🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Codes Engine Code Prefix: M302 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, sport scooter Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic Key Features Manual Benefit 1: Enables DIY servicing and repairs, leading to significant cost savings. Manual Benefit 2: Promotes longevity and optimal performance of the Gilera Nexus 500 Mk1. Manual Benefit 3: Provides in-depth understanding of the motorcycle's mechanics. 📋 Manual Details Coverage Areas Systems Covered: General Information, Specifications, Maintenance, Gearbox & Clutch, Engine Removal/Installation, Fuel System, Lubrication/Cooling, Combustion System, Alternator/Starter Clutch, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Transmission System, Front Wheel/Steering, Rear Wheel, Fenders/Exhaust, Periodic Checks/Adjustments, Chassis, Cooling System, Fuel Injection System, Braking System, Suspension, Electrical System, Body & Fixtures, Frame/Body Panels/Exhaust System, Wheels & Tyres, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Technical Information, Troubleshooting, Index Page Count Estimated Pages: Detailed information suggests a comprehensive manual, likely exceeding 300 pages. Manual Type Type: Workshop Repair Manual Language Language: English (Assumed based on product description, typical for international manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (Fuel System, Lubrication, Cooling, Combustion, Crankcase, Piston, Cylinder, Crankshaft, Transmission, Balancer), Gearbox & Clutch, Transmission System Chassis And Suspension: Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe, Chassis, Cooling System, Braking System, Suspension, Frame/Body Panels/Exhaust System, Wheels & Tyres Electrical And Electronics: Alternator/Starter Clutch, Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Fuel Injection System Procedures Included Maintenance And Repair: Routine Maintenance, Periodic Checks & Adjustments, Engine Removal and Installation, Drivetrain Overhaul, Suspension Overhaul, Braking System Service, Electrical System Diagnostics, Fuel System Service, Cooling System Service, Troubleshooting Diagnostics: Troubleshooting section for common issues, detailed wiring diagrams for electrical diagnostics Technical Depth Depth Of Information: Comprehensive (indicated by exploded diagrams, step-by-step instructions, and detailed sections like Crankshaft/Transmission/Balancer and Fuel Injection System) 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Features Diagrams And Illustrations: Highly detailed exploded pictures and diagrams ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Engine Displacement: 460 cc (approximately) Bore X Stroke: 93.5 mm x 67.5 mm (typical for this engine family) Compression Ratio: 10.5:1 (typical) Performance Horsepower: Approx. 34-35 HP @ 6500 RPM (manufacturer dependent, check specific model year) Torque: Approx. 45-46 Nm @ 5000 RPM (manufacturer dependent, check specific model year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 95 recommended) Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type Recommendation: Synthetic SAE 10W-40 (API SG or higher, JASO MA) Engine Components Valve Train: SOHC, 4 valves 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with dry clutch Features Clutch Type: Automatic centrifugal dry clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2170 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1330 mm (at windscreen) Weights Dry Weight: Approx. 185 kg Wet Weight: Approx. 197 kg (with fluids) Max Load Capacity: Approx. 180 kg (rider + passenger + luggage) Wheels And Tires Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheel Type: Alloy wheels Fuel Capacity Fuel Tank Capacity: 15 Liters (including reserve) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle safety is primarily assessed through design and rider skill) Active Features Braking System Front: Dual 260 mm discs, hydraulic actuation Braking System Rear: 240 mm disc, hydraulic actuation ABS Availability: Optional ABS (Anti-lock Braking System) available on some models Passive Features Lighting: Dual headlights, LED taillight Instrumentation: Digital and analog display (Meters) 💡 Technology Features Infotainment Dashboard Features: Digital LCD display for speed, fuel level, odometer, trip meter, clock, and warning lights. Analog tachometer. Driver Assistance ABS: Optional ABS integration for enhanced braking safety. Connectivity Diagnostic Ports: On-board diagnostics (OBD) port for fault code reading via dealer diagnostic tool. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,000 km or annually (refer to manual for precise interval) Spark Plug Replacement: Every 10,000-15,000 km Air Filter Cleaning Replacement: Every 7,500 km or as needed based on conditions Gearbox Oil Change: Every 10,000-15,000 km Coolant Replacement: Every 2 years or 20,000 km Fluid Specifications Engine Oil Capacity: Approx. 1.6 - 1.8 Liters (including filter, check manual) Coolant Type: Ethylene glycol-based antifreeze coolant, suitable for Piaggio Group engines Brake Fluid Type: DOT 4 Known Issues Common Wear Items: CVT belt wear, suspension bushings, front brake pads Electrical Gremlins: Occasional issues with wiring harness connectors or regulator/rectifier, especially on earlier models. Fuel System Maintenance: Regular cleaning of fuel injectors and throttle body recommended for optimal performance. 📚 Vehicle History Brand Heritage Manufacturer Origin: Italy Model Evolution Nexus Lineage: The Nexus line represented Gilera's foray into the premium maxi-scooter market, emphasizing sportiness...