Welcome to the comprehensive service repair workshop manual for the Nexus 500 MK1, covering model years 2005, 2006, and 2007. This maxi-scooter, originating from the esteemed Italian manufacturer, is renowned for its blend of performance and comfort, designed for riders seeking a premium urban and touring experience. The Nexus 500 stands out for its robust engineering, featuring a powerful 460cc liquid-cooled engine and an automatic CVT transmission, delivering a smooth and engaging ride. Its Italian heritage is evident in its stylish design and dynamic capabilities, making it a notable entry in the maxi-scooter market. This manual provides in-depth information essential for the maintenance, repair, and troubleshooting of your Nexus 500. It covers a wide array of systems, including detailed procedures for engine overhaul, fuel system maintenance, cooling system servicing, electrical system diagnostics, braking system repairs, suspension adjustments, and chassis work. With step-by-step instructions, detailed illustrations, and comprehensive technical specifications, this manual is an invaluable resource for both do-it-yourself enthusiasts and professional mechanics. It empowers you to perform all necessary servicing and repairs, ensuring your vehicle remains in optimal working condition while potentially reducing reliance on dealership service costs. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: MK1 Model Years Covered: 2005, 2006, 2007 Vehicle Type: Maxi-scooter 👋 Introduction Market Position Target Audience: Do-it-yourself-ers and experienced mechanics seeking professional repair information. Key Features Manual Content: Detailed illustrations, step-by-step instructions, comprehensive coverage of all major vehicle systems. Value Proposition Cost Effectiveness: Inexpensive way to keep the vehicle working properly and reduce reliance on dealership service costs. Preview Option Preview Availability: Available via a preview button for select pages. 📋 Manual Details Coverage Manual Type: Service Repair Workshop Manual Pages Total Pages: 406 Format File Format: PDF Compatibility Operating Systems: All versions of Windows & Mac Printability Print Restrictions: Printable without any restriction Language Language: English 📖 Manual Coverage Systems Covered General Information: Characteristics, Tooling, Pre-Delivery Checks, Time Adjustments Maintenance: Scheduled Maintenance, Fluid Checks and Replacements, Filter Replacements, Tire Maintenance Engine: Engine Removal from Vehicle, Engine Specifications, Engine Overhaul Procedures, Cylinder Head, Piston, Crankshaft, Valves Fuel System: Fuel Injection System (EFI), Fuel Pump, Injectors, Throttle Body, Fuel Lines Cooling System: Radiator, Coolant Pump, Thermostat, Hoses, Fan Electrical System: Wiring Diagrams, Battery, Starter Motor, Alternator/Generator, Ignition System, Lighting, Instrumentation, Sensors Braking System: Front Brake Calipers, Rear Brake Caliper, Brake Discs, Brake Lines, Master Cylinders, Bleeding Procedures, ABS (if applicable) Suspension: Front Fork Assembly (Telescopic), Rear Shock Absorber(s), Swingarm, Bushings, Bearings Chassis: Frame, Bodywork Panels, Seat, Handlebars, Footpegs, Luggage Rack (if applicable) Procedures Included Diagnostic Procedures: Troubleshooting guide for common issues, fault code interpretation (if applicable) Repair Procedures: Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly Assembly Disassembly: Complete disassembly of the machine Technical Depth Depth Of Information: Detailed illustrations, step-by-step instructions, comprehensive coverage for DIY and professional mechanics 📊 Manual Specifications File Quality Image Quality: High-resolution, clear images and diagrams Text Searchability: Likely searchable text within the PDF document Binding Type Binding: Not applicable (PDF Download) Paper Type Paper Type: Not applicable (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Displacement: 460cc (approximate, based on Gilera Nexus 500 specifications) Engine Type: Single-cylinder, 4-stroke, Liquid-cooled Bore X Stroke: Specifics available in manual (typically around 95mm x 83mm for this engine). Valve Train: SOHC, 4 valves per cylinder (typical for this engine) Performance Horsepower: Typically around 34-37 HP, exact figures in manual. Torque: Specific figures available in manual. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Engine Oil Recommended Oil Viscosity: Refer to manual for exact specification (e.g., SAE 10W-40 or 15W-50 is common). Oil Capacity: Specific oil capacity in manual. 🔧 Transmission Automatic Transmission Transmission Type: Automatic (CVT - Continuously Variable Transmission) Clutch Type: Automatic centrifugal clutch Transmission Fluid Transmission Fluid Type: Refer to manual for specific CVT fluid type and capacity. 📐 Dimensions Exterior Overall Length: Specific dimensions in manual. Overall Width: Specific dimensions in manual. Seat Height: Specific dimensions in manual. Weights Dry Weight: Approximately 190-200 kg, exact figure in manual. Gross Vehicle Weight Rating: Specific GVWR in manual. Tires Front Tire Size: Typically 120/70-14, refer to manual for exact specification. Rear Tire Size: Typically 160/60-15, refer to manual for exact specification. 🛡️ Safety Features Braking System Front Brake Type: Dual disc brakes (typical for Nexus 500) Rear Brake Type: Single disc brake (typical for Nexus 500) ABS Availability: Optional ABS was available, confirm in manual. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog displays for speed, RPM, fuel, temperature, etc. Driver Assistance ABS: Anti-lock Braking System (if equipped). Lighting Headlight Type: Halogen or HID headlights depending on original specification. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals (e.g., every 5,000-7,500 km). Air Filter Replacement: Refer to manual for specific intervals. Spark Plug Replacement: Refer to manual...