The Nexus 500, produced from 2005 onwards, is a maxi-scooter known for its sporty handling and powerful 492.7 cc engine, delivering approximately 39-40 HP and 45-46 Nm of torque. Designed for spirited riding and comfortable touring, it features a robust steel frame, a continuously variable transmission (CVT) for smooth acceleration, and a liquid-cooled, single-cylinder engine. This Euro 3 compliant model offers a substantial 15-liter fuel tank and a dry weight of around 190-200 kg, making it a capable option in the sport-scooter segment, competing with established models from Yamaha, Suzuki, and Honda. This comprehensive Service Repair Workshop Manual provides essential information for the maintenance and repair of your Nexus 500. It covers a wide range of systems, including detailed procedures for engine mechanicals, fuel injection, cooling, ignition, exhaust, transmission, braking, suspension, steering, and electrical systems. The manual also details routine maintenance tasks, troubleshooting common issues, major repair procedures, and component replacement, offering crucial technical specifications, torque values, and fluid recommendations. Its factory-type quality content is designed to empower owners and technicians in effectively servicing and maintaining the vehicle, ensuring its optimal performance and longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus Variant: 500 Year: 2005 onwards Emission Standard: Euro 3 Codes Manual Product Code: Likely specific to the publisher, not explicitly stated in product info. Vehicle Chassis Codes: Not specified in product info, but likely includes variations for different production years and regional specs. 👋 Introduction Market Position Segment: Maxi-scooter, Sport-scooter Target Audience: Owners and independent workshops performing service and repair on the Gilera Nexus 500. Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic, Piaggio Beverly. Key Features Vehicle Sporty Handling: Designed for spirited riding with a capable chassis and suspension. Powerful Engine: 500cc engine provides strong acceleration and high-speed cruising capability. Comfort: Spacious riding position and good weather protection for touring. Key Features Manual Value Proposition: Empowers users to perform repairs themselves, saving time and money. Quality: Factory-type quality ensures accuracy and completeness. 📋 Manual Details Coverage Areas Primary Coverage: Service and repair for Gilera Nexus 500 (2005 onwards) Secondary Coverage: Maintenance, troubleshooting, diagnostics, component replacement Page Count Estimated Page Count: Not specified, but 'highly detailed' suggests several hundred pages for a comprehensive service manual. Manual Type Type: Service Repair Workshop Manual Language Language: Likely English, based on product description phrasing. Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, timing, valve clearance, piston/cylinder, crankshaft, oil system. Fuel System: Fuel injection system (EFI), injectors, fuel pump, pressure regulator, fuel lines, throttle body. Cooling System: Radiator, cooling fan, coolant circulation, thermostat, hoses. Ignition System: Ignition coil, spark plugs, ECU control of ignition timing. Exhaust System: Exhaust manifold, catalytic converter, muffler, O2 sensors. Transmission Drivetrain: Automatic transmission (CVT), clutch operation, belt drive, final drive. Braking System: Hydraulic brake system (front and rear), brake calipers, master cylinders, brake pads, brake discs, bleeding procedures. Suspension System: Front fork (telescopic), rear shock absorber, linkage, adjustment procedures. Steering System: Handlebar, steering stem, bearings, adjustment. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams. Instrumentation Controls: Dashboard, switches, levers, cables. Chassis Frame: Frame inspection, body panels, seat, storage compartment. Wheels Tires: Wheel bearing inspection, tire mounting/balancing, tire pressure. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though Nexus is belt-driven), fluid level checks. Troubleshooting: Diagnostic flowcharts for common issues, error code interpretation (if ECU diagnostics are covered). Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repair. Component Replacement: Detailed steps for replacing parts like brake pads, bearings, cables, bulbs, etc. Specifications Data: Torque values, clearances, fluid capacities, electrical resistance values. Technical Depth Depth: Comprehensive. Covers everything from basic checks to complete engine and transmission overhauls. Diagnostics: Includes diagnostic procedures and potential fault finding for various systems. Rebuilds: Detailed instructions for engine and transmission rebuilds. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable, common for professionally produced PDF manuals. Print Quality Quality Description: Professional quality, high detail. Illustrations: Likely includes detailed diagrams, schematics, and photographs. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, OHC Displacement: 492.7 cc (approx.) Bore X Stroke: Not specified in product info, but typically around 92mm x 73mm for this engine family. Compression Ratio: Not specified in product info, but likely in the 10:1 to 11:1 range. Valve Train: Single Overhead Camshaft (SOHC), 4 valves Performance Horsepower: Approx. 39-40 HP (29-30 kW) @ 7,500 rpm (for Euro 3 models) Torque: Approx. 45-46 Nm @ 5,500 rpm (for Euro 3 models) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with electronic throttle control. Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 15 liters 🔧 Transmission Standard Transmission...