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Gilera Nexus 500 Mk1 Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009

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The Nexus 500 Mk1, produced from 2005 to 2009, is a maxi-scooter engineered for a blend of sporty handling and Grand Tourer comfort. Powered by the Master 500 engine, this...
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Gilera Nexus 500 Mk1 Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009
The Nexus 500 Mk1, produced from 2005 to 2009, is a maxi-scooter engineered for a blend of sporty handling and Grand Tourer comfort. Powered by the Master 500 engine, this model offers approximately 40 HP and 45 Nm of torque, making it a capable performer in its class. Its design emphasizes a powerful engine, agile chassis, and comfortable ergonomics, positioning it as a strong contender against contemporaries like the T-Max 500 and Burgman. Manufactured in Italy, the Nexus 500 is known for its robust build and performance-oriented features, including an automatic CVT transmission and optional ABS for enhanced safety. This comprehensive workshop service and repair manual provides in-depth guidance for owners, independent workshops, and mechanics. It covers all essential aspects of the Nexus 500 Mk1, including detailed procedures for engine overhaul, fuel and ignition systems, cooling, exhaust, transmission, brakes, suspension, steering, and electrical systems. The manual also includes essential information on preventive maintenance, diagnostic troubleshooting for all major systems, repair procedures, adjustment specifications, electrical component testing, critical torque values, fluid capacities and types, and detailed wiring diagrams. Its purpose is to empower users with the knowledge to perform effective DIY maintenance and repairs, ensuring the longevity and optimal performance of their vehicle.
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 500
Generation:
Mk1
Model Years Covered:
2005, 2006, 2007, 2008, 2009
Codes
Engine Code Identifier:
Master 500
👋 Introduction
Market Position
Category:
Maxi-scooter
Target Audience:
Owners, independent workshops, mechanics
Competitive Analysis
Key Competitors Era:
Yamaha T-Max 500, Suzuki Burgman 400/650, Honda Silver Wing 500
Key Features
Vehicle Usp:
Sporty handling, powerful engine, GT comfort
Manual Value Proposition:
Enables comprehensive DIY maintenance and repair, reducing reliance on expensive dealer services
📋 Manual Details
Coverage Areas
Manual Coverage:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
300-500 (typical for this type of manual)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, pistons, crankshaft, connecting rods, valve train, timing
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel tank, fuel lines
Ignition System:
Ignition coil, spark plugs, ECU control
Cooling System:
Radiator, fan, thermostat, coolant passages, water pump
Exhaust System:
Exhaust manifold, catalytic converter, muffler, lambda sensors
Transmission Drivetrain:
CVT system (automatic transmission), clutch, variator, torque converter, final drive, belt maintenance
Brakes System:
Brake fluid, front and rear brake calipers, brake discs, brake lines, ABS system (if equipped), parking brake
Suspension System:
Front telescopic fork, rear shock absorber, swingarm, bushings, bearings
Steering System:
Handlebars, steering column, steering bearings
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays
Instrumentation:
Speedometer, tachometer, LCD display, indicator lights
Bodywork Frame:
Frame inspection, body panels, fairings, seat, storage compartments, trim pieces
Chassis Components:
Wheels, tires, footrests, stands
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, spark plug checks, chain/belt adjustments, brake fluid flushes, coolant checks
Diagnostic Troubleshooting:
Step-by-step fault finding for all major systems
Repair Procedures:
Detailed instructions for component disassembly, inspection, repair, and reassembly
Adjustment Procedures:
Carburetor/throttle body synchronization, valve clearance adjustment (if applicable), brake lever adjustments
Electrical Component Testing:
Testing of sensors, actuators, lighting, charging system components
Torque Specifications:
Critical torque values for all fasteners
Schematics Diagrams:
Detailed electrical wiring diagrams, exploded views of components
Fluid Capacities Types:
Engine oil, coolant, brake fluid, transmission fluid requirements
Technical Depth
Depth:
In-depth mechanical and electrical repair, including full engine rebuilds and complex system diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, single-cylinder, 4-valve, SOHC
Displacement:
493 cc
Bore X Stroke:
94 mm x 71 mm
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 40 HP (29.4 kW) at 7,500 rpm
Torque:
Approx. 45 Nm (33.2 lb-ft) at 5,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (minimum 95 RON)
Lubrication
Oil Type Capacity:
Refer to manual (typically SAE 5W-40 or 10W-40 synthetic, approx. 1.5-1.8 liters including filter)
🔧 Transmission
Standard
Transmission Type:
Automatic Continuously Variable Transmission (CVT)
Clutch Type:
Automatic centrifugal clutch
Features
Drive Type:
Belt drive to rear wheel
Final Drive Fluid:
Refer to manual (typically SAE 80W-90 gear oil, approx. 0.2 liters)
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm
Width:
Approx. 770 mm
Height:
Approx. 1,370 mm (seat height: Approx. 780 mm)
Weights
Dry Weight:
Approx. 195 kg
Fuel Tank Capacity:
15 liters
Wheelbase:
Approx. 1,505 mm
🛡️ Safety Features
Ratings
ABS Availability:
Optional on some models
Active Features
Braking System:
Combined braking system (front and rear brake activation with single lever, also separate rear brake lever)
Passive Features
Lighting:
Halogen headlight, LED taillight and indicators
💡 Technology Features
Infotainment
Dashboard Display:
Analog speedometer and tachometer, digital multi-function display (odo, trip, fuel level, clock, service indicator)
Driver Assistance
ABS:
Available as an option, providing enhanced braking control
Connectivity
Connectivity Features:
N/A (basic model without modern connectivity)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual (typically every 5,000 - 6,000 km or annually)
Air Filter Replacement:
Refer to manual (typically every 10,000 - 12,000 km)
Spark Plug Replacement:
Refer to manual (typically every 15,000 - 20,000 km)
Belt Drive Inspection:
Refer to manual (critical at specified intervals, e.g., 15,000 - 20,000 km)
Fluid Specifications
Engine Oil Specification:
Refer to manual (e.g., Piaggio SAE 5W-40 synthetic or equivalent meeting API SG/SH/SJ/SL, ACEA A3)
Coolant Specification:
Refer to manual (e.g., Ethylene glycol based coolant with anti-corrosion inhibitors, 50% mix with distilled water)
Brake Fluid Specification:
Refer to manual (DOT 4)
Known Issues
Common Wear Items:
CVT belt wear, voltage regulator/rectifier failure, rear shock absorber degradation
Maintenance Points:
Regular lubrication of suspension linkages, frequent checks of coolant and oil levels
📚 Vehicle History
Brand Heritage
Parent Company:
Piaggio & C. S.p.A.
Model Evolution
Introduction Year:
2002 (initial Nexus 500 model)
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Segment Awards:
Not specifically noted for major awards, but recognized for its performance and GT capabilities in the maxi-scooter segment of its era.
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