The Nexus 500 MK1, produced for the 2005 and 2006 model years, represents a strong entry into the premium maxi-scooter segment. Designed with a philosophy that blends sporty handling with the comfort and practicality expected of a maxi-scooter, this model offers excellent aerodynamics for stability at higher speeds, making it suitable for both commuting and touring. Known for its performance-oriented engineering and Italian heritage, the Nexus 500 aims to provide a dynamic riding experience, distinguishing itself through its blend of agility and substantial power from its 493 cc single-cylinder engine. This comprehensive Service Repair Workshop Manual provides detailed information for the Nexus 500 MK1. It covers a wide range of topics essential for maintaining and repairing the vehicle, including in-depth engine and transmission overhauls, chassis and suspension service, brake system maintenance, and complete electrical system diagnostics with wiring diagrams. The manual also details scheduled maintenance procedures, troubleshooting common issues, and provides critical technical specifications and data, ensuring owners and technicians have the resources to keep the scooter in optimal condition. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Years Covered: 2005, 2006 Codes Internal Project Code: Project Gilera Nexus 500 (MK1) 👋 Introduction Market Position Segment: Premium Maxi-Scooter Target Audience: Commuters seeking performance, touring capability, and advanced features Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600 Key Features Design Philosophy: Sporty handling blended with maxi-scooter comfort and practicality Aerodynamics: Designed for wind protection and stability at higher speeds 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and workshop information Secondary Coverage: Maintenance schedules, troubleshooting, diagnostics, component replacement, electrical systems, wiring diagrams Page Count Estimated Pages: Over 300 Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, diagnostics, lubrication system, cooling system, fuel system, ignition system, exhaust system Transmission: Automatic transmission (CVT) operation, maintenance, disassembly, reassembly, fluid specifications Chassis Suspension: Front suspension (forks), rear suspension (shock absorber, swingarm), steering system, wheel bearings Brakes: Front and rear braking systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper and master cylinder service Electrical System: Battery, charging system (alternator, regulator/rectifier), starting system (starter motor), lighting system (headlight, taillight, indicators), ignition system components, sensors, ECU, wiring diagrams, troubleshooting electrical faults Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, throttle body, emission control systems Bodywork Fairings: Body panel removal and installation, fairing components, seating, storage compartments Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, valve clearance checks, drive belt inspection/replacement, brake service intervals, coolant checks/replacement Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, error code interpretation (if applicable), performance problems Repair Overhaul: Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly of major vehicle systems Electrical Diagnostics: Detailed wiring diagrams, component testing procedures, voltage drop tests, continuity checks Specifications Data: Torque specifications for all fasteners, fluid capacities, clearances, tolerances, electrical values Technical Depth Depth: Comprehensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds and advanced electrical diagnostics. 📊 Manual Specifications File Format Format: Portable Document Format (PDF) Searchability: Searchable text for quick information retrieval Print Quality Quality: High-resolution scans, clear text and legible diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Displacement: 493 cc Bore X Stroke: 94 mm x 71 mm (approximate, requires manual confirmation for exact spec) Compression Ratio: 10.0:1 (approximate, requires manual confirmation for exact spec) Performance Horsepower: Approximately 40 HP @ 7,000 RPM (requires manual confirmation for exact spec) Torque: Approximately 46 Nm @ 5,500 RPM (requires manual confirmation for exact spec) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Lubrication System Oil Type: Semi-synthetic or fully synthetic SAE 10W-40 motorcycle oil (refer to manual for exact API/JASO spec) Oil Capacity: Approximately 1.7 liters (dry fill), 1.5 liters (with filter change) (requires manual confirmation) Cooling System Coolant Type: Ethylene glycol based coolant (50/50 mix with distilled water) (refer to manual for exact specification) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive Type: Belt drive Optional Optional Transmission: N/A (CVT is standard) Features Gear Reduction: Automatic variable ratios for optimal performance and fuel economy Transmission Fluid: Specific CVT fluid or SAE 80W-90 gear oil (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approx. 2,250 mm (requires manual confirmation) Width: Approx. 800 mm (requires manual confirmation) Height: Approx. 1,400 mm (requires manual confirmation) Wheelbase: Approx. 1,560 mm (requires manual confirmation) Weights Dry Weight: Approx. 200 kg (requires manual confirmation) Gross Vehicle Weight Rating: Requires manual confirmation Cargo Underseat Storage: Sufficient for one full-face helmet and additional items (refer to manual for specifics) 🛡️ Safety Features Ratings Crash...