🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Years Covered: 2005-2006 👋 Introduction Market Position Product Category: Premium Maxi-Scooter Key Features Value Proposition: Cost-effective solution for maintaining optimal vehicle performance and longevity, suitable for both DIY and professional use. 📋 Manual Details Coverage Areas Primary Scope: Comprehensive service and repair Vehicle Type: Maxi-scooter Page Count Estimated Page Count: Varies by specific manual edition, typically 300+ pages for a complete workshop manual. Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage: disassembly, inspection, repair, assembly of engine components (e.g., cylinder, piston, crankshaft, valve train). Engine Electrical: Detailed coverage: ignition system, starting system, charging system, fuel injection system, sensors, ECU. Emission Control: Coverage of emission control systems, catalysts, and related components. Fuel System: Complete coverage: fuel pump, injectors, fuel lines, fuel tank, EFI diagnostics. Suspension: Front and rear suspension systems: forks, shock absorbers, linkages, adjustments. Clutch: Variator, clutch assembly, and related components. Transmission: CVT (Continuously Variable Transmission) system: maintenance, component inspection, and replacement. Drivetrain: Final drive, belt, rollers, clutch bell inspection and replacement. Steering: Handlebar assembly, steering bearings, and related components. Brakes: Front and rear brake systems: hydraulic lines, calipers, master cylinders, brake pads, discs, bleeding procedures. Body Interior Exterior: Body panels, fairings, seat, storage, lighting, mirrors. Body Electrical: Complete wiring diagrams, lighting circuits, instrument panel, switches, horn, battery, starter motor. Restraint Systems: Seat belt mechanisms (if applicable for certain markets/configurations). Procedures Included Maintenance: Scheduled maintenance: oil changes, filter replacements, spark plugs, coolant, belt checks, brake service. Troubleshooting: Extensive troubleshooting guides for common and complex issues, including electrical diagnostics. Repair: Step-by-step repair instructions for all major systems, from minor adjustments to major component overhauls. Diagnostics: Diagnostic procedures for engine management, fuel injection, and electrical systems. Wiring Schematics: Detailed and integrated wiring diagrams for all electrical components and systems. Technical Depth Depth: Factory-level technical detail suitable for professional mechanics and advanced DIY enthusiasts. 📊 Manual Specifications File Format Compatibility: Compatible with all versions of Windows and Mac OS. Print Quality Printability: Fully printable, allowing users to print specific sections or the entire manual. Navigation Searchability: Likely searchable text within PDF for quick information retrieval. Viewing Requirements Software Requirements: Adobe Acrobat Reader (or compatible PDF viewer) and WinZip (or compatible unarchiver). Viewing Capabilities Zoom Functionality: YES (Zoom IN/OUT functionality for detailed viewing of diagrams and illustrations). ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: 492.6 cc Performance Bore X Stroke: 93 mm x 73 mm Compression Ratio: 10.5:1 Power Output: Approximately 33.3 HP (24.5 kW) at 6,500 RPM (specific figures may vary slightly by region/tune). Torque: Approximately 42.5 Nm (31.3 lb-ft) at 5,500 RPM (specific figures may vary slightly by region/tune). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Features Clutch Type: Automatic centrifugal clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2,170 mm Width: Approx. 770 mm Height: Approx. 1,420 mm (seat height likely around 790 mm) Weights Dry Weight: Approx. 185 kg Gross Vehicle Weight Rating: Not explicitly specified in product info, but typically around 350-380 kg. Capacities Fuel Tank Capacity: Approx. 15 liters Oil Capacity: Engine oil: Approx. 1.6 liters (without filter change), 1.8 liters (with filter change). Transmission oil not separately specified but typically shared or contained within CVT housing. 🛡️ Safety Features Active Features Braking System: Linked braking system (front and rear brakes partially actuated simultaneously). Front Brakes: Dual 240 mm discs Rear Brakes: Single 240 mm disc Passive Features Lighting: Dual headlights, taillight, turn signals. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog display including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, and warning lights. Driver Assistance ABS: ABS (Anti-lock Braking System) was often an optional feature on this model, depending on the specific market and configuration. 🔧 Maintenance Service Intervals Engine Oil And Filter: Typically every 5,000 - 7,500 km or annually, whichever comes first. Refer to manual for precise intervals. Spark Plug: Inspect every 5,000 km, replace as needed. Refer to manual for exact type and gap. Air Filter: Inspect every 5,000 km, clean or replace as needed. Refer to manual for specific cleaning agents. Cvt Belt And Rollers: Inspect CVT belt wear and roller condition every 10,000 - 15,000 km. Replace belt if cracked, frayed, or worn. Replace rollers if damaged or excessively worn. Fluid Specifications Engine Oil: API SG or higher, SAE 10W-40 or 15W-50 (depending on ambient temperature). Refer to manual for exact specification and capacity. Coolant: Ethylene glycol based coolant, 50/50 mix with distilled water. Refer to manual for specific type and capacity. Brake Fluid: DOT 4 hydraulic brake fluid. Known Issues Common Concerns: Potential for wear on CVT...