Market Segment:
Performance maxi-scooter, offering a blend of practicality, comfort, and sporty handling.
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500.
Performance Focus:
Emphasizes sporty riding characteristics, capable engine performance for highway use, and agile handling.
Design Elements:
Aggressive styling, aerodynamic fairings, comfortable seating for rider and passenger, integrated storage.
Primary Focus:
Comprehensive repair, maintenance, and diagnostics
Estimated Pages:
Likely extensive, typical for workshop manuals covering a single model with multiple variations (Estimate: 300-600 pages)
Type:
Workshop Manual / Service Manual
Language:
English (presumed, common for downloadable workshop manuals)
Engine Mechanical:
Detailed inspection, disassembly, assembly, torque specifications, valve clearance, piston/cylinder, crankshaft, con-rod, timing system.
Engine Management Injection:
Fuel injection system (EFI), throttle body, injectors, sensors (TPS, MAP, IAT, O2), ECU, diagnostic codes, troubleshooting.
Cooling System:
Radiator, coolant pump, thermostat, hoses, fan operation, coolant type and capacity.
Braking System:
Hydraulic system, brake fluid type, bleeding procedures, caliper overhaul, disc inspection, pad replacement, master cylinder.
Suspensions:
Front fork (telescopic type), rear shock absorber, swingarm, bearings, lubrication, adjustment, replacement.
Electrical System:
Wiring diagrams, battery, starter motor, alternator/generator, ignition system, lighting, instrumentation, fuses, relays, ECU pinouts.
Chassis Bodywork:
Frame inspection, body panel removal/installation, seat, handlebars, fairings, storage compartment.
Routine Maintenance:
Oil change intervals, oil filter replacement, spark plug replacement, air filter cleaning/replacement, chain/belt adjustment, brake pad inspection.
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues. Fault code interpretation.
Major Repairs:
Engine rebuild, transmission overhaul (if applicable), suspension fork rebuild, brake system repair.
Tooling Requirements:
Specific tools and special equipment required for various maintenance and repair tasks.
Depth:
Comprehensive: Covers everything from basic checks to complete engine teardown and rebuilds, electrical system diagnostics, and chassis component repair.
Engine Type:
4-stroke, single-cylinder, 4-valve, SOHC (or DOHC depending on specific year/variant, but 4-valve is common)
Displacement:
492.7 cc (common for Nexus 500)
Bore X Stroke:
Specify actual bore and stroke from manual if available, e.g., 90.0 mm x 76.0 mm
Compression Ratio:
Specify from manual, e.g., 10.5:1
Horsepower:
Approx. 33-39 HP (at crank, depending on year/ECU mapping)
Torque:
Approx. 38-42 Nm (at crank, depending on year/ECU mapping)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (95 RON/91 AKI typical)
Cooling Method:
Liquid-cooled
Oil Type Specification:
e.g., SAE 10W-40, API SG/SH or JASO MA/MA2 certified
Oil Capacity With Filter:
e.g., 1.8 Liters
Crash Test Data:
N/A (Motorcycles/Scooters typically not rated by NCAP/IIHS)
ABS:
Optional ABS (Anti-lock Braking System) availability depending on model variant.
Braking System Type:
Dual front disc brakes, single rear disc brake.
Lighting:
Halogen headlight, LED tail/brake light (depending on year).
Instrument Cluster:
Digital and analog display with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, clock, warning lights.
ABS Availability:
Optional ABS on some models, a significant safety feature.
Diagnostic Port:
On-board diagnostics (OBD) port for fault code reading and system analysis.
Oil Change Interval:
e.g., Every 5,000 - 7,500 km or 6-12 months (refer to manual for exact mileage).
Air Filter Service:
e.g., Every 10,000 km, inspect more frequently.
Spark Plug Replacement:
e.g., Every 15,000 - 20,000 km.
Valve Clearance Check:
e.g., Every 20,000 - 25,000 km.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (e.g., 50% mix with distilled water).
Brake Fluid Type:
DOT 4 (or DOT 5.1, check manual for exact specification).
Common Wear Items:
Variator rollers, drive belt wear, brake pads, suspension seals. Potential for minor electrical gremlins if not maintained.
Temperature Management:
Ensure cooling system is clean and functioning optimally, as overheating can lead to engine damage.
Manufacturer:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for performance and sporting heritage.
Nexus Lineage:
The Nexus series represented Gilera's entry into the maxi-scooter segment, focusing on performance and sportiness.
Production Years:
Produced from early 2000s (e.g., 2003) through the 2000s and early 2010s.
Manufacturing Location:
Italy
