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Gilera Nexus 125 2007-2008 Service Manual

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The Nexus 125, produced between 2007 and 2008, is a maxi-scooter designed to offer a blend of sporty performance and touring comfort. As an Italian manufacturer with a rich heritage...
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Art.-Nr: 49980
Gilera Nexus 125 2007-2008 Service ManualGilera Nexus 125 2007-2008 Service ManualGilera Nexus 125 2007-2008 Service ManualGilera Nexus 125 2007-2008 Service Manual
The Nexus 125, produced between 2007 and 2008, is a maxi-scooter designed to offer a blend of sporty performance and touring comfort. As an Italian manufacturer with a rich heritage in performance-oriented vehicles, Gilera positioned the Nexus line as a competitive offering in the maxi-scooter market, rivaling other prominent models. This scooter typically features a liquid-cooled, single-cylinder engine with a displacement of 125cc, likely equipped with electronic fuel injection and an automatic CVT transmission, making it suitable for both urban commuting and longer journeys. Its design philosophy emphasizes agile handling and stability, reflecting Gilera's commitment to engineering quality and rider experience. This comprehensive Service Repair Workshop Manual provides essential information for the maintenance and repair of the Nexus 125. It covers a wide array of systems, including detailed procedures for the engine, power supply, suspension, chassis, braking system, cooling system, electrical system, and bodywork. The manual includes step-by-step repair instructions, scheduled maintenance tasks, troubleshooting guides with diagnostic flowcharts, and crucial technical specifications such as torque values and fluid requirements. This resource is invaluable for owners, independent repair shops, and professional technicians seeking to ensure the optimal performance and longevity of their Nexus 125.
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 125
Year:
2007-2008
👋 Introduction
Market Position
Category:
Maxi-scooter
Target Audience:
Owners, independent repair shops, and professional technicians servicing Gilera Nexus 125 scooters.
Key Features
Value Proposition:
Provides factory-level diagnostic, repair, and maintenance information for accurate and efficient servicing.
Content Source:
Original factory service manual, ensuring accuracy and completeness.
Competitive Analysis
Competitors:
Competed with models like the Yamaha X-MAX 125, Suzuki Burgman 125, and Piaggio Xevo 125.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Page Count:
327
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed engine diagnostics, overhaul, and repair procedures
Power Supply:
Ignition system, charging system, starting system
Suspensions:
Front and rear suspension inspection, adjustment, and repair
Chassis:
Frame inspection, alignment, and component replacement
Braking System:
Brake caliper, master cylinder, brake lines, and ABS (if applicable) servicing
Cooling System:
Radiator, coolant, water pump, and thermostat service
Electrical System:
Comprehensive wiring diagrams, component testing, and troubleshooting
Bodywork:
Panel removal/installation, trim, and exterior component repair
Fuel System:
Fuel tank, fuel pump, injectors/carburetor, fuel lines, and filters.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if fitted), and lambda sensor diagnostics.
Wheels And Tires:
Wheel bearing service, tire pressure, and inspection.
Steering:
Handlebar, steering stem, and bearings maintenance.
Instruments And Controls:
Dashboard, switches, cables, and levers.
Procedures Included
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements
Troubleshooting:
Diagnostic procedures for common and complex issues
Repair:
Step-by-step repair instructions for all major vehicle systems
Diagnostics:
Diagnostic flowcharts and fault code interpretation
Pre Delivery:
Pre-delivery inspection and setup procedures
Torque Specifications:
Crucial torque values for all fasteners during assembly and disassembly.
Special Tools:
List and usage of specific tools required for certain repair and maintenance procedures.
Wiring Diagrams:
Detailed electrical schematics for accurate fault finding and component identification.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced electrical diagnostics, as used by professional technicians.
Diagnostic Charts:
Flowcharts for troubleshooting various symptoms, guiding the technician through a systematic diagnostic process.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader
Searchability:
Likely text-searchable due to PDF format, aiding quick information retrieval.
Printability:
Printable pages for convenient workshop use.
Index Capability:
PDF format usually allows for keyword searching and chapter navigation, enhancing usability.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Likely single-cylinder, four-stroke (common for 125cc scooters of this era).
Displacement:
125cc (as indicated by model name)
Fuel System
Fuel Delivery:
Likely electronic fuel injection (EFI) or carburetor, depending on specific market and variant.
Performance
Power Output Estimate:
Approx. 15-18 HP (typical for 125cc maxi-scooters, specific data in manual).
Torque Estimate:
Approx. 12-14 Nm (specific data in manual).
Engine Code
Engine Code Identifier:
Specific engine codes (e.g., M381M) would be detailed within the manual, crucial for parts identification.
Cooling System
Cooling Method:
Liquid-cooled, featuring a radiator and fan.
Ignition System
Ignition Type:
Electronic ignition (CDI or similar).
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) is standard for this class of scooter.
Features
Clutch:
Automatic centrifugal clutch.
Gear Ratios
Cvt Ratios:
Specific ratio ranges for the CVT will be detailed in the manual, critical for performance tuning and diagnosis.
📐 Dimensions
Exterior
Classification:
Maxi-scooter, designed for touring and urban commuting.
Weights
Dry Weight:
Estimated around 170-180 kg; exact weight specification available in the manual.
Max Load:
Payload capacity will be specified in the manual, important for safe operation.
🛡️ Safety Features
Active Features
Braking Features:
Disc brakes front and rear, with potential ABS availability.
Passive Features
Frame Construction:
Tubular steel frame for rigidity and handling.
Lighting Safety:
Adequate lighting for visibility, including headlamp, taillamp, and turn signals.
💡 Technology Features
Infotainment
Instrument Cluster:
Likely features a combination of analog and digital displays for speed, RPM, fuel level, and warning lights.
Driver Assistance
Braking System Tech:
Integral braking system (linked front and rear brakes) and possibly ABS as an optional feature on higher trims.
Connectivity
Lighting:
Halogen headlights and LED or incandescent taillights/indicators.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Likely 4,000-6,000 km or annually, refer to manual for precise interval.
Spark Plug Replacement:
Typically every 10,000-12,000 km.
Air Filter Inspection:
Regular inspection, replacement as needed (e.g., every 8,000 km).
Coolant Replacement:
Typically every 2 years or as per manual recommendation.
Brake Fluid Replacement:
Recommended every 2 years to maintain performance and prevent moisture absorption.
Fluid Specifications
Engine Oil Type:
Likely SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified. Specific viscosity and standard in manual.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 is common for this era of scooter.
Transmission Oil:
Specific gear oil specification for the final drive reduction gears will be detailed. Not applicable to CVT fluid itself as it's typically a closed system.
Coolant Capacity:
Coolant capacity will be specified, critical for proper filling and bleeding of the system.
Known Issues
Potential Wear Items:
CVT belt, variator rollers, brake pads, suspension components, electrical connectors (common in scooters with extensive wiring).
Typical Faults:
Could include issues related to fuel system, charging system, or exhaust emissions depending on maintenance history.
Diagnostic Tools:
The manual will likely outline the use of specific diagnostic tools or methods for electronic systems.
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, known for performance and sport-oriented models.
Model Evolution
Positioning:
The Nexus line was Gilera's offering in the competitive maxi-scooter segment, emphasizing sporty handling and touring comfort.
Design Philosophy:
The Nexus was designed as a sport-touring scooter, blending the agility of a scooter with the comfort and stability of a motorcycle.
Production
Era:
Produced during the mid-to-late 2000s, a period of significant development in scooter technology.
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