The Nexus 500 Mk1, introduced in 2006, stands as a prominent example of engineering prowess in the maxi-scooter and sport-scooter market. Designed to offer a compelling blend of sporty performance, long-distance comfort, and everyday practicality, it features a robust 4-stroke, single-cylinder, liquid-cooled engine with electronic fuel injection, producing approximately 40 horsepower. Its aggressive styling, comfortable ergonomics, and premium componentry positioned it as a strong contender against rivals, appealing to commuters, sport-oriented riders, and touring enthusiasts alike. This comprehensive factory service manual provides in-depth repair, maintenance, and diagnostic information for the Nexus 500 Mk1. Covering all major systems, including the engine, fuel, ignition, cooling, transmission, chassis, suspension, brakes, and electrical systems, it details everything from routine scheduled maintenance and fluid changes to complete component disassembly, inspection, and repair. With step-by-step instructions, torque specifications, and troubleshooting guides, this manual is an essential resource for professional mechanics and experienced DIY enthusiasts seeking to maintain and restore their vehicle to optimal performance and reliability. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Year: 2006 Market Segment: Maxi-scooter / Sport-scooter Codes Engine Code: M303 Chassis Code: ZAPM30300 👋 Introduction Market Position Positioning: The Gilera Nexus 500 Mk1 represented a significant entry into the maxi-scooter market, aiming to blend sporty performance with touring comfort and practicality. Target Audience: Commuters seeking a more powerful and comfortable option than traditional scooters, sport-oriented riders, and those looking for a capable long-distance touring machine. Competitive Analysis Competitors: BMW C 650 GT (later models), Yamaha TMAX, Suzuki Burgman 650, Piaggio X9 Evolution. Key Features Features: Powerful 500cc engine, aggressive styling, comfortable ergonomics, large under-seat storage, and premium componentry. 📋 Manual Details Coverage Areas Primary Focus: Repair, Maintenance, and Diagnostics Scope: Comprehensive factory-level service information Page Count Estimated Pages: ~300-400 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, inspection, and repair of the 4-stroke, single-cylinder, liquid-cooled engine. Fuel System: Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel lines, and fuel tank maintenance and troubleshooting. Ignition System: Ignition coil, spark plug, ECU control, and ignition timing checks. Cooling System: Radiator, coolant pump, thermostat, fan, coolant lines, and fluid specifications. Transmission: Automatic CVT (Continuously Variable Transmission) disassembly, inspection, belt replacement, roller weights, and clutch assembly. Chassis Frame: Frame inspection, welding points, and structural integrity checks. Suspension: Front telescopic fork (fork oil type, level, seal replacement), rear monoshock absorber (spring preload adjustment, damping), and linkage system. Brakes: Front and rear hydraulic disc brake systems, caliper overhaul, master cylinder repair, brake pad replacement, brake fluid specifications, bleeding procedures, and ABS system (if equipped). Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, and wheel balancing. Electrical System: Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, and fuse box. Instrumentation: Speedometer, tachometer, fuel gauge, warning lights, and diagnostic indicators. Bodywork Trim: Fairing removal and installation, seat, panels, storage compartments, and cosmetic component replacement. Diagnostic Troubleshooting: Fault code interpretation (OBD-II if applicable), symptom-based troubleshooting guides, and common problem diagnosis. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel), spark plug checks, coolant flushes, brake fluid changes, and lubrication points. Disassembly Assembly: Step-by-step instructions for component removal and reinstallation with torque specifications. Repair: Detailed repair procedures for worn or damaged parts, including internal engine components, transmission elements, and electrical modules. Checks Inspections: Visual inspections, functional tests, and performance checks for all major systems. Adjustments: Throttle cable adjustment, brake lever adjustment, suspension settings, and idle speed adjustments. Technical Depth Depth: In-depth, from basic owner maintenance to complete engine rebuilds and complex electrical diagnostics. User Level: Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on PDF creation) Print Quality Quality: Digital PDF - quality dependent on original source; typically good for technical diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, single-cylinder, liquid-cooled, 4-valve per cylinder Displacement: 492.7 cc (30.08 cu in) Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.0:1 Engine Management: Electronic Fuel Injection (EFI) Lubrication: Wet sump Performance Horsepower: Approx. 40 HP (29.4 kW) @ 7,000 RPM Torque: Approx. 45 Nm (33.2 lb-ft) @ 5,500 RPM Fuel System Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 15 Liters (3.96 US gal) Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body diameter approx. 40mm. 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch Transmission Fluid: Refer to manual for specific CVT fluid and engine oil specifications (often separate). 📐 Dimensions Exterior Length: Approx. 2180 mm (85.8 in) Width: Approx. 800 mm (31.5 in) Height: Approx....