The Gilera Nexus 500, also identified by its model code XP 500, represents a significant entry in the maxi-scooter segment for the 2005 and 2006 model years. This Italian-engineered vehicle, part of a larger automotive group, is renowned for its sporty handling and Gran Turismo capabilities, offering a powerful 492.7 cc liquid-cooled, single-cylinder, four-stroke engine that produces approximately 40 horsepower. Its design emphasizes both performance and comfort for extended riding, featuring a robust chassis, dual front disc brakes, and a rear disc brake, with optional ABS for enhanced safety. The Nexus 500 combines practical commuting with engaging performance, making it a versatile choice for discerning riders. This comprehensive service and repair manual provides essential information for maintaining and troubleshooting the Gilera Nexus 500. It covers a wide array of systems, including the engine, transmission, fuel injection, electrical systems, brakes, suspension, and chassis. Within its pages, you will find detailed procedures for general maintenance, disassembly and reassembly, troubleshooting common issues, and periodic lubrication. Technical specifications, wiring diagrams, and fluid recommendations are also included to assist owners, DIY enthusiasts, and independent mechanics in keeping their Nexus 500 in optimal condition, ensuring reliability and longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Years Covered: 2005, 2006 Codes Model Codes: XP 500 👋 Introduction Market Position Target Audience: Gilera Nexus 500 owners, DIY enthusiasts, independent mechanics Competitive Analysis Value Proposition: Enables independent repair, cost savings, in-depth vehicle knowledge Key Features Accessibility: Instant PDF download, usable on Windows & Mac 📋 Manual Details Coverage Areas Primary Focus: Service and Repair Scope: Comprehensive Page Count Estimated Page Count: N/A (Digital PDF) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Yes Transmission Service Repair: Yes Brake System: Yes Electrical System: Yes Wiring Diagrams: Yes Suspension: Yes Steering: Yes Cooling System: Yes Fuel Injection Fuel System: Yes Emission System: Yes Engine Control System: Yes Chassis Body: Yes Restraint System: Yes Axle: Yes Procedures Included General Maintenance: Yes Troubleshooting: Yes Disassembly Reassembly: Yes Periodic Lubrication: Yes Technical Depth Depth: Complete, from basic maintenance to advanced repair 📊 Manual Specifications File Format Format: PDF Software Requirements: Adobe PDF Reader Print Quality Printability: Printable Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: 492.7 cc Bore X Stroke: 93 mm x 73 mm Compression Ratio: 10.5:1 Cooling System: Liquid-cooled Performance Horsepower: Approx. 40 HP @ 7,000 RPM (manufacturer figures may vary) Torque: Approx. 45 Nm @ 5,500 RPM (manufacturer figures may vary) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Features Drive Type: Belt drive 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 780 mm Height: Approx. 1300 mm (seat height approx. 780 mm) Weights Dry Weight: Approx. 190 kg Gross Vehicle Weight Rating: N/A (Specific to region and configuration) 🛡️ Safety Features Ratings Safety Standards: Meets relevant European safety directives (CE) Active Features Braking System Front: Dual 260mm discs, hydraulic calipers Braking System Rear: 240mm disc, hydraulic caliper ABS Availability: Optional (check specific model configuration) Passive Features Lighting: Halogen headlight, LED taillight 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, fuel gauge, clock, odometer, trip meter, indicator lights. Driver Assistance ABS: Available as an option on some models, enhancing braking safety. Connectivity Charging Port: May include a 12V power outlet for accessory charging. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-6,000 km or annually. Specific interval in manual. Spark Plug Replacement: Refer to manual for specific mileage or time intervals. Air Filter Inspection: Regular inspection, typically every 5,000 km or annually. Fluid Specifications Engine Oil Type: Fully synthetic SAE 5W-40 or 10W-40 (API SG/SH/SJ or higher, JASO MA recommended). Exact specification in manual. Coolant Type: Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water. Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Voltage regulator, drive belt, suspension components Potential Electrical Gremlins: Some owners report occasional electrical issues; manual provides diagnostic guidance. 📚 Vehicle History Brand Heritage Manufacturer: Gilera S.p.A. (an Italian company, part of Piaggio Group) Model Evolution Nexus Lineage: The Nexus 500 was a high-performance maxi-scooter, known for its sporty handling and GT (Gran Turismo) capabilities. Production Production Period: The Nexus 500 was produced from 2003 to 2007, with the 2005-2006 models representing a key period.