2005 2006 Gilera Nexus 500 MK1 Service Repair Workshop Manua

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The Nexus 500 MK1, produced for the 2005 and 2006 model years, represents a strong entry into the premium maxi-scooter segment. Designed with a philosophy that blends sporty handling with...

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Type: Motorcycle

Vendor:

Sku: 58119

Tags: 2005 2006 Gilera Motorcycle Motorcycles Nexus Nexus 500 MK1

Product variants

Description

The Nexus 500 MK1, produced for the 2005 and 2006 model years, represents a strong entry into the premium maxi-scooter segment. Designed with a philosophy that blends sporty handling with the comfort and practicality expected of a maxi-scooter, this model offers excellent aerodynamics for stability at higher speeds, making it suitable for both commuting and touring. Known for its performance-oriented engineering and Italian heritage, the Nexus 500 aims to provide a dynamic riding experience, distinguishing itself through its blend of agility and substantial power from its 493 cc single-cylinder engine. This comprehensive Service Repair Workshop Manual provides detailed information for the Nexus 500 MK1. It covers a wide range of topics essential for maintaining and repairing the vehicle, including in-depth engine and transmission overhauls, chassis and suspension service, brake system maintenance, and complete electrical system diagnostics with wiring diagrams. The manual also details scheduled maintenance procedures, troubleshooting common issues, and provides critical technical specifications and data, ensuring owners and technicians have the resources to keep the scooter in optimal condition.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Generation:

Model Years Covered:

2005, 2006

Codes

Internal Project Code:

Project Gilera Nexus 500 (MK1)

👋 Introduction

Market Position

Segment:

Premium Maxi-Scooter

Target Audience:

Commuters seeking performance, touring capability, and advanced features

Competitive Analysis

Key Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600

Key Features

Design Philosophy:

Sporty handling blended with maxi-scooter comfort and practicality

Aerodynamics:

Designed for wind protection and stability at higher speeds

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and workshop information

Secondary Coverage:

Maintenance schedules, troubleshooting, diagnostics, component replacement, electrical systems, wiring diagrams

Page Count

Estimated Pages:

Over 300

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system, exhaust system

Transmission:

Automatic transmission (CVT) operation, maintenance, disassembly, reassembly, fluid specifications

Chassis Suspension:

Front suspension (forks), rear suspension (shock absorber, swingarm), steering system, wheel bearings

Brakes:

Front and rear braking systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper and master cylinder service

Electrical System:

Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting system (headlight, taillight, indicators), ignition system components, sensors, ECU, wiring diagrams, troubleshooting electrical faults

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body, emission control systems

Bodywork Fairings:

Body panel removal and installation, fairing components, seating, storage compartments

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, valve clearance checks, drive belt inspection/replacement, brake service intervals, coolant checks/replacement

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, error code interpretation (if applicable), performance problems

Repair Overhaul:

Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly of major vehicle systems

Electrical Diagnostics:

Detailed wiring diagrams, component testing procedures, voltage drop tests, continuity checks

Specifications Data:

Torque specifications for all fasteners, fluid capacities, clearances, tolerances, electrical values

Technical Depth

Depth:

Comprehensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds and advanced electrical diagnostics.

📊 Manual Specifications

File Format

Format:

Portable Document Format (PDF)

Searchability:

Searchable text for quick information retrieval

Print Quality

Quality:

High-resolution scans, clear text and legible diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Single-cylinder, four-stroke, liquid-cooled, DOHC

Displacement:

493 cc

Bore X Stroke:

94 mm x 71 mm (approximate, requires manual confirmation for exact spec)

Compression Ratio:

10.0:1 (approximate, requires manual confirmation for exact spec)

Performance

Horsepower:

Approximately 40 HP @ 7,000 RPM (requires manual confirmation for exact spec)

Torque:

Approximately 46 Nm @ 5,500 RPM (requires manual confirmation for exact spec)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Lubrication System

Oil Type:

Semi-synthetic or fully synthetic SAE 10W-40 motorcycle oil (refer to manual for exact API/JASO spec)

Oil Capacity:

Approximately 1.7 liters (dry fill), 1.5 liters (with filter change) (requires manual confirmation)

Cooling System

Coolant Type:

Ethylene glycol based coolant (50/50 mix with distilled water) (refer to manual for exact specification)

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Drive Type:

Belt drive

Optional

Optional Transmission:

N/A (CVT is standard)

Features

Gear Reduction:

Automatic variable ratios for optimal performance and fuel economy

Transmission Fluid:

Specific CVT fluid or SAE 80W-90 gear oil (refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Length:

Approx. 2,250 mm (requires manual confirmation)

Width:

Approx. 800 mm (requires manual confirmation)

Height:

Approx. 1,400 mm (requires manual confirmation)

Wheelbase:

Approx. 1,560 mm (requires manual confirmation)

Weights

Dry Weight:

Approx. 200 kg (requires manual confirmation)

Gross Vehicle Weight Rating:

Requires manual confirmation

Cargo

Underseat Storage:

Sufficient for one full-face helmet and additional items (refer to manual for specifics)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle)

Active Features

Braking System:

Dual front disc brakes with potent calipers, single rear disc brake

Optional ABS:

ABS available on certain models/markets (requires manual confirmation for specific year/trim)

Passive Features

Lighting:

Halogen headlight, LED taillight and indicators (depending on market configuration)

Mirrors:

Large, adjustable mirrors for good rearward visibility

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature gauge, various indicator lights.

Driver Assistance

Optional Anti-lock Braking System (ABS) available on some models, greatly enhancing safety during braking.

Connectivity

Diagnostic Port:

On-board diagnostics port for ECU access and troubleshooting (location detailed in manual).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km or 6 months (whichever comes first) (refer to manual for exact interval)

Oil Filter Replacement:

Every 6,000 km or 12 months (refer to manual for exact interval)

Air Filter Cleaning Replacement:

Check every 3,000 km, clean/replace as needed (refer to manual)

Spark Plug Replacement:

Every 6,000 km or 12 months (refer to manual for exact interval and plug type)

Drive Belt Inspection:

Inspect every 6,000 km, replace as needed (refer to manual for replacement interval)

Valve Clearance Check:

Every 12,000 km or 24 months (refer to manual for exact interval)

Fluid Specifications

Engine Oil Specification:

SAE 10W-40 API SG or higher, JASO MA (refer to manual for precise specification)

Brake Fluid Specification:

DOT 4 hydraulic fluid (refer to manual for precise specification)

Coolant Specification:

Ethylene glycol based coolant, 50% mixture with distilled water (refer to manual for precise specification)

Known Issues

Common Complaints:

Some owners have reported issues with stator reliability, fuel pump longevity, and occasional electrical gremlins. The manual will guide on diagnosis and repair for these potential issues.

Drive Belt Wear:

Regular inspection of the CVT drive belt is crucial as wear can lead to performance degradation.

📚 Vehicle History

Brand Heritage

Manufacturer:

Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and innovative models.

Model Evolution

Nexus Lineage:

The Nexus line represented Gilera's entry into the premium maxi-scooter segment, focusing on performance and handling.

Production

Production Period:

2003-2008 (approximate for Nexus line)

Parent Company:

Gilera was part of the Piaggio Group during this period.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2005-2006 Gilera Nexus 500 MK1 are not widely documented, it was generally well-received in reviews for its performance and handling within the maxi-scooter segment.