The Gilera Nexus 500, a 2005 model, represents a capable maxi-scooter designed for both commuting and touring. It features sporty styling, a powerful 492.7cc liquid-cooled engine, and comfortable ergonomics suitable for longer journeys. Engineered with a focus on performance and stability, it offers a compelling option within the maxi-scooter segment, competing with established models from other manufacturers. Its robust construction and Italian heritage contribute to its reputation for quality and riding dynamics. This comprehensive Factory Service Repair Manual provides detailed guidance for the complete service, repair, maintenance, and diagnostics of the Gilera Nexus 500. It covers all essential systems, including the engine, fuel system, transmission, brakes, suspension, and electrical components, offering step-by-step procedures for routine maintenance, major repairs, and troubleshooting. With clear instructions, diagrams, and specifications, this manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Year: 2005 Codes Product Code: NEXUS500-2005-GILERA-SRM 👋 Introduction Market Position Category: Maxi-scooter / Sport Tourer Target Audience: Commuters, touring riders, and performance-oriented scooter enthusiasts. Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing. Key Features Vehicle Design: Sporty styling, powerful engine, comfortable ergonomics for longer distances. Manual Purpose: To provide comprehensive guidance for maintaining, servicing, diagnosing, and repairing the Gilera Nexus 500 (2005 model) to factory standards. 📋 Manual Details Coverage Areas Scope: Complete service, repair, maintenance, and diagnostics Page Count Pages: 406 Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the 500cc engine, including top-end, bottom-end, lubrication, and cooling systems. Fuel System: EFI system diagnostics, fuel pump, injectors, throttle body, and emissions control. Transmission: CVT (Continuously Variable Transmission) servicing, belt inspection and replacement, clutch and variator maintenance. Brakes: Front and rear brake system maintenance, caliper service, pad replacement, hydraulic system bleeding, ABS system (if equipped) diagnostics. Suspension: Front fork (telescopic) and rear shock absorber maintenance, adjustments, and overhaul procedures. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system, lighting, starter system, and diagnostic connector. Chassis And Frame: Frame inspection, steering head bearing maintenance, and general chassis component service. Bodywork And Trim: Panel removal and installation, seat servicing, and other cosmetic components. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, fluid level checks, drive belt inspection. Troubleshooting: Diagnostic charts, common problems, and step-by-step solutions for various systems. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, and brake system repairs. Torque Specifications: Comprehensive list of torque values for critical fasteners across all mechanical systems. Special Tools: Identification and usage guidelines for specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (text-based PDF) Printable: Yes Print Quality Quality: High-resolution scans, clear text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approx. 40 HP (29.8 kW) at 7,500 rpm Torque: Approx. 46 Nm (33.9 lb-ft) at 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with digital ignition Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 15W-50 Oil Capacity: Approx. 1.8 Liters (with filter change) 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Drive: Belt drive to rear wheel Features Clutch: Automatic centrifugal clutch Variator: Roller-type variator for automatic gear ratio adjustment 📐 Dimensions Exterior Length: Approx. 2,250 mm (88.6 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1,420 mm (55.9 in) (seat height) Weights Dry Weight: Approx. 190 kg (419 lbs) Gross Vehicle Weight: Approx. 360 kg (794 lbs) Cargo Underseat Storage: Sufficient for one full-face helmet and small items. 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle/Scooter not subjected to typical automotive crash testing protocols) Active Features Brakes: Dual front disc brakes, single rear disc brake. ABS optional on some models/markets. Lighting: Halogen headlight, LED taillight, turn signals. Passive Features Frame Construction: High-tensile steel frame for rigidity and stability. Handling: Designed for stable handling at high speeds and confident cornering. 💡 Technology Features Infotainment Features: Basic instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, and warning lights. No advanced infotainment systems. Driver Assistance Features: Optional ABS system for enhanced braking safety. Connectivity Features: No modern connectivity features (Bluetooth, smartphone integration). 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km (3,000 miles) or annually, whichever comes first. Oil Filter Replacement: Every 10,000 km...