Gilera Nexus 500 2005 Motorcycle Repair Manual

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Art.-Nr: 88170

Stichworte: 2005 Gilera Motorcycle Nexus 500

Produktvarianten

Beschreibung

The Gilera Nexus 500, a premium maxi-scooter from 2005, combines potent performance with sophisticated design for urban commuting and extended touring. Featuring a robust 460cc liquid-cooled engine, comfortable ergonomics, and an aerodynamic fairing, the Nexus 500 offers a dynamic riding experience. Its engineering quality is evident in its sporty handling and the blend of power and practicality, making it a distinguished choice in its class. This comprehensive repair manual provides detailed guidance for the Gilera Nexus 500. It covers essential maintenance procedures, troubleshooting common issues, and in-depth technical specifications for all major systems, including the engine, fuel system, transmission, chassis, and electrical components. The manual is designed to assist owners, mechanics, and technicians in maintaining the optimal performance and longevity of the vehicle through clear instructions and diagnostic information.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Year:

Vehicle Type:

Maxi-scooter

👋 Introduction

Market Position

Market Position:

The Gilera Nexus 500 was positioned as a premium maxi-scooter, offering a blend of performance, comfort, and advanced features for commuting and touring. It competed with other high-displacement scooters from brands like Yamaha (TMAX) and Suzuki (Burgman).

Key Features

Key Features:

Powerful 460cc liquid-cooled engine, comfortable ergonomics, aerodynamic fairing, under-seat storage, advanced braking systems, often featuring ABS in higher specifications.

📋 Manual Details

Coverage

Manual Type:

Repair Manual

Pages

Page Count:

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission (CVT), Clutch, Chassis, Suspension (Front & Rear), Braking System (Front & Rear, ABS if equipped), Electrical System, Lighting, Instrumentation, Bodywork, Body Panels, Storage, Maintenance Procedures, Troubleshooting, Diagnostic Procedures

Procedures

Procedures Included:

Routine Maintenance, Scheduled Servicing, Troubleshooting Faults, Component Disassembly & Reassembly, Engine Tuning & Adjustment, Electrical Diagnostics, Brake System Overhaul, Suspension Servicing, Bodywork Repairs

Depth

Technical Depth:

Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers detailed internal engine components, electrical schematics, and complex troubleshooting sequences.

📊 Manual Specifications

File Format Details:

Digital PDF document, typically searchable text and high-resolution images.

Quality

Print Quality:

Designed for digital viewing, but printable for workshop use. Illustrations are typically clear and detailed.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled

Displacement:

460 cc

Bore X Stroke:

93 mm x 82 mm (typical for this engine family)

Compression Ratio:

10.5:1 (typical for this engine family)

Performance

Horsepower:

Approx. 34-36 HP (at crankshaft, depending on specific market tune)

Torque:

Approx. 43 Nm (at crankshaft, depending on specific market tune)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Petrol (95 RON recommended)

Ignition System

Ignition Type:

Electronic ignition with CDI and spark plug

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Type And Capacity:

Refer to manual for specific API SG or higher, JASO MA certified oil. Capacity typically around 1.7-1.8 liters.

🔧 Transmission

Drive

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with dry clutch

Features

Final Drive:

Belt drive via CVT

📐 Dimensions

Exterior

Length:

Approx. 2160 mm

Width:

Approx. 780 mm

Height:

Approx. 1350 mm (seat height varies)

Weights

Dry Weight:

Approx. 185 kg

Gross Vehicle Weight Rating:

Refer to manual, typically around 380-400 kg

Cargo

Underseat Storage:

Sufficient for one full-face helmet and small items.

🛡️ Safety Features

Ratings

ABS Availability:

Optional on some models/markets

Active Features

Braking System Front:

Dual hydraulic discs, typically 260mm diameter with dual-piston calipers.

Braking System Rear:

Single hydraulic disc, typically 240mm diameter with single-piston caliper.

Passive Features

Lighting System:

Halogen headlights, LED taillight and indicators.

💡 Technology Features

Infotainment

Infotainment Features:

Basic instrumentation cluster with speedometer, tachometer, fuel gauge, coolant temperature gauge, and warning lights. No advanced infotainment systems common in modern vehicles.

Driver Assistance

Driver Assistance Features:

Optional ABS (Anti-lock Braking System) on some models.

Connectivity

Connectivity Features:

Not applicable for this model year and vehicle type.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,000 km or annually. Refer to manual for precise intervals and conditions.

Air Filter Replacement:

Every 10,000-15,000 km or as needed based on operating environment. Inspect more frequently.

Spark Plug Replacement:

Typically every 15,000-20,000 km.

Cvt Belt Inspection/Replacement:

Inspect belt wear and tension at 10,000 km intervals. Replacement typically recommended between 20,000-30,000 km, depending on usage.

Fluid Specifications

Engine Oil Specification:

API SG or higher, JASO MA certified. Viscosity typically 5W-40 or 10W-40, consult manual.

Coolant Specification:

Ethylene glycol based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water. Use Piaggio/Gilera recommended coolant if available.

Brake Fluid Specification:

DOT 4

Gearbox Oil Specification:

Refer to manual; typically a specific SAE 80W/90 gear oil or equivalent.

Known Issues

Known Issues Common:

Some owners report potential issues with the fuel pump, voltage regulator, and occasional electrical gremlins. CVT belt wear and rear shock absorber longevity can also be points of attention. Regular maintenance is crucial.

Part Numbers

Air Filter Part Number:

Varies by manufacturer of the filter. Common aftermarket filters use part numbers like HF171 (HI-FLO) or equivalent. Genuine part number would be specific to Piaggio Group.

Oil Filter Part Number:

Varies by manufacturer of the filter. Common aftermarket filters use part numbers like HF171 (HI-FLO) or equivalent. Genuine part number would be specific to Piaggio Group.

Spark Plug Part Number:

NGK CR9EB or equivalent.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Gilera, an Italian manufacturer with a long history in motorcycle racing and production, known for performance-oriented models. Acquired by Piaggio in 2001.

Model Evolution

Model Evolution Nexus:

The Nexus series represented Gilera's foray into the modern maxi-scooter market, emphasizing sporty handling and performance derived from their motorcycle expertise. The 500cc variant was a flagship model.

Production

Production Period:

The Gilera Nexus 500 was produced from approximately 2003 to 2007.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2005 Gilera Nexus 500 are not widely publicized, the Nexus range was generally well-regarded in the scooter press for its performance and handling characteristics.