Segment:
Maxi-scooter, offering a blend of performance, comfort, and practicality for urban commuting and longer journeys.
Target Audience:
Commuters, touring riders, and enthusiasts seeking a capable and versatile large-displacement scooter.
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Scarabeo 500.
Scooter Design:
Sporty styling, aerodynamic fairing, comfortable seating, ample storage.
Engine Performance:
Powerful 500cc engine providing strong acceleration and highway capability.
Handling:
Motorcycle-like chassis and suspension for stable and engaging handling.
General Coverage:
Comprehensive mechanical and electrical repair, maintenance, and troubleshooting for the Gilera Nexus 500 MK1.
Estimated Page Count:
Hundreds (exact count not specified, but described as '100 percents complete and intact' with 'hundreds of photos and illustrations')
Type:
Workshop Service Repair Manual
Searchability:
Likely text-searchable (standard for professional PDFs).
Printability:
All pages are printable.
Image Quality:
Detailed illustrations and hundreds of photos, implying high-quality visual aids.
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Engine:
Engine overhaul, cylinder head, piston, crankshaft, lubrication system, cooling system, fuel injection system (ECU, sensors, injectors), ignition system.
Transmission:
Automatic transmission (CVT - Continuously Variable Transmission) servicing, clutch operation, belt inspection and replacement, variator and torque converter servicing.
Chassis And Suspension:
Front fork assembly (disassembly, cleaning, oil changes), rear shock absorber and swingarm maintenance, wheel bearings, steering system.
Brakes:
Hydraulic brake system, front and rear brake calipers, brake discs, brake pads, brake fluid replacement and bleeding, ABS system (if equipped).
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, fuses, relays, ignition switch.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injection system troubleshooting.
Bodywork And Trim:
Panel removal and installation, seat, fairings, dashboard, lighting components.
Diagnostic Troubleshooting:
Fault finding procedures for common issues, error code interpretation (if applicable).
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, coolant checks, brake fluid replacement, tire pressure checks.
Engine Repair:
Complete engine rebuild, gasket replacement, timing chain adjustment (if applicable), valve clearance checks and adjustment.
Transmission Service:
CVT belt inspection and replacement, roller weights, clutch spring replacement, gearbox oil change.
Suspension And Steering Service:
Front fork seal replacement, fork oil viscosity and level specifications, steering head bearing adjustment.
Brake System Overhaul:
Brake caliper rebuilding, master cylinder service, brake line replacement, ABS component testing (if equipped).
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, testing components like regulators, alternators, starter solenoids.
Fuel System Maintenance:
Fuel injector cleaning, fuel pump testing, fuel pressure checks.
Bodywork Repair:
Fairing removal and installation, headlight bulb replacement, seat mechanism service.
Depth:
Full factory-level service and repair instructions, suitable for complete disassembly and reassembly of all major components.
Diagnostic Focus:
Detailed diagnostic procedures and troubleshooting charts for identifying and resolving mechanical and electrical issues.
Type:
Four-stroke, single-cylinder, liquid-cooled
Bore X Stroke:
Approx. 94 mm x 71 mm (typical for this engine family)
Compression Ratio:
Approx. 10.5:1
Horsepower:
Approx. 40-45 HP @ 7500 RPM (peak power may vary slightly by market)
Torque:
Approx. 45-50 Nm @ 5500 RPM (peak torque may vary slightly by market)
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Ignition System:
Electronic ignition with variable advance
Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 motorcycle specific oil recommended. Consult manual for exact specification.
Oil Capacity:
Approx. 1.5-1.8 liters (including filter). Exact figure in manual.
Dashboard:
Digital and analog instrumentation, including speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meters, and warning lights.
ABS:
Optional Antilock Braking System (ABS) available on some models, enhancing braking safety.
Wiring:
Comprehensive wiring diagrams are included in the manual, crucial for diagnosing electrical issues or installing accessories.
Engine Oil Change:
Every 5,000 - 7,500 km or annually. Consult manual for precise interval.
Oil Filter Replacement:
Every 5,000 - 7,500 km or annually, concurrent with oil change.
Spark Plug Replacement:
Every 10,000 - 15,000 km. Consult manual for specific spark plug type and gap.
Air Filter Cleaning:
Check every 5,000 km, clean or replace as needed. Replacement interval approx. 15,000-20,000 km.
Cvt Belt Inspection:
Inspect for wear and damage every 5,000 - 7,500 km. Replacement typically at 15,000 - 20,000 km, depending on usage.
Engine Oil Grade:
SAE 10W-40 or 15W-50 (API SG or higher). Refer to owner's manual for precise specification.
Coolant:
Ethylene glycol-based antifreeze mixture (50/50). Consult manual for specific coolant type and capacity.
Brake Fluid:
DOT 4 hydraulic brake fluid. Replace every 2 years.
Common Wear Items:
CVT belt, brake pads, tires, suspension bushings are common wear items that require regular inspection and replacement.
Potential Issues:
Some units may experience occasional electrical gremlins or fuel injection system sensor issues if not properly maintained. Referencing the workshop manual is key to diagnosing these.
