🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Year:

2005

Vehicle Type:

Motorcycle

Engine Code Identifier:

M381

Chassis Code Identifier:

ZTP

👋 Introduction

Positioning:

The Gilera Nexus 500 was positioned as a premium maxi-scooter, offering a blend of performance, comfort, and touring capability, often competing with models from Yamaha, Suzuki, and Honda in its segment.

Competitors:

Key competitors included the Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 600, and Aprilia Atlantic 500.

Vehicle Features:

The Nexus 500 was known for its powerful 493cc engine, comfortable seating, under-seat storage, and sporty chassis design, making it suitable for both urban commuting and longer-distance touring.

Purpose:

To provide owners and technicians with the necessary information to maintain, diagnose, and repair the 2005 Gilera Nexus 500 motorcycle, ensuring optimal performance and longevity.

📋 Manual Details

Primary Coverage:

Comprehensive repair and service for the 2005 Gilera Nexus 500 motorcycle.

Secondary Coverage:

Troubleshooting, maintenance, electrical system diagnostics, engine repair, suspension, braking, and chassis.

Total Pages:

406

Type:

Service Repair Manual

Classification:

Factory Service Manual (FSM) equivalent

Primary Language:

English

File Format:

PDF

Delivery Method:

Instant Digital Download

📖 Manual Coverage

Powertrain:

Engine (disassembly, assembly, diagnostics), Injection system (fuel delivery, EFI components, ECU mapping), Cooling system (radiator, hoses, thermostat, coolant), Exhaust system.

Chassis And Suspension:

Front forks (disassembly, seal replacement, oil levels), Rear shock absorber, Swingarm, Frame, Bearings (steering head, wheel).

Braking:

Front and rear brake systems, hydraulic lines, brake fluid specifications, caliper maintenance, rotor inspection, ABS (if equipped).

Electrical System:

Wiring diagrams, component identification, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition system, ECU diagnostics, sensor testing.

Bodywork And Controls:

Fairings, seat removal, handlebar controls, levers, pedals, instrumentation, storage compartments.

Maintenance:

Routine checks, oil changes, filter replacements (oil, air, fuel), spark plug service, chain adjustment, brake fluid flush, coolant service, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common performance issues, starting problems, electrical faults, braking anomalies, and handling concerns. Includes symptom-based troubleshooting guides.

Repair:

Step-by-step instructions for major component repairs and overhauls, including engine rebuilds, transmission servicing, suspension component replacement, and electrical system repairs.

Diagnostics:

Guidance on using diagnostic tools (if applicable), interpreting error codes, and performing electrical tests on sensors and actuators.

Depth:

Comprehensive, covering basic user maintenance to advanced engine and electrical system diagnostics and repair.

Detail Level:

Highly detailed with visual aids and step-by-step instructions.

📊 Manual Specifications

PDF Quality:

High-resolution, ensuring clarity of text and diagrams.

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Printability:

All pages are printable, allowing for physical reference.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Operating Systems:

Windows and macOS

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, DOHC

Displacement:

492.8 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1

Valve Train:

DOHC, 4 valves

Horsepower:

Approximately 33.3 HP (24.8 kW) @ 7,000 RPM (specification may vary slightly by region)

Torque:

Approximately 43 Nm (31.7 lb-ft) @ 5,500 RPM (specification may vary slightly by region)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Throttle Body Size:

Approximately 42 mm

Oil Type:

API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended (check manual for specific grade)

Oil Capacity With Filter:

Approximately 1.7 Liters

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Drive Type:

Belt drive

Clutch:

Automatic centrifugal clutch

Cvt Fluid Type:

Specific CVT fluid (consult manual for exact specification, typically SAE 75W-80 or similar for gearbox, not engine oil)

📐 Dimensions

Length:

Approximately 2170 mm

Width:

Approximately 790 mm

Height:

Approximately 1390 mm

Wheelbase:

Approximately 1535 mm

Dry Weight:

Approximately 184 kg

Wet Weight:

Approximately 195 kg (with fluids)

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Alloy

Fuel Tank Capacity:

15 Liters

🛡️ Safety Features

Braking System:

Hydraulic disc brakes front and rear. Front: Dual discs (260 mm). Rear: Single disc (260 mm). ABS may have been an optional feature on some models.

Lighting:

Halogen headlights, LED taillight, turn signals.

Chassis Design:

Steel frame with high-tensile strength, contributing to stability.

Ergonomics:

Comfortable riding position, hand guards (optional/standard depending on market) for rider protection.

💡 Technology Features

Instrument Panel:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, and warning lights.

ABS Availability:

Optional Anti-lock Braking System (ABS) may have been available on some 2005 models, enhancing braking safety.

Diagnostic Ports:

Likely includes a diagnostic connector for connecting electronic diagnostic tools for fault code retrieval and system analysis.

ECU System:

Electronic Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions.

🔧 Maintenance

Engine Oil Change:

Every 6,000 km or annually, whichever comes first. (Consult manual for precise interval).

Oil Filter Replacement:

At every engine oil change.

Air Filter Inspection Cleaning:

Every 6,000 km, clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km (check specific plug type and gap in manual).

Brake Fluid Flush:

Every 24,000 km or every 2 years.

Coolant Flush:

Every 24,000 km or every 2 years.

Engine Oil Viscosity:

SAE 10W-40 (recommended, verify with manual)

Coolant Type:

Ethylene glycol-based antifreeze (50% mix with distilled water)

Brake Fluid Type:

DOT 4

Common Wear Items:

CVT belt wear, wheel bearings, brake pads, fork seals, stator output over time.

Electrical Gremlins:

Potential for intermittent electrical issues due to wiring harness wear or connector corrosion, especially with age. Stator failure can lead to charging problems.

Suspension Wear:

Front fork seals can leak, and the rear shock absorber may lose damping effectiveness over time, impacting ride quality.

📚 Vehicle History

Brand Origin:

Gilera is an Italian manufacturer of motorcycles, founded in 1909. It has a rich history in racing and scooter production.

Nexus Lineage:

The Nexus 500 was part of Gilera's successful line of maxi-scooters, designed to blend motorcycle performance with scooter practicality. It was a significant model for Gilera in the large-displacement scooter market.

Manufacturing Location:

Produced in Italy.

Model Years Produced:

The Nexus 500 was produced from approximately 2003 through the late 2000s, with updates and variations.

🏆 Awards & Recognition

Market Reception:

Generally well-received for its performance and comfort, particularly in European markets, as a capable maxi-scooter.

Reliability:

Reliability is generally good when properly maintained, with common issues related to wear items and electrical components as typical for a vehicle of this era.