gilera nexus
WORKSHOP MANUAL - OWNERS MANUAL
GILERA NEXUS 500-300 - WORKSHOP MANUAL - OWNERS MANUAL - English Service Manual and Owner’s Manual to Gilera Nexus 500cc. & 300cc. CONTENTS: GILERA NEXUS 500 MK1 - WORKSHOP MANUAL - CHARACTERISTICS - Rules - Safety rules - Maintenance rules - Vehicle identification - Dimensions and mass - Engine - Transmission - Capacities - Electrical system - Frame and suspensions - Brakes - Wheels and tyres - Tightening Torques - Overhaul data - Assembly clearances - Cylinder - piston assy. - Piston rings - Crankcase - crankshaft - connecting rod - Slot packing system - Products - TOOLING - MAINTENANCE - Maintenance chart - Spark plug - Hub oil - Check - Replacement - Air filter - Engine oil - Check - Engine oil filter - Oil pressure warning light - Checking the valve clearance - Cooling system - Level check - Braking system - Level check - Top-up - Headlight adjustment - Checking the end compression pressure - ELECTRICAL SYSTEM - Components arrangement - Conceptual diagrams - Ignition - Headlights and automatic starter section - Battery recharge and starting - Level indicators and enable signals section - Checks and inspections - Battery recharge circuit - Stator check - Recharge system voltage check - Lights list - Fuses - Dashboard - Data check function - Sealed battery - Dry-charge battery - Phonic wheel - Connectors - ECU - Seat opening receiver - Immobiliser decoder - Engine rev. sensor - Dashboard - Analogue odometer - Remote seat opening - Battery replacement - Zeroing - Programming - ENGINE FROM VEHICLE - Exhaust assy. Removal - Removal of the engine from the vehicle - ENGINE - Automatic transmission - Transmission cover - Air duct - Air duct filter - Removing the driven pulley shaft bearing - Refitting the driven pulley shaft bearing - Baffle roller - Plastic roller - Removing the driven pulley - Inspecting the clutch drum - Removing the clutch - Pin retaining collar - Removing the driven half-pulley bearing - Inspecting the driven fixed half-pulley - Inspecting the driven sliding half-pulley - Refitting the driven half-pulley bearing - Refitting the driven pulley - Inspecting the clutch spring - Refitting the clutch - Refitting the driven pulley - Drive-belt - Removing the driving pulley - Inspecting the rollers case - Refitting the driving pulley - Refitting the transmission cover - End gear - Removing the hub cover - Removing the wheel axle - Removing the hub bearings - Removing the wheel axle bearings - Removing the driven pulley shaft bearing - Inspecting the hub shaft - Inspecting the hub cover - Refitting the driven pulley shaft bearing - Refitting the hub cover bearings - Refitting the hub bearings - Refitting the ub cover - Flywheel cover - Removing the hub cover - Removing the flywheel cover components - Removing the stator - Inspecting the cover components - Refitting the stator - Refitting the flywheel cover components - Refitting the flywheel cover - Flywheel and starting - Removing the starter motor - Removing the flywheel magneto - Inspecting the flywheel components - Starter gear rim - Intermediate gear - Refitting the free wheel - Refitting the intermediate gear - Refitting the flywheel magneto - Refitting the starter motor - Cylinder assy. and timing system - Removing the intake manifold - Removing the rocker-arms cover - Removing the timing system drive - Removing the cam shaft - Removing the cylinder head - Removing the valves - Removing the cylinder - piston assy. - Inspecting the small end - Inspecting the wrist pin - Inspecting the piston - Inspecting the piston rings - Removing the piston - Choosing the gasket - Refitting the piston rings - Refitting the cylinder - Inspecting the cylinder head - Inspecting the timing system components - Inspecting the valve sealings - Inspecting the valve housings - Inspecting the valves - Inspecting the valve stem guide clearance - Inspecting the springs and half-cones - Refitting the valves - Inspecting the cam shaft - Refitting the head and timing system components - Refitting the timing chain - Inspecting the radial air gap - Refitting the rocker-arms cover - Refitting the intake manifold - Crankcase - crankshaft - Splitting the crankcase halves - Removing the crankshaft - Removing the countershaft - Replacing the countershaft bearings - Inspecting the crankshaft components - Inspecting the crankshaft alignment - Inspecting the crankcase halves - Inspecting the crankshaft plain bearings - Coupling chart - Countershaft - Refitting the crankshaft - Refitting the crankcase halves - Lubrication - Conceptual diagrams - General characteristics - Diagnosis guide - Oil pressure check - Oil pump - Removal - Inspection - Refitting - INJECTION - Precautions - Terminals setup - EMS circuit diagram - Troubleshooting procedure - Engine does not start - Starting difficulties - Engine stops at idle - Engine does not rev down - Exhaust backfires in deceleration - Engine revs irregularly - Poor performance at full throttle - Engine knocking - Decoder master-box circuit - Constant supply circuit check - Key-switch power supply circuit check - Diagnostic circuit - Injection warning light circuit - Self-diagnosis system - Fuel supply system - Circuit diagram - Removing the injector - Refitting the injector - Removing the butterfly valve - Refitting the butterfly valve - Pump supply circuit - Circuit check - Circuit leak test - Pressure regulator check - Fuel pump and filter check - Pump electrics check - Resistor check - Pump consumption check - Fuel filter check - Pump bracket overhaul - Pump bracket installation - Inspecting the injector circuit - Inspecting the injector hydraulics - Troubleshooting - Immobiliser circuit - System components - Virgin circuit - Setting the circuit - LED signals - Deterring blink - Checking master-box data - Resetting the circuit - Diagnostic codes - Code 1 - Code 2 - Code 3 - Code 4 - Diagnosis guide - Tachometer - HT coil - Circuit diagram - Inspecting the spark plug shielded cap - Spark advance - Coolant temperature sensor - Intake air temperature sensor - Pressure sensor - Throttle valve opening sensor - Zeroing the throttle - Step motor - SUSPENSIONS - Front - Removing the front wheel - Front wheel hub overhaul - Refitting the front wheel - Front fork - Removal - Overhaul - Refitting - Steering bearing - Removal - Refitting - Rear - Removing the rear wheel - Refitting the rear wheel - Swing-arm - Shock absorbers - Removal - Refitting - Centre-stand - Side stand - BRAKING SYSTEM - Rear brake calliper - Removal - Overhaul - Refitting - Front brake calliper - Removal - Overhaul - Refitting - Rear brake disc - Removal - Refitting - Disc Inspection - Front brake disc - Removal - Refitting - Disc Inspection - Front brake pads - Removal - Refitting - Rear brake pads - Removal - Refitting - Fill - Rear - combined - Front - Front brake pump - Removal - Refitting - Rear brake pump - combined - Removal - Refitting - COOLING SYSTEM - Circuit diagram - Electric fan check - System sealing check - Coolant replacement - Water pump - overhaul - Thermostat - Check - diagnosis - Excessive system pressure - Cooling fluid consumption - Oil in the fluid - CHASSIS - Seat - Rear handlebar cover - Instrument panel - Headlight assy. - Frame central cover - Legshield - Knee-guard - Removing the ignition key-switch when on *off* - Front wheel housing - Taillight assy. - Footrest - Side fairings - License plate holder - Air filter - Rear mudguard - Helmet bay - spoiler - Fuel tank - Rear central cover - Front mudguard - Radiator fan - Handles and top side fairings - Flyscreen - Pilot lights kit - Battery - Lower cover - PRE-DELIVERY - Aesthetic inspection - Tightening torques inspection - Electrical system - Levels check - Road test - Static test - Functional inspection - TIME - Engine - Crankcase - Crankshaft - Cylinder assy. - Cylinder head assy. - Rocker arms support assy. - Cylinder head cover - Flywheel cover - Driven pulley - Oil pump - Final gear assy. - Driving pulley - Transmission cover - Flywheel magneto - Butterfly valve - Exhaust pipe - Air cleaner - Frame - Centre-stand - Legshield spoiler - Central cover - Mudguard - Fuel tank - Handlebar covers - Handlebar components - Seat - Locks - Turn signal lights - Front wheel - Rear wheel - Fuel pump - Electric devices - Helmet bay - Rear side fairings - Front suspension - Rear suspension - Cooling system - Braking system - Windscreen GILERA NEXUS 500 MK2 - WORKSHOP MANUAL - CHARACTERISTICS - Rules - Safety rules - Maintenance rules - Vehicle identification - Dimensions and mass - Engine - Transmission - Capacities - Electrical system - Frame and suspensions - Brakes - Wheels and tyres - Tightening Torques - Overhaul data - Assembly clearances - Cylinder - piston assy. - Piston rings - Crankcase - crankshaft - connecting rod - Slot packing system - Products - TOOLING - MAINTENANCE - Maintenance chart - Spark plug - Hub oil - Check - Replacement - Air filter - Engine oil - Check - Engine oil filter - Oil pressure warning light - Checking the valve clearance - Cooling system - Level check - Braking system - Level check - Top-up - Headlight adjustment - Checking the end compression pressure - ELECTRICAL SYSTEM - Components arrangement - Conceptual diagrams - Ignition - Battery recharge and starting - Level indicators and enable signals section - Devices and accessories - Lights and turn indicators - Checks and inspections - Battery recharge circuit - Stator check - Recharge system voltage check - Turn signals system check - Lights list - Fuses - Dashboard - Data check function - Sealed battery - Dry-charge battery - Phonic wheel - Connectors - ECU - Seat opening receiver - Immobiliser decoder - Engine rev. sensor - Dashboard - Analogue odometer - Remote seat opening - Battery replacement - Zeroing - Programming - ENGINE FROM VEHICLE - Exhaust assy. Removal - Removal of the engine from the vehicle - ENGINE - Automatic transmission - Transmission cover - Air duct - Air duct filter - Removing the driven pulley shaft bearing - Refitting the driven pulley shaft bearing - Baffle roller - Plastic roller - Removing the driven pulley - Inspecting the clutch drum - Removing the clutch - Pin retaining collar - Removing the driven half-pulley bearing - Inspecting the driven fixed half-pulley - Inspecting the driven sliding half-pulley - Refitting the driven half-pulley bearing - Refitting the driven pulley - Inspecting the clutch spring - Refitting the clutch - Refitting the driven pulley - Drive-belt - Removing the driving pulley - Inspecting the rollers case - Refitting the driving pulley - Refitting the transmission cover - End gear - Removing the hub cover - Removing the wheel axle - Removing the hub bearings - Removing the wheel axle bearings - Removing the driven pulley shaft bearing - Inspecting the hub shaft - Inspecting the hub cover - Refitting the driven pulley shaft bearing - Refitting the hub cover bearings - Refitting the hub bearings - Refitting the ub cover - Flywheel cover - Removing the hub cover - Removing the flywheel cover components - Removing the stator - Inspecting the cover components - Refitting the stator - Refitting the flywheel cover components - Refitting the flywheel cover - Flywheel and starting - Removing the starter motor - Removing the flywheel magneto - Inspecting the flywheel components - Starter gear rim - Intermediate gear - Refitting the free wheel - Refitting the intermediate gear - Refitting the flywheel magneto - Refitting the starter motor - Cylinder assy. and timing system - Removing the intake manifold - Removing the rocker-arms cover - Removing the timing system drive - Removing the cam shaft - Removing the cylinder head - Removing the valves - Removing the cylinder - piston assy. - Inspecting the small end - Inspecting the wrist pin - Inspecting the piston - Inspecting the piston rings - Removing the piston - Choosing the gasket - Refitting the piston rings - Refitting the cylinder - Inspecting the cylinder head - Inspecting the timing system components - Inspecting the valve sealings - Inspecting the valve housings - Inspecting the valves - Inspecting the valve stem guide clearance - Inspecting the springs and half-cones - Refitting the valves - Inspecting the cam shaft - Refitting the head and timing system components - Refitting the timing chain - Inspecting the radial air gap - Refitting the rocker-arms cover - Refitting the intake manifold - Crankcase - crankshaft - Splitting the crankcase halves - Removing the crankshaft - Removing the countershaft - Replacing the countershaft bearings - Inspecting the crankshaft components - Inspecting the crankshaft alignment - Inspecting the crankcase halves - Inspecting the crankshaft plain bearings - Coupling chart - Countershaft - Refitting the crankshaft - Refitting the crankcase halves - Lubrication - Conceptual diagrams - General characteristics - Diagnosis guide - Oil pressure check - Oil pump - Removal - Inspection - Refitting - INJECTION - Precautions - Terminals setup - EMS circuit diagram - Troubleshooting procedure - Engine does not start - Starting difficulties - Engine stops at idle - Engine does not rev down - Exhaust backfires in deceleration - Engine revs irregularly - Poor performance at full throttle - Engine knocking - Decoder master-box circuit - Constant supply circuit check - Key-switch power supply circuit check - Diagnostic circuit - Injection warning light circuit - Self-diagnosis system - Fuel supply system - Circuit diagram - Removing the injector - Refitting the injector - Removing the butterfly valve - Refitting the butterfly valve - Pump supply circuit - Circuit check - Circuit leak test - Pressure regulator check - Fuel pump and filter check - Pump electrics check - Resistor check - Pump consumption check - Fuel filter check - Pump bracket overhaul - Pump bracket installation - Inspecting the injector circuit - Inspecting the injector hydraulics - Troubleshooting - Immobiliser circuit - System components - Virgin circuit - Setting the circuit - LED signals - Checking master-box data - Resetting the circuit - Diagnostic codes - Code 1 - Code 2 - Code 3 - Tachometer - HT coil - Circuit diagram - Inspecting the spark plug shielded cap - Spark advance - Coolant temperature sensor - Intake air temperature sensor - Pressure sensor - Throttle valve opening sensor - Zeroing the throttle - Step motor - Lambda probe - Impianto elettroventilatore - SUSPENSIONS - Front - Removing the front wheel - Front wheel hub overhaul - Refitting the front wheel - Front fork - Removal - Overhaul - Refitting - Steering bearing - Removal - Refitting - Rear - Removing the rear wheel - Refitting the rear wheel - Swing-arm - Shock absorbers - Removal - Refitting - Centre-stand - Side stand - BRAKING SYSTEM - Rear brake calliper - Removal - Overhaul - Refitting - Front brake calliper - Removal - Overhaul - Refitting - Rear brake disc - Removal - Refitting - Disc Inspection - Front brake disc - Removal - Refitting - Disc Inspection - Front brake pads - Removal - Refitting - Rear brake pads - Removal - Refitting - Fill - Rear - combined - Front - Front brake pump - Removal - Refitting - Rear brake pump - combined - Removal - Refitting - COOLING SYSTEM - Circuit diagram - Electric fan check - System sealing check - Coolant replacement - Water pump - overhaul - Thermostat - Check - diagnosis - Excessive system pressure - Cooling fluid consumption - Oil in the fluid - CHASSIS - Seat - Rear handlebar cover - Instrument panel - Headlight assy. - Frame central cover - Legshield - Knee-guard - Removing the ignition key-switch when on *off* - Front wheel housing - Taillight assy. - Footrest - Side fairings - License plate holder - Air filter - Rear mudguard - Helmet bay - Fuel tank - Rear central cover - Front mudguard - Radiator fan - Flyscreen - Pilot lights kit - Battery - Lower cover - PRE-DELIVERY - Aesthetic inspection - Tightening torques inspection - Electrical system - Levels check - Road test - Static test - Functional inspection - TIME - Engine - Crankcase - Crankshaft - Cylinder assy. - Cylinder head assy. - Rocker arms support assy. - Cylinder head cover - Flywheel cover - Driven pulley - Oil pump - Final gear assy. - Driving pulley - Transmission cover - Flywheel magneto - Butterfly valve - Exhaust pipe - Air cleaner - Frame - Centre-stand - Legshield spoiler - Central cover - Mudguard - Fuel tank - Handlebar covers - Handlebar components - Seat - Locks - Turn signal lights - Front wheel - Rear wheel - Fuel pump - Electric devices - Helmet bay - Rear side fairings - Front suspension - Rear suspension - Cooling system - Braking system - Windscreen GILERA NEXUS 500 - PARTS MANUAL GILERA NEXUS 500 MK1 - OWNERS MANUAL GILERA NEXUS 300 - WORKSHOP MANUAL - CHARACTERISTICS - Rules - Safety rules - Maintenance rules - Vehicle identification - Dimensions and mass - Engine - Transmission - Capacities - Electrical system - Frame and suspensions - Brakes - Wheels and tyres - Tightening Torques - Overhaul data - Assembly clearances - Cylinder - piston assy. - Crankcase - crankshaft - connecting rod - Cylinder Head - Slot packing system - Products - TOOLING - MAINTENANCE - Maintenance chart - Checking the spark advance - Spark plug - Hub oil - Check - Replacement - Air filter - Engine oil - Replacement - Check - Engine oil filter - Oil pressure warning light - Checking the ignition timing - Cooling system - Level check - Braking system - Level check - Top-up - Headlight adjustment - TROUBLESHOOTING - Engine - Poor performance - Starting difficulties - Excessive oil consumption/Exhaust smoke - Insufficient lubrication pressure - Transmission and brakes - Clutch grabbing or performing inadequately - Insufficient braking - Brakes overheating - Steering and suspensions - Heavy steering - Excessive steering play - Noisy suspension - Suspension oil leakage - ELECTRICAL SYSTEM - Components arrangement - Ground points - Checks and inspections - Immobiliser - Virgin circuit - Diagnostic codes - Diagnostic code - 1 flash - Diagnostic code - 2 flashes - Diagnostic code - 3 flashes - Ignition circuit - No spark plug - Battery recharge circuit - Stator check - Recharge system voltage check - Starter motor - Horn control - Turn signals system check - level indicators - Lights list - Fuses - Dashboard - Data check function - Sealed battery - Dry-charge battery - Battery installation - Phonic wheel - Remote controls check - Switches check - Connectors - ENGINE FROM VEHICLE - Exhaust assy. Removal - Removal of the engine from the vehicle - ENGINE - Automatic transmission - Transmission cover - Air duct - Removing the driven pulley shaft bearing - Refitting the driven pulley shaft bearing - Baffle roller - Plastic roller - Removing the driven pulley - Inspecting the clutch drum - Removing the clutch - Inspecting the clutch - Pin retaining collar - Removing the driven half-pulley bearing - Inspecting the driven fixed half-pulley - Inspecting the driven sliding half-pulley - Refitting the driven half-pulley bearing - Refitting the driven pulley - Inspecting the clutch spring - Refitting the clutch - Refitting the driven pulley - Drive-belt - Removing the driving pulley - Inspecting the rollers case - Refitting the driving pulley - Refitting the transmission cover - End gear - Removing the hub cover - Removing the wheel axle - Removing the hub bearings - Removing the wheel axle bearings - Removing the driven pulley shaft bearing - Inspecting the hub shaft - Inspecting the hub cover - Refitting the wheel axle bearing - Refitting the hub cover bearings - Refitting the hub bearings - Refitting the ub cover - Flywheel cover - Removing the hub cover - Removing the stator - Refitting the stator - Refitting the flywheel cover - Flywheel and starting - Removing the starter motor - Removing the flywheel magneto - Inspecting the flywheel components - Refitting the free wheel - Refitting the flywheel magneto - Refitting the starter motor - Cylinder assy. and timing system - Removing the intake manifold - Removing the rocker-arms cover - Removing the timing system drive - Removing the cam shaft - Removing the cylinder head - Removing the valves - Removing the cylinder - piston assy. - Inspecting the small end - Inspecting the wrist pin - Inspecting the piston - Inspecting the cylinder - Inspecting the piston rings - Removing the piston - Choosing the gasket - Refitting the piston rings - Refitting the cylinder - Inspecting the cylinder head - Inspecting the timing system components - Inspecting the valve sealings - Inspecting the valves - Inspecting the springs and half-cones - Refitting the valves - Inspecting the cam shaft - Refitting the head and timing system components - Refitting the rocker-arms cover - Refitting the intake manifold - Crankcase - crankshaft - Splitting the crankcase halves - Inspecting the crankshaft alignment - Inspecting the crankcase halves - Inspecting the crankshaft plain bearings - Refitting the crankcase halves - Studs - Lubrication - Conceptual diagrams - Oil pressure check - Crankshaft oil seals - Removal - Refitting - Oil pump - Removal - Inspection - Refitting - Removing the oil sump - Inspecting the by-pass valve - Refitting the oil sump - INJECTION - Precautions - Terminals setup - EMS circuit diagram - Troubleshooting procedure - Engine does not start - Starting difficulties - Engine stops at idle - Engine does not rev down - Exhaust backfires in deceleration - Engine revs irregularly - Poor performance at full throttle - Engine knocking - Fuel supply system - Removing the butterfly valve - Refitting the butterfly valve - Pump supply circuit - Circuit leak test - Fuel filter check - Inspecting the injector circuit - Inspecting the injector hydraulics - Components location - Tachometer - HT coil - Coolant temperature sensor - Zeroing the throttle - Lambda probe - SUSPENSIONS - Front - Removing the front wheel - Front wheel hub overhaul - Refitting the front wheel - Handlebar - Removal - Refitting - Front fork - Removal - Overhaul - Refitting - Steering column - Removal - Refitting - Steering bearing - Removal - Refitting - Rear - Removing the rear wheel - Refitting the rear wheel - Swing-arm - Removal - Overhaul - Refitting - Shock absorbers - Removal - Refitting - Centre-stand - Side stand - BRAKING SYSTEM - Rear brake calliper - Removal - Overhaul - Refitting - Front brake calliper - Removal - Overhaul - Refitting - Rear brake disc - Removal - Refitting - Disc Inspection - Front brake disc - Removal - Refitting - Disc Inspection - Front brake pads - Removal - Refitting - Rear brake pads - Removal - Refitting - Fill - Rear - combined - Front - Front brake pump - Removal - COOLING SYSTEM - Circuit diagram - Electric fan check - System bleed - Thermostat - Removal - Check - Refitting - CHASSIS - Seat - Rear handlebar cover - Instrument panel - Front handlebar cover - Headlight assy. - Frame central cover - Legshield - Knee-guard - Removing the ignition key-switch when on *off* - Front wheel housing - Taillight assy. - Footrest - Side fairings - License plate holder - Rear mudguard - Helmet bay - Fuel tank - Front mudguard - Radiator fan - Flyscreen - Pilot lights kit - Battery - Lower cover - PRE-DELIVERY - Aesthetic inspection - Tightening torques inspection - Electrical system - Levels check - Road test - Static test - Functional inspection - Specific operations for the vehicle - TIME - Engine - Crankcase - Crankshaft - Cylinder assy. - Cylinder head assy. - Rocker arms support assy. - Cylinder head cover - Oil filter - Flywheel cover - Driven pulley - Oil pump - Final gear assy. - Driving pulley - Transmission cover - Starter motor - Flywheel magneto - Butterfly valve - Exhaust pipe - Air cleaner - Frame - Centre-stand - Legshield spoiler - Side fairings - Rear cover - Central cover - Mudguard - Fuel tank - Rear shock-absorber - Handlebar covers - Handlebar components - Swing-arm - Seat - Instrument panel - Turn signal lights - Front wheel - Rear wheel - Electric devices - Helmet bay - Front suspension - Cooling system - Braking system GILERA NEXUS 300 - WIRING DIAGRAM - Italian/English - French/German - Spanish/Portuguese GILERA NEXUS 300 - OWNERS MANUAL
Gilera Nexus 500-300 - Service Manual - Owners Manual
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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