Gilera Nexus 500 MK1 Service Repair Manual 2005 Onwards

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: MK1 Codes Product Code: GNS500MK12005PDF Generation Generation Identifier: MK1 👋 Introduction Market Position Positioning: The Gilera Nexus 500 was...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 26008

Stichworte: 2005 Gilera Motorcycle Nexus 500 MK1

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Model Variant:

Codes

Product Code:

GNS500MK12005PDF

Generation

Generation Identifier:

👋 Introduction

Market Position

Positioning:

The Gilera Nexus 500 was positioned as a premium, sport-touring maxi-scooter, blending performance with comfort and practicality.

Competitive Analysis

Competitors:

Competed against other high-displacement maxi-scooters like the Yamaha TMAX, Suzuki Burgman 650, and Aprilia Scarabeo 500.

Key Features

Features:

Powerful 500cc engine, advanced chassis design, comfortable ergonomics for long-distance riding, underseat storage.

📋 Manual Details

Coverage Areas

All Repairs:

Covered Models:

All MK1 models 2005 onwards

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, diagnostics, and component repair

Fuel System:

Fuel injection system, fuel pump, injectors, fuel lines, fuel filter replacement

Ignition System:

Spark plugs, ignition coils, CDI unit, wiring diagrams

Cooling System:

Radiator, coolant pump, thermostat, hoses, coolant flush and refill

Exhaust System:

Muffler, catalytic converter, exhaust pipes, gasket replacement

Transmission:

Automatic transmission (CVT) servicing, fluid changes, clutch inspection

Drivetrain:

Belt drive system, variator, torque converter, final drive servicing

Brakes:

Front and rear brake systems, hydraulic lines, brake fluid flush, pad and disc replacement, ABS system (if applicable)

Suspension:

Front fork assembly, rear shock absorber, linkage servicing and adjustment

Steering:

Handlebar assembly, steering head bearings, linkage lubrication and adjustment

Electrical System:

Battery, starter motor, alternator, lighting, horn, wiring diagrams, fault finding

Bodywork:

Panel removal and installation, fairings, seat, storage compartments, cosmetic repairs

Chassis:

Frame inspection, component mounting, torque specifications

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain/belt adjustments, general inspection

Troubleshooting:

Diagnostic procedures for common and complex issues, fault code interpretation

Engine Rebuild:

Piston, cylinder, crankshaft, valve train overhauls and reassembly

Transmission Repair:

CVT belt replacement, variator maintenance, clutch service

Brake Overhaul:

Calibrator rebuild, master cylinder servicing, bleeding procedures

Suspension Fork Rebuild:

Fork oil changes, seal replacement, spring installation

Electrical Diagnostics:

Wiring harness tracing, component testing, multimeter usage

Bodywork Refurbishment:

Panel alignment, scratch repair, decal application

Installation Guides:

Information on installing common accessories and replacement parts.

Diagnostic Charts:

Detailed flowcharts and tables for diagnosing electrical and mechanical faults.

Technical Depth

Depth:

Comprehensive, covering everything from basic rider maintenance to complete mechanical overhauls and advanced diagnostics.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Clearances And Tolerances:

Specific measurements for engine component clearances, valve lash, and bearing play.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text content for quick information retrieval

Print Quality

Quality:

High-resolution images and clear text for easy viewing and printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

493 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1

Performance

Horsepower:

Approx. 40 HP (30 kW) at 7000 RPM

Torque:

Approx. 46 Nm (34 lb-ft) at 5500 RPM

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (95 RON recommended)

Lubrication

Oil Type And Capacity:

Refer to manual for specific API SG or higher specification, approximately 1.8 liters with filter change.

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Drive:

Belt drive to rear wheel via enclosed chain/gearbox

Features

Clutch:

Automatic centrifugal clutch

Transmission Fluid:

Refer to manual for specific SAE 75W/90 GL-4 specification for final drive.

📐 Dimensions

Exterior

Length:

Approx. 2150 mm (84.6 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1370 mm (53.9 in)

Wheelbase:

Approx. 1510 mm (59.4 in)

Weights

Dry Weight:

Approx. 195 kg (430 lbs)

Gross Vehicle Weight:

Refer to vehicle plate or manual.

Cargo

Underseat Storage:

Sufficient for one full-face helmet and smaller items.

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle/Scooter safety is assessed differently than cars; focus on handling and braking features).

Active Features

Braking System:

Dual front disc brakes, single rear disc brake. ABS optional on some models.

Lighting:

Halogen headlights, LED taillight and indicators.

Passive Features

Chassis Construction:

Steel frame for rigidity and stability.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital and analog combination dashboard displaying speed, RPM, fuel level, trip meters, and warning lights.

Driver Assistance

ABS Availability:

Optional on certain MK1 models, providing enhanced braking safety.

Connectivity

Charging Port:

12V accessory socket for charging electronic devices.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km or annually. Check manual for specific mileage.

Air Filter Inspection:

Check every 5,000 km, replace as needed. Refer to manual for specific interval.

Spark Plug Replacement:

Refer to manual for recommended interval, typically around 10,000-15,000 km.

Transmission Belt Inspection:

Inspect for wear and tear every 10,000 km, replace according to manual recommendations (e.g., 20,000 km).

Fluid Specifications

Engine Oil Spec:

API SG or higher, SAE 10W-40 or 15W-50 depending on climate. Refer to manual for precise viscosity.

Coolant Spec:

Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.

Brake Fluid Spec:

DOT 4 recommended for optimal performance and longevity.

Known Issues

Common Wear Items:

CVT belt wear, brake pad and disc wear, steering head bearing adjustment/replacement, potential for electrical connector issues.

Common Issues

Engine Performance:

Some owners report occasional hesitation or slightly rough idle, often addressable with fuel system cleaning or ECU reflash.

Suspension Tuning:

Stock suspension can be firm; adjustments or aftermarket components may be desired by some riders for improved comfort.

📚 Vehicle History

Brand Heritage

Heritage:

Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and performance-oriented vehicles.

Model Evolution

Nexus Series:

The Nexus 500 was a significant model for Gilera, aiming to capture the maxi-scooter market with a focus on performance and agility.

Production

Production Period:

Introduced in the early 2000s, with the MK1 covering models from 2005 onwards.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards are not readily documented for this model, the Nexus 500 was generally well-received for its performance and handling in its segment.