This manual covers the maxi-scooter, produced for the 2005 and 2006 model years. The maxi-scooter, a product of the Piaggio Group, was designed as a sporty and agile maxi-scooter, offering motorcycle-like handling and performance within its class. It competed against other premium offerings such as the Yamaha TMAX 500 and Honda Silver Wing 600, aiming to provide a blend of comfort for longer journeys and dynamic riding characteristics. The Gilera brand, with its heritage dating back to 1909, is known for its focus on performance-oriented two-wheeled vehicles. This comprehensive English-language service and repair manual is designed to provide detailed guidance for maintaining and repairing the maxi-scooter. It covers all essential aspects of the vehicle, including in-depth engine repair, transmission maintenance, electrical system diagnostics with wiring diagrams, chassis and suspension procedures, brake system servicing, and bodywork. The manual includes routine maintenance schedules, troubleshooting guides for common and complex issues, and step-by-step instructions for component replacement and engine rebuilding. Its extensive content and detailed sub-steps are intended to empower owners and professional technicians alike. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Years Covered: 2005-2006 👋 Introduction Market Position Vehicle Type: Maxi-scooter Brand Positioning: Gilera, a Piaggio Group brand, is known for performance-oriented scooters and motorcycles. Competitive Analysis Competitors 2005 2006: Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600, Aprilia Atlantic 500. Key Features Vehicle Design Philosophy: The Nexus 500 was positioned as a sporty, agile maxi-scooter with motorcycle-like handling and performance. Key Features Manual Benefit To Owner: Empowers owners and technicians to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on specialized workshops. Content Organization: Features a numbered table of contents for quick information retrieval and utilizes bold figure numbers to link illustrations with instructions. 📋 Manual Details Coverage Areas Primary Focus: Full Service and Repair Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'very detailed' and 'comprehensive') Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed repair, maintenance, and rebuilding procedures for the 500cc engine. Transmission: Covers maintenance, repair, and diagnostics for the transmission system. Electrical System: Comprehensive coverage including detailed wiring diagrams, troubleshooting, and electrical service procedures. Chassis And Suspension: Includes procedures for suspension, steering, and chassis components. Brakes: Detailed information on brake system maintenance and repair. Fuel System: Covers fuel delivery, injection (if applicable), and related components. Cooling System: Maintenance and repair procedures for the engine's cooling system. Exhaust System: Information on exhaust system components and service. Bodywork And Trim: Procedures for body panels, trim, and related components. Procedures Included Routine Maintenance: Covers all routine maintenance tasks as per service schedules. Troubleshooting: Extensive troubleshooting guides for common and complex issues, including electrical diagnostics. Engine Rebuild: Detailed step-by-step instructions for engine rebuilding and overhaul. Component Replacement: Guidance on replacing all major and minor vehicle components. Diagnostics: In-depth diagnostic procedures for all vehicle systems. Technical Depth Depth Level: Comprehensive, suitable for professional technicians and experienced DIY mechanics. Detail Level: Detailed sub-steps, notes, cautions, and warnings provided for each procedure. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Requirements Software: Adobe PDF Reader, WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder Displacement: 493 cc (approx.) Bore X Stroke: Typically around 94 mm x 71 mm (specifics to be confirmed in manual) Cooling System: Liquid-cooled Valve Train: SOHC, 4 valves Performance Horsepower Output: Around 33-35 HP (Specific dyno figures may vary, manual will provide official specs) Torque Output: Around 40-45 Nm (Specific figures to be confirmed in manual) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or similar ECU likely Ignition System: Digital electronic ignition Lubrication System Oil Type: Full Synthetic SAE 5W-40 or 10W-40 (Specific Gilera recommendation in manual) Oil Capacity: Approx. 1.5 - 1.7 liters (check manual for precise capacity and filter change amount) 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Optional Options: N/A (CVT is standard) Features Drive Type: Belt drive to rear wheel Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Approximately 2170 mm (specifics in manual) Width: Approximately 780 mm (specifics in manual) Height: Approximately 1450 mm (specifics in manual) Wheelbase: Approximately 1505 mm (specifics in manual) Weights Dry Weight: Around 185-190 kg (specifics in manual) Gross Vehicle Weight Rating: Not explicitly stated, but implies capacity for rider and cargo. Tires Front Tire Size: 120/70-15 (Typical, verify in manual) Rear Tire Size: 160/60-15 (Typical, verify in manual) Wheels Wheel Type: Alloy 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle/Scooter safety is assessed differently than cars, but chassis integrity and braking performance are key) Active Features Braking System: Front: Dual hydraulic disc brakes; Rear:...