Gilera Nexus 500 2005-2006 WSM Service Manual Repair

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Art.-Nr: 83463

Stichworte: 2005 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500

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Beschreibung

The Gilera Nexus 500, produced from 2005 to 2006, is a performance-oriented maxi-scooter designed for both urban commuting and longer-distance touring. It features a robust 492.7 cc single-cylinder, four-stroke, liquid-cooled engine with electronic fuel injection, delivering approximately 39.4 HP. Known for its comfortable riding position, substantial under-seat storage, and capable handling, the Nexus 500 competed in the premium maxi-scooter segment against models from Suzuki, Yamaha, Honda, and Aprilia. Its Italian heritage, originating from a manufacturer with a history dating back to 1909 and now part of the Piaggio Group, underpins its engineering and design. This workshop service manual provides comprehensive guidance for the service, repair, and maintenance of the Gilera Nexus 500 (chassis code ZAPM35600). It covers all essential systems, including the engine, transmission, fuel system, cooling, electrical components, brakes, suspension, and chassis. The manual details routine maintenance procedures, troubleshooting diagnostics, component repair instructions, and includes full wiring diagrams. Its purpose is to equip owners, mechanics, and technicians with the in-depth knowledge required to maintain the vehicle's optimal condition, ensuring reliability and performance through proper care and timely servicing.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Year:

2005-2006

Codes

Chassis Code:

ZAPM35600

👋 Introduction

Market Position

Segment:

Performance Scooter / Maxi-Scooter.

Target Audience:

Owners seeking to perform their own maintenance and repairs, enthusiasts, and independent workshops.

Competitive Analysis

Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500, Aprilia Scarabeo 500, Piaggio X8/X9 Evolution 500.

Key Features

Manual Benefit 1:

Cost savings through DIY repairs and reduced labor costs.

Manual Benefit 2:

Empowerment and increased knowledge of vehicle mechanics.

Manual Benefit 3:

Time efficiency by having all necessary information readily available.

Manual Benefit 4:

Flexibility to perform repairs at one's own convenience and location (garage/workshop).

Manual Benefit 5:

Preservation of vehicle condition through proper and timely maintenance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Maintenance

Secondary Coverage:

Troubleshooting, Wiring Diagrams, Technical Specifications

Page Count

Estimated Page Count:

Extensive (Specific count not provided, but described as 'full professional quality in depth')

Manual Type

Type:

Workshop Service Manual (WSM)

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, and component identification.

Transmission:

Clutch, variator, belt drive, and associated components.

Fuel System:

Fuel injection system, fuel pump, injectors, fuel filter, and tank.

Cooling System:

Radiator, coolant, fan, thermostat, and water pump.

Electrical System:

Ignition system, lighting, starter, battery, charging system, and all wiring diagrams.

Brakes:

Brake system diagnosis, repair, fluid replacement, and component servicing (front and rear).

Suspension:

Front fork, rear shock absorber, and linkage servicing.

Steering:

Handlebar assembly, steering bearings, and related components.

Chassis And Bodywork:

Frame inspection, fairing removal and installation, seat, and storage.

Exhaust System:

Muffler, catalytic converter (if applicable), and exhaust pipe servicing.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain/belt adjustment, tire pressure, and general inspections.

Troubleshooting:

Diagnostic procedures for common and uncommon problems with detailed symptom analysis.

Component Repair:

Step-by-step instructions for the repair and replacement of all major and minor components.

Rebuilds:

Detailed procedures for engine and transmission rebuilds.

Wiring Diagrams:

Comprehensive electrical schematics for all systems, aiding in electrical fault finding.

Technical Depth

Depth:

Comprehensive, covering everything from basic checks to complete engine overhauls and electrical diagnostics.

📊 Manual Specifications

File Format

Format:

Quality:

Professional quality, printable pages.

Print Quality

Printability:

All pages are printable.

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

Compatibility

Operating Systems:

Compatible with all versions of Windows & Mac.

Requirements

Software:

Adobe PDF Reader.

Delivery

Method:

Instant Download.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled.

Engine Code:

M355M

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1

Performance

Horsepower:

Approximately 39.4 HP (29.4 kW) at 7500 rpm (DIN)

Torque:

Approximately 46.0 Nm (4.7 kgm) at 5500 rpm (DIN)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - likely Magneti Marelli system.

Fuel Type:

Unleaded gasoline, minimum 95 octane (RON).

Fuel Tank Capacity:

12 Liters (including approx. 2-liter reserve)

Lubrication

Oil Type:

SAE 10W-40 API SG or higher.

Oil Capacity:

Approximately 1.7 Liters (with filter change).

🔧 Transmission

Standard

Type:

Automatic CVT (Continuously Variable Transmission) with dry centrifugal clutch.

Optional

Options:

N/A (CVT is standard)

Features

Drive:

Belt drive to rear wheel.

📐 Dimensions

Exterior

Length:

Approx. 2160 mm

Width:

Approx. 760 mm

Height:

Approx. 1420 mm (seat height approx. 800 mm)

Weights

Dry Weight:

Approx. 198 kg

Curb Weight:

Approx. 214 kg (fully fueled)

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (As this is a scooter, formal car-style crash ratings are not typically applicable or published.)

Active Features

Braking System:

Combined braking system (linked front and rear brake operation), front dual disc brakes, rear single disc brake. ABS was an optional feature on some models.

Passive Features

Lighting:

Halogen headlights, LED taillight and indicators.

💡 Technology Features

Infotainment

Features:

Basic LCD instrument cluster displaying speed, RPM, fuel level, odometer, trip meter, and warning lights. No advanced infotainment system.

Driver Assistance

Features:

Optional ABS (Anti-lock Braking System) for enhanced braking safety. No other advanced driver-assistance systems (ADAS) present.

Connectivity

Features:

No integrated connectivity features like Bluetooth or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000 km or annually, whichever comes first.

Air Filter:

Check every 5,000 km, replace as needed (typically every 10,000-15,000 km).

Spark Plug:

Check every 10,000 km, replace as needed.

Drive Belt:

Inspect every 10,000 km, replace as recommended (typically every 20,000-30,000 km).

Coolant Flush:

Every 2 years or 20,000 km.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or higher.

Coolant:

Ethylene glycol-based coolant, mixed 50/50 with distilled water. Specific Gilera coolant or equivalent recommended.

Brake Fluid:

DOT 4.

Gear Oil:

Refer to manual for specific type and capacity (typically a heavier viscosity gear oil for the final drive).

Known Issues

Issue 1:

Potential for water pump seal leaks (routine inspection and potential replacement).

Issue 2:

Variator or clutch wear leading to performance degradation (regular inspection and replacement of worn components).

Issue 3:

Electrical connectors or grounds becoming corroded, leading to intermittent issues (cleaning and dielectric grease application).

Issue 4:

Fuel pump strainer clogging, particularly with lower quality fuel (periodic cleaning or replacement).

Issue 5:

Front suspension oil leaks or stiffness (fork seal replacement and oil change).

📚 Vehicle History

Brand Heritage

Manufacturer:

Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909.

Ownership:

Gilera is currently part of the Piaggio Group, which also owns Vespa, Aprilia, and Moto Guzzi.

Model Evolution

Genesis:

The Nexus 500 was Gilera's entry into the premium maxi-scooter market, designed for comfort, performance, and touring capabilities.

Predecessors:

Built upon the successful DNA 500 model, offering a more refined and comfortable platform.

Production

Production Years:

2005-2007 (with minor updates).

Manufacturing Location:

Italy.

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards for the 2005-2006 Gilera Nexus 500 are not widely documented, the model was recognized within its segment for its strong performance, handling, and comfort, contributing to Gilera's reputation in the maxi-scooter market.