🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Product Type: Workshop Manual Download Product Format: PDF 👋 Introduction Market Position Vehicle Segment: Premium Maxi-scooter Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 650, Aprilia Atlantic 500. Key Features Gilera Nexus 500 Appeal: Combines sporty performance with long-distance touring comfort, powered by a potent Piaggio Master engine. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair Page Count Page Count: Unknown (Digital Manual) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Electrical System: Full diagnostic and repair procedures for all electrical components, wiring diagrams included. Engine: Complete engine overhaul, disassembly, assembly, tuning, and component replacement. Injection System: Detailed coverage of the fuel injection system, including diagnostics, component testing, and calibration. Suspensions: Front and rear suspension servicing, including fork seals, shock absorber replacement, and linkage maintenance. Braking System: Comprehensive brake system service, including hydraulic system bleeding, pad and disc replacement, and caliper overhaul. Cooling System: Radiator, coolant, fan, and thermostat servicing and troubleshooting. Chassis: Frame inspection, steering head bearing service, and general chassis component maintenance. Procedures Included Maintenance: Regular scheduled maintenance, fluid changes, filter replacements, and lubrication points. Tooling: Specific tools and equipment required for various repair and maintenance procedures. Pre Delivery Inspection: Detailed checklist and procedures for pre-delivery inspection of the vehicle. Time Based Maintenance: Scheduled maintenance based on time intervals. Technical Depth Diagnostic Capabilities: Advanced diagnostics for engine, electrical, and mechanical systems. Rebuild Procedures: Detailed instructions for complete engine and component rebuilds. Troubleshooting Guides: Comprehensive troubleshooting flowcharts and symptom-based diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: All pages are printable at high quality. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Download Method Delivery: Instant Download Compatibility Operating Systems: Compatible with all versions of Windows & Mac. Requirements Software Requirement: Adobe PDF Reader required. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, liquid-cooled, single-cylinder Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Performance Max Power: Approx. 40 HP (29.4 kW) @ 7,000 rpm Max Torque: Approx. 45 Nm (33.2 lb-ft) @ 5,500 rpm Fuel System Fuel Delivery: Electronic fuel injection (EFI) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Engine Internals Valvetrain: SOHC, 4 valves per cylinder Compression Ratio: 10.0:1 (Typical for Piaggio Master 500) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Clutch Type: Automatic centrifugal clutch Features Gear Reduction: Helical gears Fluid Specifications Transmission Fluid Type: Specific CVT fluid or SAE 80W-90 gear oil (Refer to manual for exact specification) 📐 Dimensions Exterior Length: Approx. 2,150 mm (84.6 in) Width: Approx. 780 mm (30.7 in) Height: Approx. 1,380 mm (54.3 in) (Saddle height varies) Weights Dry Weight: Approx. 192 kg (423 lbs) Gross Vehicle Weight Rating: Not Specified (Refer to manual) Fuel Capacity Fuel Tank Capacity: Approx. 15 liters (3.96 US gal) Wheelbase Wheelbase: Approx. 1,505 mm (59.3 in) 🛡️ Safety Features Ratings Safety Certifications: CE Marking (European Conformity) Active Features Braking System Type: Combined braking system (linked front and rear brakes) Front Brakes: Dual 260 mm discs with 4-piston calipers (typical) Rear Brakes: 240 mm disc with 2-piston caliper (typical) Optional ABS: ABS available on some models/trims (Verify with manual) Passive Features Lighting: Halogen headlights, LED taillights 💡 Technology Features Infotainment Dashboard Features: Digital and analog instrumentation, trip computer, warning lights. Driver Assistance ABS System: Optional Anti-lock Braking System (ABS) for enhanced braking control. Connectivity Diagnostic Port: On-board diagnostic connector for electronic troubleshooting. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual, typically 5,000-7,500 km (3,000-4,500 miles) or annually. Air Filter Replacement: Refer to manual, typically 10,000-15,000 km (6,000-9,000 miles). Spark Plug Replacement: Refer to manual, typically 15,000-20,000 km (9,000-12,000 miles). Fluid Specifications Engine Oil Type: Synthetic SAE 10W-40 or 5W-40 (API SG or higher, JASO MA/MA2) Engine Oil Capacity: Approx. 1.4 liters (1.5 US qt) without filter change, 1.6 liters (1.7 US qt) with filter change (Verify with manual). Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (e.g., Piaggio coolant or equivalent) Coolant Capacity: Approx. 1.3 liters (1.4 US qt) (Verify with manual). Brake Fluid Type: DOT 4 Known Issues Common Wear Items: Brake pads, tires, drive belt, roller weights in CVT. Potential Electrical Issues: Wiring harness connectors can sometimes corrode or become loose; voltage regulator issues can occur over time. Engine Performance: Some early models might have experienced minor fuel delivery or idle stability issues that were addressed through ECU updates or component changes. 📚 Vehicle History Brand Heritage Gilera History: Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and performance-oriented models. Model Evolution Nexus 500 Introduction: The Gilera Nexus 500 was introduced in the early 2000s as a flagship maxi-scooter, aiming to blend motorcycle-like...