Segment:
Premium Maxi-Scooter
Target Audience:
Commuters seeking performance, touring capability, and advanced features
Key Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600
Design Philosophy:
Sporty handling blended with maxi-scooter comfort and practicality
Aerodynamics:
Designed for wind protection and stability at higher speeds
Primary Coverage:
Comprehensive service, repair, and workshop information
Secondary Coverage:
Maintenance schedules, troubleshooting, diagnostics, component replacement, electrical systems, wiring diagrams
Estimated Pages:
Over 300
Type:
Service Repair Workshop Manual
Format:
Digital Download (PDF)
Engine:
Complete engine overhaul, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system, exhaust system
Transmission:
Automatic transmission (CVT) operation, maintenance, disassembly, reassembly, fluid specifications
Chassis Suspension:
Front suspension (forks), rear suspension (shock absorber, swingarm), steering system, wheel bearings
Brakes:
Front and rear braking systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper and master cylinder service
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting system (headlight, taillight, indicators), ignition system components, sensors, ECU, wiring diagrams, troubleshooting electrical faults
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body, emission control systems
Bodywork Fairings:
Body panel removal and installation, fairing components, seating, storage compartments
Scheduled Maintenance:
Oil changes, filter replacements, spark plug replacement, valve clearance checks, drive belt inspection/replacement, brake service intervals, coolant checks/replacement
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, error code interpretation (if applicable), performance problems
Repair Overhaul:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly of major vehicle systems
Electrical Diagnostics:
Detailed wiring diagrams, component testing procedures, voltage drop tests, continuity checks
Specifications Data:
Torque specifications for all fasteners, fluid capacities, clearances, tolerances, electrical values
Depth:
Comprehensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds and advanced electrical diagnostics.
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, DOHC
Bore X Stroke:
94 mm x 71 mm (approximate, requires manual confirmation for exact spec)
Compression Ratio:
10.0:1 (approximate, requires manual confirmation for exact spec)
Horsepower:
Approximately 40 HP @ 7,000 RPM (requires manual confirmation for exact spec)
Torque:
Approximately 46 Nm @ 5,500 RPM (requires manual confirmation for exact spec)
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Oil Type:
Semi-synthetic or fully synthetic SAE 10W-40 motorcycle oil (refer to manual for exact API/JASO spec)
Oil Capacity:
Approximately 1.7 liters (dry fill), 1.5 liters (with filter change) (requires manual confirmation)
Coolant Type:
Ethylene glycol based coolant (50/50 mix with distilled water) (refer to manual for exact specification)
Length:
Approx. 2,250 mm (requires manual confirmation)
Width:
Approx. 800 mm (requires manual confirmation)
Height:
Approx. 1,400 mm (requires manual confirmation)
Wheelbase:
Approx. 1,560 mm (requires manual confirmation)
Dry Weight:
Approx. 200 kg (requires manual confirmation)
Gross Vehicle Weight Rating:
Requires manual confirmation
Underseat Storage:
Sufficient for one full-face helmet and additional items (refer to manual for specifics)
Crash Test Ratings:
N/A (Motorcycle)
Braking System:
Dual front disc brakes with potent calipers, single rear disc brake
Optional ABS:
ABS available on certain models/markets (requires manual confirmation for specific year/trim)
Lighting:
Halogen headlight, LED taillight and indicators (depending on market configuration)
Mirrors:
Large, adjustable mirrors for good rearward visibility
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, various indicator lights.
ABS:
Optional Anti-lock Braking System (ABS) available on some models, greatly enhancing safety during braking.
Diagnostic Port:
On-board diagnostics port for ECU access and troubleshooting (location detailed in manual).
Engine Oil Change:
Every 3,000 km or 6 months (whichever comes first) (refer to manual for exact interval)
Oil Filter Replacement:
Every 6,000 km or 12 months (refer to manual for exact interval)
Air Filter Cleaning Replacement:
Check every 3,000 km, clean/replace as needed (refer to manual)
Spark Plug Replacement:
Every 6,000 km or 12 months (refer to manual for exact interval and plug type)
Drive Belt Inspection:
Inspect every 6,000 km, replace as needed (refer to manual for replacement interval)
Valve Clearance Check:
Every 12,000 km or 24 months (refer to manual for exact interval)
Engine Oil Specification:
SAE 10W-40 API SG or higher, JASO MA (refer to manual for precise specification)
Brake Fluid Specification:
DOT 4 hydraulic fluid (refer to manual for precise specification)
Coolant Specification:
Ethylene glycol based coolant, 50% mixture with distilled water (refer to manual for precise specification)
Common Complaints:
Some owners have reported issues with stator reliability, fuel pump longevity, and occasional electrical gremlins. The manual will guide on diagnosis and repair for these potential issues.
Drive Belt Wear:
Regular inspection of the CVT drive belt is crucial as wear can lead to performance degradation.
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and innovative models.
Nexus Lineage:
The Nexus line represented Gilera's entry into the premium maxi-scooter segment, focusing on performance and handling.
Production Period:
2003-2008 (approximate for Nexus line)
Parent Company:
Gilera was part of the Piaggio Group during this period.
