The Gilera Nexus 500, produced between 2005 and 2009, represents a premium maxi-scooter designed for discerning riders seeking a blend of sporty performance and touring comfort. Featuring a powerful 460cc Piaggio Quasar engine, this Italian-engineered machine offers robust performance with approximately 34 HP and 42 Nm of torque, making it suitable for both urban commuting and longer journeys. Its design emphasizes sporty handling, comfortable ergonomics, and premium aesthetics, positioning it as a strong competitor in the sport-touring scooter segment. The Nexus 500 is built upon a high-strength steel frame and incorporates advanced features like electronic fuel injection and an automatic CVT transmission, ensuring a smooth and responsive riding experience. This comprehensive workshop service repair manual provides essential information for the maintenance and repair of the Gilera Nexus 500 (all variants) from 2005 to 2009. It covers all major vehicle systems, including the powertrain, chassis, and electrical components, offering detailed procedures for engine overhaul, transmission repair, suspension and brake system maintenance, and electrical diagnostics. The manual includes step-by-step guides for assembly and disassembly, regular servicing, troubleshooting common issues, and understanding diagnostic trouble codes. With high-resolution diagrams and clear instructions, this English-language manual is an invaluable resource for owners, mechanics, and technicians aiming to keep their Gilera Nexus 500 in optimal condition. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Year: 2005-2009 Engine Type: Euro 3 Compliant Codes Emissions Standard: Euro 3 👋 Introduction Market Position Segment: Maxi-scooter, Sport Touring Target Audience: Commuters seeking performance and comfort, touring riders Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing Key Features Vehicle Usp: Sporty handling, powerful engine, comfortable ergonomics for longer rides, premium Italian design 📋 Manual Details Coverage Areas Vehicle Coverage: Gilera Nexus 500 (all variants) from 2005 to 2009 Page Count Estimated Pages: Comprehensive (typically 300+ pages for this type of manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Fuel System, Ignition System, Exhaust System Chassis: Suspension (Front & Rear), Steering System, Braking System (Front & Rear), Wheels & Tires Electrical: Wiring Diagrams, Lighting, Ignition, Starting System, Charging System, Instrumentation, ECU (Engine Control Unit), ABS (if equipped) Bodywork: Body Panels, Fairings, Seats, Storage Compartments, Ergonomics Procedures Included Maintenance: Regular Servicing, Oil Changes, Filter Replacements, Spark Plug Replacement, Drive Belt Inspection/Replacement, Coolant Checks Diagnostics: Troubleshooting Common Issues, Diagnostic Trouble Codes (DTCs), Fault Finding Procedures Repair: Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Repair/Replacement Assembly Disassembly: Step-by-step guides for disassembling and reassembling all major vehicle components Technical Depth Depth: Complete overhaul and detailed repair procedures, suitable for professional technicians and experienced DIY enthusiasts 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Resolution: High resolution for clear viewing and printing of diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Model: Piaggio Quasar 460cc Single Cylinder Engine Displacement: 460 cc Bore X Stroke: 92 mm x 69 mm (approx.) Valve Train: SOHC, 4 Valves Cooling System: Liquid-Cooled Performance Horsepower: Approx. 34 HP (25 kW) at 7,500 rpm Torque: Approx. 42 Nm (31 lb-ft) at 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body Fuel Type: Unleaded Gasoline (95 RON recommended) Engine Oil Oil Type Specification: API SG or higher, SAE 10W-40 (or as specified in manual) Oil Capacity: Approx. 1.7 Liters (including filter replacement) Ignition Ignition System: Electronic Ignition (CDI/ECU Controlled) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with dry clutch Features Drive System: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2,220 mm (87.4 in) Width: Approx. 780 mm (30.7 in) Height: Approx. 1,440 mm (56.7 in) (seat height) Weights Dry Weight: Approx. 185 kg (407.9 lbs) Gross Vehicle Weight Rating: Approx. 360 kg (793.7 lbs) Fuel Capacity Fuel Tank Capacity: Approx. 15 Liters (3.9 US gal) Wheels Tires Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheel Bolt Pattern: N/A (typical for scooters, uses hub mounting) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (motorcycle/scooter, no standardized car ratings apply) Active Features Braking System: Disc Brakes Front and Rear, ABS (Anti-lock Braking System) Optional on some models/markets Lighting: Halogen Headlight, LED Taillight/Brake Light Passive Features Frame: High-strength steel frame Ergonomics: Comfortable seating position, hand guards (market dependent) 💡 Technology Features Infotainment Instrument Cluster: Digital/Analog Combination (Speedometer, Tachometer, Odometer, Fuel Gauge, Temp Gauge, Clock) Driver Assistance ABS: Optional (check specific model year/variant) Connectivity Charging Port: 12V Power Outlet in Glove Box/Under Seat (market dependent) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 12 months (whichever comes first) Air Filter Replacement: Every 12,000 km or 24 months Spark Plug Replacement: Every 12,000 km (check manual for specific type/gap) Drive Belt...