Vehicle Type:
Maxi-scooter
Target Audience Manual:
Mechanics, technicians, experienced DIY enthusiasts, and owners of the Gilera Nexus 500.
Competitive Segment:
High-performance maxi-scooters of its era, competing with models from brands like Yamaha (TMAX), Suzuki (Burgman), and Aprilia (SR Max).
Vehicle Selling Points:
Powerful 500cc engine, advanced fuel injection, comfortable for touring and urban commuting, sporty handling.
Manual Benefit Statement:
Empowers owners and technicians with the detailed knowledge and procedures to maintain, diagnose, and repair the Gilera Nexus 500 efficiently and correctly.
Documentation Type:
Workshop Manual, Repair and Maintenance Guide
Primary Focus:
Maintenance, Repair, Servicing
Estimated Page Count:
Not specified in product information, but typical for comprehensive workshop manuals.
Manual Format:
PDF Download
Language:
Not specified, but likely English for a widely distributed manual.
Engine Systems:
Engine overhaul, cylinder-piston assembly, crankcase-crankshaft-connecting rod, cylinder head, air duct, driven pulley shaft bearing, baffle roller, clutch, flywheel magneto, injection system, cooling system.
Transmission Systems:
Automatic transmission, driven pulley shaft bearing, clutch.
Chassis And Suspension:
Frame, suspension, wheels, tires, slot parking system.
Braking Systems:
Brakes, braking system maintenance and repair.
Electrical Systems:
Electrical system, flywheel magneto, headlight adjustment.
Vehicle Identification Data:
Yes, covers vehicle identification, dimensions, and mass.
Frame And Bodywork:
Chassis, frame, and bodywork components covered.
Maintenance Procedures:
Maintenance chart, spark plug replacement, hub oil change, engine oil change, cooling system maintenance, braking system maintenance, air filter service, headlight adjustment.
Repair Procedures:
Engine overhaul, transmission repair, suspension repair, brake system repair, electrical system diagnosis and repair, component replacements.
Diagnostic Procedures:
Troubleshooting section for identifying and resolving common issues.
Pre Delivery Inspection:
Yes, a 'Pre-delivery' section is listed, indicating procedures for initial setup and inspection before customer delivery.
Product Recommendations:
Yes, the manual includes a section on recommended 'products', likely referring to lubricants, sealants, and cleaning agents.
Tooling Requirements:
Yes, includes a dedicated 'Tooling' section detailing necessary tools for maintenance and repair.
Diagnostic Capabilities:
Covers troubleshooting, implying diagnostic procedures for the engine, electrical, and mechanical systems.
Rebuild Information:
Detailed section on engine overhaul, including cylinder-piston assembly, crankshaft, and cylinder head procedures.
Specification Data:
Includes tightening torques, overhaul data, assembly clearances, and product recommendations.
Torque Specifications Coverage:
Yes, specific tightening torque values are provided for various components, crucial for correct assembly.
Clearance Data Coverage:
Yes, assembly clearances are detailed, particularly for critical engine internal clearances.
Engine Configuration:
Single-cylinder
Engine Displacement:
500cc (approximately, based on typical designation)
Valve Train:
Single Overhead Camshaft (SOHC), 4 valves per cylinder.
Valve Control Mechanism:
Control from flywheel side chain, automatic start-up valve lifting device.
Maximum Power:
29 kW (39 CV) at 7250 rpm
Maximum Torque:
40 N·m (4 kgm) at 5500 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Diameter:
38 mm
Cooling Method:
Liquid-cooled
Circulation System:
Motor-driven pump
Thermostat:
3-way thermostat
Ignition System:
Electronic ignition with integrated tone wheel on flywheel.
Maintenance Chart Availability:
Yes, the manual includes a detailed maintenance chart.
Engine Oil:
Not explicitly stated, but typically requires a high-quality motorcycle-specific engine oil (e.g., SAE 10W-40 or 15W-50, JASO MA certified). Manual would specify exact viscosity and API classification.
Coolant:
Requires a specific ethylene glycol-based coolant mixture. Manual will specify type and mixture ratio.
Hub Oil:
Specific type and quantity for the final drive/hub oil will be detailed in the manual.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid is typical for modern scooters. Manual will specify exact type.
Common Wear Items:
Likely includes wear on drive belts, rollers, brake pads, and suspension components, all of which are covered by maintenance and repair procedures in the manual.
Electrical Gremlins:
As with many electronically managed vehicles, potential issues with sensors, wiring harnesses, or the ECU might be addressed in the electrical and troubleshooting sections.
