing the piston

    - Install piston and wrist pin onto the connecting

    rod, aligning the piston arrow the arrow facing to-

    wards the exhaust.

    - Fit the wrist pin snap ring onto the appropriate

    tool

    - With opening in the position indicated on the tool

    S = left

    D= right

    - Place the wrist pin snap ring into position using a

    punch

    - Fit the wrist pin snap ring using the plug as shown

    in the figure

    N.B.

    THE TOOL FOR INSTALLING THE STOP RINGS MUST BE

    USED MANUALLY.

    CAUTION

    USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-

    ING.

    Specific tooling

    020454Y Pin lock fitting tool

    Choosing the gasket

    - Provisionally fit the piston into the cylinder, without any base gasket.

    - Assemble a dial gauge on the specific tool.

    Specific tooling

    020428Y Piston position check support

    - Using an abutment plane, reset the comparator

    with a preload of a few millimetres.

    - Finally fix the comparator.

    - Check the perfect sliding of the feeler pin.

    - Install the tool on the cylinder without changing

    the comparator position.

    - Lock the tool using the original head fixing nuts.

    - Rotate the crankshaft up to the TDC (the inver-

    sion point of the dial gauge rotation)

    - Measure the deviation from the reset value.

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

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  • Page 131:

    - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to

    be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres-

    sion ratio.

    - Remove the special tool and the cylinder.

    N.B.

    IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF CATEGORY

    ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO DO SO, REPEAT

    THE TOOL INSTALLATION BY INVERTING ITS POSITION.

    See also

    Slot packing system

    Refitting the piston rings

    - Place the scraper ring spring on the piston.

    - Install the scraper ring keeping the opening op-

    posed to the spring junction and with the writing

    "top" facing the piston top. The chamfered side of

    the oil scraper ring should always be facing the

    piston crown.

    - Fit the second lining with the identification letter

    or the writing "top" facing the piston crown. In any

    case, the step must be facing opposite the piston

    top.

    - Install the first compression lining in the direction

    imposed by the housing.

    - It is advisable to use a fitter to facilitate the in-

    stallation of the linings.

    N.B.

    THE TWO PISTON RINGS ARE MADE WITH A TAPERED

    CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO

    ACHIEVE A BETTER BEDDING.

    - Misalign the lining openings at 120° as shown in the figure.

    - Lubricate the components with engine oil.

    - The engine uses the first compression lining with an L section.

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

    ENG - 131

  • Page 132:

    Refitting the cylinder

    - Insert the cylinder base gasket with the thickness

    determined above.

    - Using the fork support and the piston ring retain-

    ing band, refit the cylinder as shown in the figure.

    N.B.

    BEFORE FITTING THE CYLINDER, CAREFULLY BLOW

    OUT THE LUBRICATION DUCT AND OIL THE CYLINDER

    BARREL.

    Specific tooling

    020426Y Piston fitting fork

    020393Y Piston fitting band

    Inspecting the cylinder head

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder Head

    Inspecting the timing system components

    - Check that the guide shoe and the tensioner shoe

    are not worn out.

    - Ensure that the camshaft control pulley chain as-

    sembly and the sprocket wheel are not worn.

    - If you encounter wear, replace the parts or, if the

    chain, sprocket wheel and pulley are worn replace

    the whole assembly.

    - Remove the centre screw with the washer and

    the tensioner spring. Check that the one-way

    mechanism is not worn.

    - Check the condition of the tensioner spring.

    - If examples of wear are found, replace the whole

    assembly.

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

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  • Page 133:

    Inspecting the valve sealings

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder Head

    Inspecting the valves

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder Head

    Inspecting the springs and half-cones

    - Check that the upper and lower supporting spring

    washers, the cotters and the oil seal show exhibit

    no signs of abnormal wear. Replace a component

    when worn.

    - Measure the unloaded spring length.

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder Head

    Refitting the valves

    - Lubricate the valve guides with engine oil.

    - Place the valve spring supports on the head.

    - Using the special punch, fit the four valve seals.

    - Fit the valves, the springs and the caps. Using

    the appropriate tool with adapter, compress the

    springs and insert the cotters in their seats.

    N.B.

    DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE

    VALVE SPRINGS WITH THE REFERENCE COLOUR ON

    COTTER SIDE (TURNS WITH GREATER PITCH).

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

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  • Page 134:

    Specific tooling

    020306Y Punch for assembling valve seal

    rings

    020382Y Valve cotters equipped with part 012

    removal tool

    020382Y011 adapter for valve removal tool

    Inspecting the cam shaft

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Cylinder Head

    Refitting the head and timing system components

    - Refit the lower timing chain sprocket wheel on the

    crankshaft, with the chamfer facing the insertion

    side.

    - Loop the timing chain around the sprocket on the

    crankshaft.

    - Fit the chain tensioner slider from the cylinder

    head side.

    - Fit the spacer and the screw fastener.

    - Tighten the screws to the prescribed torque.

    - Fit the pins and rocker arms.

    - Lubricate the two rocking levers through the

    holes at the top.

    - Lubricate the 2 bearings and insert the cam shaft

    in the cylinder head with the cams corresponding

    to the rockers.

    - Insert the retention plate and tighten the two

    screws shown in the figure to the prescribed tor-

    que.

    - Refit the spacer on the cam shaft.

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

    ENG - 134

  • Page 135:

    - Rotate the engine so that the piston is at top dead

    centre, using the reference marks on the flywheel

    and the crankcase.

    - Holding this position insert the chain on the cam-

    shaft control pulley.

    - Insert the pulley on the cam shaft while keeping

    the reference 4V in correspondence with the ref-

    erence mark on the head.

    - Fit the counterweight and tighten the fixing screw

    to the prescribed torque.

    -Fit the end-stop ring on the automatic valve-lifter

    cam and fit the automatic valve-lifter cam to the

    cam shaft.

    - Fit the automatic valve-lifter return spring.

    - During this operation the spring must be loaded

    by approximately 180°.

    - Fit the automatic valve-lifter retaining dish, using

    the counterweight screw fastener as a reference.

    - Tighten the clamping screw to the prescribed tor-

    que.

    - Set the tensioner cursor in the rest position.

    - Fit the chain tensioner on the cylinder, using a

    new gasket, and tight the two screws to the pre-

    scribed torque.

    - Insert the chain tensioning screw, together with

    the spring and washer, tightening it to the prescri-

    bed torque.

    - Adjust the valve clearance.

    - Fit the spark plug.

    Electrode distance 0.8 mm

    N.B.

    GREASE THE END STOP RING TO PREVENT IT COMING

    OUT AND FALLING INTO THE ENGINE.

    Locking torques (N*m)

    Timing chain tensioner support screw 11 ÷ 13

    Spark plug 12 ÷ 14 Starter ground screw 7 ÷ 8.5

    Timing chain tensioner slider screw 10 ÷ 14

    Starter ground support screw 11 ÷ 15 Timing

    chain tensioner central screw 5 - 6 Camshaft re-

    tention plate screw 4 ÷ 6

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

    ENG - 135

  • Page 136:

    - Fit the timing chain guide pad.

    - Insert the centring dowel between the cylinder

    head to the cylinder, fit the cylinder head gasket

    and the cylinder head.

    - Lubricate the stud bolt threading.

    - Tighten up the nuts to an initial pre-torque of 7±1

    N·m

    - Tighten up the nuts to a second pre-torque of 10

    ±1 N·m

    - Rotate by an angle of 270°

    - To carry out the operations described above, fol-

    low the tightening sequence in the figure.

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

    ENG - 136

  • Page 137:

    - Fit the two screws on the outside of the timing

    chain side and tighten them to the specified torque.

    N.B.

    BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE

    LUBRICATION CHANNEL IS CLEAN USING A COM-

    PRESSED AIR JET.

    Locking torques (N*m)

    Timing chain tensioner support screw 11 ÷ 13

    Refitting the rocker-arms cover

    - Refit the cylinder head cover, tightening the 5

    clamping screws to the prescribed torque.

    - Make sure the gasket is positioned properly.

    Locking torques (N*m)

    Tappet cover screws 6 - 7 Nm

    Refitting the intake manifold

    Fit the intake manifold and do up the three screws.

    Locking torques (N*m)

    Inlet manifold screws 11 ÷ 13

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

    ENG - 137

  • Page 138:

    Crankcase - crankshaft

    Splitting the crankcase halves

    - Before opening the crankcase, it is advisable to

    check the axial clearance of the crankshaft. To do

    this, use a plate and a support with appropriate tool

    dial gauge.

    - Upper clearances are an indication of wear on

    the surfaces of the crankshaft casing support.

    - Remove the 10 crankshaft coupling screws.

    - Separate the crankcase while keeping the crank-

    shaft in one of the two halves of the crankcase.

    - Remove the crankshaft.

    - Remove the half crankcase coupling gasket.

    - Remove the two screws and the internal cover

    shown in the diagram.

    - Remove the oil guard on the flywheel side.

    - Remove the oil filter fitting shown in the diagram.

    - Check the axial clearance on the connecting rod.

    - Check the radial clearance on the connecting rod.

    -Check the surfaces that limit the axial free-play

    are not scored and measure the width of the crank-

    shaft between these surfaces, as shown in the

    diagram.

    - If the axial clearance between crankshaft and

    crankcase is exceeding and the crankshaft does

    not have any defect, the problem must be due to

    either excessive wear or wrong machining on the

    crankcase.

    - Check the diameters of both the bearings of the

    crankshaft in accordance with the axes and surfa-

    ces shown in the figure. The half-shafts are clas-

    sified in two categories Cat. 1 and Cat. 2 as shown

    the chart below.

    CAUTION

    THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH

    IS WITHIN THE STANDARD VALUES AND THE SURFACES

    SHOW NO SIGNS OF SCORING.

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

    ENG - 138

  • Page 139:

    CAUTION

    WHILE OPENING THE CRANKCASES AND REMOVING

    THE DRIVING SHAFT, CHECK THAT THE THREADED

    SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-

    INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN

    DAMAGE THE MAIN BUSHINGS.

    CAUTION

    KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES

    OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL

    TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY

    FALL.

    N.B.

    WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,

    MAKE SURE THAT THE MEASUREMENTS ARE NOT

    MODIFIED BY THE RADIUSES OF FITTINGS WITH THE

    CRANKSHAFT BEARINGS.

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARAN-

    CES, SEE THE SPECIFICATIONS CHAPTER.

    See also

    Crankcase - crankshaft - connecting rod

    Inspecting the crankshaft alignment

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Crankcase - crankshaft - connecting rod

    Inspecting the crankcase halves

    - Before proceeding to check the crankcase

    halves, thoroughly clean all surfaces and oil ducts.

    - On the transmission-side crankcase half, take

    particular care when handling the oil pump com-

    partment and the oil ducts, the by-pass duct, the

    main bushings and the cooling jet on the trans-

    mission side (see diagram).

    - Take particular care, also, that there are no signs

    wear in the oil by-pass valve housing (see Chapter

    Lubrication), as this could prevent a good seal in

    the valve, which regulates the oil pressure.

    - On the flywheel side crankcase half, take partic-

    ular care cleaning the oil ducts for the main bush-

    ings, the oil duct for the jet that lubricates the

    cylinder head and the oil drainage duct at the fly-

    wheel side oil seal.

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

    ENG - 139

  • Page 140:

    - Inspect the coupling surfaces on the crankcase

    halves for scratches or deformation, taking partic-

    ular care with the cylinder/crankcase surfaces and

    the crankcase halves surfaces.

    - Defects in the crankcase coupling gasket be-

    tween the crankcase halves or the mating surfaces

    shown in the diagram, could cause a drop in the

    oil pressure lubricating the main bearings and con-

    nection rod.

    - Check the main bearing seats that limit axial

    clearance in the crankshaft show no signs of wear.

    The dimension between these seats is measured

    by way of the procedure described previously for

    measuring the crankshaft axial clearance and di-

    mensions.

    N.B.

    THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-

    ER OPERATION OF THIS COMPONENT IMPROVES THE

    PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT

    ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-

    CREASE). FAILURE OR LEAK CAN CONSIDERABLY DE-

    CREASE THE MAIN BUSHING AND CONNECTING ROD

    LUBRICATION PRESSURE.

    N.B.

    THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH

    A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD

    LUBRICATION; THIS CHOICE WAS MADE TO REDUCE

    THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG-

    GING IMPAIRS THE HEAD LUBRICATION AND THE TIM-

    ING MECHANISMS. A JET FAILURE CAUSES A DE-

    CREASE OF THE MAIN BUSHING AND CONNECTING ROD

    LUBRICATION PRESSURE.

    Inspecting the crankshaft plain bearings

    - 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.

    Characteristic

    Lubrication pressure

    3.5 ÷ 4 bar

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

    ENG - 140

  • Page 141:

    - 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 chan-

    nels, the matching surface of the two half-bearings

    must be perfectly perpendicular to the cylinder ax-

    is, as shown in the figure.

    - The oil feeding channel section is also affected

    by the bushings driving depth compared with the

    crankshaft axial clearance of the limiting surface.

    N.B.

    TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP-

    TER.

    See also

    Crankcase - crankshaft - connecting rod

    Refitting the crankcase halves

    - Fit the internal bulkhead by locking the two

    screws to the prescribed torque.

    - Fit the oil filter fitting and tighten it to the specified

    torque.

    - Position the oil pre-filter element as shown in the

    photograph.

    - Place a new gasket on one of the crankcase

    halves, preferably on the transmission side, to-

    gether with the locating dowels.

    - Lubricate the main bushings and insert the crank-

    shaft in the transmission side crankcase half.

    - Reassemble the two crankcase halves.

    - Fit the 10 screws and tighten them to the pre-

    scribed torque.

    - Fit a new O-ring on the pre-filter and lubricate it.

    - Insert the filter on the engine with the relative cap.

    Tighten to the prescribed torque.

    Locking torques (N*m)

    Internal engine crankcase bulkhead (transmis-

    sion-side half shaft) screws 4 ÷ 6 Engine-crank-

    case coupling screws 11 ÷ 13 Oil filter on

    crankcase fitting 27 ÷ 33 Engine oil drainage

    plug/mesh filter 24 ÷ 30

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

    ENG - 141

  • Page 142:

    Studs

    Check that the stud bolts have not worked loose

    from their seat in the crankcase.

    Check the depth of stud bolt driving with a gauge,

    as indicated in the photograph. If it varies signifi-

    cantly from the driving depth indicated, it means

    that the stud bolt has yielded.

    In this case, replace it.

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

    ENG - 142

  • Page 143:

    By working on two fitted cylinder head fixing nuts,

    nut and lock nut, as shown in the photograph, re-

    move the stud bolt from its seat.

    Clean the threaded seat on the carter thoroughly.

    Refit a new stud bolt and apply the special product

    on the threading crankcase side.

    Tighten up to the depth of the driving indicated.

    Recommended products

    Loctite 'Quick Set' Strong 270 threadlock

    Strong 270 threadlock

    Lubrication

    Conceptual diagrams

    LUBRICATION CIRCUIT

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

    ENG - 143

  • Page 144:

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

    ENG - 144

  • Page 145:

    Oil pressure check

    - Remove the electrical minimum oil pressure

    switch connection and remove the switch.

    - Check the oil pressure reading is between 0.5

    and 1.2 atm with the engine idling at 1650 rpm and

    the oil at the required temperature (wait for at least

    one electric ventilation).

    - Check the oil pressure is between 3.2 and 4.2

    atm with the engine running at a speed 6000 rpm

    and the oil at the required temperature.

    - Remove the appropriate tools once the meas-

    urement is complete, refit the oil pressure switch

    and washer, tightening it to the specified torque

    and fit the fan cover.

    - If the oil pressure is not within the specified limits,

    in the following order, check: the oil filter, the oil

    by-pass valve, the oil pump and the crankshaft

    seals.

    N.B.

    THE CHECK MUST BE CARRIED OUT WITH OIL AT THE

    CORRECT LEVEL AND WITH AN OIL FILTER IN GOOD

    CONDITION.

    Characteristic

    Oil pressure

    Minimum pressure admitted at 6000 rpm: 3.2 atm.

    Locking torques (N*m)

    Minimum oil pressure sensor 12 ÷ 14

    Crankshaft oil seals

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

    ENG - 145

  • Page 146:

    Removal

    - First remove the transmission cover and the com-

    plete driving pulley

    - Install the base of the appropriate tool on the oil

    guard using the screws provided.

    Specific tooling

    020622Y Transmission-side oil guard punch

    - Screw the threaded bar onto the base of the tool

    and extract the oil guard.

    Specific tooling

    020622Y Transmission-side oil guard punch

    Refitting

    - Use a new oil guard for the refitting

    - Prepare the new oil guard, lubricating the sealing

    lip.

    - Preassemble the oil seal with the specific tool,

    positioning the screws.

    - Insert the sheath over the crankshaft.

    - Insert the tool with the oil seal on the crankshaft

    until it comes into contact with the crankcase.

    - Insert the adaptor bushing of the tool in the hole

    on the crankcase.

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

    ENG - 146

  • Page 147:

    - Orientate the oil guard by inserting the bracket

    which is part of the appropriate tool

    - Tighten the threaded bar onto the crankshaft as

    far as it will go.

    - Use the nut to move the base of the tool until you

    can see end of the oil guard driving stroke

    - Remove all of the tool components following the

    inverse procedure

    CAUTION

    DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO

    THE ENGINE CRANKCASE.

    CAUTION

    ORIENT THE OIL GUARD BY POSITIONING THE CHAIN

    HOUSING CHANNEL FACING DOWNWARDS. WHEN THE

    POSITION IS REACHED, DO NOT RETRACT THE OIL

    GUARD. FAILURE TO COMPLY WITH THIS RULE CAN

    CAUSE A WRONG POSITIONING OF THE OIL GUARD

    SHEATH.

    CAUTION

    FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-

    DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO

    THE WRONG TENSIONING OF THE OIL PUMP CONTROL

    CHAIN.

    Specific tooling

    020622Y Transmission-side oil guard punch

    Oil pump

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

    ENG - 147

  • Page 148:

    Removal

    - Undo the two clamping screws in the figure and

    remove the cover over the pump control crown.

    - Block the rotation of the oil pump control pulley

    with a screwdriver inserted through one of its two

    holes.

    - Remove the central screw with Belleville washer,

    as shown in the diagram.

    - Remove the chain with the crown.

    - Remove the control sprocket with relative O-ring.

    - Remove the oil pump by undoing the two screws

    in the figure.

    - Remove the oil pump seal.

    N.B.

    IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-

    SURE THAT THE INITIAL DIRECTION OF ROTATION IS

    MAINTAINED.

    Inspection

    - Remove the two screws and the oil pump cover.

    - Remove the clip retaining the innermost rotor.

    - Remove and wash the rotors thoroughly with pet-

    rol and compressed air.

    - Reassemble the rotors in the pump body, keep-

    ing the two reference marks visible Replace the

    snap ring.

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

    ENG - 148

  • Page 149:

    - Check the clearance between the rotors in the

    position shown in the diagram using a thickness

    gauge.

    Measure the distance between the outer rotor and

    the pump body (see figure).

    - Check the axial clearance of the rotors using a

    trued bar as shown in the figure.

    Characteristic

    Axial rotor clearance

    Limit values admitted: 0.09 mm

    Distance between the outer rotor and the pump

    body

    Admissible limit clearance: 0.20 mm

    Distance between the rotors

    Admissible limit clearance: 0.12 mm

    Refitting

    - Check there are no signs of wear on the oil pump

    shaft or body.

    - Check there are no signs of scoring or wear on

    the oil pump cover.

    - If you detect non-conforming measurements or

    scoring, replace the faulty parts or the unit.

    - Fit the pump cover in the position that permits the

    crankcase fixing screws to be aligned.

    - Make sure the gasket is positioned properly and

    refit the pump on the engine crankcase. The pump

    can only be fitted in one position. - Tighten the

    screws to the prescribed torque.

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

    ENG - 149

  • Page 150:

    - Fit the sprocket wheel with a new O-ring.

    - Fit the chain.

    - Fit the central screw and the belleville washer.

    Tighten to the prescribed torque.

    - Fit the oil pump cover by tightening the two

    screws to the prescribed torque.

    N.B.

    FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM

    TOUCHES THE PULLEY. MAKE SURE THAT THE PUMP

    TURNS FREELY.

    Locking torques (N*m)

    Screws fixing oil pump to crankcase 5 - 6 Oil

    pump control crown screw 10 ÷ 14 Oil pump cov-

    er screws 0.7 ÷ 0.9

    Removing the oil sump

    - Remove the oil filler plug, the transmission cover,

    the complete driving pulley assembly with belt and

    the sprocket wheel, as described in the "Trans-

    mission" chapter.

    - Drain the oil as described previously.

    - Remove the seven screws, shown in the dia-

    gram, and the two rear brake fluid pipe fixing

    brackets.

    - Remove the screw, the by-pass piston, the gas-

    ket and centring dowels shown in the figure.

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

    ENG - 150

  • Page 151:

    Inspecting the by-pass valve

    - Check the unloaded spring length.

    - Check that the small piston is not scored.

    - Ensure that it slides freely on the crankcase and

    that it guarantees a good seal.

    - If not, eliminate any impurities or replace defec-

    tive parts.

    Characteristic

    By-pass check up: Standard length

    54.2 mm

    Refitting the oil sump

    - Refit the by-pass valve plunger in its housing.

    - Insert the pressure-regulating spring.

    - Fit a new sump seal.

    - Refit the two centring dowels.

    - Refit the sump, taking care to locate the spring in

    the appropriate recess machined into the inside of

    the sump.

    - Refit the rear brake cable brackets and the

    screws in the reverse order from which they were

    removed.

    - Tighten the screws to the prescribed torque.

    - Refit the drive pulley assembly, the drive belt, the

    sprocket wheel and the transmission cover, as de-

    scribed in the "Transmissions" chapter.

    - When testing the lubrication system, refer to

    chapter "Crankcase and Crankshaft", regard-

    ing lubrication of the crankshaft and connect-

    ing rod

    Locking torques (N*m)

    Oil sump screws 10 ÷ 14

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

    ENG - 151

  • Page 152:

    INDEX OF TOPICS

    INJECTION INJEC

  • Page 153:

    INJECTION COMPONENTS

    Specification

    Desc./Quantity

    1 Throttle body and electronic injection control unit (MIU)

    2 Fuel injector

    3 Diagnostics socket connector

    4 Injection load remote control

    5 Electric fan

    6 Fuel pump

    7 Lambda sensor

    8 Engine rpm sensor

    9 HV coil

    10 Water temperature sensor

    MIU injection system

    This vehicle is fitted with an integrated injection and ignition system.

    Injection is indirect in the manifold through an electro-injector.

    The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the

    crankshaft (24-2 teeth) and pick-up sensor.

    Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further

    corrections are made according to the following parameters:

    - Coolant temperature.

    - Intake air temperature

    - Lambda probe strength

    The system implements an idle feeding correction with cold engine through a Stepper motor on a by-

    pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening

    time, thereby ensuring the idle steadiness and the proper combustion.

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

    INJEC - 153

  • Page 154:

    In all conditions of use, mixture preparation is managed by modifying the injector opening time.

    The fuel supply pressure is kept constant based on the ambient pressure.

    The fuel supply circuit consists of:

    - Fuel pump

    - Fuel filter

    - Injector

    - Pressure regulator

    The pump, the filter and the regulator are placed inside the fuel tank on a single support.

    The injector is connected by a pipe with fast-release fitting. The pressure regulator is located at the

    beginning of the circuit.

    The fuel pump is controlled by the MIU control unit ; this ensures the scooter safety

    The ignition circuit consists of:

    - HV coil

    - HV cable

    - Shielded cap

    - MIU control unit

    - Spark plug

    The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only

    in the compression phase) at the same time.

    The MIU injection-ignition system controls engine functions by means of a pre-set program.

    Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to

    reach a service station.

    Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the

    control circuits:

    - Fuel pump

    - HV coil

    - Injector

    The control unit is provided with a self-diagnosis

    system connected to an indicator light in the in-

    strument panel.

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

    INJEC - 154

  • Page 155:

    Failures are detected and restored by the diag-

    nostic tester.

    In any case, when the fault is no longer present,

    the data storage is automatically cleared after 16

    cycles of use (cold start, running at regular engine

    temperature, stop).

    The diagnostic tester is also required to adjust the

    idle mixture.

    Specific tooling

    020460Y Scooter diagnosis and tester

    The MIU injection-ignition system carries out

    checks on the rpm indicator and the electric fan for

    radiator cooling.

    The MIU control unit has a decoder for the anti-

    theft immobilizer system.

    The MIU control unit is connected to a diagnostic

    LED on the instrument panel, that also carries out

    the deterrent flashing functions.

    The MIU control unit power supply is furthermore controlled by the emergency switch; that is to provide

    further safety for the scooter.

    Precautions

    Troubleshooting hints

    1 A MIU failure is more likely to be due to the connections than to the components.

    Before troubleshooting the MIU system, carry out the following checks:

    A: Electrical power supply

    a. Battery voltage

    b. Blown fuse

    c. Remote controls

    d. Connectors

    B: Chassis earthing

    C: Fuel supply

    a. Broken fuel pump

    b. Dirty fuel filter

    D: Ignition system

    a. Faulty spark plug

    b. Broken coil

    c. Broken shielded cap

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

    INJEC - 155

  • Page 156:

    E: Intake circuit

    a. Dirty air filter

    b. Dirty by-pass circuit

    c. Faulty Stepper motor

    F: Other

    a. Incorrect distribution timing

    b. Wrong idle mixture

    c.Incorrect reset of the throttle valve position sensor

    2 MIU system faults may be caused by loose connectors. Make sure that all connections have been

    correctly made.

    Check the connections as follows:

    A check that the terminals are not bent.

    B check that the connectors have been properly connected.

    C check whether the malfunction can be fixed by shaking the connector slightly.

    3 Check the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit,

    install the original control unit again and check if the fault occurs again.

    4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm /V. Instruments that

    are not suitable might damage the MIU control unit. Instruments must be used with definitions over 0.1V

    and 0.5 W , the precision must be greater than 2%.

    1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not

    disconnect the battery before checking for faults.

    2. The fuel feed system is pressurised at 250 kPa (2.5 BAR). Before disconnecting the quick coupler

    of a pipe in the fuel supply system, check that there are no naked flames, and do not smoke. Act with

    caution to prevent spraying in the eyes.

    3. When fixing electric components, operate with the battery connected only when actually required.

    4. When functional checks are performed, check that the battery voltage is over 12V.

    5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to

    respect this norm will damage the fuel pump.

    6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the

    level. This will ensure the pump will be covered by fuel.

    7. When washing the vehicle, be careful with the electric components and wiring.

    8. When an ignition fault is detected, start the checks from the battery and the injection system con-

    nections.

    9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:

    - Set the switch to «OFF»

    - Disconnect the battery

    Failure to respect this norm may damage the control unit.

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

    INJEC - 156

  • Page 157:

    10. Do not invert the polarity when fitting the battery.

    11. To avoid damage, only disconnect and reconnect the MIU system connectors if required. Before

    reconnecting, check that the connectors are dry.

    12. When carrying out electric inspections, do not force the tester probes into the connectors. Do not

    take measurements not specifically foreseen by the manual.

    13. At the end of every check performed with the diagnostic tester, protect the system connector with

    its cap. Failure to do this may damage the MIU control unit.

    14. Before reconnecting the quick couplers of the power supply system, check that the terminals are

    perfectly clean.

    Terminals setup

    TERMINAL LAYOUT

    Specification

    Desc./Quantity

    1 Injection warning light

    2 Rpm indicator

    3 -

    4 - Lambda probe

    5 + battery under permanent power supply

    6 + Battery

    7 Immobilizer aerial

    8 Electric fan remote control

    9 Water temperature sensor

    10 -

    11 + Lambda probe

    12 Engine stop switch

    13 R.P.M. sensor (+)

    14 Fuel injector

    15 R.P.M. sensor (-)

    16 Diagnostics socket output

    17 Immobilizer LED

    18 Side stand

    19 -

    20 Injection load remote control

    21 -

    22 HV coil

    23 -

    24 Start up enabling

    25 -

    26 Ground lead

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

    INJEC - 157

  • Page 158:

    EMS circuit diagram

    KEY

    1. Battery

    2. Fuse No. 5

    3. Key switch contacts

    4. Fuse No. 7

    5. Fuse No. 8

    6. Start-up remote control

    7. Fuse No. 4

    8. Fuse No. 1

    9. Fuse No. 2

    10. Electric fan remote control

    11. Electric fan

    12. Immobilizer aerial

    13. Engine rpm sensor

    14. HV coil

    15. Lambda probe

    16. Injector

    17. Fuel pump

    18 Engine stop switch

    19. Stand button

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

    INJEC - 158

  • Page 159:

    20. Engine temperature sensor

    21. Diagnostic socket connector

    22. Injection ECU

    23. Instrument panel

    24. Digital instrument panel

    25. Immobilizer warning light

    26. Injection telltale light

    Troubleshooting procedure

    Engine does not start

    ENGINE DOES NOT START IF ONLY PULLED

    Possible Cause Operation

    Immobiliser enabling signal

    System not encoded

    System not efficient, repair according to the indi-

    cations of the self-diagnosis

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Fuel supply

    Fuel in the tank

    Fuel pump activation

    Fuel pressure (low)

    Injector capacity (low)

    Power to the spark plug Shielded spark-plug cap HV coil (secondary insulation)

    Parameter reliability

    Coolant temperature

    Distribution timing - injection ignition

    Intake air temperature

    End of compression pressure End of compression pressure

    Starting difficulties

    ENGINE START-UP PROBLEMS

    Possible Cause

    Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Start up engine speed

    Starter motor and remote control

    Battery

    Ground connections

    End of compression pressure End of compression pressure

    Power to the spark plug

    Spark plug

    Shielded cap

    HV coil

    Rpm-timing sensor

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

    INJEC - 159

  • Page 160:

    Possible Cause Operation

    Ignition advance

    Fuel supply

    Fuel pressure (low)

    Injector capacity (low)

    Injector seal (poor)

    Correctness of the parameters

    Coolant temperature

    Stepper throttle valve position intake air tempera-

    ture (steps and actual opening)

    Cleaning of the auxiliary air pipe and throttle valve;

    air filter efficiency

    Engine stops at idle

    ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW

    Possible Cause Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Ignition efficiency

    Spark plug

    Ignition timing

    Correctness of the parameters

    Throttle valve position sensor

    Stepper

    Coolant temperature sensor

    Intake air temperature sensor

    Intake system cleaning

    Air filter

    Diffuser and throttle valve

    Additional air pipe and Stepper

    Intake system sealing (infiltrations)

    Intake manifold - head

    Throttle body - manifold

    Intake sleeve

    Filter box

    Fuel feed (low pressure)

    Fuel pump

    Pressure regulator

    Fuel filter

    Injector capacity

    Engine does not rev down

    ENGINE DOES NOT RETURN TO IDLING SPEED/IDLING SPEED TOO HIGH

    Possible Cause

    Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Ignition efficiency Ignition timing

    Correctness of the parameters

    Throttle valve position sensor

    Stepper

    Coolant temperature sensor

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

    INJEC - 160

  • Page 161:

    Possible Cause Operation

    Intake air temperature sensor

    Intake system sealing (infiltrations)

    Intake manifold - head

    Throttle body - manifold

    Intake sleeve

    Filter box

    Fuel feed (low pressure)

    Fuel pump

    Pressure regulator

    Fuel filter

    Injector capacity

    Exhaust backfires in deceleration

    EXHAUST BACKFIRES WHEN DECELERATING

    Possible Cause Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Lambda sensor

    Correctness of the parameters

    Throttle valve position sensor

    Stepper

    Coolant temperature sensor

    Intake air temperature sensor

    Intake system sealing (infiltrations)

    Intake manifold - head

    Throttle body - manifold

    Intake sleeve

    Filter box

    Fuel feed (low pressure)

    Fuel pump

    Pressure regulator

    Fuel filter

    Injector capacity

    Exhaust system sealing (infiltrations)

    Manifold - head

    Manifold - muffler

    Muffler welding

    Engine revs irregularly

    ENGINE IRREGULAR PERFORMANCE WITH VALVE SLIGHTLY OPEN

    Possible Cause

    Operation

    Intake system cleaning

    Air filter

    Diffuser and throttle valve

    Additional air pipe and Stepper

    Intake system seal

    Intake sleeve

    Filter box

    Ignition system Spark plug wear check

    Parameter reliability

    Throttle valve position signal

    Coolant temperature indicator

    Intake air temperature indicator

    Ignition advance

    TPS reset successful TPS reset successful

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

    INJEC - 161

  • Page 162:

    Possible Cause Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Lambda sensor

    Poor performance at full throttle

    POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS

    ON PICKUP

    Possible Cause Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Lambda sensor

    Spark plug power supply

    Spark plug

    Shielded cap

    HV cable

    HV coil

    Intake system

    Air filter

    Filter box (sealing)

    Intake sleeve (sealing)

    Parameter reliability

    Throttle valve position signal

    Coolant temperature indicator

    Intake air temperature indicator

    Ignition advance

    Fuel supply

    Fuel level in the tank

    Fuel pressure

    Fuel filter

    Injector capacity

    Engine knocking

    PRESENCE OF KNOCKING (COMBUSTION SHOCKS)

    Possible Cause

    Operation

    Presence of faults detected by the self diagnosis

    Pump relay

    HV coil

    Injector

    revolution timing sensor

    Air temperature

    Coolant temperature

    Lambda sensor

    Ignition efficiency Spark plug

    Parameter reliability

    Throttle valve position signal

    Coolant temperature indicator

    Intake air temperature indicator

    Ignition advance

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

    INJEC - 162

  • Page 163:

    Possible Cause Operation

    Intake system seal

    Intake sleeve

    Filter box

    TPS reset successful TPS reset successful

    Fuel supply

    Fuel pressure

    Fuel filter

    Injector capacity

    Fuel quality

    Selection of the cylinder base gasket thickness Selection of the cylinder base gasket thickness

    Fuel supply system

    The fuel supply circuit includes the electric pump, the filter, the pressure regulator, the electro-injector

    and the fuel delivery pipes.

    The electrical pump is located in the tank from which the fuel is pumped and sent to the injector through

    the filter.

    The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.

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

    INJEC - 163

  • Page 164:

    Removing the butterfly valve

    Remove the helmet compartment.

    Remove the fuel piping clamping screw indicated

    in the figure.

    Remove the fast-release fitting from the injector

    support.

    Remove the injector connector.

    Remove the three screws fixing the manifold to the

    cylinder head and the clip fixing the throttle body

    to the manifold.

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

    INJEC - 164

  • Page 165:

    Remove the MIU ECU connector.

    Remove the clip fixing the throttle body to the air

    cleaner bellows.

    Remove the throttle control retainers as indicated

    in the photograph.

    Refitting the butterfly valve

    For refitting, carry out the removal operations but

    in reverse order paying particular attention to po-

    sition the reference marks of the air cleaner sleeve

    on the throttle body as indicated in the photograph.

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

    INJEC - 165

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    Pump supply circuit

    INJECTION LOADS

    Specification

    Desc./Quantity

    1 Battery 12V-14Ah

    2 Fuse 15A

    3 Fuse 15A

    4 Key switch contacts

    5 Fuse 7.5 A

    6 Injection load remote control

    7 Fuel pump

    8 HV coil

    9 Fuel injector

    10 Lambda sensor

    11 Electric fan remote control

    When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine

    starts up, in the presence of rpm timing signal the pump is continuously supplied.

    ELECTRICAL DATA

    Pump winding resistance ~ 1.5 Ohm

    Input current during normal functioning 1.4 ÷ 1.8 A

    Input current to the closed hydraulic circuit ~ 2 A (to be checked with specific tool for fuel

    pressure control, choking the circuit on the return pipe)

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

    INJEC - 166

  • Page 167:

    Check that the injection load 15A fuse No. 4 works

    properly.

    Check the efficiency of 7.5 A fuse No. 7 key-con-

    trolled control unit power supply.

    Check the efficiency of the injection load remote

    control: Check the resistance of the energising coil

    between pins 86 and 85: 40 to 80 Ohm

    Apply a voltage of 12V to pins 86 and 85; make

    sure that there is continuity between pins 30 and

    87 of the remote control.

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

    INJEC - 167

  • Page 168:

    Check the power supply line of the injection load

    remote control energising coil: After switching to

    "ON", make sure there is battery voltage, for two

    seconds, between the black/white cable and

    black-violet cable of the remote control base. If

    there is not, check the continuity of the black/white

    cable between fuse block and the remote control

    base and of the black/violet cable between pin 20

    of the control unit and the remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 168

  • Page 169:

    Check the presence of fixed voltage between the

    red/blue cable of the remote control base and

    earth. If not, check the continuity of the red/blue

    cable between the fuse box (No. 4 15A) and the

    remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 169

  • Page 170:

    After switching to «ON» and for about 2 seconds,

    check that there is battery voltage between the

    Black-Green cable of the pump connector and the

    ground lead with the pump connector disconnec-

    ted. Otherwise, check the continuity of the Black-

    Green cable between the pump connector and the

    remote control base.

    Check the efficiency of the earth line of the fuel

    pump by measuring the continuity between the

    pump connector black cable, system side, and the

    earth.

    If, when switching to "ON", the pump continues to

    turn after two seconds of activation, check, with the

    control unit disconnected and the injection load re-

    mote control disconnected, that the Black-Purple

    cable (pin 20 on the interface wiring) is insulated

    from the earth.

    Specific tooling

    020331Y Digital multimeter

    Circuit leak test

    Install the specific tool for fuel pressure control,

    with the pipe fitted with the pressure gauge on the

    indicated duct.

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

    INJEC - 170

  • Page 171:

    Check during regular operation by placing the ap-

    propriate tool between the pump and the injector.

    With the battery voltage> 12 V check that the fuel

    pressure is 2.5 BAR and that the input current is

    1.4 to 1.8 A

    With the battery voltage > 12 V, check the pump flow rate by disconnecting from the injector the pipe

    equipped with the pressure gauge of the appropriate tool. Make a graded burette available with a flow

    rate of approximately 1 L. Rotate the pump using the active diagnosis of the palm top computer. Using

    a pair of long flat needle-nose pliers, choke the fuel pipe making the pressure stabilise at approx. 2.5

    BAR. Check that, in fifteen seconds, the pump has a flow rate of around 110 cm³.

    Specific tooling

    020480Y Petrol pressure check set

    Fuel filter check

    Disconnect the terminals from the electric pump

    Remove the screw shown in the photograph

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

    INJEC - 171

  • Page 172:

    Remove the clip fixing the piping to the filter shown

    in the photograph

    Separate the lower part of the pump support as

    shown in the photograph.

    Remove the filter from the pump support

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

    INJEC - 172

  • Page 173:

    Inspecting the injector circuit

    INJECTION LOADS

    Specification

    Desc./Quantity

    1 Battery 12V-14Ah

    2 Fuse 15A

    3 Fuse 15A

    4 Key switch contacts

    5 Fuse 7.5 A

    6 Injection load remote control

    7 Fuel pump

    8 HV coil

    9 Fuel injector

    10 Lambda sensor

    11 Electric fan remote control

    Check the resistance at the injector ends: 14.5 ± 5% Ohm

    Check that the injection load 15A fuse No. 4 works

    properly.

    Check the efficiency of 7.5 A fuse No. 7 key-con-

    trolled control unit power supply.

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

    INJEC - 173

  • Page 174:

    Check the efficiency of the injection load remote

    control: Check the resistance of the energising coil

    between pins 86 and 85: 40 to 80 Ohm

    Apply a voltage of 12V to pins 86 and 85; make

    sure that there is continuity between pins 30 and

    87 of the remote control.

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

    INJEC - 174

  • Page 175:

    Check the power supply line of the injection load

    remote control energising coil: After switching to

    "ON", make sure there is battery voltage, for two

    seconds, between the black/white cable and

    black-violet cable of the remote control base. If

    there is not, check the continuity of the black/white

    cable between fuse block and the remote control

    base and of the black/violet cable between pin 20

    of the control unit and the remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 175

  • Page 176:

    Check the presence of fixed voltage between the

    red/blue cable of the remote control base and

    earth. If not, check the continuity of the red/blue

    cable between the fuse box (No. 4 15A) and the

    remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 176

  • Page 177:

    With the control unit and the injector disconnected,

    check the continuity of the Red-Yellow cable be-

    tween pin 14 of the interface wiring and the injector

    connector

    Switch to «ON» and check if there is voltage, with

    injector disconnected and control unit connected,

    between the Black-Green cable of the injector con-

    nector and the ground lead

    With injector disconnected and the injector load

    remote control disconnected, check the continuity

    of the Black-Green cable between the injector con-

    nector and remote control base.

    Inspecting the injector hydraulics

    To carry out the injector check, remove the intake

    manifold by removing the three clamping screws

    at the head and the clip connecting the control unit

    to the manifold.

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

    INJEC - 177

  • Page 178:

    Install the appropriate tool for checking fuel pres-

    sure and position the manifold over a container

    graduated by at least 100 cm³. Connect the injec-

    tor with the cable making up part of the supply for

    the injection tester. Connect the clamps of the ca-

    ble to an auxiliary battery. Activate the fuel pump

    with the active diagnosis. Check that, within fifteen

    seconds, approximately 40 cm³ of fuel is dis-

    pensed with an adjustment pressure of approxi-

    mately 2.5 BAR.

    Specific tooling

    020480Y Petrol pressure check set

    Proceed with the injector seal test.

    Dry the injector outlet with a blast of compressed

    air. Activate the fuel pump. Wait for one minute,

    making sure there are no leaks coming from the

    injector. Slight oozing is normal.

    Value limit = 1 drop per minute

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

    INJEC - 178

  • Page 179:

    Components location

    INJECTION COMPONENTS

    Specification

    Desc./Quantity

    1 Throttle body and electronic injection control unit (MIU)

    2 Fuel injector

    3 Diagnostics socket connector

    4 Injection load remote control

    5 Electric fan

    6 Fuel pump

    7 Lambda sensor

    8 Engine rpm sensor

    9 HV coil

    10 Water temperature sensor

    Tachometer

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

    INJEC - 179

  • Page 180:

    With wiring disconnected from the control unit and

    connected to the system, check that the sensor

    resistance between pins 13 - 15 is between 100

    and 150 Ohm at an engine temperature of approx-

    imately 20°

    Disconnect the fuel pipe connector. Start up the

    engine and wait for it to stop. With the wiring con-

    nected to the control unit and system try to start up

    the engine and check that the voltage between

    pins 13 and 15 is around 2.8 V

    With the interface cabling disconnected from the

    control unit, check for continuity between pin 13

    and the red cable of the rev sensor connector and

    between pin 15 and the white cable of the rev sen-

    sor connector.

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

    INJEC - 180

  • Page 181:

    With the revolution sensor connector disconnec-

    ted and interface wiring disconnected from the

    control unit, check that the red and white cables

    (pins 13 - 15) are isolated from each other and in-

    sulated from the ground connection.

    Specific tooling

    020481Y Control unit interface wiring

    020331Y Digital multimeter

    HT coil

    INJECTION LOADS

    Specification

    Desc./Quantity

    1 Battery 12V-14Ah

    2 Fuse 15A

    3 Fuse 15A

    4 Key switch contacts

    5 Fuse 7.5 A

    6 Injection load remote control

    7 Fuel pump

    8 HV coil

    9 Fuel injector

    10 Lambda sensor

    11 Electric fan remote control

    The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition.

    The control unit manages two important parameters:

    - Ignition advance

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

    INJEC - 181

  • Page 182:

    This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure

    With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ± 50 R/1'.

    - Magnetisation time

    The coil magnetisation time is controlled by the control unit. The ignition power is increased during the

    engine start-up.

    The injection system recognises the 4-stroke cycle and therefore, ignition is only controlled during

    compression.

    Specific tooling

    020331Y Digital multimeter

    Check that the injection load 15A fuse No. 4 works

    properly.

    Check the efficiency of 7.5 A fuse No. 7 key-con-

    trolled control unit power supply.

    Check the efficiency of the injection load remote

    control: Check the resistance of the energising coil

    between pins 86 and 85: 40 to 80 Ohm

    Apply a voltage of 12V to pins 86 and 85; make

    sure that there is continuity between pins 30 and

    87 of the remote control.

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

    INJEC - 182

  • Page 183:

    Check the power supply line of the injection load

    remote control energising coil: After switching to

    "ON", make sure there is battery voltage, for two

    seconds, between the black/white cable and

    black-violet cable of the remote control base. If

    there is not, check the continuity of the black/white

    cable between fuse block and the remote control

    base and of the black/violet cable between pin 20

    of the control unit and the remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 183

  • Page 184:

    Check the presence of fixed voltage between the

    red/blue cable of the remote control base and

    earth. If not, check the continuity of the red/blue

    cable between the fuse box (No. 4 15A) and the

    remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 184

  • Page 185:

    Check there is voltage between pins 22 and 26 of

    the interface wiring for around two seconds when

    switching to «ON».

    Check the resistance of the primary coil between

    pin 22 of the interface wiring and the green black

    cable of the injection load remote control base with

    the control unit disconnected and the remote con-

    trol disconnected.

    Resistance of the primary = 0.5 ± 8% Ohm

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

    INJEC - 185

  • Page 186:

    Coolant temperature sensor

    TEMPERATURE SENSOR 1

    Specification

    Desc./Quantity

    1 Engine stop switch

    2 Water temperature sensor

    With the control unit side connector disconnected

    and the coolant temperature sensor connector

    connected, check the resistance between pins 9

    and 26 in relation to the engine temperature.

    20° = 2500 ± 100 Ω

    80° = 308 ± 6 Ω

    With the control unit side connector disconnected

    and the coolant temperature connector discon-

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

    INJEC - 186

  • Page 187:

    nected, check the insulation between the two light

    blue/green and pink/yellow cables

    Zeroing the throttle

    Resetting the throttle valve position signal (TPS reset)

    The MIU control unit is supplied with a throttle valve position sensor that is pre-calibrated.

    Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of

    air under pre-set reference conditions.

    Pre-calibration ensures optimal air flow to control idling.

    This regulation must not be tampered with in any way whatsoever.

    The injection system will complete the management of the idling through the Stepper motor and the

    variation of the ignition advance.

    The throttle body after the pre-calibration has an opened valve with an angle that can vary depending

    on the tolerances of the machining of the pipe and the valve itself.

    The valve position sensor can also assume various fitting positions. For these reasons the mV of the

    sensor with the valve at idle can vary from one throttle body to another.

    To obtain the optimum fuel mixture, especially at small openings of the throttle valve, it is essential to

    match the throttle body with the control unit following the procedure known as TPS resetting.

    With this operation we inform the control unit, as the starting point, of the mV value corresponding to

    the pre-calibrated position.

    To reset, proceed as follows.

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

    INJEC - 187

  • Page 188:

    Connect the diagnostic tester.

    Switch to «ON».

    Select the functions of the diagnostic tester on

    «TPS RESET».

    Specific tooling

    020460Y Scooter diagnosis and tester

    Make sure that the throttle valve with the control is

    supporting the stop screw.

    Guaranteeing that this position will be kept, send

    a confirmation for the TPS reset procedure.

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

    INJEC - 188

  • Page 189:

    Reset should be performed in the following cases:

    - on first fitting.

    - if the injection control unit is replaced.

    N.B.

    THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE

    BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING

    MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.

    Given that the TPS resetting is also done when the

    control unit is replaced, place the control unit - filter

    box bellows at 45° during the refitting operation as

    shown in the photograph.

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

    INJEC - 189

  • Page 190:

    Lambda probe

    INJECTION LOADS

    Specification

    Desc./Quantity

    1 Battery 12V-14Ah

    2 Fuse 15A

    3 Fuse 15A

    4 Key switch contacts

    5 Fuse 7.5 A

    6 Injection load remote control

    7 Fuel pump

    8 HV coil

    9 Fuel injector

    10 Lambda sensor

    11 Electric fan remote control

    The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen

    content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,

    i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic

    converter in an area where the gas temperature is always high. The temperature at which the sensor

    works is at least 350°C at 600°C and it has a reaction time of just 50 milliseconds. The signal generated

    passes from a high value to a low value with a mixture with lambda =1.

    Specific tooling

    020481Y Control unit interface wiring

    020331Y Digital multimeter

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

    INJEC - 190

  • Page 191:

    Check that the injection load 15A fuse No. 4 works

    properly.

    Check the efficiency of 7.5 A fuse No. 7 key-con-

    trolled control unit power supply.

    Check the efficiency of the injection load remote

    control: Check the resistance of the energising coil

    between pins 86 and 85: 40 to 80 Ohm

    Apply a voltage of 12V to pins 86 and 85; make

    sure that there is continuity between pins 30 and

    87 of the remote control.

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

    INJEC - 191

  • Page 192:

    Check the power supply line of the injection load

    remote control energising coil: After switching to

    "ON", make sure there is battery voltage, for two

    seconds, between the black/white cable and

    black-violet cable of the remote control base. If

    there is not, check the continuity of the black/white

    cable between fuse block and the remote control

    base and of the black/violet cable between pin 20

    of the control unit and the remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

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

    INJEC - 192

  • Page 193:

    Check the presence of fixed voltage between the

    red/blue cable of the remote control base and

    earth. If not, check the continuity of the red/blue

    cable between the fuse box (No. 4 15A) and the

    remote control base.

    N.B.

    CONTINUITY TESTS MUST BE CARRIED OUT WITH THE

    COMPONENTS DISCONNECTED. (REMOTE CONTROLS,

    CONTROL UNIT, FUSES ETC.).

    SIGNAL CONTROL

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

    INJEC - 193

  • Page 194:

    Install the electronic control unit interface wiring.

    Start the engine and warm up until the electric fan

    switches on.

    Use an analogue multimeter with a direct voltage

    scale measuring down to 2 V.

    Place the tips of the multimeter between pins 4 (-)

    and 11 (+)

    With the engine running at idle speed, check that

    the voltage oscillates between 0V and 1V

    With the throttle valve completely open, the volt-

    age is approx. 1V.

    During the closing phase, the voltage is approx.

    0V.

    If the voltage remains constant, the sensor may be

    damaged. Remove the sensor and check that

    there are no oil or carbon deposits inside it..

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

    INJEC - 194

  • Page 195:

    INDEX OF TOPICS

    SUSPENSIONS SUSP

  • Page 196:

    This section is devoted to operations that can be carried out on the suspension.

    Front

    Removing the front wheel

    - Remove the fixing nut from the wheel axle on the

    left side of the vehicle.

    - Loosen the two screws fixing the wheel axle

    clamp and remove the clamp.

    Front wheel hub overhaul

    Check that the wheel bearings do not show signs

    of wear.

    If you have to replace the wheel bearings, proceed

    as follows:

    - Remove the two bearings on the brake disc side

    using pliers 14 and the special bell 9.

    - Remove the internal spacer.

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

    SUSP - 196

  • Page 197:

    - Support the front wheel with two wooden shims

    that make it possible to avoid scratching in the

    case of contact with the rim.

    - Insert the punch (consisting of adaptor handle,

    24 mm adaptor and 15 mm guide) from the brake

    disc side to permit the removal of the opposite side

    bearing and the spacer bushing.

    Specific tooling

    020376Y Adaptor handle

    020456Y Ø 24 mm adaptor

    020412Y 15 mm guide

    - Heat the bearing seat on the side opposite the

    brake disc with the heat gun.

    - Insert the bearing using the punch consisting of

    adaptor handle, 40x37 mm adaptor and 15 mm

    guide, and take it to the stop.

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

    SUSP - 197

  • Page 198:

    - Reinsert the spacer bushing on the brake disc

    side using the appropriate tool and take it to the

    stop.

    Specific tooling

    020376Y Adaptor handle

    020359Y 42x47-mm adaptor

    020412Y 15 mm guide

    020201Y Spacer bushing driving tube

    - Refit the cap and tighten the five fixing screws.

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

    SUSP - 198

  • Page 199:

    - Turn over the wheel and insert the internal spacer

    with the part fitted with the Seeger ring facing the

    bearing on the brake disc side.

    - Heat the bearing seat on the side the brake disc

    with the heat gun.

    2 - Insert the two bearings one at a time using the punch consisting of adaptor handle, 32x35 mm

    adaptor and 15 mm guide, and take it to the stop.

    Specific tooling

    020376Y Adaptor handle

    020357Y 32 x 35 mm adaptor

    020412Y 15 mm guide

    Refitting the front wheel

    - When refitting, pay attention in repositioning the

    odometer drive correctly.

    Locking torques (N*m)

    Wheel axle nut 45 ÷ 50 Wheel axle clamp

    screws 6 - 7 Nm

    Handlebar

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

    SUSP - 199

  • Page 200:

    Removal

    - Remove the two handlebar covers and the upper

    part of the shield back plate proceeding as indica-

    ted in the «Bodywork» chapter.

    - Remove the handlebar wiring retaining straps

    and disconnect the electric connectors from the

    brake levers.

    - Unscrew the fittings, then remove the front and

    rear brake pump piping.

    - Remove the flexible transmissions of the throttle

    grip and remove the throttle control.

    - Unscrew the indicated nut, collect the washers

    and remove the fixing pin to the steering tube.

    - Remove the handlebar by pulling it upwards.

    N.B.

    IF THE HANDLEBAR IS BEING REMOVED TO REMOVE

    THE STEERING, IT IS ONLY NECESSARY TO TILT THE

    HANDLEBAR FORWARD ONTO THE FRONT PART OF THE

    VEHICLE WITHOUT REMOVING THE PARTS FITTED SO

    AS TO AVOID DAMAGING THE SHAFTS.

    Refitting

    Carry out the removal operations but in the reverse order, observing the prescribed tightening torque.

    Locking torques (N*m)

    Handlebar fixing screw 50 ÷ 55

    Front fork

    Removal

    See also

    Removal

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

    SUSP - 200

  • Page 201:

    Overhaul

    - Support the fork in a vice.

    - Loosen the two tightening screws of the stem

    supporting clamp.

    - Unscrew the stem closing cap and slide off the

    complete fork leg from the corresponding support.

    CAUTION

    THE STEM CLOSING CAP KEEPS THE MAIN

    SPRING PRELOADED. KEEP THE CAP PROP-

    ERLY FITTED DURING THE REMOVAL FINAL

    STAGE TO AVOID ACCIDENTS.

    - Support the fork leg properly, remove the main

    spring and drain off the fork leg oil.

    - Remove the hydraulic rod fixing screw with the

    corresponding sealing gasket:

    - With a 19-mm hexagonal spanner, lock hydraulic

    rod rotation.

    - Undo the fixing screw and collect the copper

    washer.

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

    SUSP - 201

  • Page 202:

    - Remove the stem dust guard with a screwdriver.

    - Remove the circlip retaining the oil seal.

    - Take out the stem.

    - Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace

    the damaged parts.

    Characteristic

    Maximum leg diameter

    35.10 mm

    Minimum stem diameter

    34.90 mm

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

    SUSP - 202

  • Page 203:

    - Take out the oil seal using the appropriate tools.

    - Fit the tie rod into the oil seal.

    - Insert in sequence the two half-rings per Ø 35-

    mm stems.

    Specific tooling

    020487Y Fork oil seal extractor

    - Hold the tie rod manually so that it does not fall

    into the fork leg and/or that both half-rings are not

    in their position.

    - Fit the bell.

    - Tighten the nut until it stops.

    - Act on the tool until the oil seal is completely re-

    moved.

    Specific tooling

    020487Y Fork oil seal extractor

    - Remove the hydraulic rod with the corresponding

    sealing gasket, the spring and the stop bushing.

    COMPONENT CHECK

    CAUTION

    CLEAN ALL THE COMPONENTS THOROUGHLY.

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

    SUSP - 203

  • Page 204:

    - Check that the fork leg is not cracked or broken

    in the attachments.

    - Check that the stem is not scored, dented or dis-

    torted.

    - Check that the stop bushing for the hydraulic rod

    is correctly fixed through caulking.

    - Check that hydraulic rod caulkings, the return

    spring to the unloaded the end of stroke and the

    hydraulic rod sealing ring are in good conditions.

    - Check that the main spring exhibits no signs of

    yielding or abnormal wear.

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

    SUSP - 204

  • Page 205:

    - Check that the closing cap O-ring of the stem is

    in good conditions.

    Refitting

    - First grease the splitting chamber of the two seal-

    ing lips of a new oil seal.

    - Fit the sealing ring on the stem and keep the

    identification words facing upwards.

    - Drive the oil seal as far as it will go using the ap-

    propriate tool.

    Specific tooling

    020376Y Adaptor handle

    020359Y 42x47-mm adaptor

    - Pre-fit the stem with the hydraulic rod, the spring

    and the stop bushing.

    - Fit the pre-assembled components inside the fork

    leg.

    - Fit the hydraulic rod fixing screw with the copper

    sealing washer and tighten to the prescribed tor-

    que using the recommended product.

    CAUTION

    ALWAYS USE NEW COPPER WASHER.

    Locking torques (N*m)

    Hydraulic rod fixing screw 25 ÷ 35*

    (°) Apply LOCTITE 243 threadlock

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

    SUSP - 205

  • Page 206:

    - Lock hydraulic rod rotation using a 19-mm hex-

    agonal spanner.

    - Fit the oil seal retaining circlip.

    - Grease and fit a new dust guard.

    - Fit the fork leg together with the stem on the fork

    supporting clamp until it stops.

    - Tighten the two screws to the prescribed torque

    in the sequence indicated in the photograph.

    Locking torques (N*m)

    Stem support clamp tightening screws 20 ÷ 25

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

    SUSP - 206

  • Page 207:

    - Refill the fork leg with the recommended product

    to the prescribed amount.

    Recommended products

    AGIP FORK 7.5 W Oil for front fork

    Hydraulic fluid SAE 7.5 W

    Characteristic

    Oil quantity per stem

    133 ± 3 cm³

    - Bleed the hydraulic rod by actuating the stem re-

    peatedly.

    - Fit the spring into the stem.

    CAUTION

    FIT THE SPRING WITH THE SMALLER PITCH TO THE UP-

    PER PART OF THE STEM.

    - Lubricate the closing cap O-ring of the stem.

    - Preload the spring, fit the closing cap and tighten

    to the prescribed torque.

    Locking torques (N*m)

    Fork locking screws cap 15 ÷ 30

    - Repeat the procedure for the other fork leg.

    N.B.

    IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME, BE CAREFUL NOT TO INVERT THE

    RIGHT FORK LEG WITH THE LEFT ONE.

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

    SUSP - 207

  • Page 208:

    Steering column

    Removal

    - Remove the front wheel.

    - Remove the front mudguard

    - Remove the front brake calliper

    - Remove the shield back plate upper side.

    - Remove the pin mounting the handlebar to the

    steering tube.

    - Remove the handlebar and rest it on the shield

    back plate.

    - Remove by releasing the cable passages and

    sliding the protection collar upwards.

    - Using the appropriate tool, loosen and remove

    the upper ring nut, the space washer, the counter

    ring nut and the spacer.

    - Remove the cover plate and upper seat of the

    steering fifth wheel.

    - Extract the fork.

    N.B.

    TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT

    IT FROM COMING OFF ABRUPTLY

    Specific tooling

    020055Y Wrench for steering tube ring nut

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

    SUSP - 208

  • Page 209:

    Refitting

    - Fit the lower steering fifth wheel on the steering

    tube.

    - Fit the fork together with the lower steering fifth

    wheel on the headstock and hold it so that it does

    not fall.

    N.B.

    LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH

    RECOMMENDED GREASE BEFORE USE.

    Recommended products

    AGIP GREASE PV2 Grease for steering bear-

    ings, bolt seatings for swinging arms and fay-

    ing surface of driven pulley spring (only pulley

    side)

    Soap-based lithium and zinc oxide grease con-

    taining NLGI 2; ISO-L-XBCIB2

    - Fit the upper steering fifth wheel.

    CAUTION

    INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FAC-

    ING UPWARDS.

    - Fit the steering fifth wheel upper seat.

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

    SUSP - 209

  • Page 210:

    - Fit the cover plate.

    - Insert the spacer.

    - Insert the lower tightening ring nut, screw until it

    stops and, with the specific tool, tighten to the pre-

    scribed torque.

    Specific tooling

    020055Y Wrench for steering tube ring nut

    Locking torques (N*m)

    Steering tube lower ring nut 14 ÷ 17

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

    SUSP - 210

  • Page 211:

    - Fit the spacer between the two ring nuts on the

    steering tube in the position indicated.

    - Insert the upper tightening ring nut, screw until it

    stops and, with the specific tool, tighten to the in-

    dicated torque.

    Specific tooling

    020055Y Wrench for steering tube ring nut

    Locking torques (N*m)

    Steering tube upper ring nut 40 ÷ 45

    Insert the collar shown in the figure and restore the

    cable passage as shown in the figure.

    - Fit the front wheel.

    Steering bearing

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

    SUSP - 211

  • Page 212:

    Removal

    - Clean thoroughly and visually inspect if the com-

    ponents are in good conditions.

    - Check the upper steering fifth wheel for wear.

    - Check the lower steering fifth wheel for wear.

    - Visually inspect that the steering fifth wheel

    tracks, the headstock and the steering tube exhibit

    no scores or abnormal wear. Otherwise, replace

    them.

    STEERING FIFTH WHEEL TRACK REMOVAL

    - Remove the steering fifth wheel tracks on the

    chassis with the specific tool, following the indica-

    ted procedure.

    - Fit the specific tool from the lower part of the

    headstock until it makes contact with the upper

    track.

    - Hit with force the specific tool, placing it at differ-

    ent points diametrically opposed so as to remove

    the upper track.

    Specific tooling

    020004Y Punch for removing fifth wheels from

    headstock

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

    SUSP - 212

  • Page 213:

    - Repeat the procedure for the lower steering fifth wheel track.

    - Remove the lower fifth wheel seat on the steering

    tube using the specific tool.

    Specific tooling

    020004Y Punch for removing fifth wheels from

    headstock

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

    SUSP - 213

  • Page 214:

    Refitting

    STEERING FIFTH WHEEL TRACK FITTING

    - Thoroughly clean the track seats on the head-

    stock and the steering tube.

    - Fit the new tracks of the headstock with the spe-

    cific tool.

    - Screw the nut until the tracks are fully inserted.

    N.B.

    LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH

    RECOMMENDED GREASE BEFORE USE.

    Specific tooling

    001330Y Tool for fitting steering seats

    Recommended products

    AGIP GREASE PV2 Grease for steering bear-

    ings, bolt seatings for swinging arms and fay-

    ing surface of driven pulley spring (only pulley

    side)

    Soap-based lithium and zinc oxide grease con-

    taining NLGI 2; ISO-L-XBCIB2

    - Fit the lower fifth wheel seat on the steering tube.

    - Using the specific tool, fit the lower fifth wheel

    seat on the steering tube.

    N.B.

    LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH

    RECOMMENDED GREASE BEFORE USE.

    Specific tooling

    020459Y Punch for fitting bearing on steering

    tube

    Recommended products

    AGIP GREASE PV2 Grease for steering bear-

    ings, bolt seatings for swinging arms and fay-

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

    SUSP - 214

  • Page 215:

    ing surface of driven pulley spring (only pulley

    side)

    Soap-based lithium and zinc oxide grease con-

    taining NLGI 2; ISO-L-XBCIB2

    Rear

    Removing the rear wheel

    Remove the full muffler assembly.

    - Remove the cotter pin, the cap, the wheel axle

    fixing nut and the outer one of the two spacers.

    - Remove the two screws fixing the mudguard to the bracket

    - Remove the two screws fixing the bracket to the engine

    - Slide off the wheel axle bracket, using the heat

    gun if necessary.

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

    SUSP - 215

  • Page 216:

    - Remove the 5 bolts of the wheel and remove

    Refitting the rear wheel

    To fit, follow the removal steps but in the reverse

    sequence, being careful to fit the spacers on the

    wheel axle as shown in the photograph.

    Locking torques (N*m)

    Muffler arm clamping screws 27 ÷ 30 Rear wheel

    axle nut 104 ÷ 126 Shock absorber-crankcase at-

    tachment bracket 20 ÷ 25 Lower shock absorber

    clamping screw 33 ÷ 41 Nm Rear brake calliper

    fixing screws 25 ÷ 30 Nm

    Swing-arm

    Removal

    - Place the scooter on its centre stand;

    - Remove the swinging arm/engine fitting shown in

    the photo

    - Move the engine back

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

    SUSP - 216

  • Page 217:

    - remove the spring anchoring the swinging arm to

    the frame as shown in the photo

    - Remove the two screws fixing the buffer support

    bracket to the frame

    - Undo the nut on the LHS shown in the figure and

    remove the corresponding bolt from the opposite

    side.

    - Remove the swinging arm.

    - Check the entire swinging arm assembly.

    - Check all the centring bushing components and

    silent block rubber buffers.

    - Replace the work components that cause exces-

    sive clearance on the rear suspension.

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

    SUSP - 217

  • Page 218:

    Overhaul

    - Check there is no sticking in the movement of the

    connection of the swinging arm on the engine side

    to the swinging arm on the frame side.

    - Check the axial clearance between the two

    swinging arms using a feeler thickness gauge

    Characteristic

    Standard clearance

    0.40 ÷ 0.60 mm

    Allowable limit after use:

    1.5 mm

    - To check the clearance on the frame-side arm,

    mount the retainer using the pin fixing the swinging

    arm to the frame and two adaptor rings of the ap-

    propriate tool 020229Y. Alternatively use two

    washers with inner diameter for 12-mm pins, min.

    outer diameter: 30 mm: min. thickness: 4 mm.

    - Check there is no sticking in the rotation.

    - Check the axial clearance of the swinging arm on

    the frame side

    Characteristic

    Standard clearance

    0.40 ÷ 0.60 mm

    Allowable limit after use:

    1.5 mm

    - Separate the swinging arm on the engine side

    from the vehicle side arm.

    - Remove the plastic bushings and the internal

    spacer shown in the photo.

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

    SUSP - 218

  • Page 219:

    - Using a suitable pin remove the roller casings as

    shown in the photographs

    - Using an appropriate tool plant new roller cas-

    ings, being careful to position the bearings with the

    O-rings facing outwards

    Specific tooling

    020244Y 15 mm diameter punch

    020115Y Ø 18 punch

    Characteristic

    Length of the swinging arm tube on the engine

    side:

    L 175.3 + 0.3 0

    Length of the internal swinging arm spacer on

    the engine side:

    L 183 + 0.3 0

    Engine side swinging arm plastic bushing

    shim:

    3.5 ± 0.05 mm

    Frame-side swinging arm plastic bushing

    shim:

    3.5 ± 0.05 mm

    Length of the internal swinging arm spacer on

    the frame side:

    290 ± 0.1 mm

    Length of the swinging arm tube on the frame

    side:

    283 ± 0.1 mm

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

    SUSP - 219

  • Page 220:

    - Lubricate roller casings and the plastic bushings

    with grease

    - Insert the spacers

    - Assemble the two arms with the relative bolt in

    the position shown in the photograph

    - Adjust the bolt as shown in the photograph

    - Position the frame side swinging arm with the

    most protruding part pointing towards the silent

    block side as shown in the photograph

    Recommended products

    AGIP GREASE PV2 Grease for the steering

    bearings, pin seats and swinging arm

    Soap-based lithium and zinc oxide grease con-

    taining NLGI 2; ISO-L-XBCIB2 of the swinging arm

    - Make sure the silent bloc is not broken. If there

    is, replace it.

    - Remove the seeger ring shown in the photograph

    - Remove the full silent bloc bracket

    - Undo the silent bloc ring shown in the photograph

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

    SUSP - 220

  • Page 221:

    - Hold the full silent bloc bracket in the clamp

    - Using the appropriate tool, remove the silent bloc

    from the bracket from the side corresponding to

    the inside of the vehicle. This is to guarantee the

    tool is centred properly on the support

    - Install a new silent bloc, making sure it aligns

    properly with the reference tooth.

    - Fit the silent blocs, making sure the chamfered

    part of the silent bloc matches the chamfered part

    of the bracket

    - Using the appropriate tool, fit the silent bloc as

    shown in the photo

    Refitting

    - To refit, perform the removal operations in reverse.

    - Grease the bearings and the rolling parts with the recommended grease.

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

    SUSP - 221

  • Page 222:

    -Complete the fitting by tightening the nuts on the relative bolts to the proper tightening torque.

    Locking torques (N*m)

    Engine and vehicle side swinging arm junction bolt 33 ÷ 41 Nm Swinging arm pin - Engine 64 -

    72 Body shell - Swinging arm pin 76 ÷ 83 Screw fixing the silent-block support plate to the

    body 42 ÷ 52

    Shock absorbers

    Removal

    Proceed as follows:

    - place the scooter on its centre stand;

    - lift the engine a little with a jack so as to free the

    two shock absorbers;

    - remove the muffler

    - undo the shock absorber spring assembly clamp-

    ing screw from the support fixed to the engine on

    the one side and from that fixed to the muffler on

    the other;

    - unscrew the two upper nuts (one on each side)

    fixing the shock absorber spring assembly to the

    frame and remove the shock absorbers.

    Refitting

    Carry out the previous operations but in reverse order.

    Locking torques (N*m)

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

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

    SUSP - 222

  • Page 223:

    Centre-stand

    REMOVAL

    - Use a jack to support the vehicle properly.

    - Remove the two return springs from the centre

    stand.

    - Undo the nut shown in the figure.

    - Remove the bolt from the right side.

    - Remove the centre stand.

    FITTING

    - On refitting tighten the nut to the specified torque.

    Locking torques (N*m)

    Centre stand bolt 32 ÷ 40

    Side stand

    REMOVAL

    - Uncouple the centre stand return spring;

    Remove the screw shown in the photograph

    FITTING

    To refit, carry out the removal operations in re-

    verse order and comply with the specified torque.

    Locking torques (N*m)

    Side stand fixing bolt 35 ÷ 40

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

    SUSP - 223

  • Page 224:

    INDEX OF TOPICS

    B

    RAKING SYSTEM BRAK SYS

  • Page 225:

    This section è is devoted to the description of the braking system components.

    Rear brake calliper

    Removal

    - Remove the rear wheel.

    - Remove the two rear brake calliper devices fas-

    tening them to the support as shown in the photo-

    graph.

    N.B.

    SHOULD THE BRAKE CALLIPER BE REPLACED OR

    SERVICED, BEFORE REMOVING THE FITTINGS FIXING

    THE CALLIPER TO THE SUPPORT BRACKET, LOOSEN

    THE OIL HOSE FITTING AFTER HAVING EMPTIED THE

    SYSTEM OF THE CIRCUIT BEING EXAMINED.

    Overhaul

    - Remove the brake calliper.

    - Suitably support the brake calliper in a vice

    - Remove the two pad fixing screws.

    - Remove the pads being careful with the stop

    spring.

    - Remove the fixed plate by undoing the screw

    shown in the photograph.

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 225

  • Page 226:

    - Remove the internal parts from the floating body

    with short blasts of compressed air through the

    brake liquid pipe to facilitate expelling the plung-

    ers.

    - Check:

    that the plates and the body are whole

    and in good condition;

    that the cylinders of the calliper floating

    body do not show signs of scratches or

    erosion, otherwise replace the entire

    calliper:

    that the guides of the fixed plate are not

    scratched or eroded, otherwise re-

    place the entire plate;

    that the brake pad check spring works

    properly

    CAUTION

    ALL THE SEALS AND GASKETS MUST BE REPLACED EV-

    ERY TIME THE PUMP IS SERVICED.

    Refitting

    - Insert the O-rings and small pistons the floating

    body, lubricating all the components with brake

    fluid.

    - Fit the fixed plate being careful to grease guide

    A and to insert washer B as indicated in the photo.

    - Fit the pad retention spring

    - Fit the pads and screw up the relative clamping screws to the specified torque

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 226

  • Page 227:

    - Hold the pads in the correct position and insert the calliper in the brake disc.

    - Fix the support calliper by means of the two screws at the specified torque

    - Secure the pipe fitting to the calliper at the specified torque.

    - Bleed the air from the system.

    Locking torques (N*m)

    Rear brake calliper fixing screws 20 ÷ 25 Engine- calliper support plate fixing screws 48 ÷ 52

    Front brake calliper

    Removal

    - Remove the two front brake calliper devices fas-

    tening them to the support as shown in the photo-

    graph.

    N.B.

    WHEN A PROCEDURE IS PLANNED INCLUDING THE

    SERVICE OR REPLACEMENT OF THE CALLIPER, FIRST

    LOOSEN THE FITTING CONNECTING THE PIPE TO THE

    BRAKE CALLIPER

    Overhaul

    - Remove the brake calliper.

    - Suitably support the brake calliper in a vice

    - Remove the two pad fixing screws.

    - Remove the pads being careful with the stop

    spring.

    - Remove the fixed plate by undoing the screw

    shown in the photograph.

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 227

  • Page 228:

    - Remove the internal parts from the floating body

    with short blasts of compressed air through the

    brake liquid pipe to facilitate expelling the plung-

    ers.

    - Check:

    that the plates and the body are whole

    and in good condition;

    that the cylinders of the calliper floating

    body do not show signs of scratches or

    erosion, otherwise replace the entire

    calliper:

    that the guides of the fixed plate are not

    scratched or eroded, otherwise re-

    place the entire plate;

    that the brake pad check spring works

    properly

    CAUTION

    ALL THE SEALS AND GASKETS MUST BE REPLACED EV-

    ERY TIME THE PUMP IS SERVICED.

    Refitting

    - Insert the O-rings and small pistons the floating

    body, lubricating all the components with brake

    fluid.

    - Fit the fixed plate being careful to grease guide

    A and to insert washer B as indicated in the photo.

    - Fit the pad retention spring

    - Fit the pads and screw up the relative clamping screws to the specified torque

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 228

  • Page 229:

    - Hold the pads in the correct position and insert the calliper in the brake disc.

    - Fix the support calliper by means of the two screws at the specified torque

    - Secure the pipe fitting to the calliper at the specified torque.

    - Bleed the air from the system.

    Locking torques (N*m)

    Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5 Calliper support

    plate - fork fixing screws 41 ÷ 51

    Rear brake disc

    Removal

    - Remove the rear wheel.

    - Remove the brake calliper.

    - Remove the disc from the wheel axle.

    - Undo the five screws and remove the disc from

    the wheel hub.

    Refitting

    For fitting, position the disc correctly using the arrow stamped on it as reference.

    - Do up the screws to the prescribed torque and apply the recommended product

    N.B.

    THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED

    TOWARDS THE OUTSIDE OF THE VEHICLE.

    Recommended products

    Loctite 243 Medium strength threadlock

    Loctite 243 medium-strength threadlock

    Locking torques (N*m)

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 229

  • Page 230:

    Brake disc screws 8 ÷ 10

    Disc Inspection

    - Remove the rear brake calliper.

    - Check the disc thickness with a micrometer

    Characteristic

    Standard thickness:

    5 +0.2-0.1 mm

    Disc thickness at wear limit

    4.5 mm

    - Repeat the measurement at no fewer than six points on the disc.

    - Check the regular nature of the rotation of the brake disc assembly using the appropriate tool fixed

    onto the brake calliper as shown in the photo.

    - In order to be able to anchor the appropriate tool properly use a metal plate with M8 threaded hole

    and fix it to one of the two rear brake calliper attachment points.

    - Suitably fix the flange to the wheel axle with the original nut and spacer and a Æ 17 mm bearing.

    N.B.

    SO AS NOT TO GET A DISTORTED READING, CAUSE THE DRIVEN PULLEY SHAFT TO TURN

    IN ORDER TO ROTATE THE DISC.

    Specific tooling

    020335Y Magnetic support for dial gauge

    Characteristic

    Max. deviation allowed:

    0.1 mm

    - If you detect incorrect values, replace the disc. If

    the anomaly persists, replace the hub.

    Front brake disc

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 230

  • Page 231:

    Removal

    - Remove the front wheel.

    - Undo the five clamping screws shown in the pho-

    tograph

    Refitting

    For fitting, position the disc correctly using the arrow stamped on it as reference.

    - Do up the screws to the prescribed torque and apply the recommended product

    N.B.

    THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED

    TOWARDS THE OUTSIDE OF THE VEHICLE.

    Recommended products

    Loctite 243 Medium strength threadlock

    Loctite 243 medium-strength threadlock

    Locking torques (N*m)

    Brake disc screws 8 ÷ 10

    Disc Inspection

    Checking the disc is important; it must be perfectly

    clean, with no sign of rust, oil or grease or any oth-

    er dirt, and must show no signs of deep scoring.

    Characteristic

    Standard thickness:

    5 +0.2-0.1 mm

    Disc thickness at wear limit

    4.5 mm

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 231

  • Page 232:

    Using the appropriate tool, measure

    how much the disc protrudes when the

    wheel is fitted properly. The protrusion,

    measured near the external edge of

    the disc, must be less than 0.1 mm.

    If a value is measured other than the

    specified value, remove the front wheel

    (Front/Rear Suspension chapter) and

    check the protrusion of the disc. Maxi-

    mum permissible out of true is 0.1 mm.

    If the value measured is greater, re-

    place the disc and repeat the check.

    If the problem persists, check and re-

    place the wheel hub if necessary.

    Specific tooling

    020335Y Magnetic support for dial gauge

    Front brake pads

    Removal

    Proceed as follows:

    - Remove the front brake calliper.

    - Loosen the two pins shown in the figure that lock

    the two pads.

    - Remove the pads, being careful with the pad

    spring clamp.

    - Check the thickness of the pads.

    Characteristic

    Minimum value

    1.5 mm

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 232

  • Page 233:

    See also

    Front

    brake calliper

    Refitting

    To fit, proceed as follows:

    - Insert the two pads in the callipers.

    - Screw the two pad lock pins to the correct torque, and apply the recommended product.

    - Fit the calliper on its support, tightening the two screws to the prescribed torque.

    N.B.

    IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-

    TING, GENTLY EXPAND THE PADS.

    Recommended products

    Loctite 243 Medium strength threadlock

    Loctite 243 medium-strength threadlock

    Locking torques (N*m)

    Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5

    Rear brake pads

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 233

  • Page 234:

    Removal

    Proceed as follows:

    - Remove the rear brake calliper.

    - Loosen the two pins shown in the figure that lock

    the two pads.

    - Remove the pads, being careful with the pad

    spring clamp.

    - Check the thickness of the pads.

    Characteristic

    Minimum value

    1.5 mm

    See also

    Removal

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 234

  • Page 235:

    Refitting

    To fit, proceed as follows:

    - Insert the two pads in the callipers.

    - Screw the two pad lock pins to the correct torque, and apply the recommended product.

    - Fit the calliper on its support, tightening the two screws to the prescribed torque.

    N.B.

    IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-

    TING, GENTLY EXPAND THE PADS.

    Recommended products

    Loctite 243 Medium strength threadlock

    Loctite 243 medium-strength threadlock

    Locking torques (N*m)

    Screw tightening calliper to the support 24 ÷ 27 Pad fastening pin 19.6 ÷ 24.5

    Fill

    Rear - combined

    - Remove the rubber hood from the bleed screw.

    - Insert a rubber pipe in the bleed screw to permit

    the brake fluid to be recovered.

    - With the left-had brake lever, load the system and

    bring it up to the required pressure.

    - Keeping the left-hand brake lever pulled, loosen

    the bleed screw to permit the air in the system to

    escape. Then tighten the bleed screw

    - Repeat the operation until only brake fluid comes out of the rubber pipe.

    - Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.

    - Top up the brake fluid to the right level in the reservoir.

    If necessary, bleeding can be done using a special vacuum pump

    N.B.

    DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO

    CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE

    BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE

    FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE

    PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND

    EFFICIENCY OF THE BRAKING SYSTEM

    Specific tooling

    020329Y MityVac vacuum-operated pump

    Locking torques (N*m)

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 235

  • Page 236:

    System bleed calliper fitting: 12 ÷ 16 Nm

    Front

    - Remove the rubber hood from the bleed screw.

    - Insert a rubber pipe in the bleed screw to permit

    the brake fluid to be recovered.

    - With the right-hand brake lever, load the system

    and bring it up to the required pressure.

    - Keeping the right-hand brake lever pulled, loosen

    the bleed screw to permit the air in the system to

    escape. Then do up the bleed screw

    - Repeat the operation until only brake fluid comes out of the rubber pipe.

    - Remove the fluid recovery pipe and refit the rubber cap over the bleed screw.

    - Top up the brake fluid to the right level in the reservoir.

    If necessary, bleeding can be done using a special vacuum pump

    N.B.

    DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO

    CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE

    BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE

    FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE

    PADS. FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND

    EFFICIENCY OF THE BRAKING SYSTEM

    Specific tooling

    020329Y MityVac vacuum-operated pump

    Locking torques (N*m)

    System bleed calliper fitting: 12 ÷ 16 Nm

    Front brake pump

    Removal

    The procedure is valid for both brake pumps.

    - Remove the front and rear handlebar covers.

    - Place a suitable container to collect the oil, dis-

    connect the oil pipe from the calliper and operate

    the brake lever until no more oil comes out.

    - Disconnect the oil pipe «A» from the pump, then

    unscrew the two retainers «B» from the U-bolt and

    remove the pump.

    Braking system MSS Nexus 300 i.e. E3 ( 2008)

    BRAK SYS - 236

  • Page 237:

    - Upon refitting, tighten up the fitting to the speci-

    fied torque and bleed the system.

    CAUTION

    ALWAYS USE NEW COPPER WASHERS.

    Locking torques (N*m)

    Brake fluid pump-hose fitting 16 ÷ 20 Fixing

    screws for handlebar control assembly U-

    bolts 7 ÷ 10

    MSS Nexus 300 i.e. E3 ( 2008) Braking system

    BRAK SYS - 237

  • Page 238:

    INDEX OF TOPICS

    COOLING SYSTEM COOL SYS

  • Page 239:

    Circuit diagram

    KEY

    A = Expansion tank

    B = Radiator

    C = Radiator intake pipe

    D = Water pump

    E = Delivery pipe to cylinder

    F = By-Pass pipe

    G = Thermostat

    H = Radiator delivery pipe

    Electric fan check

    - Check and, if necessary, restore the correct battery voltage.

    MSS Nexus 300 i.e. E3 ( 2008) Cooling system

    COOL SYS - 239

  • Page 240:

    Characteristic

    Battery voltage

    12V

    - Check that the electric ventilation relay is working

    properly.

    - If the relay is not working, replace it.

    - If the relay is operating, remove it and jump the

    red-green and red-black wires (85 - 86); all the

    components in proper operating conditions, the

    electric ventilation should be able to start.

    - For checking the coolant temperature sensor, see the «Injection» chapter.

    See also

    Remote controls check

    System bleed

    - Start up the engine until the operating tempera-

    ture is reached.

    - Remove the rubber hood over the bleed valve

    - Obtain a rubber tube that is of the right length to

    connect the valve to the expansion tank

    - Place one end of the pipe on the bleed valve and

    the other in the expansion tank

    - Loosen the screw by two turns until the commu-

    nication hole is revealed with the head as shown

    in the photo

    - Wait until only coolant comes out of the rubber

    pipe so as to eliminate any air bubbles inside the

    circuit.

    Cooling system MSS Nexus 300 i.e. E3 ( 2008)

    COOL SYS - 240

  • Page 241:

    - Tighten the bleed valve respecting the maximum

    torque.

    - Bring the coolant up to the correct level inside the

    expansion tank

    Locking torques (N*m)

    Bleed screw 3

    Thermostat

    Removal

    - Remove the helmet compartment inspection cov-

    er.

    - Place a + 2.0 l container under the vehicle to col-

    lect the coolant.

    - Undo the two screws indicated, lift the cover and

    remove the thermostat.

    MSS Nexus 300 i.e. E3 ( 2008) Cooling system

    COOL SYS - 241

  • Page 242:

    Check

    1) Visually inspect that the thermostat is not dam-

    aged.

    2) Fill a metal container with approx. 1 litre of wa-

    ter.

    Immerse the thermostat, and keep it in the centre

    of the container.

    Immerse the multimeter temperature probe, and

    keep it close to the thermostat.

    Heat up the container using the thermal gun.

    Check the temperature at which the thermostat

    starts to open:

    Heat up until the thermostat is completely open.

    3) Replace the thermostat if it is not working prop-

    erly.

    CAUTION

    TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-

    THER THE THERMOSTAT NOR THE THERMOMETER

    TOUCHES THE CONTAINER.

    Specific tooling

    020331Y Digital multimeter

    020151Y Air heater

    THERMOSTAT

    Specification

    Desc./Quantity

    Type Wax-type, with deviator

    Starts opening 85±2°C

    Refitting

    - Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque.

    Locking torques (N*m)

    Thermostat cover screws 3 ÷ 4

    - Once the cooling circuit is restored, refill using the recommended product and purge the circuit as

    expressly indicated in the «Cooling System» chapter.

    Cooling system MSS Nexus 300 i.e. E3 ( 2008)

    COOL SYS - 242

  • Page 243:

    INDEX OF TOPICS

    CHASSIS CHAS

  • Page 244:

    This section è is devoted to the operations that can be carried out on the vehicle's bodywork.

    Seat

    - Remove the two clamping screws on the frame.

    - Remove the control button of the undersaddle

    light.

    Rear handlebar cover

    - Release the three retaining tabs of the rear han-

    dlebar cover shown in the figure using a screw-

    driver and paying attention not to damage the

    paintwork.

    - Remove the five fixing screws from the rear han-

    dlebar cover.

    - Remove the rear cover.

    N.B.

    WHEN INSTALLING, THE CENTRE SCREW IS A METAL

    SCREW, THE OTHER 4 ARE PLASTIC.

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

    CHAS - 244

  • Page 245:

    Instrument panel

    - Remove the instrument panel.

    - Loosen the five fixing nuts of the instrument pan-

    el.

    Front handlebar cover

    - Remove the rear handlebar cover.

    - Remove the left and right frames of the brake

    pump secured with two retaining fins.

    - Loosen the four fixing screws of the front han-

    dlebar cover with the handlebar itself.

    - Disconnect the warning light unit connector «A».

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

    CHAS - 245

  • Page 246:

    Headlight assy.

    - Remove the centre cover of the shield.

    - Remove the 4 front retainers of the front light as-

    semblies.

    - To remove the right-hand light assembly, remove

    the screw located near the cover of the expansion

    tank.

    - To remove the left-hand light assembly, remove

    the screw located in the left-hand storage com-

    partment.

    Remove the light, disconnecting the electric con-

    nector from the light and the complete lamp holder

    of the position light.

    N.B.

    THE TWO REAR ADJUSTMENT SCREWS SHOWN IN THE

    FIGURE ARE ADJUSTED DURING ASSEMBLY OF THE

    LIGHT AND MUST NOT BE ALTERED.

    Frame central cover

    The chassis central cover has a central tunnel and two side fairings, the procedure is the following:

    CENTRAL TUNNEL:

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

    CHAS - 246

  • Page 247:

    - Remove the saddle together with the hinge.

    - Open the fuel tank flap.

    - Undo the screw indicated in the figure.

    - Undo the three screws indicated in the figure.

    N.B.

    THE OTHER 3 SCREWS HAVE ONLY AN AESTHETIC

    FUNCTION

    - Undo and remove from both vehicle sides the

    screw indicated in the figure.

    - Undo the five screws indicated in the figure.

    CAUTION

    PROVISIONALLY PROTECT THE NECK OF THE FUEL

    TANK USING A CLEAN CLOTH TO PREVENT ANY DIRT OR

    OBJECTS ACCIDENTALLY FALLING INTO THE TANK.

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

    CHAS - 247

  • Page 248:

    - Working from both sides, undo the screw indica-

    ted and release the retaining tongues to remove

    the side air deflectors.

    - Undo from both sides the screw indicated in the

    figure.

    - Remove the central tunnel sliding it from the

    tongues.

    SIDE FAIRING:

    - Remove the central tunnel.

    - Remove the side fairings.

    - Remove the handgrips and top side fairings.

    - Remove the right and left footrests (see FOOTREST).

    - Working from both sides, undo the screw indica-

    ted in the figure.

    - Remove the side fairing sliding it from the

    tongues.

    Legshield

    The front shield has a lot of sections. The removal procedure is described below:

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

    CHAS - 248

  • Page 249:

    FRONT LOWER FRAME:

    - Using a screwdriver, remove the «GILERA» clip-

    on badge.

    - Undo and remove the screw under the badge.

    - Undo and remove the screw «A».

    - Taking care not to damage the plastic tongues,

    remove the front lower frame sliding it upwards

    from bottom to top.

    FRONT UPPER FRAME:

    - Remove the FRONT LOWER FRAME.

    - Remove the windshield together with the supports.

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

    CHAS - 249

  • Page 250:

    - Undo and remove the two screws «B» and the

    four screws «C».

    - Remove the frame sliding it from the tongues.

    FRONT TURN INDICATORS:

    - Undo and remove the three screws indicated.

    - Disconnect the front turn indicator connector.

    - Undo and remove the three screws to remove the

    bulb holder from the support.

    FRONT SHIELD:

    - Remove the front lower frame.

    - Remove the front upper frame.

    - Remove the front headlight assemblies.

    - Remove the instrument panel (see SHIELD BACK PLATE).

    - Remove the lower shield back plate (see SHIELD BACK PLATE).

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

    CHAS - 250

  • Page 251:

    - Remove the hand guards unscrewing, from both

    sides, the two screws «A» collecting the washers

    and the screw «B».

    - Undo the central screw.

    - Undo the two screws indicated.

    - Undo the rider footrest fixing screw «C» and the

    spoiler fixing screw «D».

    - Remove the front shield releasing the different

    cable harness from the clamps.

    To refit follow the reverse order paying attention to fasten the cable harness with the relative clamps.

    Knee-guard

    The shield back plate is made by two sections. The instrument panel, with instrument unit and lower

    shield back plate. The procedure for both is described below:

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

    CHAS - 251

  • Page 252:

    INSTRUMENT PANEL:

    - Remove the windshield.

    - Remove the rear handlebar cover.

    - Remove the front handlebar cover

    - Remove the handlebar.

    - Undo and remove the two screws «A».

    - Working from both vehicle sides, undo and re-

    move the screw «B».

    - Undo and remove the two screws «C» placed on

    and inside the glove compartment.

    - Undo and remove the two screws «D» placed on

    and inside the coolant loading compartment.

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

    CHAS - 252

  • Page 253:

    - Undo and remove the expansion tank cap and

    the gasket below.

    - Remove the instrument panel and release the in-

    strument panel connector «E» and the instrument

    panel lighting connector «F». Remove the instru-

    ment panel.

    LOWER SHIELD BACK PLATE:

    - Remove the central tunnel (see CENTRAL CHASSIS COVER).

    - Remove the instrument panel (see SHIELD BACK PLATE).

    - Working from both vehicle sides, undo and re-

    move the two screws «A».

    - Turn the key switch frame anticlockwise (it may

    be necessary to use pliers), releasing the catch.

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

    CHAS - 253

  • Page 254:

    Removing the ignition key-switch when on *off*

    - Remove the lower shield back plate.

    - Unscrew the seat opening transmission from the

    side.

    - Remove in advance the ring of the immobiliser

    antenna.

    - Loosen the 2 hex. socket head screws and re-

    move the complete switch.

    - From the underside it is possible to loosen the 3

    retaining screws and to release the 2 locking tabs

    to raise the mounting plate of the steering lock

    strut.

    - The latter has a retaining tab with cylindrical teeth

    that cannot be replaced.

    Front wheel housing

    To remove the front wheel housing, proceed as

    follows:

    - Remove the spoiler.

    - Remove the front fork.

    - Remove the plate supporting bracket for the horn

    and voltage regulator by loosening the two fixing

    screws shown in the figure in order to release the

    two lower retainers of the wheel housing.

    - Remove the upper fixing screw of the wheel

    housing to permit movement.

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

    CHAS - 254

  • Page 255:

    - In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and

    combination with the splitter.

    To remove the front wheel housing, proceed as

    follows:

    - Remove the spoiler.

    - Remove the front fork.

    - Remove the plate supporting bracket for the horn

    and voltage regulator by loosening the two fixing

    screws shown in the figure in order to release the

    two lower retainers of the wheel housing.

    - Remove the upper fixing screw of the wheel

    housing to permit movement.

    - In order to remove the wheel housing it is necessary to remove the front brake hose to the tank and

    combination with the splitter.

    Taillight assy.

    To remove the rear light assembly, proceed as fol-

    lows:

    - Remove the rear upper central cover.

    - Remove the handgrips and the upper side fair-

    ings.

    - Undo and remove the central screw.

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

    CHAS - 255

  • Page 256:

    - Using a jointed wrench between the helmet com-

    partment and the chassis pipes, loosen the two

    rear fixing nuts and then disconnect the light stud

    bolts from the support extensions.

    - Remove the light and disconnect the bulb holder

    by turning it through 30° in anticlockwise direction.

    To remove the rear light assembly, proceed as fol-

    lows:

    - Remove the rear upper central cover.

    - Remove the handgrips and the upper side fair-

    ings.

    - Undo and remove the central screw.

    - Using a jointed wrench between the helmet com-

    partment and the chassis pipes, loosen the two

    rear fixing nuts and then disconnect the light stud

    bolts from the support extensions.

    - Remove the light and disconnect the bulb holder

    by turning it through 30° in anticlockwise direction.

    Footrest

    The footrest comprises a right and left footrest, a passenger footrest and a rider footrest. The whole

    procedure is described below:

    PASSENGER FOOTREST:

    - Remove the side fairings.

    - Unscrew the nut «A» from both vehicle sides and

    release the footrests.

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

    CHAS - 256

  • Page 257:

    RIGHT AND LEFT FOOTREST:

    - Working from both vehicle sides, remove the mat.

    - Undo and remove the two screws «B» and the

    four screws «C».

    - Remove the footrest

    RIDER FOOTREST:

    To remove the rider footrest, proceed as follows:

    - Remove the central cover.

    - Remove the shield back plate.

    - Remove the right and left footrest (see FOOTREST).

    - Undo the screw «D» and the screw «E» and re-

    move the rider footrest.

    The footrest comprises a right and left footrest, a passenger footrest and a rider footrest. The whole

    procedure is described below:

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

    CHAS - 257

  • Page 258:

    PASSENGER FOOTREST:

    - Remove the side fairings.

    - Unscrew the nut «A» from both vehicle sides and

    release the footrests.

    RIGHT AND LEFT FOOTREST:

    - Working from both vehicle sides, remove the mat.

    - Undo and remove the two screws «B» and the

    four screws «C».

    - Remove the footrest

    RIDER FOOTREST:

    To remove the rider footrest, proceed as follows:

    - Remove the central cover.

    - Remove the shield back plate.

    - Remove the right and left footrest (see FOOTREST).

    - Undo the screw «D» and the screw «E» and re-

    move the rider footrest.

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

    CHAS - 258

  • Page 259:

    Side fairings

    - Remove the rear central cover.

    - Remove the passenger handles.

    - Remove the lower cover.

    - Remove the lower side cover.

    - Remove the eight screws shown in the figure

    (four on each side).

    - Pull out the fairing.

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

    CHAS - 259

  • Page 260:

    - Remove the three screws indicated in the figure.

    License plate holder

    - Remove the rear lower central cover.

    - Remove the four fixing screws (two per side) and

    disconnect the electric connectors.

    - To access the license plate light bulb, remove the

    two fixing screws of the support rear cover and ex-

    tract the complete bulb holder.

    Rear mudguard

    To remove the rear mudguard, proceed as follows:

    - From the right side of the vehicle, undo the screw

    «A».

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

    CHAS - 260

  • Page 261:

    - From the left side of the vehicle, undo the two

    screws «B».

    - Remove the rear mudguard.

    Helmet bay

    To remove the helmet compartment, proceed as follows:

    - Remove the saddle.

    - Remove the battery.

    - Remove the rear upper central cover.

    - Remove the handgrips and top side fairings.

    - Working from both vehicle sides, undo the three

    screws «A» and the screw «B».

    - Undo and remove the two screws «C» from the

    battery compartment.

    - Lift the helmet compartment from the rear side

    and remove the saddle lock.

    - Disconnect the connectors of the power socket and the under seat light.

    - Remove the plug socket due to the interference with the chassis.

    - Remove the fuse box releasing the side hook teeth.

    - Remove the complete helmet compartment.

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

    CHAS - 261

  • Page 262:

    Fuel tank

    To remove the fuel tank, proceed as follows:

    N.B.

    THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY.

    - Remove the shield back plate.

    - Remove the central chassis cover.

    - Remove the footrest.

    - Remove the spoiler.

    - Remove the filler unscrewing the two tank retain-

    ing straps.

    - Remove the "too full" pipe «A» and the tank ven-

    tilation pipe «B».

    - Remove the horn plate support bracket and the

    voltage regulator unscrewing the two nuts shown

    in the figure.

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

    CHAS - 262

  • Page 263:

    - Release the fuel pipe removing the clamp «C».

    - Disconnect the fuel probe connector.

    - Undo the two tank fixing screws.

    - Remove the tank through the front lower part of

    the vehicle.

    Front mudguard

    - Working from both vehicle sides, undo and re-

    move the two screws «A».

    Slide the mudguard to the front part of the vehicle.

    CAUTION

    WHEN REFITTING PAY ATTENTION TO THE CORRECT

    POSITION OF THE PIPE RETAINING STRAPS.

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

    CHAS - 263

  • Page 264:

    Radiator fan

    - Remove the spoiler.

    - Remove the front fork.

    - Remove the plate supporting bracket for the horn

    and voltage regulator by loosening the two fixing

    screws shown in the figure in order to release the

    two lower retainers of the wheel housing.

    - Remove the upper fixing screw of the wheel

    housing to permit movement.

    - Prepare a container to collect the coolant.

    - Remove the feed and return hoses from the ex-

    pansion tank.

    - Remove the coolant feed and return hoses from

    the radiator.

    - Remove the retaining screws of the radiator to

    the frame shown in the figure.

    - Disengage the complete radiator and the electric

    fan.

    Flyscreen

    - Remove the three hex. socket head screws, then

    remove the windshield together with the rubber

    rings.

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

    CHAS - 264

  • Page 265:

    To remove the windshield supports, proceed as

    follows:

    - Remove the caps and the gaskets on the two

    windshield supports.

    - Remove the FRONT UPPER FRAME.

    - Working from both vehicle sides, undo and re-

    move the two screws «A».

    - Remove the supports.

    Pilot lights kit

    - Remove the front handlebar cover.

    - Remove the three screws shown in the figure,

    then slide off the complete unit from the front han-

    dlebar cover.

    Battery

    - Remove the elastic strap and the battery cover.

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

    CHAS - 265

  • Page 266:

    - First disconnect the negative terminal «A», then

    the positive terminal «B».

    - Remove the battery.

    Lower cover

    - Remove the two screws of the lower spoiler (long

    type).

    - Remove the 2 screws located under the footrests.

    - Remove the 4 union screws with the front wheel

    housing cover.

    - Pull the spoiler from the lower part of the scooter.

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

    CHAS - 266

  • Page 267:

    INDEX OF TOPICS

    PRE-DELIVERY PRE DE

  • Page 268:

    Carry out the listed tests before delivering the vehicle.

    Warning- be very careful when handling fuel.

    Aesthetic inspection

    Appearance check:

    - Paintwork

    - Fitting of plastics

    - Scratches

    - Dirt

    Tightening torques inspection

    - Visually check that there is a yellow mark on the following clamps:

    FRONT WHEEL

    Wheel pin fixing nut

    Safety screws on left fork leg

    FRONT BRAKE

    Brake pipe to brake calliper fitting

    Calliper to calliper support fixing screws

    Calliper to fork support fixing screws

    SWINGING ARM

    Nut fixing swinging arm pin to engine

    COOLING SYSTEM

    Water pump cover - delivery pipe fixing clamp

    Water pump cover - return pipe fixing clamp

    REAR WHEEL

    Screws fixing wheel to hub

    REAR BRAKE

    Brake pipe - brake calliper fitting

    Calliper - calliper support fixing screws

    Engine - calliper support fixing screws

    REAR SUSPENSION

    Left shock absorber lower retainer

    Right shock absorber lower retainer

    MUFFLER SUPPORTING ARM

    Pre-delivery MSS Nexus 300 i.e. E3 ( 2008)

    PRE DE - 268

  • Page 269:

    Muffler- supporting arm fixing screws

    Engine- supporting arm fixing screws

    Electrical system

    • Main switch

    • Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights

    - Regulating the headlights according to the regulations currently in force

    • Front and rear stop light buttons and relative light •Turn indicators and relative telltales

    • Instrument lighting

    • instruments: fuel and temperature indicator

    •Instrument panel lights

    • Horn

    • electric start up

    • Engine stopping with emergency stop switch

    • electric saddle opening button

    CAUTION

    TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.

    INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE

    IT IS FIRST USED SHORTENS BATTERY LIFE.

    CAUTION

    WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-

    ATIVE LEAD.

    WARNING

    BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-

    PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.

    IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15

    MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.

    IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE

    OIL. SEEK IMMEDIATE MEDICAL ATTENTION.

    BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS

    AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN-

    SURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO

    BATTERIES.

    KEEP OUT OF THE REACH OF CHILDREN

    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.

    Levels check

    Level check:

    - Hydraulic brake system liquid level.

    - Rear hub oil level

    - Engine coolant level

    MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery

    PRE DE - 269

  • Page 270:

    - Engine oil level

    Road test

    Test ride

    - Cold start

    - Instrument operations

    - Response to the throttle control

    - Stability on acceleration and braking

    - Rear and front brake efficiency

    - Rear and front suspension efficiency

    - Abnormal noise

    Static test

    Static control after the test ride:

    • Hot engine restart

    • Minimum seal (turning the handlebar)

    • Uniform steering rotation

    • Possible losses

    • electric radiator fan operation

    CAUTION

    CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.

    CAUTION

    NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.

    Functional inspection

    Functional check up:

    • Hydraulic braking system: lever travel

    • Clutch: proper functioning check

    • Engine: proper general functioning and no abnormal noise check

    • Other: papers check, frame and engine number check, tools and equipment, licence plate fitting, lock

    check, tyre pressure check, rear-view mirror and any accessory fitting

    Pre-delivery MSS Nexus 300 i.e. E3 ( 2008)

    PRE DE - 270

  • Page 271:

    Specific operations for the vehicle

    Windshield fitting:

    - Remove the legshield upper cover.

    - Fit the indicated nut in the seat at the back of the

    windshield support brackets.

    - With the screws supplied fasten the windshield

    support brackets to the front frame .

    - Fit the legshield upper cover.

    - Remove the protection film from the windshield,

    fit the rubber buffers in the three holes.

    MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery

    PRE DE - 271

  • Page 272:

    - Fit the three plastic spacers in the three rubber

    buffers.

    - Fit the central protection.

    - Fit the rubber protection on the windshield sup-

    port brackets, make sure that the clamps are cor-

    rectly snapped in the holes.

    N.B.

    THE WINDSHIELD CAN BE ADJUSTED TO THREE POSITIONS. HEIGHT MAY VARY DEPENDING

    ON THE RETAINER USED.

    Pre-delivery MSS Nexus 300 i.e. E3 ( 2008)

    PRE DE - 272

  • Page 273:

    - Fit the supplied cover caps in order to cover the

    holes not used.

    - Fit the windshield to the vehicle with the three

    screws supplied.

    MSS Nexus 300 i.e. E3 ( 2008) Pre-delivery

    PRE DE - 273

  • Page 274:

    INDEX OF TOPICS

    TIME TIME

  • Page 275:

    This section is devoted to the time necessary to carry out repairs.

    For each operation, the description, code and time envisages are specified.

    Engine

    ENGINE

    Code

    Action Duration

    1 001001 Engine from frame - Removal and re-

    fit.

    2 003064 Engine oil - Change

    Crankcase

    CRANKCASE

    Code

    Action Duration

    1 001153 Crankcase halves gasket - Replace-

    ment

    2 001133 Engine crankcase- Replacement

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

    TIME - 275

  • Page 276:

    Crankshaft

    CRANKSHAFT

    Code

    Action Duration

    1 001117 Crankshaft - Replacement

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

    TIME - 276

  • Page 277:

    Cylinder assy.

    CYLINDER- PISTON

    Code

    Action Duration

    1 001002 Cylinder-Piston - Replacement

    2 001154 Pin-ring-piston assembly - Service

    3 001129 Chain tightener - Overhaul and re-

    placement

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

    TIME - 277

  • Page 278:

    Cylinder head assy.

    VALVE HEAD

    Code

    Action Duration

    1 001126 Head - Replacement

    2 001045 Valves - Replacement

    3 001049 Valves - Adjustment

    4 001056 Head gasket - Replacement

    5 001083 Thermistor - Replacement

    6 001057 Thermostat - Replacement

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

    TIME - 278

  • Page 279:

    Rocker arms support assy.

    CAMSHAFT

    Code

    Action Duration

    1 001148 Rocking lever valve - Replacement

    2 001044 Camshaft - Replacement

    3 001169 Decompressor - Replacement

    Cylinder head cover

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

    TIME - 279

  • Page 280:

    HEAD COVER

    Code Action Duration

    1 001093 Spark plug - Replacement

    2 001089 Head cover - Replacement

    3 001088 Head cover gasket - Replacement

    4 001074 Oil vapour recovery pipe - Replace-

    ment

    Oil filter

    OIL FILTER

    Code

    Action Duration

    1 001123 Oil filter -Replacement

    2 001160 Oil pressure sensor - Replacement

    3 001102 Net oil filter - Replacement / Cleaning

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

    TIME - 280

  • Page 281:

    Flywheel cover

    FLYWHEEL COVER

    Code

    Action Duration

    1 001087 Flywheel cover - Replacement

    2 001150 Flywheel cover gasket - Replace-

    ment

    3 007007 Water pump rotor - Replacement

    4 007017 Water pump cover - Replacement

    5 007003 Coolant delivery and return pipe - Re-

    placement

    Driven pulley

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

    TIME - 281

  • Page 282:

    DRIVEN PULLEY

    Code Action Duration

    1 001022 Clutch - Replacement

    2 001012 Driven pulley - Service

    3 001110 Driven pulley - Replacement

    4 001155 Clutch bell - Replacement

    Oil pump

    OIL PUMP

    Code

    Action Duration

    1 001125 Chain guide pads - Replacement

    2 001051 Belt/Timing chain - Change

    3 001042 Oil pump - Service

    4 001112 Oil pump - change

    5 001122 Oil pump chain - Replacement

    6 001130 Oil sump - Replacement

    7 001172 Chain cover flap - change

    8 001124 Lubrication by-pass - Replacement

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

    TIME - 282

  • Page 283:

    Final gear assy.

    FINAL REDUCTION GEAR

    Code

    Action Duration

    1 001010 Reduction gear - Replacement

    2 003065 Gear box oil - Replacement

    3 001156 Geared reduction unit cover - Re-

    placement

    4 004125 Rear wheel axle - Replacement

    5 004180 Reduction gear breather pipe - Re-

    placement

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

    TIME - 283

  • Page 284:

    Driving pulley

    DRIVING PULLEY

    Code

    Action Duration

    1 001086 Driving half-pulley - Replacement

    2 001011 Driving belt - Replacement

    3 001066 Driving pulley - Removal and refitting

    4 001177 Variator rollers / shoes - Replace-

    ment

    5 001141 Belt anti-flapping roller - Replace-

    ment

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

    TIME - 284

  • Page 285:

    Transmission cover

    TRANSMISSION COVER

    Code

    Action Duration

    1 001135 Transmission cover bearing - Re-

    placement

    2 001096 Transmission crankcase cover - Re-

    placement

    3 001131 Transmission air intake - Replace-

    ment

    4 001065 Transmission cover - Replacement

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

    TIME - 285

  • Page 286:

    Starter motor

    ELECTRICAL START-UP

    Code

    Action Duration

    1 001020 Starter motor - Replacement

    2 001104 Start-up freewheel - Replacement

    3 001151 Start-up driven gearing - Replace-

    ment

    4 001017 Start-up pinion - Replacement

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

    TIME - 286

  • Page 287:

    Flywheel magneto

    MAGNETO FLYWHEEL

    Code

    Action Duration

    1 001067 Stator - Removal and Refitting

    2 001173 Rotor - Replacement

    3 001058 Complete flywheel - Replacement

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

    TIME - 287

  • Page 288:

    Butterfly valve

    THROTTLE BODY

    Code

    Action Duration

    1 001166 Throttle body - Replacement

    2 001047 Injector - Replacement

    3 001013 Intake manifold - Replacement

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

    TIME - 288

  • Page 289:

    Exhaust pipe

    MUFFLER

    Code

    Action Duration

    1 001009 Muffler - Replacement

    2 001092 Exhaust manifold - Replacement

    3 001095 Muffler guard - Replacement

    4 005138 Lambda probe - Replacement

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

    TIME - 289

  • Page 290:

    Air cleaner

    AIR CLEANER

    Code

    Action Duration

    1 001015 Air filter box - Replacement

    2 001014 Air filter - Replacement / cleaning

    3 004122 Air cleaner/ carburettor union - Re-

    placement

    4 001027 Body / air cleaner union - Replace-

    ment

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

    TIME - 290

  • Page 291:

    Frame

    FRAME

    Code

    Action Duration

    1 004001 Frame - replace

    2 004146 Front frame - Replacement

    3 001032 Engine support pin - Replacement

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

    TIME - 291

  • Page 292:

    Centre-stand

    STAND

    Code

    Action Duration

    1 004102 Side stand - Replacement

    2 004004 Stand - Replacement

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

    TIME - 292

  • Page 293:

    Legshield spoiler

    FRONT SHIELD - SPOILER

    Code

    Action Duration

    1 004066 Driving mirror - Replacement

    2 005091 Turn indicator glass - Replacement

    3 005067 Front direction indicator bulb - Re-

    placement

    4 004064 Front shield - Replacement

    5 004149 Shield central cover - Replacement

    6 004065 Shield back plate - Replacement

    7 005080 Front fuse-holder - Replacement

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

    TIME - 293

  • Page 294:

    Side fairings

    SIDE COVERS

    Code

    Action Duration

    1 004068 One passenger grab handle - Re-

    placement

    2 004085 Fairing (1) - Replacement

    3 004012 Rear side panels - Replacement

    4 004053 Spoiler - Replacement

    5 004036 Frame cover - Replacement

    6 004075 Front mat - Replacement

    7 004059 Spark plug inspection flap - Replace-

    ment

    8 004013 Side bumper- Replacement

    9 004015 Footrest - Replacement

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

    TIME - 294

  • Page 295:

    Rear cover

    SHIELD BACK PLATE

    Code

    Action Duration

    1 004065 Shield back plate - Replacement

    2 004156 Glove box flap and/or support - Re-

    placement

    3 004145 Glove box - Replacement

    4 007024 Expansion tank cap - Replacement

    5 004142 electric socket - Replacement

    6 005085 Reset button - Replacement

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

    TIME - 295

  • Page 296:

    Central cover

    CENTRAL FRAME COVER

    Code

    Action Duration

    1 004011 Central chassis cover - Replacement

    2 004104 Left side cover - Replacement

    3 004105 Right side cover - Replacement

    4 004079 Rear footrest - Replacement

    5 004143 Footrest support - replace

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

    TIME - 296

  • Page 297:

    CENTRAL COVER

    Code

    Action Duration

    1 002082 Fuel tank cap opening drive - Re-

    placement

    2 004135 Fuel tank lid - Replacement

    3 004011 Frame central cover - Replacement

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

    TIME - 297

  • Page 298:

    Mudguard

    MUDGUARDS

    Code

    Action Duration

    1 004167 Grill / radiator cover - replace

    2 004009 Rear mudguard - Replacement

    3 004002 Front mudguard - change

    4 003087 Wheel housing - Replacement

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

    TIME - 298

  • Page 299:

    Fuel tank

    FUEL TANK

    Code

    Action Duration

    1 004005 Fuel tank - replace

    2 004170 Tank filler neck - Replacement

    3 004168 Fuel filler flap - Replacement

    4 004109 Fuel tank breather - replace

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

    TIME - 299

  • Page 300:

    Rear shock-absorber

    REAR SHOCK ABSORBER

    Code

    Action Duration

    1 003007 Rear shock absorber - Replacement

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

    TIME - 300

  • Page 301:

    Handlebar covers

    HANDLEBAR COVERS

    Code

    Action Duration

    1 004018 Handlebar front section - Replace-

    ment

    2 004019 Handlebar rear section - Replace-

    ment

    3 005129 Warning light group - Replacement

    4 004156 Glove-box flap - Replacement

    5 005038 Instrument panel warning light bulbs

    - Replacement

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

    TIME - 301

  • Page 302:

    Handlebar components

    HANDLEBAR COMPONENTS

    Code

    Action Duration

    1 003001 Handlebar - Replacement

    2 005017 Stop switch - Replacement

    3 002037 Brake or clutch lever - Replacement

    4 002060 Complete gas command - Replace-

    ment

    5 002059 Right hand grip - Replacement

    6 003059 Counterweight - Replacement

    7 002063 Throttle control transmission - Re-

    placement

    8 003061 Accelerator transmission - Adjust-

    ment

    9 002024 Front brake pump - replace

    10 002071 Left hand grip - Replacement

    11 002088 Integral brake pump - Replacement

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

    TIME - 302

  • Page 303:

    Swing-arm

    SWINGING ARM

    Code

    Action Duration

    1 003081 Swinging arm supporting flange - Re-

    placement

    2 004058 Silent-block - Replacement

    3 001072 Engine/frame swinging arm attach-

    ment - Replacement

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

    TIME - 303

  • Page 304:

    Seat

    SADDLE

    Code

    Action Duration

    1 004003 Saddle - Replacement

    2 004150 Saddle shock absorber - Replace-

    ment

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

    TIME - 304

  • Page 305:

    Instrument panel

    INSTRUMENT PANEL + COMMANDS ON HANDLEBAR

    Code

    Action Duration

    1 005078 Odometer glass - Replacement

    2 005014 Odometer - Replacement

    3 005006 Light switch or turn indicators - Re-

    placement

    4 005039 Light switch - Replacement

    5 005040 Horn button - Replacement

    6 005121 Saddle opening button - Replace-

    ment

    7 005132 Trunk opening button - Replacement

    8 005041 Starter button - replace

    9 005077 Emergency stop switch - Replace-

    ment

    10 005038 Dashboard warning/telltale lights -

    Replacement

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

    TIME - 305

  • Page 306:

    Turn signal lights

    FRONT LIGHTS

    Code

    Action Duration

    1 005002 Front headlamp - replace

    2 005008 Front headlamp bulbs - replace

    3 005044 Front lights cable unit - replace

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

    TIME - 306

  • Page 307:

    REAR LIGHTS

    Code

    Action Duration

    1 005005 Taillight - change

    2 005022 Rear turn indicators - Replacement

    3 005068 Rear turn indicator bulb- Replace-

    ment

    4 005091 Turn indicator glass - Replacement

    5 005031 Licence plate light bulb - Replace-

    ment

    6 004136 License plate holder support - Re-

    placement

    7 005030 Rear headlight cable unit- Replace-

    ment

    8 005048 Licence plate holder - Replacement

    9 005032 Transparent licence plate cover - re-

    place

    10 005028 Rear light assembly glass - Replace-

    ment

    11 005066 Rear light bulbs - Replacement

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

    TIME - 307

  • Page 308:

    Front wheel

    FRONT WHEEL

    Code

    Action Duration

    1 005089 Tone wheel - Replacement

    2 002041 Front brake disc - Replacement

    3 003037 Front wheel rim- Replacement

    4 003038 Front wheel axle - Replacement

    5 003040 Front wheel bearings - Replacement

    6 003047 Front tyre - Replacement

    7 003063 Tyre pressure - Check

    8 004123 Front wheel - Replacement

    Grease tone wheel or drive

    Please take note that the code has been intro-

    duced:

    900001 - Tone wheel / drive greasing - 15'.

    Never mistake the codes 002011 (movement sen-

    sor replacement) and 005089 (tone wheel replace-

    ment) in the event of noise of the indicated

    components. The grease recommended is TUTE-

    LA MRM 2 (soap-based lithium grease with Mo-

    lybdenum disulphide).

    In the following points we indicate with an arrow

    the area to be greased (1 - Drive, 2 - Tone wheel)

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

    TIME - 308

  • Page 309:

    Rear wheel

    REAR WHEEL

    Code

    Action Duration

    1 001016 Rear wheel - Replacement

    2 001071 Rear wheel rim - Replacement

    3 004126 Rear wheel tyre - Replacement

    4 002070 Rear brake disc - Replacement

    5 003077 muffler/rear shock absorber support

    arm - Service

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

    TIME - 309

  • Page 310:

    Electric devices

    ELECTRICAL DEVICES

    Code

    Action Duration

    1 001094 Spark plug cap - Replacement

    2 001069 HV coil - Replacement

    3 005003 Horn - Replacement

    4 005009 Voltage regulator - Replacement

    5 005052 Fuse (1) - Replacement

    6 005007 Battery - Replacement

    7 005120 Control unit power supply remote

    control - Replacement

    8 005035 Headlight remote control - Replace-

    ment

    9 005117 Electric fan remote control - Replace-

    ment

    10 005011 Start-up remote control switch - Re-

    placement

    11 005001 Electrical system - Removal and re-

    fitting

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

    TIME - 310

  • Page 311:

    Helmet bay

    HELMET COMPARTMENT

    Code

    Action Duration

    1 004016 Helmet compartment - replace

    2 005033 Glove-box light switch - Replace-

    ment

    3 005026 Helmet compartment light - Replace-

    ment

    4 004142 Plug socket - Replacement

    5 005027 Helmet compartment bulb support -

    Replacement

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

    TIME - 311

  • Page 312:

    Front suspension

    FRONT SUSPENSION

    Code

    Action Duration

    1 003051 Complete fork - Replacement

    2 003010 Front suspension - Service

    3 003076 Fork sheath - Replacement

    4 003079 Fork stem - Replacement

    5 003048 Fork oil seal - Replacement

    6 003002 Steering thrust washer - Replace-

    ment

    7 004119 Upper steering bearing - Housing

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

    TIME - 312

  • Page 313:

    Cooling system

    COOLING SYSTEM

    Code

    Action Duration

    1 007002 Water cooling radiator - Replace-

    ment

    2 007016 Fan with support - Replacement

    3 007001 Expansion tank - Replacement

    4 007024 Expansion tank cap - Replacement

    5 007019 Coolant return pipe - replacement

    6 007013 Expansion tank / radiator connecting

    hose - Replacement

    7 001052 Coolant and air bleed - replacement

    8 007022 Coolant delivery pipe - Replacement

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

    TIME - 313

  • Page 314:

    Braking system

    BRAKE SYSTEM

    Code

    Action Duration

    1 002039 Front brake calliper - Replacement

    2 002007 Front brake pads - Replacement

    3 002021 Front brake piping - Replacement

    4 002047 Front brake fluid and air bleeding

    system - Replacement

    5 002020 Rear brake disc piping - Replace-

    ment

    6 002080 Rear brake oil bleeding system - Re-

    placement

    7 002002 Rear brake pads - Replacement

    8 002048 Rear brake calliper - Replacement

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

    TIME - 314

  • Page 315:

    A

    Air filter: 44

    B

    Battery: 68, 79–81, 265

    Brake: 225, 227, 229, 230, 232, 233, 236

    C

    Coolant: 186

    E

    Engine oil: 44

    F

    Fuel: 163, 171, 262, 299

    Fuses: 74

    H

    Headlight: 51, 246

    Horn: 71

    Hub oil: 42

    I

    Identification: 8

    Instrument panel: 245, 305

    M

    Maintenance: 7, 40

    O

    Oil filter: 47, 280

    S

    Saddle:

    Shock absorbers: 222

    Spark plug: 42, 68

    Stand: 223

    Start-up:

    T

    Tank: 262, 299

    Technical Data:

    Transmission: 10, 54, 98, 112, 285

    Tyre pressure:

    Tyres: 11

DOC-9edf18d1:

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