The Gilera Nexus 500 is a premium maxi-scooter, produced approximately from 2003 to 2013, known for combining sporty performance with long-distance touring comfort. Powered by a potent 492.7 cc liquid-cooled, single-cylinder engine, it delivers approximately 40 HP and 45 Nm of torque, featuring electronic fuel injection for efficient power delivery. This Italian-manufactured scooter was designed to compete with other high-performance maxi-scooters, offering a compelling blend of agile handling and practicality. Its robust engineering is evident in its comprehensive braking system, featuring dual front discs and a rear disc, with optional ABS available on some models, and its comfortable riding dynamics. This comprehensive English-language factory service repair manual provides detailed guidance for the Gilera Nexus 500. It covers a wide array of essential maintenance and repair procedures, including full engine overhaul, electrical system diagnostics, fuel injection system servicing, and suspension and braking system maintenance. The manual also includes information on regular scheduled maintenance, specific tooling requirements, and troubleshooting guides with diagnostic flowcharts. This resource is invaluable for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their Gilera Nexus 500, offering clear instructions for everything from routine fluid changes to complex component rebuilds. 🏷️ 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)...