Gilera Nexus 500 2005-2006 Full Service Repair Manual

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This manual covers the maxi-scooter, produced for the 2005 and 2006 model years. The maxi-scooter, a product of the Piaggio Group, was designed as a sporty and agile maxi-scooter, offering...

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Tipo: Motorcycle

Proveedor:

SKU: 75397

Etiquetas: 2005 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500

Variantes de producto

Descripción

This manual covers the maxi-scooter, produced for the 2005 and 2006 model years. The maxi-scooter, a product of the Piaggio Group, was designed as a sporty and agile maxi-scooter, offering motorcycle-like handling and performance within its class. It competed against other premium offerings such as the Yamaha TMAX 500 and Honda Silver Wing 600, aiming to provide a blend of comfort for longer journeys and dynamic riding characteristics. The Gilera brand, with its heritage dating back to 1909, is known for its focus on performance-oriented two-wheeled vehicles. This comprehensive English-language service and repair manual is designed to provide detailed guidance for maintaining and repairing the maxi-scooter. It covers all essential aspects of the vehicle, including in-depth engine repair, transmission maintenance, electrical system diagnostics with wiring diagrams, chassis and suspension procedures, brake system servicing, and bodywork. The manual includes routine maintenance schedules, troubleshooting guides for common and complex issues, and step-by-step instructions for component replacement and engine rebuilding. Its extensive content and detailed sub-steps are intended to empower owners and professional technicians alike.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Model Years Covered:

2005-2006

👋 Introduction

Market Position

Vehicle Type:

Maxi-scooter

Brand Positioning:

Gilera, a Piaggio Group brand, is known for performance-oriented scooters and motorcycles.

Competitive Analysis

Competitors 2005 2006:

Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600, Aprilia Atlantic 500.

Key Features Vehicle

Design Philosophy:

The Nexus 500 was positioned as a sporty, agile maxi-scooter with motorcycle-like handling and performance.

Key Features Manual

Benefit To Owner:

Empowers owners and technicians to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on specialized workshops.

Content Organization:

Features a numbered table of contents for quick information retrieval and utilizes bold figure numbers to link illustrations with instructions.

📋 Manual Details

Coverage Areas

Primary Focus:

Full Service and Repair

Page Count

Estimated Page Count:

Extensive (Specific count not provided, but described as 'very detailed' and 'comprehensive')

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed repair, maintenance, and rebuilding procedures for the 500cc engine.

Transmission:

Covers maintenance, repair, and diagnostics for the transmission system.

Electrical System:

Comprehensive coverage including detailed wiring diagrams, troubleshooting, and electrical service procedures.

Chassis And Suspension:

Includes procedures for suspension, steering, and chassis components.

Brakes:

Detailed information on brake system maintenance and repair.

Fuel System:

Covers fuel delivery, injection (if applicable), and related components.

Cooling System:

Maintenance and repair procedures for the engine's cooling system.

Exhaust System:

Information on exhaust system components and service.

Bodywork And Trim:

Procedures for body panels, trim, and related components.

Procedures Included

Routine Maintenance:

Covers all routine maintenance tasks as per service schedules.

Troubleshooting:

Extensive troubleshooting guides for common and complex issues, including electrical diagnostics.

Engine Rebuild:

Detailed step-by-step instructions for engine rebuilding and overhaul.

Component Replacement:

Guidance on replacing all major and minor vehicle components.

Diagnostics:

In-depth diagnostic procedures for all vehicle systems.

Technical Depth

Depth Level:

Comprehensive, suitable for professional technicians and experienced DIY mechanics.

Detail Level:

Detailed sub-steps, notes, cautions, and warnings provided for each procedure.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Full Printable

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

Requirements

Software:

Adobe PDF Reader, WinRAR

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder

Displacement:

493 cc (approx.)

Bore X Stroke:

Typically around 94 mm x 71 mm (specifics to be confirmed in manual)

Cooling System:

Liquid-cooled

Valve Train:

SOHC, 4 valves

Performance

Horsepower Output:

Around 33-35 HP (Specific dyno figures may vary, manual will provide official specs)

Torque Output:

Around 40-45 Nm (Specific figures to be confirmed in manual)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Keihin or similar ECU likely

Ignition System:

Digital electronic ignition

Lubrication System

Oil Type:

Full Synthetic SAE 5W-40 or 10W-40 (Specific Gilera recommendation in manual)

Oil Capacity:

Approx. 1.5 - 1.7 liters (check manual for precise capacity and filter change amount)

🔧 Transmission

Standard

Type:

Automatic CVT (Continuously Variable Transmission)

Optional

Options:

N/A (CVT is standard)

Features

Drive Type:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

📐 Dimensions

Exterior

Length:

Approximately 2170 mm (specifics in manual)

Width:

Approximately 780 mm (specifics in manual)

Height:

Approximately 1450 mm (specifics in manual)

Wheelbase:

Approximately 1505 mm (specifics in manual)

Weights

Dry Weight:

Around 185-190 kg (specifics in manual)

Gross Vehicle Weight Rating:

Not explicitly stated, but implies capacity for rider and cargo.

Tires

Front Tire Size:

120/70-15 (Typical, verify in manual)

Rear Tire Size:

160/60-15 (Typical, verify in manual)

Wheels

Wheel Type:

Alloy

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle/Scooter safety is assessed differently than cars, but chassis integrity and braking performance are key)

Active Features

Braking System:

Front: Dual hydraulic disc brakes; Rear: Single hydraulic disc brake. ABS may have been an option on some models, verify for 2005-2006.

Passive Features

Lighting:

Dual headlights, LED taillight (typical for the era).

💡 Technology Features

Infotainment

Instrument Cluster:

Digital and analog display for speed, RPM, fuel level, engine temperature, clock, odometer, trip meter. Indicator lights for turn signals, high beam, oil pressure, etc.

Driver Assistance

ABS Availability:

ABS was an optional feature for some models in this range. Manual will clarify if ABS is covered and its operation.

Connectivity

Charging Port:

Likely features a 12V auxiliary power outlet for charging devices (verify in manual).

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km or annually (verify specific interval in manual)

Air Filter Check:

Every 6,000 km (clean/replace as needed, verify in manual)

Spark Plug Replacement:

Every 12,000 km (verify in manual)

Valve Clearance Check:

Every 12,000 km or 24,000 km (verify in manual)

Fluid Specifications

Coolant Type:

Ethylene glycol based coolant (e.g., Piaggio Coolant or equivalent, verify in manual)

Brake Fluid Type:

DOT 4 (verify in manual for specific requirements)

Known Issues

Common Wear Items:

CVT belt and rollers, suspension bushings, brake pads.

Potential Electrical Gremlins:

While not endemic, any older Italian scooter can have minor electrical connection issues if not maintained. The manual's electrical diagrams are invaluable.

Engine Reliability:

The 500cc engine is generally robust, but regular maintenance is key to longevity. Overheating can be an issue if the cooling system is neglected.

📚 Vehicle History

Brand Heritage

Manufacturer:

Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, now part of the Piaggio Group.

Model Evolution

Nexus Lineage:

The Nexus 500 represented Gilera's strong offering in the performance maxi-scooter segment, emphasizing sportiness and comfort.

Production

Manufacturing Location:

Italy (Piaggio Group plants)

🏆 Awards & Recognition

Recognitions

Segment Accolades:

The Nexus 500 was generally well-regarded in its segment for its performance and handling, though specific awards are not widely publicized.