Positioning:
Performance maxi-scooter aimed at touring and commuting with a sporty edge
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Leonardo
Features:
Powerful 500cc engine, comfortable ergonomics, large underseat storage, modern styling
Engine Management:
Engine disassembly, assembly, tuning, injection system, cooling system
Electrical System:
Complete electrical schematics, component testing, troubleshooting
Chassis And Suspension:
Front and rear suspension, steering, wheel bearings, frame components
Braking System:
Brake system overhaul, fluid replacement, component diagnostics
Bodywork And Trim:
Body panel removal and installation, fairings, seating
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, adjustments
Repair:
Component-level repair, engine rebuild, electrical troubleshooting, suspension servicing
Diagnostics:
Troubleshooting common issues, fault code diagnosis (if applicable to the system)
Pre Delivery Inspection:
Includes pre-delivery inspection checklist and procedures for new vehicle setup.
Engine Tuning:
Details on engine tuning and performance adjustments.
Suspension Adjustment:
Information on adjusting suspension components for optimal ride quality and handling.
Depth:
Comprehensive: From basic maintenance to in-depth engine and electrical system repair
Diagnostic Codes:
While not explicitly stated, a comprehensive manual often includes information on diagnostic codes or procedures for the electronic fuel injection system.
Searchability:
PDF format allows for text searching within the document.
Quality:
High-quality diagrams and instructions
Diagrams Quality:
High-quality, clear diagrams that are essential for mechanical work.
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download - Printable)
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Engine Type:
Single-cylinder, four-stroke, liquid-cooled
Engine Displacement:
460cc (approximate based on typical Gilera 500cc engines of the era)
Bore X Stroke:
Specifics to be detailed in the manual (typical for Gilera 500cc would be around 92mm x 69mm)
Horsepower Est:
33-35 HP (estimated, actual figures to be confirmed in manual)
Torque Est:
37-40 Nm (estimated, actual figures to be confirmed in manual)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Oil Type:
Specific SAE viscosity and API classification to be detailed in the manual (e.g., SAE 10W-40, API SG or higher)
Oil Capacity:
Specific capacity to be detailed in the manual (typically 1.5-1.8 liters for this class)
Cooling Medium:
Liquid (coolant)
Coolant Type:
Ethylene glycol-based antifreeze mixture (specific ratio and type in manual)
Engine Control Unit:
Details on ECU operation and potential diagnostic procedures for the EFI system.
Length:
Specifics to be detailed in the manual (typical maxi-scooter length around 2100-2200 mm)
Width:
Specifics to be detailed in the manual
Height:
Specifics to be detailed in the manual
Dry Weight:
Specifics to be detailed in the manual (typically around 180-200 kg)
Curb Weight:
Specifics to be detailed in the manual
Max Payload:
Specifics to be detailed in the manual
Fuel Tank Capacity:
Specifics to be detailed in the manual (typically 14-16 liters)
Crash Test Data:
N/A (Motorcycle specific safety ratings are less standardized than cars)
Braking System Type:
Front and Rear Disc Brakes
ABS:
Optional ABS may have been available (check manual for specifics)
Lighting:
Halogen headlights, LED taillight (typical)
Dashboard:
Analog tachometer and speedometer, digital display for fuel level, temperature, clock, odometer.
ABS Availability:
ABS was an optional feature, requiring specific diagnostic procedures if equipped.
Charging Port:
May feature a 12V power outlet for charging accessories (check manual for location and specifications).
Oil Change Interval:
Specific interval detailed in manual (typically 5,000-7,500 km or annually)
Spark Plug Replacement:
Specific interval detailed in manual (e.g., 10,000-15,000 km)
Air Filter Cleaning Replacement:
Specific interval detailed in manual (dependent on usage conditions)
Coolant Flush Interval:
Specific interval detailed in manual (e.g., every 2 years)
Brake Fluid Type:
DOT 4 recommended (specific in manual)
Transmission Fluid Type:
Specifics for CVT transmission fluid, if applicable, or gearbox oil type and capacity.
Common Problems:
Potential for minor electrical gremlins, wear on CVT components over high mileage, radiator hose degradation (typical for older scooters; detailed solutions in manual).
Troubleshooting Guidance:
Manual provides comprehensive troubleshooting for various systems, aiding in identifying and rectifying common issues.
Heritage:
Gilera is an Italian manufacturer with a long history in motorcycle racing and production, known for performance-oriented scooters and motorcycles.
Evolution:
The Nexus series represented Gilera's flagship maxi-scooter, evolving from earlier models with larger engines and more advanced features, emphasizing sport-touring capabilities.
Engine Development:
The 500cc engine was a key development for Gilera, offering a significant power upgrade over smaller scooter engines.
Manufacturing Location:
Italy
