The Gilera Nexus 500 MK1, produced for the 2005 and 2006 model years, is a maxi-scooter engineered for performance and versatility. It offers a compelling blend of sporty styling, aerodynamic efficiency, and comfortable ergonomics, making it suitable for both urban commuting and longer journeys. Powered by a robust 493cc four-stroke, liquid-cooled engine with electronic fuel injection, the Nexus 500 delivers strong acceleration and highway capability. Its motorcycle-like chassis and suspension contribute to stable and engaging handling, setting it apart in its segment. This comprehensive workshop service repair manual in English provides in-depth guidance for the maintenance, repair, and troubleshooting of the Gilera Nexus 500 MK1. It covers all major mechanical and electrical systems, including detailed procedures for engine overhaul, transmission servicing, chassis and suspension maintenance, brake system repairs, and electrical diagnostics. With hundreds of photos and illustrations, this manual is an essential resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle. 🏷️ 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...