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    Gilera Nexus 500 2005-2006 Workshop Service Repair Manual

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    The Gilera Nexus 500 is a premium maxi-scooter model produced for the 2005-2006 model years. Combining Italian design heritage with robust engineering, this scooter was developed to offer a balance...
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    Type: Motorcycle
    Vendor:
    Sku: 80165
    The Gilera Nexus 500 is a premium maxi-scooter model produced for the 2005-2006 model years. Combining Italian design heritage with robust engineering, this scooter was developed to offer a balance of sporty performance and comfortable touring capabilities. It features a powerful 492.6 cc single-cylinder, 4-stroke, liquid-cooled engine with electronic fuel injection, delivering approximately 33.3 HP and 42.5 Nm of torque. Key aspects include its automatic CVT transmission, linked braking system with dual front discs and a rear disc, and a substantial fuel tank capacity of approximately 15 liters, making it suitable for both urban commuting and longer journeys. This comprehensive workshop service repair manual in English provides detailed guidance for the maintenance and repair of the Gilera Nexus 500. It covers all major systems, including engine mechanicals, engine electricals, fuel system, suspension, clutch, transmission, drivetrain, steering, brakes, and body components. The manual includes step-by-step repair instructions, diagnostic procedures, troubleshooting guides for common issues, and detailed wiring diagrams. It is designed to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of the vehicle, offering factory-level technical detail for effective service.
    🏷️ Basic Information
    Identification
    Make:
    Gilera
    Model:
    Nexus 500
    Years Covered:
    2005-2006
    👋 Introduction
    Market Position
    Product Category:
    Premium Maxi-Scooter
    Key Features
    Value Proposition:
    Cost-effective solution for maintaining optimal vehicle performance and longevity, suitable for both DIY and professional use.
    📋 Manual Details
    Coverage Areas
    Primary Scope:
    Comprehensive service and repair
    Vehicle Type:
    Maxi-scooter
    Page Count
    Estimated Page Count:
    Varies by specific manual edition, typically 300+ pages for a complete workshop manual.
    Manual Type
    Type:
    Workshop Service Repair Manual
    Language
    Language:
    English
    Format
    File Format:
    PDF
    📖 Manual Coverage
    Systems Covered
    Engine Mechanical:
    Full coverage: disassembly, inspection, repair, assembly of engine components (e.g., cylinder, piston, crankshaft, valve train).
    Engine Electrical:
    Detailed coverage: ignition system, starting system, charging system, fuel injection system, sensors, ECU.
    Emission Control:
    Coverage of emission control systems, catalysts, and related components.
    Fuel System:
    Complete coverage: fuel pump, injectors, fuel lines, fuel tank, EFI diagnostics.
    Suspension:
    Front and rear suspension systems: forks, shock absorbers, linkages, adjustments.
    Clutch:
    Variator, clutch assembly, and related components.
    Transmission:
    CVT (Continuously Variable Transmission) system: maintenance, component inspection, and replacement.
    Drivetrain:
    Final drive, belt, rollers, clutch bell inspection and replacement.
    Steering:
    Handlebar assembly, steering bearings, and related components.
    Brakes:
    Front and rear brake systems: hydraulic lines, calipers, master cylinders, brake pads, discs, bleeding procedures.
    Body Interior Exterior:
    Body panels, fairings, seat, storage, lighting, mirrors.
    Body Electrical:
    Complete wiring diagrams, lighting circuits, instrument panel, switches, horn, battery, starter motor.
    Restraint Systems:
    Seat belt mechanisms (if applicable for certain markets/configurations).
    Procedures Included
    Maintenance:
    Scheduled maintenance: oil changes, filter replacements, spark plugs, coolant, belt checks, brake service.
    Troubleshooting:
    Extensive troubleshooting guides for common and complex issues, including electrical diagnostics.
    Repair:
    Step-by-step repair instructions for all major systems, from minor adjustments to major component overhauls.
    Diagnostics:
    Diagnostic procedures for engine management, fuel injection, and electrical systems.
    Wiring Schematics:
    Detailed and integrated wiring diagrams for all electrical components and systems.
    Technical Depth
    Depth:
    Factory-level technical detail suitable for professional mechanics and advanced DIY enthusiasts.
    📊 Manual Specifications
    File Format
    Compatibility:
    Compatible with all versions of Windows and Mac OS.
    Print Quality
    Printability:
    Fully printable, allowing users to print specific sections or the entire manual.
    Navigation
    Searchability:
    Likely searchable text within PDF for quick information retrieval.
    Viewing Requirements
    Software Requirements:
    Adobe Acrobat Reader (or compatible PDF viewer) and WinZip (or compatible unarchiver).
    Viewing Capabilities
    Zoom Functionality:
    YES (Zoom IN/OUT functionality for detailed viewing of diagrams and illustrations).
    ⚙️ Engine Specifications
    Primary Engine
    Engine Type:
    Single-cylinder, 4-stroke, liquid-cooled
    Displacement:
    492.6 cc
    Performance
    Bore X Stroke:
    93 mm x 73 mm
    Compression Ratio:
    10.5:1
    Power Output:
    Approximately 33.3 HP (24.5 kW) at 6,500 RPM (specific figures may vary slightly by region/tune).
    Torque:
    Approximately 42.5 Nm (31.3 lb-ft) at 5,500 RPM (specific figures may vary slightly by region/tune).
    Fuel System
    Fuel Delivery:
    Electronic Fuel Injection (EFI)
    Fuel Type:
    Unleaded gasoline (95 RON recommended)
    🔧 Transmission
    Standard
    Type:
    Automatic (CVT - Continuously Variable Transmission)
    Features
    Clutch Type:
    Automatic centrifugal clutch
    Final Drive:
    Belt drive to rear wheel
    📐 Dimensions
    Exterior
    Length:
    Approx. 2,170 mm
    Width:
    Approx. 770 mm
    Height:
    Approx. 1,420 mm (seat height likely around 790 mm)
    Weights
    Dry Weight:
    Approx. 185 kg
    Gross Vehicle Weight Rating:
    Not explicitly specified in product info, but typically around 350-380 kg.
    Capacities
    Fuel Tank Capacity:
    Approx. 15 liters
    Oil Capacity:
    Engine oil: Approx. 1.6 liters (without filter change), 1.8 liters (with filter change). Transmission oil not separately specified but typically shared or contained within CVT housing.
    🛡️ Safety Features
    Active Features
    Braking System:
    Linked braking system (front and rear brakes partially actuated simultaneously).
    Front Brakes:
    Dual 240 mm discs
    Rear Brakes:
    Single 240 mm disc
    Passive Features
    Lighting:
    Dual headlights, taillight, turn signals.
    💡 Technology Features
    Infotainment
    Instrument Cluster:
    Digital and analog display including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, and warning lights.
    Driver Assistance
    ABS:
    ABS (Anti-lock Braking System) was often an optional feature on this model, depending on the specific market and configuration.
    🔧 Maintenance
    Service Intervals
    Engine Oil And Filter:
    Typically every 5,000 - 7,500 km or annually, whichever comes first. Refer to manual for precise intervals.
    Spark Plug:
    Inspect every 5,000 km, replace as needed. Refer to manual for exact type and gap.
    Air Filter:
    Inspect every 5,000 km, clean or replace as needed. Refer to manual for specific cleaning agents.
    Cvt Belt And Rollers:
    Inspect CVT belt wear and roller condition every 10,000 - 15,000 km. Replace belt if cracked, frayed, or worn. Replace rollers if damaged or excessively worn.
    Fluid Specifications
    Engine Oil:
    API SG or higher, SAE 10W-40 or 15W-50 (depending on ambient temperature). Refer to manual for exact specification and capacity.
    Coolant:
    Ethylene glycol based coolant, 50/50 mix with distilled water. Refer to manual for specific type and capacity.
    Brake Fluid:
    DOT 4 hydraulic brake fluid.
    Known Issues
    Common Concerns:
    Potential for wear on CVT components (belt, rollers) over time. Some units may experience minor electrical gremlins if not maintained. Regular checks of fuel system and cooling system are recommended.
    📚 Vehicle History
    Brand Heritage
    Manufacturer:
    Gilera is an Italian manufacturer with a long history in motorcycle production, known for performance-oriented vehicles.
    Model Evolution
    Introduction Context:
    The Nexus 500 was a flagship model for Gilera in the maxi-scooter segment, aimed at providing touring comfort with sporty performance.
    Production
    Manufacturing Origin:
    Italy
    🏆 Awards & Recognition
    Recognitions
    Awards:
    Specific awards for the Gilera Nexus 500 are not widely publicized, but it was recognized in its segment for its performance and comfort upon release.
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