🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: MK1 Codes Product Code: GNS500MK12005PDF Generation Generation Identifier: MK1 👋 Introduction Market Position Positioning: The Gilera Nexus 500 was positioned as a premium, sport-touring maxi-scooter, blending performance with comfort and practicality. Competitive Analysis Competitors: Competed against other high-displacement maxi-scooters like the Yamaha TMAX, Suzuki Burgman 650, and Aprilia Scarabeo 500. Key Features Features: Powerful 500cc engine, advanced chassis design, comfortable ergonomics for long-distance riding, underseat storage. 📋 Manual Details Coverage Areas All Repairs: A-Z Covered Models: All MK1 models 2005 onwards Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, diagnostics, and component repair Fuel System: Fuel injection system, fuel pump, injectors, fuel lines, fuel filter replacement Ignition System: Spark plugs, ignition coils, CDI unit, wiring diagrams Cooling System: Radiator, coolant pump, thermostat, hoses, coolant flush and refill Exhaust System: Muffler, catalytic converter, exhaust pipes, gasket replacement Transmission: Automatic transmission (CVT) servicing, fluid changes, clutch inspection Drivetrain: Belt drive system, variator, torque converter, final drive servicing Brakes: Front and rear brake systems, hydraulic lines, brake fluid flush, pad and disc replacement, ABS system (if applicable) Suspension: Front fork assembly, rear shock absorber, linkage servicing and adjustment Steering: Handlebar assembly, steering head bearings, linkage lubrication and adjustment Electrical System: Battery, starter motor, alternator, lighting, horn, wiring diagrams, fault finding Bodywork: Panel removal and installation, fairings, seat, storage compartments, cosmetic repairs Chassis: Frame inspection, component mounting, torque specifications Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain/belt adjustments, general inspection Troubleshooting: Diagnostic procedures for common and complex issues, fault code interpretation Engine Rebuild: Piston, cylinder, crankshaft, valve train overhauls and reassembly Transmission Repair: CVT belt replacement, variator maintenance, clutch service Brake Overhaul: Calibrator rebuild, master cylinder servicing, bleeding procedures Suspension Fork Rebuild: Fork oil changes, seal replacement, spring installation Electrical Diagnostics: Wiring harness tracing, component testing, multimeter usage Bodywork Refurbishment: Panel alignment, scratch repair, decal application Installation Guides: Information on installing common accessories and replacement parts. Diagnostic Charts: Detailed flowcharts and tables for diagnosing electrical and mechanical faults. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to complete mechanical overhauls and advanced diagnostics. Torque Specifications: Precise torque values for all critical fasteners and components. Clearances And Tolerances: Specific measurements for engine component clearances, valve lash, and bearing play. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content for quick information retrieval Print Quality Quality: High-resolution images and clear text for easy viewing and printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 493 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approx. 40 HP (30 kW) at 7000 RPM Torque: Approx. 46 Nm (34 lb-ft) at 5500 RPM Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type And Capacity: Refer to manual for specific API SG or higher specification, approximately 1.8 liters with filter change. 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive to rear wheel via enclosed chain/gearbox Features Clutch: Automatic centrifugal clutch Transmission Fluid: Refer to manual for specific SAE 75W/90 GL-4 specification for final drive. 📐 Dimensions Exterior Length: Approx. 2150 mm (84.6 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1370 mm (53.9 in) Wheelbase: Approx. 1510 mm (59.4 in) Weights Dry Weight: Approx. 195 kg (430 lbs) Gross Vehicle Weight: Refer to vehicle plate or manual. Cargo Underseat Storage: Sufficient for one full-face helmet and smaller items. 🛡️ Safety Features Ratings Crash Test Results: N/A (Motorcycle/Scooter safety is assessed differently than cars; focus on handling and braking features). Active Features Braking System: Dual front disc brakes, single rear disc brake. ABS optional on some models. Lighting: Halogen headlights, LED taillight and indicators. Passive Features Chassis Construction: Steel frame for rigidity and stability. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog combination dashboard displaying speed, RPM, fuel level, trip meters, and warning lights. Driver Assistance ABS Availability: Optional on certain MK1 models, providing enhanced braking safety. Connectivity Charging Port: 12V accessory socket for charging electronic devices. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 km or annually. Check manual for specific mileage. Air Filter Inspection: Check every 5,000 km, replace as needed. Refer to manual for specific interval. Spark Plug Replacement: Refer to manual for recommended interval, typically around 10,000-15,000 km. Transmission Belt Inspection: Inspect for wear and tear every 10,000 km, replace according to manual recommendations (e.g., 20,000 km). Fluid Specifications Engine Oil Spec: API SG or higher, SAE 10W-40 or 15W-50 depending on climate. Refer to manual for precise viscosity. Coolant Spec: Ethylene glycol-based coolant...