Category:
Maxi-scooter / Sport scooter
Target Audience:
Owners seeking to perform their own maintenance and repairs, independent repair shops.
Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500, Aprilia Leonardo 300/500.
Vehicle Usp:
Sporty handling, powerful engine for its class, comfortable ergonomics for longer rides.
Benefit 1:
Empowers owners to perform DIY maintenance and repairs, saving on labor costs.
Benefit 2:
Provides in-depth understanding of the vehicle's systems for efficient troubleshooting and proactive care.
Benefit 3:
Ensures correct procedures are followed, maintaining vehicle integrity and resale value.
Primary Coverage:
Gilera Nexus 500 (2005-2006 models)
Secondary Coverage:
Troubleshooting, diagnostics, routine maintenance, major repairs, electrical systems, engine rebuilds.
Estimated Page Count:
Likely 300-500+ pages (typical for factory service manuals of this era)
Type:
Factory Service Repair Manual
Delivery Method:
Digital download
Software Requirements:
Adobe PDF Reader and WinZip (or equivalent decompression software).
Engine:
Complete overhaul, disassembly, assembly, lubrication, cooling system, fuel system (injection), ignition system, emissions control.
Transmission:
Automatic transmission (CVT) operation, maintenance, troubleshooting, component replacement.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires.
Brakes:
Hydraulic system, caliper service, disc replacement, bleeding procedures, parking brake.
Electrical:
Wiring diagrams, charging system, starting system, lighting, instruments, ECU, sensor diagnostics.
Body:
Fairings, seat, storage, body panels, lighting components, instrumentation.
Routine Maintenance:
Oil changes, filter replacement, spark plug service, brake fluid replacement, coolant checks, chain/belt adjustment (if applicable).
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, error code interpretation.
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs.
Specifications:
Torque values, clearances, fluid capacities, electrical resistance values.
Depth:
Comprehensive, covering all aspects from basic adjustments to complete engine and electrical system rebuilds. Includes detailed diagnostic charts and troubleshooting trees.
Type Description:
This is a factory-level repair manual, providing detailed instructions for mechanics and advanced DIY users. It is not an owner's manual or a simple repair guide; it's intended for comprehensive service.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, 4-valve SOHC
Bore X Stroke:
94 mm x 87.4 mm (typical for Piaggio Quasar engine family)
Compression Ratio:
10.5:1 (typical)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Horsepower:
Approx. 40 HP (at crankshaft) @ 7,500 RPM (typical for this engine)
Torque:
Approx. 43 Nm (at crankshaft) @ 5,500 RPM (typical for this engine)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
12.2 Liters
Oil Type:
API SG or higher, SAE 10W-40 synthetic or semi-synthetic motorcycle oil
Oil Capacity:
Approx. 1.2 - 1.4 Liters (including filter)
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water
Coolant Capacity:
Approx. 1.5 Liters
Type:
Automatic Continuously Variable Transmission (CVT)
Drive:
Belt drive to rear wheel via reduction gear
Features:
Automatic clutch, variable gear ratios for optimal performance and fuel efficiency.
Fluid Type:
Specific CVT fluid required (refer to manual for exact specification, often a GL-4 or similar gear oil specification for the final drive, and specific CVT fluid for the transmission unit itself).
Brakes Front:
Dual 240 mm discs, hydraulic calipers
Brakes Rear:
240 mm disc, hydraulic caliper
ABS:
Optional (check specific model variant)
Lighting:
Halogen headlamp, LED taillight
Mirrors:
Large, adjustable mirrors for improved visibility
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, engine fault indicator.
ABS:
Available as an option on some models.
Diagnostics:
On-board diagnostic (OBD) port for engine diagnostics and fault code retrieval.
Initial Service:
1,000 km (600 miles) - Oil and filter change, check all fasteners, adjust chain/belt tension (if applicable).
Regular Service:
Every 5,000 km (3,000 miles) or 12 months - Oil and filter change, air filter inspection/replacement, spark plug check/replacement, brake fluid check, coolant level check.
Major Service:
Every 10,000 km (6,000 miles) - Includes all regular service items plus: transmission fluid change, spark plug replacement, valve clearance check, brake pad inspection, coolant flush.
Engine Oil Capacity:
1.3 Liters (approx.)
Coolant Capacity:
1.5 Liters (approx.)
Common Problem 1:
Wear on the CVT variator and belt, leading to reduced acceleration and potential slippage.
Common Problem 2:
Potential issues with the fuel injection system (sensors, injectors) requiring diagnostic scans.
Common Problem 3:
Water ingress into electrical connectors or components, especially if stored outdoors without protection.
Common Problem 4:
Front suspension wear, leading to a less controlled ride.
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycling, founded in 1909. It is now part of the Piaggio Group.
Introduction Year:
The Nexus 500 was introduced in 2003, with significant updates for the 2005-2006 models.
Engine Platform:
Utilizes the Piaggio Quasar 500 engine, known for its performance and reliability, also found in other Piaggio Group scooters.
Manufacturing Location:
Italy
