Gilera Nordwest User Manual

Name: Gilera Nordwest
Brand: Gilera
Rating: 4 (1 reviews)

136 pages

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WORKSHOP MANUAL

NORDWEST

(Nordcape in Germany)

Workshop Manual1
Table of Contents3
Index3
General Information4
Known Faults5
Long Rear Engine Bolts Can Seize5
Fork Seals Leak5
General Maintenance Tips5
Tappet Adjustment6
Gear Selection Problem6
Changing Cam Belt6
Late Amendment7
Headlight Modification (RH Drive to LH Drive)8
Chains & Sprockets8
Brake Fluid8
Nordwest Speedo Cable8
Paioli Front Forks9
Cables - Oiling9
Torque Your Head Studs10
Steering Head Races10
Nordwest Tyres10
Choke10
Greasing the Bearings11
Safety Procedures12
Maintenance Procedures12
Model Identification13
Technical Data14
Dimensions14
Engine Overhaul Data17
Piston/Cylinder Matching Chart17
Tightening Torque18
Special Tools19
- Maintenance24
- Maintenance Programme25
- Adjustments27
- Engine Oil and Filter Replacement27
- Engine Oil Check27
- Air Filter33
- Decompression System33
- Spark Plug33
- Front Brake Control35
- Rear Brake Control35
- Transmission Chain35
- Rear Suspension36
- Front Suspension36
- Engine Removal38
- Working Procedures39
- Engine Installation41
Generator - Timing Belt - Gearbox Selector42
- Disassembly43
- Inspection46
- Reassembly46
- Valve Timing46
- Torque Wrench Settings47
Cylinder Head - Valvetrain Components48
- Head53
- Valves53
- Springs53
- Rocker Arms53
Cylinder - Piston56
- Cylinder58
- Piston58
- Piston Rings60
- Gudgeon Pin60
Clutch - Primary Drive - Oil Pump62
- Drain the Oil64
- Torque Wrench Setting67
Crankcase - Gearbox - Crankshaft Components68
- Crankshaft72
- Connecting Rod72
- Gearbox72
- Frames74
- Front Wheel74
Working Procedures75
Front Wheel76
- Rim78
- Bearing Inspection78
- Spindle Straightness Inspection78
- Disconnect the Speedometer Cable78
- Wheel Installation79
- Bearings Reassembly79
- Trouble Shooting80
- Stiff Steering80
- Tends to Steer to One Side and Has Poor Handling80
- Front Wheel Oscillation80
- Suspension - Steering81
- Handlebar82
Front Suspension - Steering82
- Steering Sleeve83
- Paioli Fork85
- Oil Seal Removal and Replacement85
- Rear Suspension - Wheel87
- Motorcycle Oscillations and Vibrations88
- Suspension too Soft88
- Suspension too Stiff88
- Wheel Removal and Checks88
- Rear Absorber Shock89
- Chain Check90
- Chain, Drive and Driven Sprockets Inspection90
- Drive Chain90
- Final Drive90
- Chain Status Inspection91
- Brakes92
- Fluid Drainage93
- Brake Fluid Filling93
- Brake Pedal Is Soft or Spongy93
- Brake Pedal Is too Hard93
- Drain the Brake Fluid94
- Pistons Check95
- Pads Placement97
Battery - Charging Circuit98
- Battery Voltage99
- Battery Charging99
- Leakages Checks99
- Charge Circuit Check99
- Rectifier Check100
- Alternator Stator Coil Check101
- Troubleshooting102
- No Voltage with the Key in the “ON” Position102
- Battery Removal102
- Battery Inspection102
- Battery Reinstallation103
- Capacity Discharge Ignition System104
- Inductive Discharge Ignition System104
- Flywheel Magneto105
- C.D.I. Control Unit105
- Revolution Reductor105
- HT Coil105
- Ignition Coil Test106
- Pick-Up Coil Test106
- HT Coil Test107
- CDI Control Unit Test107
- Revolution Reduction Test107
- Ignition Coil Faulty108
- Lack of Spark to Spark Plug108
- Ignition Not Turned on108
- The Engine Start to Run but Not Regularly108
Electric Starter112
- Starter Motor113
- Casing Insulation Check113
- Starter Motor Doesn’t Turn113
- Starter Motor Turns Engine Slowly113
- Electric Starter113
Switches - Horn - Lights115
- Turn Signal Indicators116
- Instruments116
- Tail Lamp116
- Headlamp116
- Temperature Indicator118
- Oil Pressure Sensor118
- Reserve Fuel Indicator118
- Thermoswitch118
- Brake Light Switches119
- Horn119
- All Lights Are on but Are Weak119
- Troubleshooting120
- Engine Doesn’t Start or Starts with Difficulty121
- Poor Performance122
- Poor Road Handling124
Electrical System125
- Nordwest / Rc600 ‘91126
- Nordwest 600 / 93128
- Nordwest Inductive Discharge Ignition System130
Additional Information132
- Capacitive Discharge133
- Inductive Discharge133

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Gilera Nordwest Specifications

General

Manufacturer	Gilera
Cooling System	Liquid cooled
Fuel System	Carburetor
Ignition	Electronic
Transmission	5-speed
Front Suspension	Telescopic fork
Engine Type	Single cylinder
Rear Suspension	Mono shock

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