Positioning:
The Gilera Nexus 500 was positioned as a premium maxi-scooter, offering a blend of performance, comfort, and touring capability, often competing with models from Yamaha, Suzuki, and Honda in its segment.
Competitors:
Key competitors included the Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 600, and Aprilia Atlantic 500.
Vehicle Features:
The Nexus 500 was known for its powerful 493cc engine, comfortable seating, under-seat storage, and sporty chassis design, making it suitable for both urban commuting and longer-distance touring.
Purpose:
To provide owners and technicians with the necessary information to maintain, diagnose, and repair the 2005 Gilera Nexus 500 motorcycle, ensuring optimal performance and longevity.
Primary Coverage:
Comprehensive repair and service for the 2005 Gilera Nexus 500 motorcycle.
Secondary Coverage:
Troubleshooting, maintenance, electrical system diagnostics, engine repair, suspension, braking, and chassis.
Type:
Service Repair Manual
Classification:
Factory Service Manual (FSM) equivalent
Primary Language:
English
Delivery Method:
Instant Digital Download
Powertrain:
Engine (disassembly, assembly, diagnostics), Injection system (fuel delivery, EFI components, ECU mapping), Cooling system (radiator, hoses, thermostat, coolant), Exhaust system.
Chassis And Suspension:
Front forks (disassembly, seal replacement, oil levels), Rear shock absorber, Swingarm, Frame, Bearings (steering head, wheel).
Braking:
Front and rear brake systems, hydraulic lines, brake fluid specifications, caliper maintenance, rotor inspection, ABS (if equipped).
Electrical System:
Wiring diagrams, component identification, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system, ignition system, ECU diagnostics, sensor testing.
Bodywork And Controls:
Fairings, seat removal, handlebar controls, levers, pedals, instrumentation, storage compartments.
Maintenance:
Routine checks, oil changes, filter replacements (oil, air, fuel), spark plug service, chain adjustment, brake fluid flush, coolant service, tire pressure checks.
Troubleshooting:
Diagnostic procedures for common performance issues, starting problems, electrical faults, braking anomalies, and handling concerns. Includes symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for major component repairs and overhauls, including engine rebuilds, transmission servicing, suspension component replacement, and electrical system repairs.
Diagnostics:
Guidance on using diagnostic tools (if applicable), interpreting error codes, and performing electrical tests on sensors and actuators.
Depth:
Comprehensive, covering basic user maintenance to advanced engine and electrical system diagnostics and repair.
Detail Level:
Highly detailed with visual aids and step-by-step instructions.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1
Valve Train:
DOHC, 4 valves
Horsepower:
Approximately 33.3 HP (24.8 kW) @ 7,000 RPM (specification may vary slightly by region)
Torque:
Approximately 43 Nm (31.7 lb-ft) @ 5,500 RPM (specification may vary slightly by region)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Size:
Approximately 42 mm
Oil Type:
API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 recommended (check manual for specific grade)
Oil Capacity With Filter:
Approximately 1.7 Liters
Braking System:
Hydraulic disc brakes front and rear. Front: Dual discs (260 mm). Rear: Single disc (260 mm). ABS may have been an optional feature on some models.
Lighting:
Halogen headlights, LED taillight, turn signals.
Chassis Design:
Steel frame with high-tensile strength, contributing to stability.
Ergonomics:
Comfortable riding position, hand guards (optional/standard depending on market) for rider protection.
Instrument Panel:
Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, and warning lights.
ABS Availability:
Optional Anti-lock Braking System (ABS) may have been available on some 2005 models, enhancing braking safety.
Diagnostic Ports:
Likely includes a diagnostic connector for connecting electronic diagnostic tools for fault code retrieval and system analysis.
ECU System:
Electronic Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions.
Engine Oil Change:
Every 6,000 km or annually, whichever comes first. (Consult manual for precise interval).
Oil Filter Replacement:
At every engine oil change.
Air Filter Inspection Cleaning:
Every 6,000 km, clean or replace as needed.
Spark Plug Replacement:
Every 12,000 km (check specific plug type and gap in manual).
Brake Fluid Flush:
Every 24,000 km or every 2 years.
Coolant Flush:
Every 24,000 km or every 2 years.
Engine Oil Viscosity:
SAE 10W-40 (recommended, verify with manual)
Coolant Type:
Ethylene glycol-based antifreeze (50% mix with distilled water)
Common Wear Items:
CVT belt wear, wheel bearings, brake pads, fork seals, stator output over time.
Electrical Gremlins:
Potential for intermittent electrical issues due to wiring harness wear or connector corrosion, especially with age. Stator failure can lead to charging problems.
Suspension Wear:
Front fork seals can leak, and the rear shock absorber may lose damping effectiveness over time, impacting ride quality.
Brand Origin:
Gilera is an Italian manufacturer of motorcycles, founded in 1909. It has a rich history in racing and scooter production.
Nexus Lineage:
The Nexus 500 was part of Gilera's successful line of maxi-scooters, designed to blend motorcycle performance with scooter practicality. It was a significant model for Gilera in the large-displacement scooter market.
Manufacturing Location:
Produced in Italy.
Model Years Produced:
The Nexus 500 was produced from approximately 2003 through the late 2000s, with updates and variations.
