🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Sub Model: Nexus 500S Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Segment: High-performance maxi-scooter. Competitive Analysis Competitors: Key competitors in the maxi-scooter segment of its era would include models from Yamaha (e.g., TMAX), Suzuki (e.g., Burgman), Honda (e.g., Silver Wing), and Aprilia (e.g., Atlantic). Key Features Features Of Vehicle: Sporty handling, powerful engine for a scooter, comfortable for touring and urban commuting. Manual Value Value Proposition: Provides owners and technicians with the necessary information to maintain and repair the Gilera Nexus 500/500S, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Primary Coverage: Complete service, repair, maintenance, and troubleshooting of the Gilera Nexus 500/500S. Page Count Estimated Pages: Hundreds of pages (specific count not provided, but implies comprehensive content). Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF Compatibility Operating Systems: All versions of Windows and Mac Delivery Downloadable: Yes Shipping: No shipping cost Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction if zipped) 📖 Manual Coverage Systems Covered Engine: Engine general information, troubleshooting, cooling and lubrication system, engine tune-up. Driveline Transmission: Driveline/axle tune-up, transmission/transaxle. Fuel System: Fuel system and throttle. Electrical: Electrical systems. Suspension Steering: Suspension, steering. Brakes: Brake system. Frame Body: Frame, bodywork. Procedures Included Maintenance: Periodic maintenance, periodic inspection and adjustment. Repair Troubleshooting: Step-by-step instructions for troubleshooting and repair. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to detailed repair and troubleshooting. Illustrations Detail Level: Detailed illustrations included. 📊 Manual Specifications File Format Quality: High-quality PDF, allowing for printing and saving. Print Quality Reproducibility: Printable (user can print sections or the entire manual). Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled, DOHC (exact configuration inferred from typical 500cc maxi-scooters of the era). Displacement: Approximately 493 cc (common for Gilera 500cc engines of this period, exact figure requires manual confirmation). Bore X Stroke: Requires manual confirmation. Compression Ratio: Requires manual confirmation. Performance Horsepower: Typically in the range of 30-40 HP (exact figure requires manual confirmation). Torque: Requires manual confirmation. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) likely utilized. Fuel Type: Unleaded gasoline. Lubrication Oil Type: Requires manual confirmation for specific SAE viscosity grade and API/JASO specification (e.g., SAE 10W-40, JASO MA). Cooling Cooling System: Liquid-cooled with coolant reservoir and radiator. Coolant Type: Requires manual confirmation for specific coolant mixture ratio (e.g., 50/50 ethylene glycol-based). 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) with dry centrifugal clutch. Optional Optional Transmissions: N/A (CVT is standard for this type of scooter). Features Drive System: Belt drive to rear wheel. 📐 Dimensions Exterior Length: Requires manual confirmation. Width: Requires manual confirmation. Height: Requires manual confirmation. Weights Dry Weight: Requires manual confirmation (typically around 180-200 kg). Gross Vehicle Weight Rating: Requires manual confirmation. Capacities Fuel Tank Capacity: Requires manual confirmation (likely around 12-15 liters). Oil Capacity: Requires manual confirmation for engine oil capacity with filter change. 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycles/scooters are not typically rated by organizations like NHTSA or Euro NCAP in the same way as cars). Active Features Braking System: Disc brakes (front and rear), likely with ABS as an option on some variants. Lighting: Headlight, taillight, brake lights, turn signals. Passive Features Frame Construction: Steel frame (specific type requires manual confirmation). 💡 Technology Features Infotainment Instrument Cluster: Likely features a combination analog/digital display with speedometer, tachometer, fuel gauge, odometer, trip meter, and warning lights. Driver Assistance ABS Availability: ABS was an optional feature on some Nexus models, requiring specific diagnostic procedures if equipped. Connectivity Wiring Diagrams: Manual includes detailed electrical system schematics crucial for diagnosing electronic issues. 🔧 Maintenance Service Intervals Oil Change Interval: Requires manual confirmation (typically every 3,000-5,000 km or annually). Air Filter Inspection: Requires manual confirmation (e.g., every 6,000 km). Spark Plug Replacement: Requires manual confirmation (e.g., every 12,000-16,000 km). Valve Clearance Check: Requires manual confirmation (critical for engine health). Fluid Specifications Brake Fluid: Requires manual confirmation for DOT specification (e.g., DOT 4). Transmission Fluid: N/A (CVT typically uses engine oil for lubrication and transmission functionality; separate transmission fluid not applicable in the traditional sense). Known Issues Common Problems: Potential issues could include CVT belt wear, regulator/rectifier failure, and exhaust system corrosion, as commonly seen in maxi-scooters of this era. Specific issues detailed in the manual. 📚 Vehicle History Brand Heritage Heritage: Gilera is an Italian manufacturer with a long history in motorcycling, known for performance and sporty designs. Model Evolution Development: The Nexus series represented Gilera's entry into the premium maxi-scooter segment, focusing on performance and rideability. Production Production Years: The Nexus 500 was produced primarily in the mid-2000s, with variations like the 500S likely being specific trims...