2005 2006 Gilera Nexus 500 MK1 Service Repair Workshop Manual Download (2005 2006) PDF

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 MK1 Year: 2005-2006 Market Segment: Maxi-scooter 👋 Introduction Market Position Vehicle Class: High-performance maxi-scooter Competitive Analysis Key Competitors: Suzuki Burgman 400/650,...

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Type: Motorcycle

Vendor:

Sku: 40778

Tags: 2005 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500 MK1

Product variants

Description

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500 MK1

Year:

2005-2006

Market Segment:

Maxi-scooter

👋 Introduction

Market Position

Vehicle Class:

High-performance maxi-scooter

Competitive Analysis

Key Competitors:

Suzuki Burgman 400/650, Yamaha TMAX, Honda Silver Wing

Key Features

Manual Benefit:

Empowers both DIY enthusiasts and professional mechanics with detailed, factory-level information.

Manual Benefit Cost Savings:

Inexpensive method to maintain optimal vehicle performance and reduce repair costs.

Manual Advantage

User Focus:

Specifically written for both the do-it-yourselfer and the experienced mechanic.

📋 Manual Details

Coverage

Manual Type:

Service Repair Workshop Manual

Language:

English

Format

File Format:

Availability

Delivery Method:

Instant Download

Completeness

Coverage Statement:

Covers every single detail on the machine from basic checks to complete disassembly.

📖 Manual Coverage

Systems

Systems Covered:

• General Characteristics

• Tooling

• Maintenance

• Electrical System

• Engine

• Injection System

• Suspension System

• Braking System

• Cooling System

• Chassis

• Pre-Delivery Checks

• Timing System

Procedures

Procedures Included:

• Routine Maintenance

• Troubleshooting

• Component Disassembly

• Component Reassembly

• Repair Procedures

• Adjustments

• Inspections

• Lubrication

• Electrical Diagnostics

• Engine Rebuilds

Depth

Technical Depth:

Comprehensive (from basic maintenance to complete disassembly and rebuild)

Diagrams Illustrations

Visual Aid Quality:

Top quality diagrams and exploded pictures for clear instruction.

Instructions Style

Instruction Format:

Step-by-step instructions.

Troubleshooting Assistance

Diagnostic Capabilities:

Includes troubleshooting sections to diagnose and resolve common issues.

📊 Manual Specifications

File Properties

Printability:

All pages printable

Searchability:

Likely text-searchable within PDF, though not explicitly stated

Software Requirements

PDF Reader:

Adobe PDF Reader

Unzipping Tool:

WinZip or equivalent

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke

Displacement:

460 cc (28.0 cu in)

Cooling System:

Liquid-cooled

Performance

Horsepower Estimated:

~33.3 hp (24.8 kW) @ 7000 rpm (estimated)

Torque Estimated:

~36 Nm (26.5 lb-ft) @ 5500 rpm (estimated)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Ignition System:

Electronic Ignition

Engine Management

Engine Control Unit:

ECU controlled fuel and ignition timing

Engine Identification

Engine Code Family:

Quasar (common Piaggio/Gilera engine family)

🔧 Transmission

Powertrain

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Drive Type:

Belt drive to rear wheel

Features

Clutch Type:

Wet multi-plate automatic clutch

📐 Dimensions

Exterior

Length Estimated:

Approx. 2,170 mm (85.4 in)

Width Estimated:

Approx. 780 mm (30.7 in)

Height Estimated:

Approx. 1,390 mm (54.7 in)

Weights

Dry Weight Estimated:

Approx. 195 kg (430 lbs)

Wet Weight Estimated:

Approx. 208 kg (459 lbs)

Fuel Capacity:

15 Liters (3.96 US gal)

Wheelbase

Wheelbase Estimated:

Approx. 1,500 mm (59.1 in)

🛡️ Safety Features

Braking System

Front Brake Type:

Dual disc brakes

Rear Brake Type:

Single disc brake

ABS Availability:

Optional on some models

Features

Lighting:

Halogen headlight, LED tail light

💡 Technology Features

Infotainment

Dashboard Display:

Digital and analog instrument cluster with speed, RPM, fuel level, engine temperature, and clock.

Connectivity

Storage Compartment:

Under-seat storage with ample space for a helmet.

Comfort Features

Windscreen:

Adjustable or fixed windscreen for rider protection.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/time intervals (typically 5,000-7,500 km or annually)

Spark Plug Replacement:

Refer to manual for specific intervals

Fluid Specifications

Engine Oil Type Recommendation:

Refer to manual for exact API/JASO specifications (e.g., SAE 5W-40 Synthetic)

Coolant Type:

Ethylene glycol-based antifreeze/coolant (refer to manual for specific mix ratio and type)

Brake Fluid Type:

DOT 4 (refer to manual for confirmation)

Known Issues

Common Wear Items:

Transmission belt, variator rollers, brake pads, suspension bushings (typical for maxi-scooters of this era)

Potential Electrical Faults:

Wiring harness integrity, regulator/rectifier issues (common in many scooters)

Parts Information

Manual Utility For Parts:

Provides diagrams and part identification crucial for ordering correct replacement components.

Maintenance Schedule Overview

Manual Utility Schedule:

Provides detailed maintenance schedules and procedures.

📚 Vehicle History

Brand Heritage

Parent Company:

Piaggio & C. S.p.A.

Model Evolution

Gilera Nexus Lineage:

The Nexus 500 was Gilera's flagship maxi-scooter, known for its sporty handling and powerful engine.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Industry Perception:

Praised by enthusiasts for its powerful engine and agile handling for a maxi-scooter.