The Nexus 500, produced for the 2005 and 2006 model years, represents a premium maxi-scooter engineered for performance and comfort, making it suitable for both commuting and touring. It is powered by a robust 4-stroke, liquid-cooled, single-cylinder engine with a displacement of 492.6 cc, delivering approximately 39 horsepower. Notable features include an advanced suspension system, comfortable seating, and ample under-seat storage, all built upon a rigid steel twin-spar frame. As an Italian marque with a heritage dating back to 1909, now part of a larger group, the Nexus 500 has been positioned as a competitive offering in its segment, known for its dynamic capabilities and refined rider experience. This comprehensive workshop service and repair manual provides detailed information for maintaining and repairing the Nexus 500. It covers all essential systems, including the powertrain, chassis, brakes, and electrical components, offering step-by-step instructions for maintenance, troubleshooting, and overhaul procedures. Technicians and owners will find valuable resources such as wiring diagrams, fluid specifications, and recommended service intervals for critical components like the engine oil, air filter, spark plug, and drive belt. The manual is designed to empower users with the knowledge necessary for accurate diagnostics and efficient repairs, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Years Covered: 2005, 2006 Codes Chassis Code: ZP5TT0000... 👋 Introduction Market Position Segment: Premium Maxi-Scooter Target Audience: Commuters, touring riders seeking performance and comfort. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing. Key Features Vehicle Features: Powerful single-cylinder engine, advanced suspension, comfortable seating, ample under-seat storage. Manual Value Proposition Benefit To Owner: Empowers owners to perform maintenance and repairs, reducing labor costs and increasing vehicle longevity. Professional Advantage: Provides technicians with authoritative, manufacturer-backed information for efficient and accurate service. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Overhaul Procedures, Wiring Diagrams Page Count Estimated Pages: Hundreds (Exact count not specified, typical for factory workshop manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine disassembly, assembly, tuning, lubrication, cooling, fuel injection, exhaust. Chassis: Frame, suspension (front and rear), steering, wheels, tires. Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, bleeding procedures. Electrical: Wiring diagrams, starter system, charging system, ignition system, lighting, instrumentation, ECU diagnostics. Bodywork: Fairings, seat, fuel tank, body panels, minor adjustments. Procedures Included Maintenance: Periodic maintenance charts, fluid changes, filter replacements, spark plug service, drive belt inspection. Repair: Step-by-step repair instructions for all major components and systems. Troubleshooting: Diagnostic procedures, common fault finding, symptom-based troubleshooting guides. Overhaul: Detailed overhaul procedures for engine, transmission, and other major assemblies. Technical Depth Depth: Comprehensive, suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Requirements: Adobe PDF Reader, WinRAR Print Quality Printability: Full Printable Zoom Capability: Zoom IN/OUT capable Binding Type Type: Digital Download (No physical binding) Paper Type Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, single-cylinder, DOHC Displacement: 492.6 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approx. 39 hp (29 kW) @ 7,500 rpm Torque: Approx. 44 Nm (32.5 lb-ft) @ 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), likely with a throttle body Fuel Type: Unleaded Gasoline Lubrication Oil Type Recommendation: Refer to manual for specific API/JASO MA specifications (e.g., SAE 10W-40) Cooling System Type: Liquid-cooled 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Optional Transmission Options: N/A (CVT is standard) Features Drive Type: Belt drive to rear wheel Fluid Specifications Transmission Fluid: Refer to manual for specific CVT fluid requirements. 📐 Dimensions Exterior Length: Approx. 2,150 mm (Not explicitly stated, typical for class) Width: Approx. 760 mm (Not explicitly stated, typical for class) Height: Approx. 1,380 mm (Not explicitly stated, typical for class) Weights Dry Weight: Approx. 195 kg (Not explicitly stated, typical for class) Wet Weight: Approx. 215 kg (Not explicitly stated, typical for class) Cargo Under Seat Storage: Significant capacity, capable of holding a full-face helmet and more. 🛡️ Safety Features Ratings Crash Test Results: Not applicable for motorcycles/scooters in the same way as cars. Active Features Braking System: Combined braking system (front and rear operated by one lever), ABS likely optional or unavailable for these years. Lighting: Halogen headlight, LED taillight/brake light. Passive Features Frame Construction: Steel twin-spar frame for rigidity. Handlebar Design: Ergonomic handlebar position for rider control. 💡 Technology Features Infotainment Dashboard Display: Analog speedometer and tachometer, digital odometer, fuel gauge, engine temp gauge, various warning lights. Driver Assistance ABS: Optional or not available for 2005-2006 models. Check VIN if equipped. Connectivity Connectivity Features: None in the modern sense; primarily mechanical and electrical systems. 🔧 Maintenance Service Intervals Oil Change: Typically...