The Gilera Nexus 500, a 2006 model, represents a sophisticated maxi-scooter designed to bridge the gap between agile sport-scooters and comfortable touring machines. It features a powerful 460 cc liquid-cooled, 4-stroke engine with electronic fuel injection, delivering approximately 34 horsepower and 43 Nm of torque. Known for its premium build quality and sporty handling, the Nexus 500 competed in the high-displacement segment with models from Yamaha and Suzuki, offering a blend of performance, practicality, and advanced engineering. Its design prioritizes rider comfort and control, making it suitable for both urban commuting and longer journeys. This comprehensive 407-page Factory Service Repair Workshop Manual in English provides in-depth information for the Gilera Nexus 500. It covers essential areas including routine maintenance, detailed repair procedures, diagnostics, electrical system troubleshooting with wiring diagrams, and pre-delivery checks. The manual is structured to assist owners, mechanics, and technicians in maintaining and repairing all major systems, such as the engine, cooling, braking, suspension, chassis, and electrical components. It also includes specific maintenance schedules and fluid specifications to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Year: 2006 👋 Introduction Market Position Positioning: The Gilera Nexus 500 was positioned as a premium, high-performance maxi-scooter, blending sport-scooter agility with touring comfort and substantial power. Competitive Analysis Competitors: Competed with other high-displacement maxi-scooters from brands like Yamaha (TMAX series), Suzuki (Burgman series), and Aprilia (Atlantic series) in the premium segment. Key Features Features: Powerful single-cylinder engine, sophisticated chassis dynamics, ample storage, comfortable ergonomics, and premium build quality. 📋 Manual Details Coverage Areas Coverage: Comprehensive service, repair, diagnostic, and maintenance information. Page Count Page Count: 407 Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Systems: Engine, Power Supply, Cooling System, Braking System, Suspensions, Chassis, Electrical System, Bodywork, Pre-Delivery Checks, Maintenance, Troubleshooting. Procedures Included Procedures: Routine maintenance, diagnostics, repair procedures, component removal and installation, electrical system troubleshooting, wiring diagrams, special tool usage, pre-delivery inspection and setup. Technical Depth Depth: Professional-level diagnostic, repair, and maintenance information for technicians. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader Print Quality Print Quality: High-resolution, designed for clarity of diagrams and text. Binding Type Binding Type: Digital Download (PDF) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder Displacement: 460 cc Bore X Stroke: 92 mm x 69 mm Valvetrain: SOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approx. 34 HP (25 kW) at 6,750 rpm (Actual figures may vary slightly based on region and specific tuning) Torque: Approx. 43 Nm (31.7 lb-ft) at 5,500 rpm (Actual figures may vary) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for exact specifications). Oil Capacity: Approx. 1.6 liters (1.7 US qt) with filter change. 🔧 Transmission Standard Transmission Type: Automatic, CVT (Continuously Variable Transmission) Features Clutch: Automatic centrifugal clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2150 mm (84.6 in) Width: Approx. 780 mm (30.7 in) Height: Approx. 1430 mm (56.3 in) (seat height) Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 205 kg (452 lbs) (with all fluids) Capacity Fuel Tank Capacity: 15 Liters (3.96 US gal) Chassis Wheelbase: Approx. 1530 mm (60.2 in) 🛡️ Safety Features Ratings Safety Standards: Designed to meet European safety standards for motorcycles and scooters. Active Features Braking System: Dual front disc brakes with four-piston calipers, single rear disc brake. Optional ABS (Anti-lock Braking System) may be available depending on market and specific trim. Lighting: Halogen headlights, LED taillight and indicators. Passive Features Chassis Construction: Steel frame with integrated passenger grab handles and robust bodywork. Security: Immobilizer system may be standard or optional. 💡 Technology Features Infotainment Dashboard: Analog speedometer and tachometer, digital multi-function display showing fuel level, coolant temperature, trip meter, clock, etc. Driver Assistance ABS: Optional ABS available on some models, significantly enhancing braking safety. Connectivity Lighting System: Integrated lighting systems, including hazard light function, likely with standard bulb technology but LED elements for taillights/indicators. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 km (3,000 miles) or annually. Refer to manual for precise intervals. Air Filter Check: Inspect every 5,000 km (3,000 miles), replace as needed. Spark Plug Replacement: Typically at 10,000 km (6,000 miles) or as per manual recommendations. Belt Replacement: CVT belt inspection and replacement at recommended intervals (e.g., 15,000-20,000 km / 9,000-12,000 miles), subject to condition. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze mixture, 50% water, 50% coolant concentrate (refer to manual for specific type). Brake Fluid Type: DOT 4 brake fluid. Gear Oil Type: API...