Gilera Nexus 500 - Workshop Manual

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WORKSHOP MANUAL

633309

Nexus 500

Main Page

Index of Topics5
Characteristics7
Safety Rules8
Maintenance Rules8
Vehicle Identification9
Dimensions and Mass9
Weight9
Engine9
Transmissions10
Capacity10
Electrical System10
Brakes11
Chassis and Suspensions11
Frame and Suspensions11
Wheels and Tyres12
Tightening Torques12
Front Suspension13
Rear Suspension13
Engine Assembly13
Thermal Unit and Timing System13
Crankcase and Crankshaft14
Final Reduction14
Transmission Cover14
Flywheel Cover14
Cylinder - Piston Assy15
Overhaul Data15
Assembly Clearances15
Lubrication15
Piston Rings16
Crankcase - Crankshaft - Connecting Rod16
Categories of Coupling16
Sealing Rings16
Crankshaft17
Max. Admissible Displacement17
Axial Clearance between Crankshaft and Connecting Rod18
Slot Packing System19
Base Gasket Thickness19
Products19
Tooling21
Tools22
Maintenance33
Maintenance Chart34
Every 2 Years34
Every 3,000 Km34
After 1,000 Km or 4 Months34
After 6,000 Km or 12 Months35
After 12,000 Km or 24 Months and 60,000 Km35
After 18,000 Km and after 54,000 Km35
After 24,000 Km36
After 30,000 Km, 42,000 Km and 66,000 Km36
After 36,000 Km37
After 48,000 Km37
After 72,000 Km38
Spark Plug39
Check and Replacement39
Hub Oil39
Air Filter41
Engine Oil42
Engine Oil Filter43
Oil Pressure Warning Light45
Checking the Valve Clearance45
Warning Light (Low Oil Pressure)45
Cooling System45
Level Check46
Braking System47
Top-Up47
Headlight Adjustment48
Checking the End Compression Pressure49
Wiring Colour Chart53
Components Arrangement54
Diagnostic Socket54
Overturn Sensor54
H.V. Coil54
Electronic Control Unit ECU55
Immobiliser Decoder55
Relays and Diode Group56
Voltage Regulator56
Ignition57
Headlights and Automatic Starter Section58
Light and Flashing Light Bulbs Section59
Battery Recharge and Starting60
Level Indicators and Enable Signals Section61
Safety Switches and Level Indicator Section61
Checks and Inspections62
Battery Recharge Circuit62
Stator Check62
Stator Winding Check-Up62
Lights List63
Look for any Leakage63
Maximum Current Output Check63
Voltage Regulator/Rectifier63
Fuses64
Dashboard66
Data Check Function68
Sealed Battery69
Dry-Charge Battery70
Checking the Electrolyte Level71
Charging Status Check71
Specific Tooling71
Phonic Wheel72
Connectors73
Ecu73
Seat Opening Receiver74
Engine Rev. Sensor75
Analogue Odometer77
Remote Seat Opening77
Battery Replacement77
Zeroing78
Programming78
Engine from Vehicle79
Removal of the Engine from the Vehicle80
Removal of Engine81
Automatic Transmission84
Air Duct85
Air Duct Filter86
Removing the Driven Pulley Shaft Bearing86
Refitting the Driven Pulley Shaft Bearing87
Baffle Roller87
Plastic Roller87
Removing the Driven Pulley88
Inspecting the Clutch Drum88
Removing the Clutch89
Pin Retaining Collar89
Removing the Driven Half-Pulley Bearing90
Refitting the Driven Half-Pulley Bearing91
Inspecting the Driven Sliding Half-Pulley91
Inspecting the Driven Fixed Half-Pulley91
Refitting the Driven Pulley92
Inspecting the Clutch Spring93
Refitting the Clutch94
Bell Assembly94
Removing the Driving Pulley95
Inspecting the Rollers Case96
Refitting the Driving Pulley97
Installing the Roller Container97
Installing the Fixed Driving Half-Pulley98
Refitting the Transmission Cover100
Removing the Hub Cover101
End Gear101
Removing the Wheel Axle102
Removing the Hub Bearings102
Removing the Wheel Axle Bearings103
Inspecting the Hub Shaft104
Inspecting the Hub Cover105
Refitting the Hub Cover Bearings107
Refitting the Hub Bearings108
Refitting the Ub Cover108
Removing the Flywheel Cover Components110
Removing the Stator111
Inspecting the Cover Components114
Refitting the Stator116
Refitting the Flywheel Cover Components117
Refitting the Flywheel Cover119
Flywheel and Starting121
Starter Motor121
Battery121
Start-Up Remote Control Switch121
Removing the Starter Motor124
Removing the Flywheel Magneto124
Inspecting the Flywheel Components128
Starter Gear Rim128
Intermediate Gear129
Loctite 243 Medium-Strength Threadlock130
Refitting the Intermediate Gear130
Refitting the Flywheel Magneto131
Refitting the Starter Motor133
Cylinder Assy. and Timing System133
Removing the Intake Manifold134
Removing the Rocker-Arms Cover134
Removing the Timing System Drive134
Removing the Cam Shaft137
Removing the Cylinder Head137
Removing the Valves139
Removing the Cylinder - Piston Assy.140
Inspecting the Wrist Pin141
Inspecting the Small End141
Inspecting the Piston142
Inspecting the Piston Rings143
Fitting Clearance (Cylindrin/Pison)143
Removing the Piston144
Choosing the Gasket145
Refitting the Piston Rings146
Refitting the Cylinder146
Inspecting the Cylinder Head147
Inspecting the Timing System Components147
Standard Diameter147
Inspecting the Valve Sealings148
Minimum Admissible Diameter149
Inspecting the Valve Housings149
Inspecting the Valves149
Inspecting the Valve Stem Guide Clearance150
Inlet150
Outlet150
Standard Valve Length151
Inspecting the Springs and Half-Cones151
Refitting the Valves152
Inspecting the Cam Shaft152
Standard Height153
Admissible Limits153
Refitting the Head and Timing System Components155
Prescribed Clearance161
Refitting the Timing Chain161
Inspecting the Radial Air Gap163
Refitting the Rocker-Arms Cover164
Refitting the Intake Manifold165
Crankcase - Crankshaft166
Splitting the Crankcase Halves167
Removing the Crankshaft168
Removing the Countershaft169
Replacing the Countershaft Bearings170
Inspecting the Crankshaft Components172
Max Admissible Displacement173
Inspecting the Crankcase Halves174
Inspecting the Crankshaft Plain Bearings176
Check the Bench Bush176
Refitting the Crankshaft177
Coupling Chart177
Countershaft177
Refitting the Crankcase Halves179
Technical Specifications181
Sump Capacity181
Recommended Engine Oil181
Oil Pump182
By-Pass182
Pre-Filter182
Oil Filter182
General Characteristics183
Principle Diagram183
Conceptual Diagrams183
Diagnosis Guide184
Standard Values185
Oil Pressure Check186
Oil Pump187
Circuit Layout194
Standard Values with the Engine Idling197
EMS Injection System201
Precautions203
Terminals Setup204
Electronic Control Unit Side204
System Side204
Immobilizer Decoder205
EMS Circuit Diagram206
Troubleshooting Procedure207
Engine Does Not Start207
Starting Difficulties207
Engine Start-Up Problems207
Engine Stops at Idle208
Engine Does Not Rev down208
Exhaust Backfires in Deceleration209
Engine Revs Irregularly209
Poor Performance at Full Throttle210
Constant Supply Circuit Check211
Engine Knocking211
Decoder Master-Box Circuit211
Presence of Knocking (Overhead Knocking)211
Table of Contents212
Key-Switch Power Supply Circuit Check213
YES Go to 2 no Go to 4213
YES Go to 11213
YES Go to 5 no Go to 6214
YES Go to 7214
- Diagnostic Circuit216
- Injection Warning Light Circuit217
YES Go to 6 no Go to 7217
YES Go to 4218
- Checking Stored Failures219
- Self-Diagnosis System219
- Fuel Supply System221
- Circuit Diagram222
- Removing the Injector222
- Refitting the Injector223
- Pump Supply Circuit225
- Refitting the Butterfly Valve225
- Circuit Check226
- Circuit Leak Test229
- Pressure Regulator Check230
- 020460Y Scooter Diagnosis and Tester231
- Fuel Pump and Filter Check231
- Specific Tooling231
- YES Go to 2231
- YES Go to 4 no Go to 5231
- YES Go to 2232
  - Pump Electrics Check234
  - Resistor Check234
  - Fuel Filter Check235
  - Pump Consumption Check235
  - Pump Bracket Overhaul236
  - Limit Values237
  - Pump Bracket Installation240
- Injector - H.V. Coil241
- Inspecting the Injector Circuit241
- YES Go to 2241
- YES Go to 3242
- YES Point 12242
- Inspecting the Injector Hydraulics244
- Troubleshooting245
- Suggestion for Troubleshooting246
- Immobiliser Circuit246
- System Components247
- Virgin Circuit248
- Setting the Circuit249
- LED Signals250
- Deterring Blink250
- Checking Master-Box Data251
- Resetting the Circuit251
- Replacing the Small Cylinder251
- Decoder Replacement251
- HT Coil261
- Circuit Diagram261
- Inspecting the Spark Plug Shielded Cap266
- Spark Advance266
- Coolant Temperature Sensor268
- Temperature Voltage272
- Intake Air Temperature Sensor273
- Throttle Valve Opening Sensor279
- Connect the Diagnostic Tester284
- Step Motor286
- Suspensions293
- Removing the Front Wheel294
- Front Wheel Hub Overhaul294
- Refitting the Front Wheel296
- Front Fork296
- Servicing Fork Stems298
- Servicing Tapered Bearing Seats298
- Check Pump Unit298
- Installing Stems on Fork Legs300
- Tube Size301
- Steering Bearing303
- Reassembly of Tapered Bearing in Steering305
- Removing the Rear Wheel307
- Swing-Arm308
- Shock Absorbers309
- Centre-Stand309
- Side Stand310
- Specifications312
- Rear Brake Calliper313
- Front Brake Calliper316
- Rear Brake Disc318
- Disc Inspection319
- Front Brake Disc320
- Front Brake Pads321
- Rear Brake Pads323
- Rear - Combined324
- Brake Pump Technical Data326
- Coolant Replacement333
- Water Pump - Overhaul334
- Water Pump Ceramic Seal335
- Thermostat336
- Excessive System Pressure337
- Oil in the Fluid338
- Cooling Fluid Consumption338
- Chassis339
- Seat340
- Rear Handlebar Cover340
- Instrument Panel341
- Headlight Assy.342
- Frame Central Cover343
- Legshield343
- Knee-Guard344
- Removing the Ignition Key-Switch When on *Off*346
- Front Wheel Housing347
- Taillight Assy.347
- Footrest348
- Side Fairings349
- License Plate Holder349
- Rear Mudguard351
- Helmet Bay351
- Spoiler352
- Fuel Tank353
- Rear Central Cover354
- Front Mudguard355
- Radiator Fan355
- Handles and Top Side Fairings356
- Flyscreen356
- Pilot Lights Kit357
- Lower Cover358
- Pre-Delivery359
- Aesthetic Inspection360
- Tightening Torques Inspection360
- Levels Check361
- Road Test361
- Static Test361
- Functional Inspection362
- Time363
- Crankcase365
- Cylinder Assy.367
- Cylinder Head Assy.368
- Rocker Arms Support Assy.369
- Cylinder Head Cover370
- Driven Pulley372
- Final Gear Assy.374
- Driving Pulley375
- Transmission Cover376
- Flywheel Magneto377
- Butterfly Valve378
- Exhaust Pipe379
- Air Cleaner380
- Legshield Spoiler383
- Central Cover384
- Mudguard385
- Handlebar Covers387
- Handlebar Components388
- Locks390
- Turn Signal Lights391
- Front Wheel393
- Rear Wheel394
- Fuel Pump395
- Electric Devices396
- Front Suspension402
- Rear Suspension403
- Cooling System404
- Windscreen406

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