Gilera Nexus 300 and 500 - Service Repair Manual - Wiring Diagrams - Owners

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GILERA NEXUS 500-300 - WORKSHOP MANUAL - OWNERS MANUAL

- English Service Repair Manual, Wiring Diagrams and Owners Manual for motorcycles Gilera Nexus 300 and 500.


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

AND MORE...


GILERA NEXUS 300 - WIRING DIAGRAM

- Italian/English
- French/German
- Spanish/Portuguese


GILERA NEXUS 300 - OWNERS MANUAL