🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Years Covered: 2005-2006 👋 Introduction Market Position Target Audience: Professional motorcycle technicians, experienced DIY mechanics, and Gilera Nexus 500 owners seeking detailed repair and maintenance information. Competitive Analysis Value Proposition: Provides comprehensive, factory-level repair information in an easily accessible digital format, enabling cost-effective maintenance and repair. Key Features Comprehensive Coverage: Mirrors factory service manual content, covering all aspects of the vehicle's mechanical and electrical systems. Step By Step Instructions: Clear, sequential guidance for all repair and maintenance tasks, empowering users to perform procedures confidently. Diagrams And Illustrations: Includes necessary visual aids to clarify complex procedures and component identification. Instant Access: Immediate download allows users to start working on their vehicle without delay. 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual Language: English Format: PDF Delivery Method: Instant Download Printability: Full Printable Zoom Functionality: Yes Software Requirements: Adobe PDF Reader, WinZip Operating System Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and repair procedures for the entire engine, including cylinder head, piston, crankshaft, connecting rods, valves, and camshafts. Torque specifications and clearances provided. Fuel System: Information on fuel injection system, fuel pump, fuel filter, injectors, throttle body, and associated sensors. Troubleshooting and diagnostic procedures. Cooling System: Details on the radiator, cooling fan, coolant pump, thermostat, hoses, and coolant specifications. Flush and refill procedures. Ignition System: Coverage of spark plugs, ignition coils, CDI unit, and related wiring. Timing specifications and troubleshooting. Exhaust System: Information on exhaust pipes, muffler, and catalytic converter (if applicable). Gasket replacement and leak detection. Transmission And Drivetrain: Details on the CVT (Continuously Variable Transmission) system, including belt, rollers, clutch, and variator. Oil change procedures and specifications. Suspension System: Front and rear suspension components, including forks, shock absorbers, bushings, and bearings. Adjustment and replacement procedures. Braking System: Front and rear brake calipers, master cylinders, brake lines, brake pads, and rotors. Bleeding procedures and fluid specifications. Electrical System: Comprehensive wiring diagrams, battery, starter motor, alternator, lighting system, fuses, relays, and switches. Troubleshooting electrical faults. Chassis And Frame: Frame construction, steering system components (handlebars, steering stem, bearings), and subframe. Alignment and inspection procedures. Bodywork And Trim: Fairings, seat, body panels, storage compartments, and associated fasteners. Removal and installation guidelines. Wheels And Tires: Wheel bearing maintenance, tire pressure recommendations, and tire replacement. Rim specifications. Procedures Included Scheduled Maintenance: Detailed maintenance schedules for routine services, including oil changes, filter replacements, spark plug checks, and belt inspections. Specific service intervals provided. Troubleshooting Guides: Systematic diagnostic procedures for identifying and resolving common mechanical and electrical issues. Flowcharts and symptom-based problem solving. Disassembly And Assembly: Step-by-step instructions for the removal and reinstallation of all major components and subassemblies with clear visuals and torque values. Cleaning And Lubrication: Guidelines for cleaning specific components and recommended lubrication points and types for optimal performance and longevity. Adjustments: Procedures for adjusting critical systems such as throttle cable, brake levers, and CVT components for optimal operation. Special Tools: Identification and usage instructions for specialized tools required for certain repair and maintenance tasks. Torque Specifications: Comprehensive list of all critical torque values for fasteners across all systems to ensure proper assembly and prevent damage. Technical Depth Depth Of Coverage: Covers everything from basic rider maintenance to in-depth engine overhauls and complex electrical system diagnostics. Prepared for both professional technicians and experienced DIY enthusiasts. 📊 Manual Specifications File Specifications File Type: PDF Searchability: Likely searchable due to PDF format, allowing for quick access to specific information. Quality: High-resolution digital scans, ensuring clarity of text and diagrams for printing and viewing. Binding Type: Digital Download (no physical binding) Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: 493 cc (approximate) Bore X Stroke: Specifications typically found in the manual, crucial for engine rebuilds. Performance Horsepower: Specific figures will be detailed in the manual, likely in the 30-40 HP range for this class. Torque: Specific figures will be detailed in the manual, crucial for acceleration and cruising performance. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Engine Internals Compression Ratio: Key specification for engine tuning and diagnostics, provided in manual. Cooling Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Features Clutch Type: Automatic centrifugal clutch Fluid Requirements Transmission Fluid Type: Specific CVT fluid type and capacity outlined in the manual. 📐 Dimensions Exterior Length: Dimensions provided in manual for chassis reference. Width: Dimensions provided in manual for chassis reference. Height: Dimensions provided in manual for chassis reference. Weights Dry Weight: Specifications will be detailed in the manual, crucial for handling and transport. Gross Vehicle Weight Rating: Specifications will be detailed in the manual, important for load capacity. 🛡️ Safety Features Active Features Braking System Type: Hydraulic disc brakes...