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Gilera Nexus 500 MK1 Workshop Manual 2005-2010

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Years: 2005, 2006, 2007, 2008, 2009, 2010 Codes Product Code: GIL-NEX500-MK1-WSM-PDF 👋 Introduction Market Position Vehicle Segment: Maxi-scooter...
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Gilera Nexus 500 MK1 Workshop Manual 2005-2010
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 500
Generation:
MK1
Model Years:
2005, 2006, 2007, 2008, 2009, 2010
Codes
Product Code:
GIL-NEX500-MK1-WSM-PDF
👋 Introduction
Market Position
Vehicle Segment:
Maxi-scooter / Sport Scooter
Target Audience:
Commuters, touring riders, performance-oriented scooter enthusiasts
Competitive Analysis
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500
Key Features
Performance Orientation:
Known for its powerful 500cc engine and sporty handling compared to many competitors
Touring Capability:
Comfortable riding position, ample storage (under-seat), and stability at higher speeds
📋 Manual Details
Coverage Areas
Overall Coverage:
Comprehensive A-Z coverage for all models and repairs
Mechanical Coverage:
Complete mechanical repair and maintenance procedures
Electrical Coverage:
Complete electrical system diagnostics and repair
Page Count
Estimated Pages:
Likely 500+ pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine System:
Engine disassembly, assembly, diagnosis, tuning, internal components, cooling system, lubrication system, fuel system, ignition system
Transmission System:
Automatic transmission (CVT) operation, diagnosis, maintenance, and repair
Chassis And Suspension:
Front fork, rear shock absorber, swingarm, steering system, wheel bearings, hub maintenance
Braking System:
Hydraulic brake system diagnosis, caliper overhaul, master cylinder, brake lines, ABS (if equipped) operation and maintenance
Electrical System:
Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), starter system, battery maintenance, ECU diagnosis, sensors, and actuators
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel filter replacement
Exhaust System:
Exhaust pipe, muffler, catalytic converter maintenance and replacement
Bodywork And Trim:
Panel removal, fairing installation, seat, storage compartment access
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, valve clearance checks, coolant replacement, brake fluid flush, chain adjustment (if applicable), tire pressure checks
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults
Repair Procedures:
Step-by-step instructions for component overhaul and replacement
Disassembly And Assembly:
Detailed procedures for engine, transmission, suspension, and body component removal and installation
Electrical Diagnostics:
Component testing, wiring harness continuity checks, fault code reading (if applicable)
Technical Depth
Depth:
Full workshop level, suitable for professional technicians and experienced DIY enthusiasts
Diagnostic Information:
Includes torque specifications, clearances, fluid capacities, electrical values, and diagnostic flowcharts
Rebuild Information:
Detailed procedures for complete engine and transmission rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF (as per standard practice for modern manuals)
Print Quality
Printability:
All pages are printable
Image Quality:
High-quality, includes tons of detailed pictures & diagrams
Binding Type
Binding:
N/A (PDF Download)
Paper Type
Paper Quality:
N/A (PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Displacement:
493 cc (approx.)
Bore X Stroke:
Not explicitly stated, but typical for 500cc class
Compression Ratio:
Not explicitly stated, but typical for 500cc class
Performance
Horsepower:
Approx. 39-40 HP (at crankshaft)
Torque:
Approx. 45-46 Nm (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
Lubrication
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA)
Oil Capacity:
Approx. 1.6 - 1.7 Liters (with filter change)
Cooling System
Coolant Type:
Ethylene glycol based antifreeze coolant with corrosion inhibitors (50% mixture with distilled water recommended)
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Drive:
Belt drive
Features
Transmission Fluid:
Specific CVT fluid or gear oil (refer to manual for exact specification, often SAE 75W-90 or similar for final drive)
📐 Dimensions
Exterior
Length:
Approx. 2150 mm
Width:
Approx. 770 mm
Height:
Approx. 1350 mm (seat height approx. 790 mm)
Weights
Dry Weight:
Approx. 185 kg
Curb Weight:
Approx. 195 kg (with fluids)
Max Load Capacity:
Approx. 160 kg (rider + passenger + luggage)
Cargo
Under Seat Storage:
Sufficient for one full-face helmet plus other items
🛡️ Safety Features
Ratings
Crash Test Information:
N/A (Motorcycles/Scooters typically not rated by standard automotive crash test agencies)
Active Features
Braking System Type:
Dual disc front, single disc rear (typically Brembo or similar quality components)
ABS Availability:
Optional on some models/markets
Passive Features
Lighting:
Halogen headlights, LED taillight
Mirrors:
Large, adjustable mirrors for good rear visibility
💡 Technology Features
Infotainment
Dashboard:
Digital and analog display with speedometer, tachometer, fuel gauge, odometer, trip meters, coolant temperature warning, oil pressure warning, and indicator lights.
Lighting System:
Multi-reflector halogen headlight, LED taillight and brake light.
Driver Assistance
ABS:
Available as an option on certain models, providing anti-lock braking for enhanced safety.
Connectivity
Diagnostics Port:
On-board diagnostic (OBD) port for electronic fault diagnosis (manual will detail access and basic procedures).
🔧 Maintenance
Service Intervals
First Service:
Typically 1,000 km or 1 month
Regular Service:
Every 6,000 km or 6 months (whichever comes first), including oil and filter changes.
Major Service:
At higher mileages (e.g., 12,000 km, 24,000 km), involving more in-depth checks like valve adjustments, coolant flush, and CVT belt inspection.
Fluid Specifications
Engine Oil:
SAE 10W-40 or 15W-50 (API SG/SH/SJ/SL/SM/SN, JASO MA)
Coolant:
50% Ethylene Glycol Antifreeze with distilled water
Brake Fluid:
DOT 4 (refer to manual for specific DOT rating)
Known Issues
Common Wear Items:
CVT belt, drive variator rollers, spark plugs, brake pads
Potential Electrical Issues:
Regulator/rectifier failure, stator coil issues (common on many scooters of this era, manual will detail testing)
Suspension Wear:
Front fork seals and rear shock absorber may require service or replacement over time due to mileage.
📚 Vehicle History
Brand Heritage
Gilera History:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for performance and racing heritage.
Model Evolution
Nexus Development:
The Nexus was Gilera's flagship maxi-scooter, designed to compete in the premium performance scooter segment, offering car-like comfort and motorcycle-like performance.
Production
Manufacturing Location:
Italy (Piaggio Group)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Gilera Nexus series was generally well-regarded for its performance and handling within the maxi-scooter market during its production years.
Ratings
Review Scores:
Professional reviews from the period often praised its powerful engine and chassis dynamics, positioning it as a sportier alternative.
Certifications
Emissions Standards:
Compliant with European emissions standards for its model years (e.g., Euro 3).
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