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Gilera Nexus 500 MK1 Workshop Manual 2005 Onwards

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Production Years Covered: 2005 onwards Codes Engine Code Variant: M357 👋 Introduction Market Position Segment: Performance Maxi-Scooter Target Audience:...
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Gilera Nexus 500 MK1 Workshop Manual 2005 OnwardsGilera Nexus 500 MK1 Workshop Manual 2005 OnwardsGilera Nexus 500 MK1 Workshop Manual 2005 OnwardsGilera Nexus 500 MK1 Workshop Manual 2005 Onwards
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 500
Generation:
MK1
Production Years Covered:
2005 onwards
Codes
Engine Code Variant:
M357
👋 Introduction
Market Position
Segment:
Performance Maxi-Scooter
Target Audience:
Enthusiast owners, independent repair shops, DIY mechanics
Competitive Analysis
Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600
Key Features
Unique Selling Points:
Powerful 500cc engine, sport-oriented handling, comprehensive workshop manual coverage
Manual Value:
Enables owners to perform professional-level maintenance and repairs, saving on dealership costs
📋 Manual Details
Coverage Areas
General Coverage:
All models and repairs A-Z
Mechanical Coverage:
Comprehensive mechanical repairs
Electrical Coverage:
Comprehensive electrical system diagnostics and repair
Page Count
Estimated Page Count:
N/A (Digital PDF, content is comprehensive)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine assembly, disassembly, tuning, cooling system, lubrication system, fuel injection, ignition system
Transmission Drivetrain:
Automatic transmission operation, maintenance, and repair, CVT components, drive belts, final drive
Braking System:
Hydraulic braking system, ABS components, brake fluid, pad and disc replacement
Suspension Steering:
Front and rear suspension components, shock absorbers, fork seals, steering head bearings, steering column
Electrical System:
Wiring diagrams, battery, charging system, lighting, starting system, instrument cluster, sensors
Fuel System:
Fuel tank, fuel pump, fuel filter, injectors, fuel pressure regulation
Exhaust System:
Exhaust manifold, catalytic converter, muffler, lambda sensor
Cooling System:
Radiator, coolant, fan, water pump, thermostat
Bodywork Chassis:
Fairings, body panels, seat, frame inspection, mounting points
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug checks, coolant flushes, brake fluid changes, chain/belt adjustment (if applicable)
Diagnostic Procedures:
Troubleshooting guides for common faults, fault code interpretation (if applicable), component testing
Repair Procedures:
Step-by-step instructions for major component overhauls, component replacement, seal and gasket renewal
Electrical Repairs:
Wiring harness repair, component replacement (lights, ignition coils, sensors), battery charging system repair
Assembly Disassembly:
Complete instructions for dismantling and reassembling all major vehicle systems
Technical Depth
Depth Of Coverage:
Comprehensive, from basic checks to complete engine rebuilds and electrical system diagnostics
Diagrams Illustrations:
Tons of detailed pictures and diagrams
Torque Specifications:
Included for critical fasteners across all systems
Clearances Tolerances:
Engine component clearances, bearing tolerances, etc.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
All pages are printable
Image Resolution:
High quality for clear viewing of diagrams and images
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Recommendation:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke, 4-valve, SOHC
Displacement:
493 cc
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.4:1
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approximately 40 HP (29.8 kW) at 7,500 rpm
Torque:
Approximately 46 Nm (33.9 lb-ft) at 5,500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Keihin system
Fuel Type:
Unleaded Gasoline (Octane rating typically 95 RON)
Lubrication System
Oil Type:
API SG or higher, JASO MA certified 4-stroke motorcycle oil (e.g., SAE 10W-40)
Oil Capacity With Filter:
Approximately 1.8 Liters
Oil Filter Part Number:
Commonly Piaggio/Vespa equivalent, e.g., 828495, 828068, 1A013773
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Clutch Type:
Automatic centrifugal clutch
Features
Gear Reduction:
Integrated final drive with reduction gears
Transmission Fluid Type:
Specific CVT fluid or API GL-4 gear oil (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
Approximately 2150 mm
Width:
Approximately 780 mm
Height:
Approximately 1430 mm
Weights
Dry Weight:
Approximately 170-180 kg
Fuel Tank Capacity:
Approximately 15 Liters
🛡️ Safety Features
Ratings
ABS:
Optional ABS available on some models
Active Features
Braking System Type:
Dual disc front, single disc rear
Passive Features
Lighting:
Halogen headlights, LED taillight
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/Analog combination with tachometer, speedometer, fuel gauge, coolant temperature, and warning lights
Driver Assistance
ABS Availability:
Optional anti-lock braking system
Connectivity
Charging Port:
Some models may feature a 12V accessory socket
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or annually
Air Filter Check:
Every 6,000 km
Spark Plug Replacement:
Every 12,000 km
Cv Belt Inspection:
Every 12,000 km or as recommended
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, minimum 30% concentration (refer to manual for specific mix ratio and type)
Brake Fluid Type:
DOT 4
Known Issues
Common Problems:
Voltage regulator failure, water pump seal leaks, CVT belt wear, steering head bearing adjustment
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera is an Italian manufacturer of scooters and motorcycles, now part of the Piaggio Group.
Model Evolution
Development:
The Nexus 500 was developed as a premium, sporty maxi-scooter, offering car-like comfort with motorcycle-like performance.
Production
Manufacturing Location:
Italy
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