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Gilera Nexus 300 ie Service Repair Workshop Manual 2008 Onwards

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 300 ie Model Variant: All models Model Year Start: 2008 Model Year End: Current (as of product information) 👋 Introduction Market Position Product Segment: Performance Scooter / Maxi-scooter Target Audience: Owners, independent repair shops, technical enthusiasts. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman, Kymco Xciting, Honda Forza (depending on exact market and year). Key Features Vehicle Appeal: Sporty handling, powerful engine for its class, comfortable for commuting and longer rides. Manual Value Proposition: Provides technicians and owners with the authoritative information required for accurate and efficient maintenance and repair, directly comparable to factory service documentation. 📋 Manual Details Coverage Areas Coverage Scope: All repairs A-Z Coverage Type: Vehicle-specific Professional Equivalence: Same type used by dealership technicians Page Count Page Count Estimate: Estimated 300-500 pages (typical for comprehensive service manuals) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (presumed based on product description and market) Format Format: PDF Download Download Speed: Instant 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, diagnostics, lubrication system, cooling system, fuel system (injection), ignition system, emission control systems. Fuel And Emission Control: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), ECU mapping, evaporative emission control (EVAP), secondary air injection. Ignition And Electrical: Ignition coil, spark plugs, starter motor, charging system (alternator/stator, rectifier/regulator), battery, lighting system (headlights, taillights, indicators), wiring diagrams, fuse box, relays, sensors (crankshaft position, camshaft position, lambda). Transmission And Drivetrain: Automatic transmission (CVT operation, variator, clutch, belt drive, reduction gear), torque converter, final drive assembly, oil specifications and change intervals. Chassis And Suspension: Front fork (telescopic, oil type, seals, assembly), rear shock absorber (monoshock, preload adjustment, damping), swingarm, bearings, steering head assembly. Braking System: Front and rear hydraulic disc brakes, brake calipers (piston size, seal replacement), brake master cylinders, brake lines, brake fluid type and bleeding procedures, parking brake mechanism. Wheels And Tires: Wheel bearing replacement, tire pressure recommendations, tire size specifications, rim types. Bodywork And Trim: Fairing removal and installation, seat removal, panel fasteners, lighting unit replacement, instrument cluster diagnostics. Cooling System: Radiator, coolant type and capacity, water pump, thermostat, cooling fan operation. Exhaust System: Catalytic converter function, exhaust manifold, muffler inspection and replacement. Steering And Handlebars: Handlebar removal/installation, throttle cable adjustment, brake lever replacement, steering bearing lubrication. Manual Coverage Procedures Included: Scheduled maintenance, routine servicing, troubleshooting guides, diagnostic procedures, repair and replacement of all components, disassembly and reassembly instructions. Procedures Included Troubleshooting: Systematic troubleshooting for common and uncommon issues, fault codes (if applicable), diagnostic flowcharts. Maintenance Schedule: Detailed maintenance intervals for all service points (e.g., oil changes, filter replacements, belt inspection). Torque Specifications: Crucial torque values for critical fasteners (e.g., engine bolts, suspension components, brake caliper bolts). Special Tools: Identification and usage of any specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive, from basic fluid changes to complete engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic information, including electrical system tracing and sensor testing. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text-based PDF for efficient information retrieval. Print Quality Print Quality Recommendation: High-resolution for clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 278 cc (approximately) Bore X Stroke: Not explicitly stated in product info, but typical for this class is around 75mm x 63mm. Valve Train: SOHC, 4 valves per cylinder Compression Ratio: Typically around 11.0:1 to 12.5:1 Performance Horsepower: Approximately 22-24 HP (at crankshaft) Torque: Approximately 23-25 Nm (at crankshaft) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating typically 91 RON or higher) Lubrication Oil Type: Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 5W-40 API SG or higher JASO MA/MA2 certified. Oil Capacity: Approximately 1.1 - 1.3 liters (including filter, refer to manual for precise figure) Cooling System Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with Dry Clutch Optional Optional Transmission: N/A Features Gear Reduction: Planetary gear reduction for final drive Transmission Fluid: Not applicable; the dry clutch system and reduction gears use engine oil. 📐 Dimensions Exterior Length: Approx. 2,150 mm (typical for this class) Width: Approx. 780 mm Height: Approx. 1,430 mm (seat height around 800 mm) Weights Dry Weight: Approx. 170-180 kg Curb Weight: Approx. 185-195 kg (with fluids) Max Load Capacity: Approx. 180-200 kg (rider and passenger) Cargo Underseat Storage: Sufficient for one full-face helmet and small items. 🛡️ Safety Features Ratings Safety Ratings: No formal crash test ratings for scooters typically available in the same way as cars. Focus is on design and component safety. Active Features Braking System: Dual 260mm front discs with 4-piston...
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Gilera Nexus 300 ie Service Repair Workshop Manual 2008 Onwards
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 300 ie
Model Variant:
All models
Model Year Start:
2008
Model Year End:
Current (as of product information)
👋 Introduction
Market Position
Product Segment:
Performance Scooter / Maxi-scooter
Target Audience:
Owners, independent repair shops, technical enthusiasts.
Competitive Analysis
Key Competitors:
Yamaha TMAX, Suzuki Burgman, Kymco Xciting, Honda Forza (depending on exact market and year).
Key Features
Vehicle Appeal:
Sporty handling, powerful engine for its class, comfortable for commuting and longer rides.
Manual Value Proposition:
Provides technicians and owners with the authoritative information required for accurate and efficient maintenance and repair, directly comparable to factory service documentation.
📋 Manual Details
Coverage Areas
Coverage Scope:
All repairs A-Z
Coverage Type:
Vehicle-specific
Professional Equivalence:
Same type used by dealership technicians
Page Count
Page Count Estimate:
Estimated 300-500 pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English (presumed based on product description and market)
Format
Format:
PDF Download
Download Speed:
Instant
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, disassembly, assembly, diagnostics, lubrication system, cooling system, fuel system (injection), ignition system, emission control systems.
Fuel And Emission Control:
Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), ECU mapping, evaporative emission control (EVAP), secondary air injection.
Ignition And Electrical:
Ignition coil, spark plugs, starter motor, charging system (alternator/stator, rectifier/regulator), battery, lighting system (headlights, taillights, indicators), wiring diagrams, fuse box, relays, sensors (crankshaft position, camshaft position, lambda).
Transmission And Drivetrain:
Automatic transmission (CVT operation, variator, clutch, belt drive, reduction gear), torque converter, final drive assembly, oil specifications and change intervals.
Chassis And Suspension:
Front fork (telescopic, oil type, seals, assembly), rear shock absorber (monoshock, preload adjustment, damping), swingarm, bearings, steering head assembly.
Braking System:
Front and rear hydraulic disc brakes, brake calipers (piston size, seal replacement), brake master cylinders, brake lines, brake fluid type and bleeding procedures, parking brake mechanism.
Wheels And Tires:
Wheel bearing replacement, tire pressure recommendations, tire size specifications, rim types.
Bodywork And Trim:
Fairing removal and installation, seat removal, panel fasteners, lighting unit replacement, instrument cluster diagnostics.
Cooling System:
Radiator, coolant type and capacity, water pump, thermostat, cooling fan operation.
Exhaust System:
Catalytic converter function, exhaust manifold, muffler inspection and replacement.
Steering And Handlebars:
Handlebar removal/installation, throttle cable adjustment, brake lever replacement, steering bearing lubrication.
Manual Coverage
Procedures Included:
Scheduled maintenance, routine servicing, troubleshooting guides, diagnostic procedures, repair and replacement of all components, disassembly and reassembly instructions.
Procedures Included
Troubleshooting:
Systematic troubleshooting for common and uncommon issues, fault codes (if applicable), diagnostic flowcharts.
Maintenance Schedule:
Detailed maintenance intervals for all service points (e.g., oil changes, filter replacements, belt inspection).
Torque Specifications:
Crucial torque values for critical fasteners (e.g., engine bolts, suspension components, brake caliper bolts).
Special Tools:
Identification and usage of any specialized tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive, from basic fluid changes to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic information, including electrical system tracing and sensor testing.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text-based PDF for efficient information retrieval.
Print Quality
Print Quality Recommendation:
High-resolution for clear diagrams and text.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
278 cc (approximately)
Bore X Stroke:
Not explicitly stated in product info, but typical for this class is around 75mm x 63mm.
Valve Train:
SOHC, 4 valves per cylinder
Compression Ratio:
Typically around 11.0:1 to 12.5:1
Performance
Horsepower:
Approximately 22-24 HP (at crankshaft)
Torque:
Approximately 23-25 Nm (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 RON or higher)
Lubrication
Oil Type:
Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 5W-40 API SG or higher JASO MA/MA2 certified.
Oil Capacity:
Approximately 1.1 - 1.3 liters (including filter, refer to manual for precise figure)
Cooling System
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
🔧 Transmission
Standard
Transmission Type:
Automatic Continuously Variable Transmission (CVT) with Dry Clutch
Optional
Optional Transmission:
N/A
Features
Gear Reduction:
Planetary gear reduction for final drive
Transmission Fluid:
Not applicable; the dry clutch system and reduction gears use engine oil.
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm (typical for this class)
Width:
Approx. 780 mm
Height:
Approx. 1,430 mm (seat height around 800 mm)
Weights
Dry Weight:
Approx. 170-180 kg
Curb Weight:
Approx. 185-195 kg (with fluids)
Max Load Capacity:
Approx. 180-200 kg (rider and passenger)
Cargo
Underseat Storage:
Sufficient for one full-face helmet and small items.
🛡️ Safety Features
Ratings
Safety Ratings:
No formal crash test ratings for scooters typically available in the same way as cars. Focus is on design and component safety.
Active Features
Braking System:
Dual 260mm front discs with 4-piston calipers, 240mm rear disc with 2-piston caliper. Optional ABS (Anti-lock Braking System) availability may exist on some models/markets.
Lighting:
Dual Halogen or Projector Headlights, LED taillight and brake light, front and rear turn signals.
Suspension Stability:
Designed for stable handling at higher speeds due to chassis geometry and suspension tuning.
Passive Features
Frame Construction:
Steel underbone frame for rigidity.
Instrumentation:
Multi-function LCD display with speed, RPM, fuel level, odometer, trip meter, and warning lights.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital LCD display with analog tachometer, offering comprehensive vehicle status information.
Driver Assistance
ABS Availability:
Optional ABS available on some configurations, significantly enhancing braking safety.
Connectivity
Connectivity Features:
None specified; focus is on core mechanical and electrical systems.
Engine Management
ECU System:
Advanced electronic fuel injection (EFI) system for precise fuel delivery, emissions control, and performance optimization.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-6,000 km or annually, whichever comes first.
Air Filter Cleaning Replacement:
Inspect every 5,000 km, clean/replace as needed. Replacement recommended every 10,000-15,000 km.
Spark Plug Replacement:
Every 10,000-12,000 km. Use specified plug type.
Cv Belt Inspection Replacement:
Inspect every 10,000 km, replace every 20,000-25,000 km (or sooner if signs of wear are present).
Brake Fluid Replacement:
Every 2 years or 20,000 km, regardless of mileage.
Coolant Replacement:
Every 3-4 years or 30,000-40,000 km.
Fluid Specifications
Engine Oil Specification:
SAE 10W-40 or 5W-40, API SG or higher, JASO MA/MA2 certified.
Brake Fluid Specification:
DOT 4 (high-performance synthetic brake fluid)
Coolant Specification:
Ethylene glycol based, 50% distilled water mixture.
Known Issues
Common Wear Items:
CV belt, rear shock absorber bushings, wheel bearings, brake pads.
Potential Electrical Issues:
Occasional issues with stator or voltage regulator on higher mileage units, wiring harness integrity.
Engine Performance:
Some owners report minor power fluctuations if ignition coils or fuel injectors are not perfectly clean.
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera is an Italian motorcycle manufacturer with a long history, known for its performance-oriented scooters and motorcycles. It is part of the Piaggio Group.
Model Evolution
Nexus Lineage:
The Nexus line represents Gilera's flagship sport-scooter offering, emphasizing performance and handling. It evolved from earlier models like the Gilera Runner.
Production
Manufacturing Location:
Primarily Italy (Piaggio Group facilities)
🏆 Awards & Recognition
Recognitions
Awards And Recognition:
No specific awards mentioned in product information; Gilera Nexus generally recognized within the performance scooter segment for its dynamic capabilities.
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