The Nexus 500 Mk1, produced for the 2005 and 2006 model years, is a high-performance maxi-scooter powered by a 500cc single-cylinder, liquid-cooled engine. Known for its sporty handling and robust chassis design, the Nexus 500 represents a commitment to dynamic scooter engineering, offering a blend of power and rider confidence. This manufacturer, with a heritage dating back to 1909 and now part of a larger group, has equipped the Nexus line with advanced features for its segment, including electronic fuel injection and an automatic CVT transmission, making it a capable choice for both commuting and longer journeys. This comprehensive factory service manual provides detailed information for the Nexus 500 Mk1, covering all aspects of maintenance, troubleshooting, and repair. It is designed as the definitive guide for DIY enthusiasts, independent repair shops, and owners, offering the same level of detail utilized by authorized technicians. The manual includes step-by-step procedures for engine overhaul, fuel and electrical systems, braking, suspension, and chassis, alongside diagnostic capabilities and rebuild instructions. Preventive maintenance schedules, fluid specifications, and systematic troubleshooting for common issues are also thoroughly detailed, ensuring owners can effectively maintain and repair their vehicle throughout its lifespan. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Model Years Covered: 2005, 2006 Engine Variant: 500cc Single-Cylinder 👋 Introduction Market Position Vehicle Type: Maxi-scooter / Sport-scooter Target Audience Manual: DIY enthusiasts, independent repair shops, Gilera owners seeking comprehensive service information. Competitive Analysis Manual Advantage: Provides the same level of detail as used by authorized dealer technicians, ensuring accurate and efficient repairs. Key Features Manual Scope: Covers all repair procedures needed, making it a complete resource for the vehicle's lifespan. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: High (exact number not specified, but described as 'COMPLETE FACTORY SERVICE MANUAL') Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format File Format: PDF/ZIP 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, disassembly, assembly, lubrication, cooling, and internal component inspection. Fuel And Injection System: Fuel injection system diagnosis, component testing, fuel pump, injectors, throttle body, ECU mapping. Electrical System: Wiring diagrams, lighting, ignition system, starter motor, battery, charging system, fuses, relays, sensors. Braking System: Brake fluid service, caliper maintenance, rotor inspection, brake line replacement, ABS system diagnosis (if applicable). Suspension System: Front fork service, rear shock absorber maintenance, bushing inspection, alignment specifications. Chassis And Frame: Frame inspection, steering head bearing service, subframe checks, body panel removal and installation. Cooling System: Coolant type, capacity, bleeding procedures, radiator and fan service. Procedures Included Preventive Maintenance: Scheduled maintenance checks, lubrication points, filter replacement intervals, fluid level checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly. Pre Delivery Inspection: Factory procedures for new vehicle setup and initial inspection before delivery. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including use of specialized tools and interpretation of sensor data. Rebuild Procedures: Comprehensive instructions for engine and major component rebuilds, including torque specifications and clearances. 📊 Manual Specifications File Format File Compatibility: Windows, macOS, Linux Unzipping Requirement: WinRAR or compatible unzipper required Print Quality Print Readability: Designed for clarity and ease of use, suitable for printing. Binding Type Delivery Method: Instant PDF/ZIP Download ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, 4-valve, SOHC Displacement: 493 cc Bore X Stroke: Not specified in product info, but detailed in manual Cooling System: Liquid-cooled Performance Horsepower: Approx. 39 HP (actual spec detailed in manual) Torque: Approx. 45 Nm (actual spec detailed in manual) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (specific octane rating detailed in manual) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Features Drive System: Belt drive to rear wheel 📐 Dimensions Exterior Wheelbase: Not specified in product info, but detailed in manual Weights Dry Weight: Approx. 199 kg (detailed in manual) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear (specifics detailed in manual). Passive Features Chassis Design: Robust chassis designed for stability and rider confidence. 💡 Technology Features Infotainment Dashboard Features: Digital and analog instrumentation, warning lights for engine, oil, fuel, etc. Driver Assistance ABS Availability: Optional ABS system, diagnostic procedures for which are included in the manual. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals (typically 5,000-7,500 km for synthetic oil). Spark Plug Replacement: Refer to manual for specific intervals and plug type. Belt Check Replacement: Crucial component; refer to manual for inspection and replacement intervals (e.g., 15,000-20,000 km). Fluid Specifications Engine Oil Type: High-quality synthetic motorcycle oil (e.g., SAE 5W-40 or 10W-40, API SG or higher). Specific viscosity and API rating detailed in manual. Engine Oil...