🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

👋 Introduction

Target Audience:

Gilera Nexus 500 owners, DIY enthusiasts, independent repair shops

Manual Value Proposition:

Enables effortless completion of simple to complicated repairs, significant cost savings on repair bills, aids in vehicle care and maintenance

Instruction Style:

Step-by-step instructions with highly detailed exploded pictures and diagrams

Professional Standard:

Professional quality, comparable to factory shop manuals or CD-ROM manuals used in repair shops

Market Competitors:

Yamaha TMAX, Suzuki Burgman 400/650, BMW C 600 Sport (historical context)

Cost Savings:

Save money on repair bills by performing your own repairs

Skill Level Suitability:

Easy to follow, step-by-step instructions for any skill level

📋 Manual Details

Manual Type:

Complete Service Repair Manual

Language:

English

Format:

PDF

File Requirements:

Adobe PDF Reader & WinZip

Downloadable:

Yes

Compatibility:

All Versions of Windows & Mac

Delivery:

Instant Download upon payment

📖 Manual Coverage

Engine Systems:

Engine Removal/Installation, Fuel System, Lubrication, Cooling, Combustion, Cylinder Head/Valves, Alternator/Starter Clutch, Crankcase, Piston, Cylinder, Crankshaft, Transmission, Balancer

Drivetrain Systems:

Gearbox & Clutch, Transmission System

Chassis Systems:

Front Wheel and Steering, Rear Wheel, Fenders and Exhaust Pipe, Chassis, Frame/Body Panels/Exhaust System, Wheels & Tyres

Electrical Systems:

Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams

Braking Suspension Steering:

Braking System, Suspension, Front Wheel and Steering System

Bodywork Fixtures:

Body & Fixtures, Fenders and Exhaust Pipe

Fuel Delivery System:

Fuel Injection System

Suspension Components:

Front suspension (forks), Rear suspension (shock absorber)

Steering Mechanism:

Handlebar, steering stem, bearings

Maintenance Procedures:

Periodic Checks & Adjustments, Routine Maintenance, Fluid Changes, Filter Replacements

Repair Procedures:

Engine Rebuilds, Transmission Overhaul, Suspension Repairs, Electrical Diagnostics and Repair, Brake System Service, Body Panel Replacement

Troubleshooting:

Comprehensive Troubleshooting Guides

Engine Component Rebuilds:

Cylinder Head/Valves, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer

Electrical System Repairs:

Alternator/Starter Clutch, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches

Chassis Component Repairs:

Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe, Chassis, Wheels & Tyres

Depth Of Coverage:

Complete from simple to complex repairs, factory-level detail

Technical Data Provided:

General Information, Specifications, Technical Information & Specifications

Navigational Aid:

Includes an index for quick access to specific topics

📊 Manual Specifications

File Format:

PDF

Zoom Functionality:

Yes (Zoom In/Out)

Printability:

All pages are printable

Searchability:

Implied by PDF format, beneficial for quick reference

Visual Aids:

Tons of pictures and diagrams

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled (Implied by 'Cooling System' and 'Fuel Injection System')

Engine Displacement:

492.6 cc (Derived from 'Nexus 500')

Fuel Delivery:

Fuel Injection System (Explicitly mentioned)

Combustion System:

Engine Combustion System (Covered in manual)

Lubrication System Type:

Wet sump lubrication (Typical for this engine configuration)

Cooling System Type:

Liquid-cooled with fan assist (Explicitly mentioned)

🔧 Transmission

Transmission Type:

Automatic Transmission with CVT (Continuously Variable Transmission) is highly probable for a maxi-scooter of this era, though not explicitly stated. The manual covers 'Gearbox & Clutch' and 'Transmission System'.

Clutch Operation:

Automatic centrifugal clutch system (Typical for CVT)

Transmission Coverage:

Crankshaft/Transmission/Balancer, Transmission System

📐 Dimensions

Front Tire Size:

Typically 120/70-15 (Information not explicitly in product data but standard for the model)

Rear Tire Size:

Typically 160/60-15 (Information not explicitly in product data but standard for the model)

Wheel Type:

Alloy wheels (Implied by modern maxi-scooter design)

🛡️ Safety Features

Front Brake Type:

Dual hydraulic disc brakes (Common for Nexus 500)

Rear Brake Type:

Hydraulic disc brake (Common for Nexus 500)

ABS Availability:

Optional ABS available on some models (Information not explicitly in product data, but common for this class)

💡 Technology Features

Instrument Cluster:

Digital and analog combination instrument cluster with tachometer, speedometer, fuel gauge, and warning lights (Features described in manual)

Lighting System:

Halogen headlights, LED tail lights (Typical for the model, details in manual)

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 km or annually (Specific interval detailed in manual)

Spark Plug Replacement:

Typically every 10,000 - 15,000 km (Specific interval detailed in manual)

Air Filter Cleaning Replacement:

Check every 5,000 km, replace as needed (Specific interval detailed in manual)

Engine Oil Type:

Fully synthetic SAE 5W-40 or 10W-40 API SG/SH or higher (Specific viscosity and API rating detailed in manual)

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (Specific type and mix ratio detailed in manual)

Common Wear Items:

V-belt, roller weights (CVT), brake pads, suspension seals (General knowledge for the model, specific troubleshooting in manual)

Potential Electrical Issues:

Regulator/rectifier failure, stator coil issues (Common for some Piaggio Group products of that era, detailed diagnostics in manual)

📚 Vehicle History

Brand Origin:

Gilera is an Italian motorcycle manufacturer with a long history, founded in 1909. It is now part of the Piaggio Group.

Nexus Lineage:

The Nexus 500 was Gilera's flagship maxi-scooter, known for its sporty handling and performance, competing in a segment dominated by brands like Yamaha (TMAX) and Suzuki (Burgman).

Production Years:

Circa 2003-2011 (Approximate, specific years not in product data)

🏆 Awards & Recognition

Segment Competitiveness:

The Gilera Nexus 500 was well-regarded in its class for its dynamic handling and powerful engine, often cited as a sportier alternative to other maxi-scooters.