The Gilera Nexus 500, produced between 2005 and 2006, represents a sophisticated maxi-scooter designed for riders seeking a blend of sporty handling and comfortable ergonomics for extended journeys. It is powered by a robust 492.6 cc liquid-cooled, single-cylinder engine featuring electronic fuel injection, delivering approximately 40 horsepower and 43 Nm of torque. Notable for its sporty performance and comfortable riding position, the Nexus 500 competed in a segment with established models from Suzuki, Yamaha, and Honda, offering a compelling package for discerning riders. This comprehensive factory service repair manual provides in-depth guidance for the Gilera Nexus 500 (2005-2006 models). It covers all essential aspects of maintenance and repair, including detailed procedures for engine overhaul, transmission service, chassis and suspension work, brake system maintenance, and electrical system diagnostics. The manual includes troubleshooting guides, torque specifications, fluid capacities, and wiring diagrams, empowering owners and technicians to perform everything from routine maintenance to major component rebuilds, ensuring the longevity and optimal performance of the vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Code: ZAPM35800 Production Years: 2005-2006 👋 Introduction Market Position Category: Maxi-scooter / Sport scooter Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops. Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500, Aprilia Leonardo 300/500. Key Features Vehicle Usp: Sporty handling, powerful engine for its class, comfortable ergonomics for longer rides. Manual Value Proposition Benefit 1: Empowers owners to perform DIY maintenance and repairs, saving on labor costs. Benefit 2: Provides in-depth understanding of the vehicle's systems for efficient troubleshooting and proactive care. Benefit 3: Ensures correct procedures are followed, maintaining vehicle integrity and resale value. 📋 Manual Details Coverage Areas Primary Coverage: Gilera Nexus 500 (2005-2006 models) Secondary Coverage: Troubleshooting, diagnostics, routine maintenance, major repairs, electrical systems, engine rebuilds. Page Count Estimated Page Count: Likely 300-500+ pages (typical for factory service manuals of this era) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download Info Delivery Method: Digital download Software Requirements: Adobe PDF Reader and WinZip (or equivalent decompression software). 📖 Manual Coverage Systems Covered Engine: Complete overhaul, disassembly, assembly, lubrication, cooling system, fuel system (injection), ignition system, emissions control. Transmission: Automatic transmission (CVT) operation, maintenance, troubleshooting, component replacement. Chassis: Frame, suspension (front and rear), steering system, wheels, tires. Brakes: Hydraulic system, caliper service, disc replacement, bleeding procedures, parking brake. Electrical: Wiring diagrams, charging system, starting system, lighting, instruments, ECU, sensor diagnostics. Body: Fairings, seat, storage, body panels, lighting components, instrumentation. Procedures Included Routine Maintenance: Oil changes, filter replacement, spark plug service, brake fluid replacement, coolant checks, chain/belt adjustment (if applicable). Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, error code interpretation. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, electrical system repairs. Specifications: Torque values, clearances, fluid capacities, electrical resistance values. Technical Depth Depth: Comprehensive, covering all aspects from basic adjustments to complete engine and electrical system rebuilds. Includes detailed diagnostic charts and troubleshooting trees. Manual Type Detail Type Description: This is a factory-level repair manual, providing detailed instructions for mechanics and advanced DIY users. It is not an owner's manual or a simple repair guide; it's intended for comprehensive service. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if professionally scanned and OCR'd. Compatibility: Compatible with Adobe PDF Reader on Windows and Mac operating systems. Print Quality Printability: Designed for printing, with clear diagrams and text. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, 4-valve SOHC Displacement: 492.6 cc Bore X Stroke: 94 mm x 87.4 mm (typical for Piaggio Quasar engine family) Compression Ratio: 10.5:1 (typical) Fuel Delivery: Electronic Fuel Injection (EFI) Performance Horsepower: Approx. 40 HP (at crankshaft) @ 7,500 RPM (typical for this engine) Torque: Approx. 43 Nm (at crankshaft) @ 5,500 RPM (typical for this engine) Fuel System Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 12.2 Liters Engine Oil Oil Type: API SG or higher, SAE 10W-40 synthetic or semi-synthetic motorcycle oil Oil Capacity: Approx. 1.2 - 1.4 Liters (including filter) Cooling System Coolant Type: Ethylene glycol-based antifreeze, 50/50 mix with distilled water Coolant Capacity: Approx. 1.5 Liters 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive to rear wheel via reduction gear Features Features: Automatic clutch, variable gear ratios for optimal performance and fuel efficiency. Transmission Fluid Fluid Type: Specific CVT fluid required (refer to manual for exact specification, often a GL-4 or similar gear oil specification for the final drive, and specific CVT fluid for the transmission unit itself). 📐 Dimensions Exterior Length: Approx. 2,170 mm Width: Approx. 770 mm (at handlebars) Height: Approx. 1,420 mm (at windshield) Weights Dry Weight: Approx. 187 kg Wet Weight: Approx. 205...