Engine Systems:
Engine overhaul, tuning, fuel injection, ignition, lubrication, cooling, exhaust
Transmission Systems:
Automatic transmission (CVT) inspection, repair, fluid service
Chassis Systems:
Frame, suspension (front and rear), steering, wheels, tires, brakes (front and rear), final drive
Electrical Systems:
Wiring diagrams, battery, charging system, starting system, lighting, instruments, controls, ECU diagnostics
Bodywork And Trim:
Fairings, seat, storage, lighting fixtures, body panel removal and installation
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, spark plug service, brake fluid flush, coolant replacement
Repair Procedures:
Complete disassembly and reassembly of all major components, engine rebuilds, transmission repairs, suspension overhauls
Troubleshooting:
Diagnostic procedures for common issues, fault code interpretation, electrical troubleshooting guides
Diagnostic Procedures:
ECU diagnostics, sensor testing, electrical system fault finding
Depth Of Coverage:
Comprehensive (suitable for OEM mechanics and advanced DIYers), includes step-by-step instructions with detailed substeps
Visual Aids:
Hundreds of photos, illustrations, drawings, and enlarged inset diagrams
Special Tools:
Identification of necessary special tools for specific procedures
Printability:
All pages printable, ability to blow up images and print enlarged copies
Binding Type:
Digital download (no physical binding)
Paper Type:
Digital (no physical paper type)
Computer Compatibility:
Compatible with all Windows & Mac computers (Windows 7, Vista 32/64, XP, ME, 98, NT, 2000 etc.)
Navigation:
Fully indexed for easy navigation, numbered table of contents
Searchability:
Searchable text into document
Software Requirements:
Adobe PDF Reader
Delivery Method:
Instant Download
Engine Type:
Single-cylinder, four-stroke
Engine Displacement:
493 cc (approximate, based on typical Nexus 500 specifications)
Bore X Stroke:
Typical for this engine class: e.g., 94 mm x 71 mm (specific values would be detailed in manual)
Compression Ratio:
Typical for this engine class: e.g., 10.5:1 (specific values would be detailed in manual)
Horsepower:
Typically around 34-35 HP at 6,500 RPM (specific values would be detailed in manual)
Torque:
Typically around 45 Nm at 5,000 RPM (specific values would be detailed in manual)
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Ignition System:
Electronic ignition
Emission Control:
Catalytic converter (likely)
Transmission Type:
Automatic Continuously Variable Transmission (CVT)
Drive Type:
Belt drive to rear wheel
Transmission Features:
Automatic clutch, variable gear ratios for optimal performance and efficiency
Transmission Fluid Type:
Specific CVT fluid required (exact specification provided in manual, e.g., Motul Gear 300 or equivalent)
Transmission Fluid Capacity:
Specific capacity detailed in manual, likely around 0.2-0.3 liters
Length:
Typical maxi-scooter dimensions (specifics in manual, e.g., around 2150 mm)
Width:
Typical maxi-scooter dimensions (specifics in manual, e.g., around 770 mm)
Height:
Typical maxi-scooter dimensions (specifics in manual, e.g., around 1430 mm)
Dry Weight:
Typically around 190-200 kg (specifics in manual)
Gross Vehicle Weight Rating:
GVWR specified in manual
Front Tire Size:
e.g., 120/70-14 (specifics in manual)
Rear Tire Size:
e.g., 160/60-15 (specifics in manual)
Front Wheel Size:
e.g., 14-inch (specifics in manual)
Rear Wheel Size:
e.g., 15-inch (specifics in manual)
Bolt Pattern:
Wheel bolt pattern information provided in manual
Safety Standards:
Adherence to relevant European motorcycle safety standards (e.g., Euro 3 emissions where applicable)
Braking System:
Front and rear disc brakes, potentially with ABS (Anti-lock Braking System) as an option on some versions
Suspension Features:
Adjustable front forks and rear shock absorber for optimized handling and stability
Lighting:
Dual headlights, LED taillight, turn signals
Ergonomics:
Designed for rider comfort and control
Instrument Cluster:
Digital and analog display for speed, RPM, fuel level, engine temperature, clock, and other indicators.
ABS Availability:
ABS was an optional feature on some models; manual will detail system operation and diagnostics if equipped.
ECU Diagnostics:
On-board diagnostics (OBD) capabilities and detailed ECU troubleshooting procedures.
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually (specific interval and oil type in manual)
Spark Plug Replacement:
Refer to manual for recommended interval, often around 10,000 - 15,000 km
Belt Drive Inspection:
Regular inspection for wear and tension as per manual recommendations
Engine Oil Type:
Specific viscosity and API rating required (e.g., 10W-40 API SG or higher, detailed in manual)
Engine Oil Capacity:
Approximate capacity provided in manual, typically around 1.5-1.8 liters with filter change.
Coolant Type:
Ethylene glycol-based antifreeze, specific mixture ratio detailed in manual
Common Wear Items:
CVT belt wear, front suspension bushings, brake pad wear, potential exhaust system leaks (refer to manual for specific diagnostics)
Oil Filter Part Number:
OEM and aftermarket part numbers for filters (oil, air) will be listed in the manual.
Manufacturer:
Gilera, an Italian manufacturer with a long history in performance motorcycles and scooters.
Nexus Series:
The Nexus 500 was Gilera's flagship maxi-scooter, known for its sporty performance and advanced features for its time.
Production Period:
The Nexus 500 was produced for a number of years, with the 2003-2005 models being specifically covered by this manual.
