Gilera Nexus 500 Mk1 2006 Factory Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 54349

Etiquetas: 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500 Mk1

Variantes de producto

Descripción

The Nexus 500 Mk1, introduced in 2006, stands as a prominent example of engineering prowess in the maxi-scooter and sport-scooter market. Designed to offer a compelling blend of sporty performance, long-distance comfort, and everyday practicality, it features a robust 4-stroke, single-cylinder, liquid-cooled engine with electronic fuel injection, producing approximately 40 horsepower. Its aggressive styling, comfortable ergonomics, and premium componentry positioned it as a strong contender against rivals, appealing to commuters, sport-oriented riders, and touring enthusiasts alike. This comprehensive factory service manual provides in-depth repair, maintenance, and diagnostic information for the Nexus 500 Mk1. Covering all major systems, including the engine, fuel, ignition, cooling, transmission, chassis, suspension, brakes, and electrical systems, it details everything from routine scheduled maintenance and fluid changes to complete component disassembly, inspection, and repair. With step-by-step instructions, torque specifications, and troubleshooting guides, this manual is an essential resource for professional mechanics and experienced DIY enthusiasts seeking to maintain and restore their vehicle to optimal performance and reliability.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Generation:

Year:

Market Segment:

Maxi-scooter / Sport-scooter

Codes

Engine Code:

Chassis Code:

ZAPM30300

👋 Introduction

Market Position

Positioning:

The Gilera Nexus 500 Mk1 represented a significant entry into the maxi-scooter market, aiming to blend sporty performance with touring comfort and practicality.

Target Audience:

Commuters seeking a more powerful and comfortable option than traditional scooters, sport-oriented riders, and those looking for a capable long-distance touring machine.

Competitive Analysis

Competitors:

BMW C 650 GT (later models), Yamaha TMAX, Suzuki Burgman 650, Piaggio X9 Evolution.

Key Features

Features:

Powerful 500cc engine, aggressive styling, comfortable ergonomics, large under-seat storage, and premium componentry.

📋 Manual Details

Coverage Areas

Primary Focus:

Repair, Maintenance, and Diagnostics

Scope:

Comprehensive factory-level service information

Page Count

Estimated Pages:

~300-400

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete disassembly, assembly, inspection, and repair of the 4-stroke, single-cylinder, liquid-cooled engine.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel lines, and fuel tank maintenance and troubleshooting.

Ignition System:

Ignition coil, spark plug, ECU control, and ignition timing checks.

Cooling System:

Radiator, coolant pump, thermostat, fan, coolant lines, and fluid specifications.

Transmission:

Automatic CVT (Continuously Variable Transmission) disassembly, inspection, belt replacement, roller weights, and clutch assembly.

Chassis Frame:

Frame inspection, welding points, and structural integrity checks.

Suspension:

Front telescopic fork (fork oil type, level, seal replacement), rear monoshock absorber (spring preload adjustment, damping), and linkage system.

Brakes:

Front and rear hydraulic disc brake systems, caliper overhaul, master cylinder repair, brake pad replacement, brake fluid specifications, bleeding procedures, and ABS system (if equipped).

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, and wheel balancing.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, and fuse box.

Instrumentation:

Speedometer, tachometer, fuel gauge, warning lights, and diagnostic indicators.

Bodywork Trim:

Fairing removal and installation, seat, panels, storage compartments, and cosmetic component replacement.

Diagnostic Troubleshooting:

Fault code interpretation (OBD-II if applicable), symptom-based troubleshooting guides, and common problem diagnosis.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel), spark plug checks, coolant flushes, brake fluid changes, and lubrication points.

Disassembly Assembly:

Step-by-step instructions for component removal and reinstallation with torque specifications.

Repair:

Detailed repair procedures for worn or damaged parts, including internal engine components, transmission elements, and electrical modules.

Checks Inspections:

Visual inspections, functional tests, and performance checks for all major systems.

Adjustments:

Throttle cable adjustment, brake lever adjustment, suspension settings, and idle speed adjustments.

Technical Depth

Depth:

In-depth, from basic owner maintenance to complete engine rebuilds and complex electrical diagnostics.

User Level:

Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (depending on PDF creation)

Print Quality

Quality:

Digital PDF - quality dependent on original source; typically good for technical diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, single-cylinder, liquid-cooled, 4-valve per cylinder

Displacement:

492.7 cc (30.08 cu in)

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.0:1

Engine Management:

Electronic Fuel Injection (EFI)

Lubrication:

Wet sump

Performance

Horsepower:

Approx. 40 HP (29.4 kW) @ 7,000 RPM

Torque:

Approx. 45 Nm (33.2 lb-ft) @ 5,500 RPM

Fuel System

Fuel Type:

Unleaded gasoline (95 RON recommended)

Fuel Tank Capacity:

15 Liters (3.96 US gal)

Fuel Delivery:

Electronic Fuel Injection (EFI) with throttle body diameter approx. 40mm.

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Drive:

Belt drive to rear wheel

Features

Clutch Type:

Automatic centrifugal clutch

Transmission Fluid:

Refer to manual for specific CVT fluid and engine oil specifications (often separate).

📐 Dimensions

Exterior

Length:

Approx. 2180 mm (85.8 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1480 mm (58.3 in) (with windscreen)

Wheelbase:

Approx. 1535 mm (60.4 in)

Weights

Dry Weight:

Approx. 196 kg (432 lbs)

Wet Weight:

Approx. 208 kg (459 lbs)

Maximum Load:

Refer to manual, typically around 170-180 kg rider + luggage.

🛡️ Safety Features

Active Features

Braking System:

Dual hydraulic disc front, single hydraulic disc rear. Some models may feature ABS (Anti-lock Braking System).

Lighting:

Halogen headlights, LED taillight and brake light, amber turn signals.

Passive Features

Frame Construction:

High-strength steel frame, designed for stability and rigidity.

Windscreen:

Aerodynamic windscreen for rider protection.

💡 Technology Features

Infotainment

Instrument Panel:

Digital LCD display for odometer, trip meter, fuel level, and clock; analog tachometer and speedometer.

Driver Assistance

Optional ABS system available on some models for enhanced braking safety.

Connectivity

Diagnostic Port:

On-board diagnostic capabilities allowing for fault code retrieval via an OBD-II compliant port or proprietary connector.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 km or 1 year, whichever comes first.

Oil Filter Replacement:

Every 10,000 km or 2 years.

Air Filter Cleaning Replacement:

Check every 5,000 km, replace as needed or every 10,000 km.

Spark Plug Check Replacement:

Check every 10,000 km, replace as needed (e.g., NGK CR9EB).

Cvt Belt Inspection Replacement:

Inspect every 10,000 km, replace typically around 20,000-30,000 km depending on wear.

Brake Fluid Change:

Every 2 years.

Coolant Flush Replacement:

Every 2-3 years or 20,000 km.

Fluid Specifications

Engine Oil Type:

Semi-synthetic or fully synthetic SAE 5W-40 API SG or higher.

Engine Oil Capacity:

Approx. 1.5 Liters (1.6 US qt) without filter change, 1.7 Liters (1.8 US qt) with filter change.

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.

Known Issues

Common Problems:

Potential for voltage regulator failure (leading to battery charging issues), CVT belt wear requiring timely replacement, occasional issues with fuel pump reliability, and some electrical connector corrosion.

Maintenance Tips:

Regular cleaning of electrical connectors, keeping battery terminals clean and charged, and adhering strictly to scheduled CVT belt inspections and replacements are crucial for longevity.

📚 Vehicle History

Brand Heritage

Heritage:

Gilera, an Italian manufacturer with a long history dating back to 1909, is renowned for its sporty motorcycles and scooters, often associated with performance and innovative design. It is part of the Piaggio Group.

Model Evolution

Evolution:

The Nexus series was Gilera's flagship maxi-scooter line, competing at the higher end of the market with a focus on performance and premium features. The 500cc model was a key offering in this segment.

Production

Manufacturing Location:

Italy

Production Period:

The Nexus 500 was produced for several years, with the Mk1 designation referring to the initial generation and variations.

🏆 Awards & Recognition

Recognitions

Recognition:

While specific awards for the 2006 Mk1 may not be widely documented, the Gilera Nexus line generally received positive reviews for its performance and styling within the maxi-scooter segment.