The Gilera Nexus 500, a premium maxi-scooter from 2005, combines potent performance with sophisticated design for urban commuting and extended touring. Featuring a robust 460cc liquid-cooled engine, comfortable ergonomics, and an aerodynamic fairing, the Nexus 500 offers a dynamic riding experience. Its engineering quality is evident in its sporty handling and the blend of power and practicality, making it a distinguished choice in its class. This comprehensive repair manual provides detailed guidance for the Gilera Nexus 500. It covers essential maintenance procedures, troubleshooting common issues, and in-depth technical specifications for all major systems, including the engine, fuel system, transmission, chassis, and electrical components. The manual is designed to assist owners, mechanics, and technicians in maintaining the optimal performance and longevity of the vehicle through clear instructions and diagnostic information. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Year: 2005 Vehicle Type: Maxi-scooter 👋 Introduction Market Position Market Position: The Gilera Nexus 500 was positioned as a premium maxi-scooter, offering a blend of performance, comfort, and advanced features for commuting and touring. It competed with other high-displacement scooters from brands like Yamaha (TMAX) and Suzuki (Burgman). Key Features Key Features: Powerful 460cc liquid-cooled engine, comfortable ergonomics, aerodynamic fairing, under-seat storage, advanced braking systems, often featuring ABS in higher specifications. 📋 Manual Details Coverage Manual Type: Repair Manual Pages Page Count: 406 Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Transmission (CVT), Clutch, Chassis, Suspension (Front & Rear), Braking System (Front & Rear, ABS if equipped), Electrical System, Lighting, Instrumentation, Bodywork, Body Panels, Storage, Maintenance Procedures, Troubleshooting, Diagnostic Procedures Procedures Procedures Included: Routine Maintenance, Scheduled Servicing, Troubleshooting Faults, Component Disassembly & Reassembly, Engine Tuning & Adjustment, Electrical Diagnostics, Brake System Overhaul, Suspension Servicing, Bodywork Repairs Depth Technical Depth: Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers detailed internal engine components, electrical schematics, and complex troubleshooting sequences. 📊 Manual Specifications File File Format Details: Digital PDF document, typically searchable text and high-resolution images. Quality Print Quality: Designed for digital viewing, but printable for workshop use. Illustrations are typically clear and detailed. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled Displacement: 460 cc Bore X Stroke: 93 mm x 82 mm (typical for this engine family) Compression Ratio: 10.5:1 (typical for this engine family) Performance Horsepower: Approx. 34-36 HP (at crankshaft, depending on specific market tune) Torque: Approx. 43 Nm (at crankshaft, depending on specific market tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Petrol (95 RON recommended) Ignition System Ignition Type: Electronic ignition with CDI and spark plug Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type And Capacity: Refer to manual for specific API SG or higher, JASO MA certified oil. Capacity typically around 1.7-1.8 liters. 🔧 Transmission Drive Transmission Type: Automatic Continuously Variable Transmission (CVT) with dry clutch Features Final Drive: Belt drive via CVT 📐 Dimensions Exterior Length: Approx. 2160 mm Width: Approx. 780 mm Height: Approx. 1350 mm (seat height varies) Weights Dry Weight: Approx. 185 kg Gross Vehicle Weight Rating: Refer to manual, typically around 380-400 kg Cargo Underseat Storage: Sufficient for one full-face helmet and small items. 🛡️ Safety Features Ratings ABS Availability: Optional on some models/markets Active Features Braking System Front: Dual hydraulic discs, typically 260mm diameter with dual-piston calipers. Braking System Rear: Single hydraulic disc, typically 240mm diameter with single-piston caliper. Passive Features Lighting System: Halogen headlights, LED taillight and indicators. 💡 Technology Features Infotainment Infotainment Features: Basic instrumentation cluster with speedometer, tachometer, fuel gauge, coolant temperature gauge, and warning lights. No advanced infotainment systems common in modern vehicles. Driver Assistance Driver Assistance Features: Optional ABS (Anti-lock Braking System) on some models. Connectivity Connectivity Features: Not applicable for this model year and vehicle type. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,000 km or annually. Refer to manual for precise intervals and conditions. Air Filter Replacement: Every 10,000-15,000 km or as needed based on operating environment. Inspect more frequently. Spark Plug Replacement: Typically every 15,000-20,000 km. Cvt Belt Inspection/Replacement: Inspect belt wear and tension at 10,000 km intervals. Replacement typically recommended between 20,000-30,000 km, depending on usage. Fluid Specifications Engine Oil Specification: API SG or higher, JASO MA certified. Viscosity typically 5W-40 or 10W-40, consult manual. Coolant Specification: Ethylene glycol based antifreeze with corrosion inhibitors. Typically a 50/50 mix with distilled water. Use Piaggio/Gilera recommended coolant if available. Brake Fluid Specification: DOT 4 Gearbox Oil Specification: Refer to manual; typically a specific SAE 80W/90 gear oil or equivalent. Known Issues Known Issues Common: Some owners report potential issues with the fuel pump, voltage regulator, and occasional electrical gremlins. CVT belt wear and rear shock absorber longevity can also be points of attention. Regular maintenance is crucial. Part Numbers...