User Manuals: Gilera Nexus 500 Maxi Scooter

User Manuals: Gilera Nexus 500 Maxi Scooter

Manuals and User Guides for Gilera Nexus 500 Maxi Scooter. We have 2 Gilera Nexus 500 Maxi Scooter manuals available for free PDF download: Workshop Manual, User Manual

Gilera Nexus 500 Workshop Manual

Gilera Nexus 500 Workshop Manual (400 pages)

Brand: Gilera | Category: Scooter | Size: 12 MB

Table of Contents

Index of Topics
5
Characteristics
6
Maintenance Rules
7
Safety Rules
7
Dimensions and Mass
8
Vehicle Identification
8
Weight
8
Capacities
9
Electrical System
9
Frame and Suspensions
9
Braking Plant Installation
10
Wheels and Tyres
10
Tightening Torques
11
Table of Contents
12
Assembly Clearances
13
Cylinder - Piston Assy
13
Muffler Retainer
13
Notice of Technical Servicing
13
Overhaul Data
13
Categories of Coupling
14
Crankcase - Crankshaft - Connecting Rod
14
Height at Which the Diameter Should be Measured
14
Piston Rings
14
Crankshaft Alignment
15
Diameter of Crankshaft Bearings
15
Max. Admissible Displacement
15
Axial Clearance between Crankshaft and Connecting Rod
16
Slot Packing System
16
Base Gasket Thickness
17
Products
17
Tooling
18
Tools
19
Maintenance
30
After 1,000 Km or 4 Months
31
Every 2 Years
31
Every 3,000 Km
31
Maintenance Chart
31
After 12,000 Km or 24 Months and 60,000 Km
32
After 18,000 Km and after 54,000 Km
32
After 6,000 Km or 12 Months
32
After 24,000 Km
33
After 30,000 Km, 42,000 Km and 66,000 Km
33
After 36,000 Km
33
After 48,000 Km
34
After 72,000 Km
34
Check and Replacement
35
Hub Oil
35
Spark Plug
35
- Air Filter
  37
- Engine Oil
  38
Engine Oil Filter
39
Engine Oil Drainage Plug
40
- Checking the Valve Clearance
  41
- Cooling System
  41
- Oil Pressure Warning Light
  41
- Level Check
  42
- Braking System
  43
- Top-Up
  43
- Headlight Adjustment
  44
- Checking the End Compression Pressure
  45
- Components Arrangement
  48
- Diagnostic Socket
  48
- Wiring Colour Chart
  48
- H.V. Coil
  49
- Overturn Sensor
  49
- Saddle Opening ECU Remote Control
  49
- Electronic Control Unit ECU
  50
- Immobiliser Decoder
  50
- Relays and Diode Group
  50
- Conceptual Diagrams
  51
- Ignition
  51
- Voltage Regulator
  51
- Headlights and Automatic Starter Section
  53
- Light and Flashing Light Bulbs Section
  53
- Battery Recharge and Starting
  54
- Level Indicators and Enable Signals Section
  55
- Safety Switches and Level Indicator Section
  55
- Battery Recharge Circuit
  56
- Checks and Inspections
  56
- Recharge System Voltage Check
  56
- Stator Check
  56
- Lights List
  57
- Look for any Leakage
  57
- Maximum Current Output Check
  57
- Voltage Regulator/Rectifier
  57
- Fuses
  58
- Dashboard
  59
- Fuse Holder
  59
- Data Check Function
  62
- Commissioning Sealed Batteries
  63
- Sealed Battery
  63
- Dry-Charge Battery
  64
- Check the Signal
  66
- Phonic Wheel
  66
- Ecu
  67
- Receiver Control Unit for Saddle Opener
  68
- Seat Opening Receiver
  68
- Engine Rev. Sensor
  69
- Analogue Odometer
  70
- Remote Seat Opening
  70
- Battery Replacement
  71
- Programming
  71
- Zeroing
  71
- Engine from Vehicle
  73
- Exhaust Assy. Removal
  74
- Removal of the Engine from the Vehicle
  74
- Engine
  76
- Automatic Transmission
  77
- Transmission Cover
  77
- Air Duct
  78
- Transmission Cover
  78
  - Air Duct Filter
    79
  - Removing the Driven Pulley Shaft Bearing
    79
  - Transmission Cover
    79
  - Baffle Roller
    80
  - Plastic Roller
    80
  - Refitting the Driven Pulley Shaft Bearing
    80
  - Transmission Cover
    80
  - Inspecting the Clutch Drum
    81
  - Removing the Driven Pulley
    81
  - Pin Retaining Collar
    82
  - Removing the Clutch
    82
  - Removing the Driven Half-Pulley Bearing
    83
  - Inspecting the Driven Fixed Half-Pulley
    84
  - Inspecting the Driven Sliding Half-Pulley
    84
  - Refitting the Driven Half-Pulley Bearing
    84
  - Refitting the Driven Pulley
    85
  - Inspecting the Clutch Spring
    86
- Clutch Ring Nut
  87
  - Refitting the Clutch
    87
  - Drive-Belt
    88
  - Removing the Driving Pulley
    88
  - Inspecting the Rollers Case
    89
  - Installing the Roller Container
    91
  - Refitting the Driving Pulley
    91
  - Installing the Fixed Driving Half-Pulley
    92
- Driving Pulley Nut
  93
  - Refitting the Transmission Cover
    93
  - End Gear
    95
  - Removing the Hub Cover
    95
  - Removing the Wheel Axle
    95
  - Transmission Cover
    95
  - Removing the Hub Bearings
    96
  - Removing the Wheel Axle Bearings
    96
  - Transmission Cover
    97
  - Inspecting the Hub Cover
    98
  - Inspecting the Hub Shaft
    98
  - Refitting the Hub Cover Bearings
    100
  - Refitting the Hub Bearings
    101
  - Flywheel Cover
    102
  - Removing the Flywheel Cover Components
    104
  - Removing the Stator
    104
  - Inspecting the Cover Components
    107
  - Refitting the Stator
    109
  - Refitting the Flywheel Cover Components
    110
  - Refitting the Flywheel Cover
    113
  - Battery
    114
  - Flywheel and Starting
    114
  - Starter Motor
    114
  - Start-Up Remote Control Switch
    115
  - Starter Transmission
    115
  - Removing the Flywheel Magneto
    117
  - Removing the Starter Motor
    117
  - Inspecting the Flywheel Components
    121
  - Starter Gear Rim
    121
  - Intermediate Gear
    122
  - Refitting the Free Wheel
    122
  - Refitting the Intermediate Gear
    123
  - Refitting the Flywheel Magneto
    124
  - Cylinder Assy. and Timing System
    126
  - Refitting the Starter Motor
    126
  - Removing the Intake Manifold
    127
  - Removing the Rocker-Arms Cover
    127
  - Removing the Timing System Drive
    128
  - Removing the Cam Shaft
    130
  - Removing the Cylinder Head
    131
  - Removing the Valves
    132
  - Removing the Cylinder - Piston Assy.
    133
  - Inspecting the Small End
    134
  - Inspecting the Wrist Pin
    134
  - Inspecting the Piston
    135
  - Inspecting the Piston Rings
    136
  - Removing the Piston
    137
  - Choosing the Gasket
    138
  - Refitting the Cylinder
    139
  - Refitting the Piston Rings
    139
  - Inspecting the Cylinder Head
    140
  - Inspecting the Timing System Components
    140
  - Inspecting the Valve Sealings
    141
  - Inspecting the Valve Housings
    142
  - Inspecting the Valves
    142
  - Minimum Admissible Diameter
    142
  - Standard Diameter
    142
  - Inlet
    143
  - Inspecting the Valve Stem Guide Clearance
    143
  - Outlet
    143
  - Standard Valve Length
    144
  - Inspecting the Cam Shaft
    145
  - Refitting the Valves
    145
  - Admissible Limits
    146
  - Standard Height
    146
  - Refitting the Head and Timing System Components
    147
Exhaust / Intake Head Fixing Nuts
148
Coolant Temperature Sensor:
149
Camshaft Retaining Bracket Screws:
150
- Prescribed Clearance
  154
- Refitting the Timing Chain
  154
Valve Lifter Mass Stop Bell Fixing Screws
154
- Inspecting the Radial Air Gap
  156
- Refitting the Rocker-Arms Cover
  157
- Refitting the Intake Manifold
  158
Tappet Cover Fixing Screws
158
- Splitting the Crankcase Halves
  160
- Removing the Crankshaft
  161
- Removing the Countershaft
  162
- Replacing the Countershaft Bearings
  163
- Inspecting the Crankshaft Components
  165
- Inspecting the Crankshaft Alignment
  166
- Max Admissible Displacement:
  166
- Inspecting the Crankcase Halves
  167
- Check the Bench Bush
  169
- Inspecting the Crankshaft Plain Bearings
  169
- Countershaft
  170
- Coupling Chart
  170
- Coupling the Semi-Shafts with the Semi-Chassis and Bushes
  170
- Refitting the Crankshaft
  170
Gear Mounting on Crankshaft Screws
171
Bulkhead Screws for Oil Pump Housing Cover
172
- Refitting the Crankcase Halves
  172
- Lubrication
  174
- Recommended Engine Oil
  174
- Sump Capacity
  174
Head Lubrication Control Jet
175
- General Characteristics
  176
- Principle Diagram
  176
- Diagnosis Guide
  177
- Standard Values
  178
- Oil Pressure Check
  179
- Oil Pump Removal
  180
- Injection
  186
- Circuit Layout
  187
- Standard Values with the Engine Idling
  190
- EMS Injection System
  194
- Precautions
  196
- Electronic Control Unit Side
  197
- Ems Controller
  197
- Terminals Setup
  197
- EMS Circuit Diagram
  198
- Immobilizer Decoder
  198
- Engine Does Not Start
  199
- Engine Start-Up Problems
  199
- Engine Does Not Return to the Idling Speed/Idling Speed too High
  201
- Engine Does Not Rev down
  201
- Exhaust Backfires When Decelerating
  201
- Engine Revs Irregularly
  202
- Irregular Progress of the Engine with Valve Slightly Open
  202
- Poor Performance at Full Throttle
  202
- Constant Supply Circuit Check
  203
- Decoder Master-Box Circuit
  203
- Engine Knocking
  203
- Presence of Knocking (Overhead Knocking)
  203
- Key-Switch Power Supply Circuit Check
  205
- YES Go to 11
  205
- YES Go to 2 no Go to 4
  205
- YES Go to 5 no Go to 6
  206
- YES Go to 7
  206
  - Diagnostic Circuit
    208
  - Injection Warning Light Circuit
    209
- YES Go to 6 no Go to 7
  209
- YES Go to 4
  210
  - Checking Stored Failures
    211
  - Self-Diagnosis System
    211
  - Deleting Stored Failures
    212
  - Fuel Supply System
    212
  - Circuit Diagram
    213
  - Removing the Injector
    214
- Injector Fixing Screw
  215
  - Refitting the Injector
    215
  - Circuit Check
    217
  - Pump Supply Circuit
    217
  - Refitting the Butterfly Valve
    217
- YES Go to 22
  219
  - Circuit Leak Test
    221
  - Pressure Regulator Check
    222
  - Fuel Pump and Filter Check
    223
  - Pump Electrics Check
    226
  - Resistor Check
    226
  - Fuel Filter Check
    227
  - Pump Consumption Check
    227
  - Pump Bracket Overhaul
    228
  - Limit Values
    229
  - Inspecting the Injector Circuit
    232
  - Pump Bracket Installation
    232
- Injector - H.V. Coil
  233
- YES Go to 2
  233
- 020481Y Control Unit Interface Wiring
  234
- Specific Tooling
  234
- YES Go to 8
  234
- YES Point 12
  234
- YES Go to 16 no Go to 17
  235
  - Inspecting the Injector Hydraulics
    236
  - Troubleshooting
    237
  - Immobiliser Circuit
    238
  - System Components
    238
  - Virgin Circuit
    239
  - LED Signals
    241
  - Setting the Circuit
    241
  - Checking Master-Box Data
    242
  - Deterring Blink
    242
  - Resetting the Circuit
    242
  - Code 1
    243
  - Diagnostic Codes
    243
  - Code 2
    244
  - Code 3
    245
  - Code 4
    246
  - Immobiliser LED Does Not Come on
    246
  - Tachometer
    247
  - Resistance of the Rpm Timing Sensor
    250
  - HT Coil
    252
  - Spark Advance
    258
  - Coolant Temperature Sensor
    259
  - Temperature Voltage
    263
  - Intake Air Temperature Sensor
    264
  - Pressure Sensor
    270
  - Throttle Valve Opening Sensor
    270
  - Resetting the Throttle Valve Position Signal (TPS Reset)
    275
  - Zeroing the Throttle
    275
  - Step Motor
    277
  - Suspensions
    283
  - Front Wheel Hub Overhaul
    284
  - Removing the Front Wheel
    284
  - Front Fork
    286
  - Refitting the Front Wheel
    286
  - Check Pump Unit
    287
  - Check the Spring Length
    287
  - Servicing Fork Stems
    288
  - Servicing Tapered Bearing Seats
    288
  - Refitting Stems on Fork Legs
    290
  - Tube Size
    290
  - Steering Bearing
    293
  - Reassembly of Steering Tapered Bearing Seats
    294
  - Reassembly of Tapered Bearing in Steering
    295
Assembly Plate Mounting on Strut Support
295
- Refitting the Rear Wheel
  297
- Removing the Rear Wheel
  297
- Swing-Arm
  297
- Shock Absorbers
  298
- Centre-Stand
  299
- Side Stand
  300
- Rear Brake Calliper
  303
- Front Brake Calliper
  306
- Rear Brake Disc
  308
- Disc Inspection
  309
- Front Brake Disc
  310
- Front Brake Pads
  312
- Rear - Combined
  315
- Brake Pump Technical Data
  317
- Replace the Pressure Distribution Valve
  318
- Electric Fan Check
  322
- Technical Specifications
  322
- System Sealing Check
  323
- Coolant Replacement
  324
- System Top-Up Instructions
  324
- Water Pump - Overhaul
  325
- Water Pump Ceramic Seal
  326
Water Pump Cover Screws
326
- Thermostat
  327
- Excessive System Pressure
  328
- Cooling Fluid Consumption
  329
- Oil in the Fluid
  329
- Chassis
  330
- Rear Handlebar Cover
  331
- Seat
  331
- Instrument Panel
  332
- Headlight Assy.
  333
- Frame Central Cover
  334
- Legshield
  334
- Knee-Guard
  335
- Removing the Ignition Key-Switch When on *Off*
  337
- Front Wheel Housing
  338
- Taillight Assy.
  338
- Footrest
  339
- License Plate Holder
  340
- Side Fairings
  340
- Helmet Bay
  342
- Rear Mudguard
  342
- Helmet Compartment
  343
- Spoiler
  343
- Fuel Tank
  344
- Rear Central Cover
  345
- Front Mudguard
  346
- Radiator Fan
  346
- Flyscreen
  347
- Handles and Top Side Fairings
  347
- Pilot Lights Kit
  348
- Lower Cover
  349
- Pre-Delivery
  350
- Aesthetic Inspection
  351
- Safety Locks
  351
- Tightening Torques Inspection
  351
- Levels Check
  352
- Road Test
  352
- Static Test
  352
- Functional Inspection
  353
- Time
  354
- Crankcase
  356
- Crankshaft
  357
- Cylinder Assy.
  358
- Cylinder Head Assy.
  359
- Rocker Arms Support Assy
  360
- Rocking Lever Support Unit
  360
- Cylinder Head Cover
  361
- Driven Pulley
  363
  - Oil Pump
    364
  - Final Gear Assy
    365
  - Final Reduction Gear Assembly
    365
  - Driving Pulley
    366
  - Flywheel Magneto
    368
  - Butterfly Valve
    369
Throttle Body
369
- Exhaust Pipe
  370
- Air Cleaner
  371
- Frame
  372
- Side/Central Stand
  373
- Front Shield - Spoiler
  374
- Legshield Spoiler
  374
- Central Cover
  375
- Central Frame Cover
  375
- Mudguard
  376
- Handlebar Covers
  378
- Handlebar Components
  379
- Saddle
  380
- Locks
  381
- Turn Signal Lights
  382
- Front Wheel
  384
- Grease Tone Wheel or Drive
  384
- Rear Wheel
  385
- Fuel Pump
  386
- Electric Devices
  387
- Helmet Compartment
  391
- Rear Side Fairings
  392
- Front Suspension
  393
- Rear Suspension
  394
- Brake System
  396
- Windscreen
  397

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Gilera Nexus 500 User Manual

Gilera Nexus 500 User Manual (110 pages)

Brand: Gilera | Category: Scooter | Size: 1 MB

Table of Contents

Table of Contents
5
Vehicle

7
- Dashboard
  9
- Instruments
  11
- Indicator Unir
  12
- Clock
  13
- Digital Lcd Display
  14
  - Maintenance Icons
    15
  - Setting the Total and Trip Odometers
    15
  - Setting the Date Function
    16
  - MODE* Button
    16
- Key Switch
  17
  - Locking the Steering Wheel
    18
  - Releasing the Steering Wheel
    18
- Switch Direction Indicators
  18
- Horn Button
  19
- Light Switch
  19
- Emergency Flashing Light Button
  20
- Start-Up Button
  20
- Engine Stop Button
  21
- The Immobilizer System
  21
  - Keys
    22
  - Immobilizerdevice Enabled Indicator Led
    23
  - Operation
    23
  - Programming the Immobilizer System
    24
- Saddle Opening Remote Control
  25
  - Remote Control Programming
    25
- Accessing the Fuel Tank
  27
- Power Supply Socket
  28
- The Saddle
  29
  - Opening the Saddle to Access the Helmet Compartment by Remote Control
    29
- Identification
  31
- Adjusting the Windscreen
  32
Use

35
- Checks
  36
- Tyre Pressure
  37
- Shock Absorbers Adjustment
  38
- Alignment Adjustment
  39
- Anti-Overturning Sensor
  39
- Running in
  40
- Starting up the Engine
  40
  - Precautions
    42
- Difficult Start up
  43
- Stopping the Engine
  43
- Stand
  44
- Automatic Transmission
  46
- Safe Driving
  46
Maintenance

49
- Engine Oil Level
  50
- Hub Oil Level
  53
- Tyres
  55
- Spark Plug Dismantlement
  57
- Removing the Air Filter
  58
- Cooling Fluid Level
  61
- Checking the Brake Oil Level
  62
  - Braking System Fluid Top up
    63
- Battery
  64
  - Use of a New Battery
    64
  - Checking the Electrolyte Level
    65
- Long Periods of Inactivity
  66
- Fuses
  67
- Front Light Group
  72
  - Headlight Adjustment
    74
- Front Direction Indicators
  75
- Rear Turn Indicators
  75
- Number Plate Light
  76
- Helmet Compartment Lighting Bulb
  76
- Brake Light
  77
- Rear-View Mirrors
  78
- Front and Rear Disc Brake
  79
- Puncture
  80
- Periods of Inactivity
  81
- Cleaning the Vehicle
  81
Technical Data

87
- Kit Equipment
  93
Spare Parts and Accessories

95
Programmed Maintenance

97
- Scheduled Maintenance Table
  98

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