Target Audience:
Professional motorcycle technicians, experienced DIY mechanics, and Gilera Nexus 500 owners seeking detailed repair and maintenance information.
Value Proposition:
Provides comprehensive, factory-level repair information in an easily accessible digital format, enabling cost-effective maintenance and repair.
Comprehensive Coverage:
Mirrors factory service manual content, covering all aspects of the vehicle's mechanical and electrical systems.
Step By Step Instructions:
Clear, sequential guidance for all repair and maintenance tasks, empowering users to perform procedures confidently.
Diagrams And Illustrations:
Includes necessary visual aids to clarify complex procedures and component identification.
Instant Access:
Immediate download allows users to start working on their vehicle without delay.
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair procedures for the entire engine, including cylinder head, piston, crankshaft, connecting rods, valves, and camshafts. Torque specifications and clearances provided.
Fuel System:
Information on fuel injection system, fuel pump, fuel filter, injectors, throttle body, and associated sensors. Troubleshooting and diagnostic procedures.
Cooling System:
Details on the radiator, cooling fan, coolant pump, thermostat, hoses, and coolant specifications. Flush and refill procedures.
Ignition System:
Coverage of spark plugs, ignition coils, CDI unit, and related wiring. Timing specifications and troubleshooting.
Exhaust System:
Information on exhaust pipes, muffler, and catalytic converter (if applicable). Gasket replacement and leak detection.
Transmission And Drivetrain:
Details on the CVT (Continuously Variable Transmission) system, including belt, rollers, clutch, and variator. Oil change procedures and specifications.
Suspension System:
Front and rear suspension components, including forks, shock absorbers, bushings, and bearings. Adjustment and replacement procedures.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake pads, and rotors. Bleeding procedures and fluid specifications.
Electrical System:
Comprehensive wiring diagrams, battery, starter motor, alternator, lighting system, fuses, relays, and switches. Troubleshooting electrical faults.
Chassis And Frame:
Frame construction, steering system components (handlebars, steering stem, bearings), and subframe. Alignment and inspection procedures.
Bodywork And Trim:
Fairings, seat, body panels, storage compartments, and associated fasteners. Removal and installation guidelines.
Wheels And Tires:
Wheel bearing maintenance, tire pressure recommendations, and tire replacement. Rim specifications.
Scheduled Maintenance:
Detailed maintenance schedules for routine services, including oil changes, filter replacements, spark plug checks, and belt inspections. Specific service intervals provided.
Troubleshooting Guides:
Systematic diagnostic procedures for identifying and resolving common mechanical and electrical issues. Flowcharts and symptom-based problem solving.
Disassembly And Assembly:
Step-by-step instructions for the removal and reinstallation of all major components and subassemblies with clear visuals and torque values.
Cleaning And Lubrication:
Guidelines for cleaning specific components and recommended lubrication points and types for optimal performance and longevity.
Adjustments:
Procedures for adjusting critical systems such as throttle cable, brake levers, and CVT components for optimal operation.
Special Tools:
Identification and usage instructions for specialized tools required for certain repair and maintenance tasks.
Torque Specifications:
Comprehensive list of all critical torque values for fasteners across all systems to ensure proper assembly and prevent damage.
Depth Of Coverage:
Covers everything from basic rider maintenance to in-depth engine overhauls and complex electrical system diagnostics. Prepared for both professional technicians and experienced DIY enthusiasts.
Engine Type:
Single-cylinder, 4-stroke
Displacement:
493 cc (approximate)
Bore X Stroke:
Specifications typically found in the manual, crucial for engine rebuilds.
Horsepower:
Specific figures will be detailed in the manual, likely in the 30-40 HP range for this class.
Torque:
Specific figures will be detailed in the manual, crucial for acceleration and cruising performance.
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Compression Ratio:
Key specification for engine tuning and diagnostics, provided in manual.
Cooling Method:
Liquid-cooled
Engine Oil Change Interval:
Specific mileage or time interval detailed in the manual, crucial for engine longevity.
Air Filter Replacement Interval:
Intervals for cleaning or replacing the air filter will be provided for optimal engine breathing.
Spark Plug Replacement Interval:
Recommended interval for spark plug replacement to ensure proper ignition.
Transmission Fluid Change Interval:
Critical interval for CVT fluid replacement to maintain transmission performance and prevent wear.
Engine Oil Type And Viscosity:
Exact API service classification, JASO standard, and SAE viscosity grade will be specified (e.g., SAE 10W-40, API SG or higher).
Engine Oil Capacity:
Capacity in liters or quarts for oil changes with and without filter replacement, critical for correct filling.
Coolant Type:
Type of antifreeze/coolant and its required mixture ratio (e.g., ethylene glycol-based with corrosion inhibitors).
Brake Fluid Type:
Specification for brake fluid, typically DOT 4.
Common Wear Items:
As with many scooters of this era, common wear items might include CVT belt, brake pads, tires, and suspension bushings. Manual will detail inspection points.
Electrical Connector Corrosion:
Potential for corrosion in electrical connectors, particularly in humid environments, requiring inspection and cleaning as detailed in the manual.
