This manual covers the Gilera Nexus 500, a premium maxi-scooter produced from 2005 onward, designed to offer a blend of sporty performance and touring comfort. As part of a larger automotive group, Gilera is an Italian manufacturer with a heritage in performance-oriented vehicles. The Nexus 500 is noted for its powerful single-cylinder, 4-stroke, liquid-cooled engine, featuring electronic fuel injection and an automatic CVT transmission. Its engineering emphasizes reliable operation and agile handling, making it suitable for both urban commuting and longer journeys. This model adheres to Euro 3 emission standards, reflecting its production era. This comprehensive Service Repair Manual provides everything necessary to maintain and repair the Gilera Nexus 500. It details workshop procedures for all major systems, including engine removal and installation, fuel system, drivetrain components, chassis, and electrical systems. The manual includes step-by-step repair instructions, routine maintenance guidance, troubleshooting procedures, and electrical diagrams. It is designed for Gilera Nexus 500 owners, DIY mechanics, and professional repair shops, enabling them to effectively service, maintain, and overhaul their vehicles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus Model Variant: 500 Production Years Covered: 2005 Onward Emission Standard: Euro 3 👋 Introduction Market Position Target Audience: Gilera Nexus 500 owners, DIY mechanics, repair shops Competitive Analysis Differentiation: Make, model, and year specific, not generic; comprehensive coverage including electrical diagrams and detailed procedures Key Features Manual Benefit: Enables users to repair, maintain, or overhaul their Gilera Nexus 500 Information Type: Detailed instructions, step-by-step diagrams, electrical diagrams, service procedures, fluid capacities 📋 Manual Details Coverage Areas Coverage: Comprehensive Workshop Repair Procedures Page Count Page Count: Not specified, but described as 'everything you will ever need to know' Manual Type Manual Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine Removal/Installation, Cylinder Head/Valve, Cylinder/Piston, Crankcase, Transmission, Crankshaft/Primary Shaft, Fuel System Drivetrain Systems: Clutch, Gearshift Linkage, Sub transmission, Transmission Chassis Systems: Front Wheel/Suspension, Rear Wheel/Suspension, Hydraulic Brake Electrical Systems: Battery/Charging System, Ignition System, Electric Starter, Switches General Maintenance: General Information, Lubrication, Inspection and Adjustment Procedures Included Repair Procedures: Rebuilding the engine, step-by-step repair instructions for all covered systems Maintenance Procedures: Routine maintenance, fluid changes, adjustments Diagnostic Procedures: Troubleshooting guides Technical Depth Depth: Detailed instructions from basic maintenance to complete engine rebuilds, including electrical diagrams 📊 Manual Specifications File Format File Format: PDF File Compatibility: PC/MAC Compatible Interactivity: Zoom In/Out Functionality Delivery Delivery Method: Instant Download Delivery Process: Email with download link from Tradebit System Print Quality Print Options: Print selected pages or entire manual Viewing Options Viewing Options: View from screen ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: 493 cc (approximately, based on common Nexus 500 variants) Bore X Stroke: Not specified, but typically around 94.0 mm x 87.0 mm for this engine family Compression Ratio: Not specified, but typically around 10.5:1 to 11.0:1 Performance Horsepower: Around 34-39 HP (estimated, actual figures vary by specific model year and tuning) Torque: Around 45-48 Nm (estimated) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Ignition Type: Electronic Ignition Lubrication Oil Type: Refer to manual for specific API/JASO rating (typically semi-synthetic or fully synthetic motorcycle oil) Oil Capacity: Refer to manual for exact capacity (typically around 1.5-1.8 liters) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Drive Type: Belt Drive Features Transmission Components: Clutch, Primary Shaft, Sub transmission, Gearshift Linkage (for CVT operation) 📐 Dimensions Exterior Wheelbase: Approximately 1525 mm (based on common Nexus 500 dimensions) Weights Dry Weight: Approximately 195 kg (based on common Nexus 500 variants) Fuel Tank Capacity: Approximately 15 liters (including reserve, based on common Nexus 500 variants) 🛡️ Safety Features Ratings Safety Features General: Integral braking system (combined front and rear brake actuation), ABS availability varies by market/trim. Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Passive Features Lighting: Halogen headlights, LED taillight (specifications vary) 💡 Technology Features Infotainment Dashboard: Digital and analog instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meter, clock. Driver Assistance ABS Availability: Optional or standard depending on market and specific model year. Connectivity Lighting Technology: Halogen projector headlights, LED rear lighting (depending on specific variant). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual (typically every 3,000-5,000 km or annually) Spark Plug Replacement: Refer to manual (typical interval 6,000-10,000 km) Drive Belt Inspection: Refer to manual (typically inspected at 5,000-10,000 km, replacement based on condition) Fluid Specifications Coolant Type: Refer to manual (typically ethylene glycol-based antifreeze) Brake Fluid Type: Refer to manual (DOT 4 recommended) Transmission Oil Type: Refer to manual (often a specific CVT fluid or gear oil for final drive) Known Issues Common Wear Items: Drive belt, rollers, spark plugs, brake pads, coolant hoses, regulator/rectifier (common on many scooters) Electrical Potential Issues: Wiring harness integrity, stator/regulator issues can occur...