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GILERA NEXUS 500 MK1 PDF Service Repair Workshop Manual 2005 ONWARDS Download

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Year Coverage: 2005 onwards Codes Engine Code: M305M (Piaggio Quasar) 👋 Introduction Market Position Segment: Premium Maxi-Scooter Target...
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GILERA NEXUS 500 MK1 PDF Service Repair Workshop Manual 2005 ONWARDS DownloadGILERA NEXUS 500 MK1 PDF Service Repair Workshop Manual 2005 ONWARDS DownloadGILERA NEXUS 500 MK1 PDF Service Repair Workshop Manual 2005 ONWARDS DownloadGILERA NEXUS 500 MK1 PDF Service Repair Workshop Manual 2005 ONWARDS Download
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 500
Generation:
MK1
Model Year Coverage:
2005 onwards
Codes
Engine Code:
M305M (Piaggio Quasar)
👋 Introduction
Market Position
Segment:
Premium Maxi-Scooter
Target Consumer:
Commuters seeking performance, touring capability, and style
Competitive Analysis
Key Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600
Key Features
Design Philosophy:
Sporty styling, motorcycle-like ergonomics, advanced technology for its era
Unique Selling Points:
Powerful 500cc engine, agile handling for its class, premium Italian engineering
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
PDF Download
Completeness:
Complete, no missing pages
Page Count
Estimated Page Count:
300+
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, assembly, inspection, tuning, performance
Fuel System:
Fuel injection, fuel pump, injectors, fuel filter replacement
Cooling System:
Radiator, water pump, coolant flow, thermostat operation
Exhaust System:
Muffler, catalytic converter, exhaust pipe inspection and replacement
Transmission:
Automatic CVT, variator, clutch, belt inspection and replacement
Brakes:
Hydraulic system, disc brake components, caliper maintenance, bleeding procedures
Suspension:
Front telescopic forks, rear shock absorber, tuning and replacement
Electrical System:
Battery, charging system, lighting, ignition system, starter motor
Wiring Diagrams:
Comprehensive electrical schematics for all systems
Bodywork And Chassis:
Frame inspection, fairing removal and installation, seat, luggage options
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain/belt adjustment
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Repair Procedures:
Step-by-step instructions for component overhaul and replacement
Diagnostic Charts:
Flowcharts for identifying and resolving faults
Specifications And Tolerances:
Detailed torque values, clearances, and measurements
Special Tool Requirements:
Identification and usage of specialized tools
Technical Depth
Depth Level:
Comprehensive, covering from basic rider maintenance to complete engine rebuilds and advanced electrical diagnostics
Target Audience:
DIY enthusiasts, independent workshops, experienced mechanics
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes, text-searchable
Printable:
Yes, designed for printing
Print Quality
Image Resolution:
High-resolution images and diagrams
Binding Type
Binding Type For Print:
N/A (Digital PDF Download)
Paper Type
Paper Type For Print:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, SOHC, 4-valve, single-cylinder
Displacement:
493 cc
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1
Performance
Horsepower:
Approx. 40 HP (29.4 kW) @ 7,000 rpm
Torque:
Approx. 45 Nm (33.2 lb-ft) @ 5,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Lubrication
Oil Type:
SAE 15W-40 API SG or higher (e.g., Piaggio/Motul 5100 15W-50)
Oil Capacity:
Approx. 1.5 Liters (with filter change)
Ignition
Ignition System:
Electronic CDI with variable ignition timing
Cooling
Cooling Medium:
Liquid (Ethylene glycol based coolant)
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive System:
Belt drive to rear wheel
Features
Variator Rollers:
Specific weight and dimensions critical for performance tuning
Clutch Type:
Centrifugal automatic clutch
Fluid Specifications
Final Drive Oil Type:
SAE 80W-90 API GL-4 (Check specific manual for exact type)
📐 Dimensions
Exterior
Length:
Approx. 2150 mm
Width:
Approx. 800 mm
Height:
Approx. 1400 mm
Wheelbase:
Approx. 1525 mm
Weights
Dry Weight:
Approx. 203 kg
Curb Weight:
Approx. 220 kg (with all fluids)
Cargo
Underseat Storage:
Sufficient for one full-face helmet and smaller items
🛡️ Safety Features
Ratings
Crash Test Information:
N/A (Motorcycle/Scooter classification)
Active Features
Braking System:
Front: Dual 240 mm discs with 2-piston calipers. Rear: 240 mm disc with 1-piston caliper. ABS optional on some models.
Lighting System:
Halogen headlamp, LED taillight, integrated turn signals
Passive Features
Frame Construction:
High-tensile steel double cradle frame
Ergonomics:
Motorcycle-style riding position for enhanced control
💡 Technology Features
Infotainment
Dashboard Display:
Digital and analog gauges including speedometer, tachometer, fuel gauge, temperature gauge, clock
Lighting Technology:
Multi-reflector halogen headlamp
Driver Assistance
ABS Availability:
Optional on some markets/trims
Connectivity
Diagnostic Port:
On-board diagnostics (OBD) port for electronic fault diagnosis
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km or 12 months, whichever comes first
Air Filter Inspection:
Every 6,000 km
Spark Plug Replacement:
Every 12,000 km
Cvt Belt Inspection:
Every 12,000 km, replacement typically around 24,000 km or as needed
Brake Fluid Change:
Every 24 months
Fluid Specifications
Coolant Type:
Piaggio Genuine Coolant or equivalent (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
CVT belt, variator rollers, starter motor solenoid, voltage regulator
Potential Faults:
Fuel injector clogging, regulator failure leading to battery charging issues
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Group Affiliation:
Part of the Piaggio & C. S.p.A. group (which also owns Vespa, Aprilia, Moto Guzzi)
Model Evolution
Development Basis:
Developed to bridge the gap between traditional scooters and motorcycles, offering performance and comfort
Production
Production Period:
Introduced around 2003/2004, with MK1 being the initial iteration
🏆 Awards & Recognition
Recognitions
Industry Awards:
Generally well-regarded for its performance and handling within the maxi-scooter segment during its production era.
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