Product Description:
This is a complete informational book offering the most comprehensive diagnostic, repair, and maintenance data for the Gilera Nexus 500 (1998-2005), written by the manufacturer for professional technicians.
Manual Utility:
Provides hundreds of pages of diagrams and detailed information, including original service manuals, wiring diagrams, and bulletins for accurate and complete repair guidance.
Systems Covered:
Engine (from vehicle, general), Power Supply, Cooling System, Braking System, Suspensions, Chassis, Electrical System, Bodywork, Pre-Delivery
Electrical System Details:
Extensive coverage including wiring diagrams, component testing, troubleshooting electrical faults, ignition system, lighting, and battery charging system.
Engine From Vehicle:
Procedures for engine removal and reinstallation from the chassis are included.
Engine Internal:
Detailed procedures for internal engine components such as cylinder head, piston, crankshaft, valve train, lubrication system, and cooling system.
Power Supply Details:
Information related to the electrical power generation and distribution system.
Suspension System Details:
Covers front forks and rear shock absorber servicing, adjustment, and repair.
Chassis Details:
Includes information on frame inspection, steering head bearing maintenance, and general chassis component checks.
Braking System Details:
Comprehensive coverage of hydraulic braking systems, including disc brake servicing, caliper maintenance, fluid replacement, and bleeding procedures.
Cooling System Details:
Detailed procedures for radiator, water pump, thermostat, and coolant flow management.
Bodywork Details:
Information on fairings, body panels, seat, storage compartments, and related fasteners.
Procedures Included:
Maintenance, Troubleshooting, Diagnostics, Repair Procedures, Special Tools Identification
Pre Delivery Inspection:
Guidance on pre-delivery checks and initial setup procedures.
Troubleshooting Methodology:
Systematic approach to diagnosing and resolving common operational faults.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance tasks.
Engine Rebuild:
The manual is expected to cover detailed engine rebuild procedures, including torque specifications and clearances.
Technical Depth:
Comprehensive diagnostic, repair, and maintenance information as used by professional technicians, including detailed diagrams and information for specific vehicle repair.
Diagnostic Tools:
The manual will guide users on how to use diagnostic tools or interpret diagnostic trouble codes (DTCs) if applicable to the model's ECU.
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled (details within manual)
Engine Displacement:
Approximately 492cc (refer to specific sections for exact variant)
Fuel Delivery:
Fuel Injection (details and specifications within manual)
Power Output:
Estimated 39-43 HP (specific data available in manual)
Torque:
Estimated 44-47 Nm (specific data available in manual)
Cooling System Type:
Liquid-cooled
Engine Configuration:
Single-cylinder, forward-inclined
Valve Actuation:
SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) – details confirmed in manual.
Starter System:
Electric starter
Oil Change Interval:
Specific mileage and time intervals for engine oil, gearbox oil, and filter changes detailed within the manual.
Engine Oil:
Specific API classification, viscosity grade (e.g., SAE 5W-40 or 10W-50), and capacity provided in the manual.
Coolant:
Type and mixture ratio for the cooling system detailed in the manual.
Brake Fluid:
DOT classification (e.g., DOT 4) specified for the braking system.
Known Issues Coverage:
The manual provides troubleshooting sections that address common issues, wear patterns, and diagnostic procedures for various components.
Battery Spec:
Information on battery type, capacity, and charging procedures will be included.
Tire Pressure:
Recommended tire pressures for front and rear tires will be specified.
Brake Pad Wear:
Procedures for inspecting and replacing brake pads and discs are covered.
Cooling System Maintenance
Radiator Checks:
Guidance on checking coolant levels, hoses, and radiator condition.
Fork Oil Change:
While not explicitly stated, suspension component servicing is a standard inclusion in such manuals.
Scheduled Maintenance:
The manual will outline recommended service schedules for various components at defined mileage or time intervals.
Spark Plug Replacement:
Specifications for spark plug type, gap, and replacement intervals will be provided.
Air Filter Replacement:
Procedures for inspecting and replacing the air filter element.
Belt Drive Inspection:
While not a belt drive, CVT maintenance (roller weights, clutch, variator) procedures are typically detailed.
Fuel Filter Replacement:
Information on fuel filter inspection and replacement, particularly relevant for fuel-injected systems.
Wheel Bolt Pattern:
Specifications for wheel mounting will be included in chassis or wheel sections.
Tire Sizes:
Recommended front and rear tire sizes will be specified.
