🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Year: 2005 Codes Internal Code: GIL-NEX500-2005-SM-PDF 👋 Introduction Market Position Segment: Premium Sport Maxi-Scooter Target Audience: Commuters seeking performance and comfort, touring riders, and enthusiasts valuing European engineering. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic. Key Features Design Philosophy: Sporty handling blended with maxi-scooter comfort and practicality, inspired by motorcycle chassis dynamics. Unique Selling Points: Strong performance from the 500cc engine, sophisticated Italian design, motorcycle-like riding ergonomics. 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive repair and maintenance for Gilera Nexus 500 Mk1 (2005) Page Count Estimated Pages: 400+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, inspection, and repair procedures, including valve clearance, timing, and lubrication systems. Fuel System: Fuel injection system (throttle body, injectors, fuel pump, pressure regulator), fuel tank, lines, and filter servicing. Ignition System: Ignition coil, spark plugs, ECU control, and diagnostic procedures. Cooling System: Radiator, coolant pump, thermostat, hoses, and fan assembly maintenance and repair. Transmission: Automatic transmission (CVT) operation, maintenance, fluid changes, and component servicing. Chassis And Frame: Frame inspection, headstock bearings, and suspension mounting points. Suspension: Front telescopic fork (oil change, seal replacement, assembly) and rear monoshock absorber servicing and adjustment. Brakes: Front and rear hydraulic brake system, including caliper overhaul, disc inspection, brake pad replacement, fluid bleeding, and master cylinder servicing. Electrical System: Wiring diagrams, battery, starter motor, alternator, lighting system, fuses, relays, and ECU diagnostics. Bodywork: Fairing removal and installation, seat, storage compartment, and panel work. Procedures Included Maintenance: Scheduled maintenance tasks, oil and filter changes, air filter replacement, spark plug replacement, brake fluid replacement, coolant replacement, drive belt inspection/replacement. Troubleshooting: Diagnostic flowcharts for common starting, running, and electrical issues. Repair: Detailed step-by-step repair instructions for all major mechanical and electrical components. Disassembly Assembly: Complete instructions for dismantling and reassembling engine, transmission, and chassis components. Adjustment: Carburetor/throttle body synchronization, brake lever adjustment, suspension preload adjustment. Diagnostic Codes: OBD (On-Board Diagnostics) code retrieval and interpretation for EFI systems. Technical Depth Depth: Factory-level detail suitable for professional mechanics and experienced DIY enthusiasts, covering everything from routine servicing to complete engine rebuilds. 📊 Manual Specifications File Format Quality: High-resolution PDF, optimized for digital viewing and printing. Searchability: Text-searchable for quick information retrieval. Print Quality Printability: Printable pages, allowing for hard copy reference. Binding Type Binding: N/A (PDF Download) Paper Type Paper: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, four-stroke, liquid-cooled, DOHC Displacement: 492.7 cc Bore X Stroke: 92 mm x 90 mm Compression Ratio: 10.5:1 Power Output: Approx. 40 HP (29.4 kW) @ 7,500 RPM Torque Output: Approx. 46 Nm (33.9 lb-ft) @ 5,500 RPM Performance Top Speed: Approx. 150 km/h (93 mph) Fuel System Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication Oil Type: Synthetic SAE 10W-40 or 15W-50 motorcycle oil (API SG or higher, JASO MA) Oil Capacity: Approx. 1.8 liters (including filter) 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Features Features: Smooth acceleration, automatic gear ratio adjustment for optimal performance and fuel efficiency. 📐 Dimensions Exterior Length: Approx. 2,160 mm Width: Approx. 770 mm Height: Approx. 1,430 mm (seat height) Wheelbase: Approx. 1,500 mm Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 205 kg (fully fueled) Fuel Tank Capacity: Approx. 15 liters (including 2-liter reserve) 🛡️ Safety Features Active Features Brakes: Front: Dual 282mm discs with 4-piston calipers. Rear: 260mm disc with 2-piston caliper. Optional ABS available on some models. Lighting: Halogen headlight, LED taillight and turn signals. Passive Features Frame Construction: High-strength steel tubular frame. Ergonomics: Motorcycle-style seating position for improved rider control and comfort. 💡 Technology Features Infotainment Dashboard: Digital and analog instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meter, clock. Driver Assistance ABS: Optional ABS (Anti-lock Braking System) integrated into the hydraulic brake system. Connectivity Diagnostic Port: OBD-II compliant diagnostic connector for electronic system troubleshooting. 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km or annually, whichever comes first. Air Filter Replacement: Every 12,000 km. Spark Plug Replacement: Every 12,000 km. Brake Fluid Replacement: Every 2 years or as needed. Coolant Replacement: Every 2 years or 40,000 km. Drive Belt Inspection: Every 12,000 km; replacement typically around 24,000-36,000 km depending on usage. Fluid Specifications Engine Oil: Synthetic SAE 10W-40 or 15W-50 motorcycle oil (API SG or higher, JASO MA) Coolant: Ethylene glycol based coolant, pre-mixed 50/50 with distilled water. Brake Fluid: DOT 4 hydraulic brake fluid. Transmission Fluid: Not applicable (CVT uses enclosed belt system, no separate transmission fluid to change). Known Issues Common Wear Items: Drive belt wear, front fork seals, rear shock absorber, starter motor reliability. Potential Faults: EFI sensor issues...