🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Years Covered: 2005, 2006 Codes Engine Code: M361M (likely, based on Piaggio/Aprilia shared platforms) 👋 Introduction Market Position Segment: Maxi-scooter, offering a blend of performance, comfort, and practicality for urban commuting and longer journeys. Target Audience: Commuters, touring riders, and enthusiasts seeking a capable and versatile large-displacement scooter. Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Scarabeo 500. Key Features Scooter Design: Sporty styling, aerodynamic fairing, comfortable seating, ample storage. Engine Performance: Powerful 500cc engine providing strong acceleration and highway capability. Handling: Motorcycle-like chassis and suspension for stable and engaging handling. 📋 Manual Details Coverage Areas General Coverage: Comprehensive mechanical and electrical repair, maintenance, and troubleshooting for the Gilera Nexus 500 MK1. Page Count Estimated Page Count: Hundreds (exact count not specified, but described as '100 percents complete and intact' with 'hundreds of photos and illustrations') Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download File Format File Type: PDF Searchability: Likely text-searchable (standard for professional PDFs). Print Quality Printability: All pages are printable. Image Quality: Detailed illustrations and hundreds of photos, implying high-quality visual aids. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine: Engine overhaul, cylinder head, piston, crankshaft, lubrication system, cooling system, fuel injection system (ECU, sensors, injectors), ignition system. Transmission: Automatic transmission (CVT - Continuously Variable Transmission) servicing, clutch operation, belt inspection and replacement, variator and torque converter servicing. Chassis And Suspension: Front fork assembly (disassembly, cleaning, oil changes), rear shock absorber and swingarm maintenance, wheel bearings, steering system. Brakes: Hydraulic brake system, front and rear brake calipers, brake discs, brake pads, brake fluid replacement and bleeding, ABS system (if equipped). Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, fuses, relays, ignition switch. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, fuel injection system troubleshooting. Bodywork And Trim: Panel removal and installation, seat, fairings, dashboard, lighting components. Diagnostic Troubleshooting: Fault finding procedures for common issues, error code interpretation (if applicable). Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter cleaning/replacement, coolant checks, brake fluid replacement, tire pressure checks. Engine Repair: Complete engine rebuild, gasket replacement, timing chain adjustment (if applicable), valve clearance checks and adjustment. Transmission Service: CVT belt inspection and replacement, roller weights, clutch spring replacement, gearbox oil change. Suspension And Steering Service: Front fork seal replacement, fork oil viscosity and level specifications, steering head bearing adjustment. Brake System Overhaul: Brake caliper rebuilding, master cylinder service, brake line replacement, ABS component testing (if equipped). Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, testing components like regulators, alternators, starter solenoids. Fuel System Maintenance: Fuel injector cleaning, fuel pump testing, fuel pressure checks. Bodywork Repair: Fairing removal and installation, headlight bulb replacement, seat mechanism service. Technical Depth Depth: Full factory-level service and repair instructions, suitable for complete disassembly and reassembly of all major components. Diagnostic Focus: Detailed diagnostic procedures and troubleshooting charts for identifying and resolving mechanical and electrical issues. ⚙️ Engine Specifications Primary Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 493 cc Bore X Stroke: Approx. 94 mm x 71 mm (typical for this engine family) Compression Ratio: Approx. 10.5:1 Performance Horsepower: Approx. 40-45 HP @ 7500 RPM (peak power may vary slightly by market) Torque: Approx. 45-50 Nm @ 5500 RPM (peak torque may vary slightly by market) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Ignition Ignition System: Electronic ignition with variable advance Lubrication Oil Type: API SG or higher, SAE 10W-40 or 15W-50 motorcycle specific oil recommended. Consult manual for exact specification. Oil Capacity: Approx. 1.5-1.8 liters (including filter). Exact figure in manual. 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive to rear wheel Features Clutch: Automatic centrifugal dry clutch Gear Ratios: Continuously variable, optimized for acceleration and economy. Transmission Fluid: Refer to manual for specific CVT lubricant requirements. Typically a dedicated CVT fluid or specific gear oil for final drive. 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 790 mm (at handlebars) Height: Approx. 1450 mm (to windshield top) Wheelbase: Approx. 1540 mm Weights Dry Weight: Approx. 200-210 kg (exact specification may vary) Gross Vehicle Weight Rating: Consult manual or VIN plate for precise GVWR. Cargo Underseat Storage: Sufficient for at least one full-face helmet, expandable with additional top box. 🛡️ Safety Features Ratings Crash Test Results: N/A (Not typically tested by consumer safety organizations for motorcycles/scooters). Active Features Brakes: Dual disc front brakes, single disc rear brake. Optional ABS on some models/markets. Lighting: Halogen headlights, LED taillight and brake light, front and rear turn signals. Passive Features Frame: Steel frame for rigidity and stability....