Mk1 Nexus buyers guide?

[Taipan]

My belt damper pulley thing finally turned up from Portugal yesterday and I dropped a new bearing into it. After strggling to get the clutch nut undone I fittd it. The old one was very noise ina really dry bearing type way. But it wasnt the source of my rattle. The rattle is the funny shaped plate on the back of the clutch thats held on by 3 posts with circlips. I dont know if thats serviceable? Can you get individual parts for the clutch assembly?

The clutch bell has some scoring on it and the pads are grooved to fit it. So I'm tempted to lob out on the parts below or maybe just source a complete 2nd hand unit? Will any X9/Beverley e clutch fit?

http://www.ebay.co.uk/itm/GENUINE-PIAGG ... 5651be5b98" onclick="window.open(this.href);return false;

http://www.ebay.co.uk/itm/GENUINE-PIAGG ... 25799ca311" onclick="window.open(this.href);return false;

[michaelphillips]

hi mate, the 3 posts with circlips, rattle with age of the clutch, i think one of the lads sorted his temp for sale purposes, , you can use a hammer and large screwdriver to try stop them rattling, when i got my nexus and started checking out, i found that the washer that sits after the drum and before crankcase was missing, they also took out the variator washer too... the clutch washer was taken off to stop the squeel of the crankcase bearing, but this caused the the drum to move around and caused the drum to score all over. so this was my first job, changed the crankcase bearing ordered the washers and i sourced a complete clutch and drum assembly of a 2006 scoot with 12000kms from italy which had the 5 shoe clutch, and put on a polini drum . to cut a long story short i never used the drum that came from italy and sat in the shed doing nowt, not scored at all very good condition, your welcome to have that, if you pay postage, regarding the clutch post clips you either live with it or change clutch... or try the hammer/screwdriver... i would go for the 5 shoe clutch version http://www.ebay.it/itm/KUPPLUNG-CLUTCH- ... 009wt_1139" onclick="window.open(this.href);return false;

if i was gonna buy both i would prob go http://scooterbits.co.uk/product/Maxi_F ... utch_Drum/" onclick="window.open(this.href);return false;
as they in bristol,, only have a few bits but generally good prices http://scooterbits.co.uk/find/Standard/ ... Nexus_500/" onclick="window.open(this.href);return false;

you could ring them and ask if they sell the malossi clutch separate???? and then use my unloved shed drum

you have to make sure those washers are all in place

[Taipan]

Hi. A bit worried the clutch was going to self destruct especially as I'm off to France on it for a few days on Friday! If its quite common I'll not worry about it so much and will leave it to next month. I'll definitely buy the clutch bell of you. Do you have a PayPal account? I can send the money as a gift so you dont charges etc. If not, or you'd prefer cash PM me your address and I'll get the cash sent to you. Just let me know how much you want and I'll get it sorted asap. I'm very grateful for it too. Cheers. Dave

[michaelphillips]

Hi. A bit worried the clutch was going to self destruct especially as I'm off to France on it for a few days on Friday! If its quite common I'll not worry about it so much and will leave it to next month. I'll definitely buy the clutch bell of you. Do you have a PayPal account? I can send the money as a gift so you dont charges etc. If not, or you'd prefer cash PM me your address and I'll get the cash sent to you. Just let me know how much you want and I'll get it sorted asap. I'm very grateful for it too. Cheers. Dave

no it wont go wrong, its just noisy, the bell should not have scored unless there was movement, was the spacer (washer in place) after you took the crankcase off? it sits after you put the bell on, and then you put the crankcase back???? or could be the clutch linings down to rivits? which is unusual, is the scoring all over the bell? it will suffice till you get a new clutch, i was lucky to find a complete unit as i dont have a spring compressor as they are a tightly compact spring, there is one complete one on the bay but the spring looks a little rusty so prob a bad buy.. i have the one i took of the scoot but its got clutch pin rattle also so was going to use as spare , but the bell from italy is perfect. but i would not put it on without changing the clutch at same time, as if its the clutch linings it will score this one as well
Yes i have a paypal account, dont want owt for it , just the recorded postage, as i have no need for it, so might as well go to a good home, i will find out how much the postage is, then if you can PM me your address i will post it and let you know the amount . cheers

[Taipan]

All the washers were there. The drum is groovy man. The shoes were a little ridgy but not a lot. I deglazed them and rubbed them down so they are flat now anyway. I think i'll upgrade to a 5 shoe clutch, presumably piaggio changed it to improve it?

Fitted a LED bulb to the light under teh seat and promptly left it on all night. I can confirm this doesn't drain the battery like a normal bulb as it started up fine. Also put two LEDs in the sidelights which make it look a bit more up to date. I noticed my speedo is a lot dimmer than my rev counter? Are they all like that?

I also fitted new pads after cleaning up the filthy and cruddy calipers. They were barely sliding on the sliders and the pads were crudded in and struggling to move on the pin. I dont actually know how it was braking! It took very long time to do such simple jobs and I even worked in the rain to get it finished. Still, all done now and its one hell of an improvement! Its now ready for the France trip. Shame the intake coupling hasn't arrived yet but i'll have to live with that for now.

Thanks again for your generosity on the clutch bell.

http://www.ebay.co.uk/itm/290635006488? ... 1497.l2649" onclick="window.open(this.href);return false;
http://www.ebay.co.uk/itm/151033732550" onclick="window.open(this.href);return false;

[michaelphillips]

you all set for france now, you should get the bell before you go, will treat myself to the underseat bulb as removed mine 18months ago as did not want to drain the battery, cheers for the link just bought one, i got PHILIPS H7 XENON ULTIMATE EFFECT BLUE VISION ULTRA HEADLIGHT BULBS which came with the sidelight blue tip as well and use the 48 led daylight running lights as well, so im sussed there, been out today hamoriting black the stand etc, then did a job i have been wanting to do for ages, black vinyl wrapping the left and right side footpeg rest assembly, only managed one side, do other tomorrow, and finally got to put on the Gilera graphics on front mudguard and the two sides of the belly, will post pics when done,

[michaelphillips]

i remember tmax9 posting a reply regarding the dash bulbs, the speedo, rev counter and digi dash are sealed LED all the others are instrument panel bulbs 12v 1.2w i think the number is 286
i got 10 as cheap like these http://www.ebay.co.uk/itm/CAR-DASH-LIGH ... 3f2498d5de" onclick="window.open(this.href);return false;

[Taipan]

Yes looks like I'll have to take the dash out now.Might as well get it right. Clutch bell turned up today.

In other news it broke down tonight! 2 days before I go away! It has cut out on idle a couple of times since i've had it but always starts straight up again. Tonight it just cut out at low speed as I was slowing down and I couldn't start it again? Had to push it to the side of the road where it fired straight up again! Ho hum.

[michaelphillips]

Yes looks like I'll have to take the dash out now.Might as well get it right. Clutch bell turned up today.

In other news it broke down tonight! 2 days before I go away! It has cut out on idle a couple of times since i've had it but always starts straight up again. Tonight it just cut out at low speed as I was slowing down and I couldn't start it again? Had to push it to the side of the road where it fired straight up again! Ho hum.

hi, there would be no point taking the dash out, if you thinking bulbs... the speedo rev counter and digi dash are sealed LED`s dont think you can get to them,
if the scoot stalls, firstly i would check the cleanliness of the side stand switch, just clean the area and plenty of wd40 on it and then back and forth to work the switch, and see if that does it, with the ignition then set to on put the side stand down and see if the system knows its up or down, you will hear the click and if bulb working see the red warning light up, just a thought.
if i look at the workshop manual for troubleshooting the below:
ENGINE START-UP PROBLEMS
Engine stops at idle / deceleration
EXHAUST BACKFIRES WHEN DECELERATING

they all seem to indicate the same points, some easy steps and some i have no ideas on, as never done them.. from what you have previously posted from day one and the yellow engine light being on , it comes on with Presence of faults detected by the self diagnosis system on the scoot, and comes on generally for the following reasons for the highlighted items above:

Presence of faults detected by the self diagnosis could be
Pump relay
H.V. coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Atmospheric pressure

Correctness of the parameters the below is for all causes
Throttle valve position sensor IF YOU REMEMBER YOU SAID: When I put the intake coupling back on I did notice there was a sensor in front of where it was split. I thought afterwards I probably should have cleaned that or at least inspected it. I'll do so when the new coupling arrives, THIS WOULD BE YOUR BEST INITIAL ACTION AS YOU CAN CLEAN IT WD 40 IT AND THE OTHER SIDE WHERE THE INJECTOR HAS A ELECTRICAL CONNECTION CLEAN AS WELL, ALSO CHECK THE TIGHTENING OF THE THREE BOLTS THAT HOLD THE THROTTLE BODY ( THINK OF IT AS AS CARBURETTOR) TO THE INTAKE TO ENSURE NO LEAKS TO THE INTAKE.
Stepper (dont know about this
Coolant temperature sensor if this was faulty then your electric fan would be on continuous when driving, so if its not you can eliminate this
Intake air temperature sensorThe sucked air temperature sensor is installed in the bottom side of the throttle body on the filter box
side. so this can also be checked when checking the above items

i would also check H.V. coil lead is tightly into the plug cap, unscrew if in doubt then retighten, also correct gap on plug Electrode gap
0.7-0.8 mm or a new plug if you got one NGK CR 7 EKB if you need to get one as a spare.
i would definitely get a good view of the throttle body and check connections as above, as a bad connection or untightened bolts to the intake will cause the warning light and backfiring , sucking in air and bad fuel mix, chin up lad the air mix has been wrong from the start and could all need a good clean, the injector could be dirty with all the unfiltered air, not sure what you could squirt in there , somebody will know, or if a petrol additive for cleaning injector could be used?????? keep posting....

[michaelphillips]

The FUEL system implements an idle feeding correction with cold engine through a stepper motor on a bypass
circuit of the throttle valve. The control unit manages the stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, fuel preparation is managed by modifying the injector opening time.
The fuel feed pressure is held steady in accordance with the environmental pressure.
The feed circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
Pump, filter and regulator are placed into the fuel tank using a single support. YOU MENTIONED THE FUEL PUMP WAS CHANGED , SO I WOULD ELIMINATE Pump, filter and regulator and so just the connection ELECTRICAL couplings to the throttle body and the Injector and the tightness of bolts to intake from throttle body needs checking
The injector is connected by two pipes provided with quick couplings. This allows obtaining a continuous
circulation. THEY SAY NEVER REMOVE THE INJECTOR FROM THE THROTTLE BODY.... AND THE QUICK COUPLINGS OF THE TWO PIPES ARE A PAIN AND I WOULD NOT REMOVE THEM AS THEY HAVE A TENDENCY NOT TO COUPLE UP AGAIN PROPERLY AND LEAK UNDER PRESSURE


The ignition circuit consists of:
- H.V. coil
- H.V. cable
- Screened cap
- EMS control unit
- Spark plug
The EMS control unit manages the ignition with optimum timing, ensuring the timing on the 4-stroke
cycle (ignition only during compression). SO I WOULD CHECK H.V. coil - H.V. cable - Screened cap AND - Spark plug