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Table Of Contents

Maintenance rules
Vehicle identification
Dimensions and mass
Frame and suspensions
Wheels and tyres
Tightening Torques
Overhaul data
Assembly clearances
Cylinder - piston assy
Crankcase - crankshaft - connecting rod
Slot packing system
Maintenance chart
Spark plug
Air filter
Engine oil
Engine oil filter
Oil pressure warning light
Checking the valve clearance
Cooling system
Level check
Braking system
Headlight adjustment
Checking the end compression pressure
Components arrangement
Conceptual diagrams
Battery recharge and starting
Lights and turn indicators
Checks and inspections
Battery recharge circuit
Stator check
Recharge system voltage check
Turn signals system check
Lights list
Data check function
Sealed battery
Dry-charge battery
Phonic wheel
Seat opening receiver
Engine rev. sensor
Analogue odometer
Remote seat opening
Battery replacement
Exhaust assy. Removal
Removal of the engine from the vehicle
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
Removing the driving pulley
Inspecting the rollers case
Refitting the driving pulley
Refitting the transmission cover
End gear
Removing the wheel axle
Removing the hub bearings
Removing the wheel axle bearings
Inspecting the hub shaft
Inspecting the hub cover
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
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
Refitting the crankshaft
Refitting the crankcase halves
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
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 hydraulics
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
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
Removing the front wheel
Front wheel hub overhaul
Refitting the front wheel
Front fork
Shock absorbers
Side stand
Rear brake calliper
Front brake calliper
Rear brake disc
Disc Inspection
Front brake disc
Rear brake pump - combined
Electric fan check
System sealing check
Coolant replacement
Water pump - overhaul
Excessive system pressure
Cooling fluid consumption
Oil in the fluid
Rear handlebar cover
Instrument panel
Headlight assy
Frame central cover
Removing the ignition key-switch when on *off*
Front wheel housing
Taillight assy
Side fairings
License plate holder
Rear mudguard
Helmet bay
Fuel tank
Rear central cover
Front mudguard
Radiator fan
Pilot lights kit
Lower cover
Aesthetic inspection
Tightening torques inspection
Electrical system
Levels check
Road test
Static test
Functional inspection
Cylinder assy
Cylinder head assy
Rocker arms support assy
Cylinder head cover
Driven pulley
Final gear assy
Driving pulley
Flywheel magneto
Butterfly valve
Exhaust pipe
Air cleaner
Legshield spoiler
Central cover
Handlebar covers
Handlebar components
Turn signal lights
Front wheel
Rear wheel
Fuel pump
Electric devices
Rear side fairings
Front suspension
Rear suspension
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Gilera Nexus 500SP Mk2 Workshop Manual

Gilera Nexus 500SP Mk2 Workshop Manual



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Published by jusani

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Published by: jusani on Dec 29, 2008
Copyright:Attribution Non-commercial


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