Gilera 2005 2006 Nexus 500 euro 3 Service Repair Manual

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Type: Motorcycle

Vendor:

Sku: 52625

Tags: 2005 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500 euro 3

Product variants

Description

The Nexus 500, produced for the 2005 and 2006 model years, represents a commitment to performance-oriented maxi-scooters, blending sporty handling with everyday practicality. Featuring a Euro 3 compliant engine, this model offers a robust platform for both commuting and longer journeys. Its design, rooted in a long heritage of Italian engineering excellence, provides a unique combination of style and capability, making it a notable option in its class. This comprehensive workshop and service repair manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the Nexus 500. It covers essential areas including routine maintenance, detailed engine and transmission service, chassis and electrical system diagnostics, and bodywork. With step-by-step procedures, troubleshooting guides, and OEM specifications, this manual empowers users to perform all necessary upkeep and repairs efficiently and accurately.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Model Year:

2005, 2006

Engine Variant:

Euro 3 Compliant

👋 Introduction

Market Position

Target Audience:

Owners, mechanics, and enthusiasts of the Gilera Nexus 500 (2005-2006 models)

Key Features

Delivery Method:

Instant download link via email after purchase

Support:

Lifetime Protection Policy (replacement if lost or damaged)

Value Proposition

Benefit:

Empowers users to perform repairs, maintenance, and diagnostics efficiently and accurately, saving time and money on dealership visits.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Troubleshooting, Diagnostics

Page Count

Estimated Page Count:

Estimated 300-500 pages (typical for comprehensive service manuals, exact count not provided)

Manual Type

Type:

Workshop Manual / Service Repair Manual

Language

Language:

English

Format

Digital Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine Removal and Installation, Engine Specifications, Lubrication and Cooling System, Fuel System (including EFI diagnostics), Intake & Exhaust

Drivetrain Systems:

Transmission, Drive Chain & Sprockets

Chassis Systems:

Steering System, Shocks (Suspension), Brakes, Wheels and Tires

Electrical Systems:

Electrical System (wiring diagrams, component testing, ignition, lighting)

Bodywork And Frame:

Body Work, Frame Inspection and Repair

Procedures Included

Routine Maintenance:

Lubrication, Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Coolant Checks

Disassembly Assembly:

Detailed step-by-step procedures for component removal and installation, including major sub-assemblies

Troubleshooting:

Advanced Troubleshooting guides for common and complex issues, diagnostic flowcharts

Engine Rebuild:

Major engine repair and rebuild procedures, including piston, ring, valve, and cylinder head service

Electrical Diagnostics:

Component testing, wiring harness inspection, diagnostic codes interpretation

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIY enthusiasts

Data Accuracy:

OEM Specifications (torque values, clearances, tolerances, fluid capacities, pressure charts)

Illustrations:

Exploded diagrams, charts, and photos for visual guidance

📊 Manual Specifications

File Format

Format:

Compatibility:

All Windows & Mac versions, smartphones, iPads, tablets

Print Quality

Printability:

Printable

Binding Type

Binding Type:

Digital Download (no physical binding)

Paper Type

Paper Type:

N/A (Digital PDF)

Requirements

Software Requirement:

Adobe PDF Reader (free download available)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled (likely Piaggio Master engine)

Displacement:

Approx. 492 cc (exact figure may be detailed in manual)

Bore X Stroke:

Specifics available in manual

Performance

Horsepower:

Estimated 34-38 HP (specific figures in manual)

Torque:

Estimated 43-46 Nm (specific figures in manual)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Emission Standard:

Euro 3

Engine Components

Valve Train:

SOHC, 4 valves (typical for Piaggio Master)

Cooling System:

Liquid-cooled, Radiator, Fan

🔧 Transmission

Standard

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Clutch Type:

Automatic Centrifugal Clutch

Features

Drive Type:

Belt Drive to Rear Wheel via Final Drive

📐 Dimensions

Exterior

Length:

Specifics available in manual

Width:

Specifics available in manual

Height:

Specifics available in manual

Weights

Dry Weight:

Approx. 198 kg (specifics in manual)

Gross Vehicle Weight Rating:

Specifics available in manual

🛡️ Safety Features

Active Features

Brakes Front:

Dual Disc Brakes (specific diameters in manual)

Brakes Rear:

Single Disc Brake (specific diameter in manual)

Available as optional equipment on some models, details in manual

Passive Features

Lighting:

Halogen Headlight, LED Taillight (specific bulb types in manual)

💡 Technology Features

Infotainment

Dashboard:

Analog/Digital combination instrument cluster with features like speedometer, tachometer, fuel gauge, odometer, trip meter, clock, and warning lights. Specifics detailed in manual.

Driver Assistance

Optional ABS system; troubleshooting and maintenance for ABS components covered if equipped.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual (typically 5,000-10,000 km or annually)

Spark Plug Replacement:

Refer to manual (specific intervals for replacement and checking)

Belt Check Replacement:

Refer to manual for inspection intervals and replacement recommendations for the CVT belt.

Fluid Specifications

Engine Oil Type:

Specific viscosity and API/JASO rating (e.g., SAE 10W-40, API SG/SH or higher, JASO MA) detailed in manual.

Engine Oil Capacity:

Specific capacity for oil change and with filter replacement provided in manual.

Coolant Type:

Ethylene glycol-based antifreeze/coolant mixture, specific type and ratio in manual.

Brake Fluid Type:

DOT 4 recommended, specific type and change interval in manual.

Known Issues

Common Problems:

While not explicitly stated, common maxi-scooter issues can include CVT belt wear, occasional electrical gremlins, and fuel injection system maintenance. The manual will detail troubleshooting for these.

📚 Vehicle History

Brand Heritage

Manufacturer:

Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for performance-oriented scooters and motorcycles. It is now part of the Piaggio Group.

Model Evolution

Model Lineage:

The Nexus 500 represented a move towards larger displacement, more powerful maxi-scooters for Gilera, blending sportbike-like handling with urban practicality.

Production

Manufacturing Location:

Likely Italy (as part of Piaggio Group)

🏆 Awards & Recognition

Recognitions

Design Awards:

While specific awards for the 2005-2006 Nexus 500 are not widely publicized, Gilera models are generally recognized for their Italian styling and engineering.