🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Year Coverage: 2005 onwards Codes Engine Code: M305M (Piaggio Quasar) 👋 Introduction Market Position Segment: Premium Maxi-Scooter Target Consumer: Commuters seeking performance, touring capability, and style Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600 Key Features Design Philosophy: Sporty styling, motorcycle-like ergonomics, advanced technology for its era Unique Selling Points: Powerful 500cc engine, agile handling for its class, premium Italian engineering 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Completeness: Complete, no missing pages Page Count Estimated Page Count: 300+ 📖 Manual Coverage Systems Covered Engine: Disassembly, assembly, inspection, tuning, performance Fuel System: Fuel injection, fuel pump, injectors, fuel filter replacement Cooling System: Radiator, water pump, coolant flow, thermostat operation Exhaust System: Muffler, catalytic converter, exhaust pipe inspection and replacement Transmission: Automatic CVT, variator, clutch, belt inspection and replacement Brakes: Hydraulic system, disc brake components, caliper maintenance, bleeding procedures Suspension: Front telescopic forks, rear shock absorber, tuning and replacement Electrical System: Battery, charging system, lighting, ignition system, starter motor Wiring Diagrams: Comprehensive electrical schematics for all systems Bodywork And Chassis: Frame inspection, fairing removal and installation, seat, luggage options Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, chain/belt adjustment Troubleshooting: Diagnostic procedures for common and uncommon issues Repair Procedures: Step-by-step instructions for component overhaul and replacement Diagnostic Charts: Flowcharts for identifying and resolving faults Specifications And Tolerances: Detailed torque values, clearances, and measurements Special Tool Requirements: Identification and usage of specialized tools Technical Depth Depth Level: Comprehensive, covering from basic rider maintenance to complete engine rebuilds and advanced electrical diagnostics Target Audience: DIY enthusiasts, independent workshops, experienced mechanics 📊 Manual Specifications File Format File Type: PDF Searchable: Yes, text-searchable Printable: Yes, designed for printing Print Quality Image Resolution: High-resolution images and diagrams Binding Type Binding Type For Print: N/A (Digital PDF Download) Paper Type Paper Type For Print: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, SOHC, 4-valve, single-cylinder Displacement: 493 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approx. 40 HP (29.4 kW) @ 7,000 rpm Torque: Approx. 45 Nm (33.2 lb-ft) @ 5,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: SAE 15W-40 API SG or higher (e.g., Piaggio/Motul 5100 15W-50) Oil Capacity: Approx. 1.5 Liters (with filter change) Ignition Ignition System: Electronic CDI with variable ignition timing Cooling Cooling Medium: Liquid (Ethylene glycol based coolant) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive System: Belt drive to rear wheel Features Variator Rollers: Specific weight and dimensions critical for performance tuning Clutch Type: Centrifugal automatic clutch Fluid Specifications Final Drive Oil Type: SAE 80W-90 API GL-4 (Check specific manual for exact type) 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 800 mm Height: Approx. 1400 mm Wheelbase: Approx. 1525 mm Weights Dry Weight: Approx. 203 kg Curb Weight: Approx. 220 kg (with all fluids) Cargo Underseat Storage: Sufficient for one full-face helmet and smaller items 🛡️ Safety Features Ratings Crash Test Information: N/A (Motorcycle/Scooter classification) Active Features Braking System: Front: Dual 240 mm discs with 2-piston calipers. Rear: 240 mm disc with 1-piston caliper. ABS optional on some models. Lighting System: Halogen headlamp, LED taillight, integrated turn signals Passive Features Frame Construction: High-tensile steel double cradle frame Ergonomics: Motorcycle-style riding position for enhanced control 💡 Technology Features Infotainment Dashboard Display: Digital and analog gauges including speedometer, tachometer, fuel gauge, temperature gauge, clock Lighting Technology: Multi-reflector halogen headlamp Driver Assistance ABS Availability: Optional on some markets/trims Connectivity Diagnostic Port: On-board diagnostics (OBD) port for electronic fault diagnosis 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months, whichever comes first Air Filter Inspection: Every 6,000 km Spark Plug Replacement: Every 12,000 km Cvt Belt Inspection: Every 12,000 km, replacement typically around 24,000 km or as needed Brake Fluid Change: Every 24 months Fluid Specifications Coolant Type: Piaggio Genuine Coolant or equivalent (50/50 mix with distilled water) Brake Fluid Type: DOT 4 Known Issues Common Wear Items: CVT belt, variator rollers, starter motor solenoid, voltage regulator Potential Faults: Fuel injector clogging, regulator failure leading to battery charging issues 📚 Vehicle History Brand Heritage Manufacturer Origin: Italy Group Affiliation: Part of the Piaggio & C. S.p.A. group (which also owns Vespa, Aprilia, Moto Guzzi) Model Evolution Development Basis: Developed to bridge the gap between traditional scooters and motorcycles, offering performance and comfort Production Production Period: Introduced around 2003/2004, with MK1 being the initial iteration 🏆 Awards & Recognition Recognitions Industry Awards: Generally well-regarded for its performance and handling within the maxi-scooter segment during its production era.