🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: Mk Codes Model Code: Not specified in product data, typically internal manufacturer codes Generation Generation Designation: Mk (Mark) indicates this is a specific iteration or revision of the Nexus 500 model 👋 Introduction Market Position Segment: Premium maxi-scooter segment, known for its sporty handling and GT (Grand Tourer) comfort. Target Audience: Riders seeking a capable and comfortable scooter for commuting, touring, and spirited riding. Competitive Analysis Key Competitors: Competed with models like the Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, and Aprilia Atlantic 500/Scarabeo 500. Key Features Engine Type: Liquid-cooled, four-stroke single-cylinder engine, known for its strong performance and torque. Chassis Design: Steel frame with a motorcycle-like chassis layout contributing to superior handling and stability compared to many other scooters. Suspension: Upside-down (USD) front forks and a sophisticated rear suspension setup for enhanced ride quality and cornering. Braking System: Dual front disc brakes and a single rear disc brake, often with advanced braking technology like ABS (Anti-lock Braking System) as an option on some models. 📋 Manual Details Coverage Areas Applicable Model Years: 2005-Onward Specific Model Variants: Gilera Nexus 500 Mk Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive service manuals of this era and complexity) Manual Type Type: Factory Service Repair Workshop Manual Language Language: Likely English, with potential for multiple languages depending on the original factory release. Confirmation typically requires manual inspection. Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Engine systems including disassembly, assembly, inspection, lubrication, cooling, fuel delivery (carburetor/injection), ignition, and emissions control. Transmission: Automatic transmission (CVT - Continuously Variable Transmission) system, including belt, variator, clutch, and gearbox maintenance and repair. Chassis: Frame, swingarm, suspension (front fork, rear shock absorber), steering system, and wheel components. Brakes: Braking system including front and rear brake caliper maintenance, brake fluid replacement, hose inspection, and hydraulic system bleeding. Electrical System: Wiring diagrams, lighting systems, battery, charging system (alternator/stator, regulator/rectifier), starting system, ignition system, and instrument cluster. Fuel System: Fuel tank, fuel pump, fuel lines, and potential fuel injection system components (depending on specific 500 Mk variant). Given the era, a carburetor is also highly probable. Bodywork And Trim: Fairings, body panels, seat, storage compartments, and other trim components, including removal and installation procedures. Cooling System: Radiator, coolant hoses, coolant fan, and thermostat, including coolant type and flush procedures. Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter cleaning/replacement, drive belt inspection/replacement, coolant checks, brake pad inspection. Troubleshooting: Diagnostic procedures for common faults, error code interpretation (if applicable), and systematic approaches to identifying problems. Engine Overhaul: Detailed steps for engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), reassembly, and critical torque specifications. Transmission Repair: CVT clutch and variator service, gearbox internal checks and adjustments. Electrical Diagnostics: Tracing electrical faults, testing components, and understanding wiring diagrams for accurate repairs. Suspension And Steering Service: Fork seal replacement, shock absorber servicing, steering bearing adjustment and replacement. Brake System Maintenance: Brake fluid flush and bleeding, caliper piston service, pad replacement. Technical Depth Depth: Comprehensive, covering from basic user maintenance to in-depth mechanical and electrical diagnostics and repair. Suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy navigation of technical terms and procedures. Print Quality Printability: Designed for digital viewing and can be printed for workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Completeness Level: Complete Factory Service Repair Workshop Manual Licensing Expiry Dates: No expiry dates mentioned, implying perpetual access after download. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, SOHC (Single Overhead Camshaft), 4 valves per cylinder Displacement: 492.7 cc (Cubic Centimeters) Bore X Stroke: 94 mm x 71 mm (Typical for this engine, may vary slightly) Compression Ratio: 10.5:1 (Typical for this engine) Cooling System: Liquid-cooled Ignition System: Electronic ignition with variable spark advance Performance Horsepower: Approximately 39.4 HP (29.4 kW) at 7,500 RPM (May vary slightly based on specific market regulations) Torque: Approximately 44.2 Nm (32.6 lb-ft) at 5,500 RPM (May vary slightly) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) or Carburetor depending on exact sub-model and market. The 4-valve design suggests EFI for better performance and emissions. Fuel Type: Unleaded gasoline Lubrication Oil Type: Refer to manual for exact specification. Typically SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified for wet clutch compatibility. Oil Capacity: Refer to manual for exact specification. Typically around 1.5 - 1.8 liters including filter. 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive Features Variator: Roller variator system for seamless gear ratio changes. Clutch: Centrifugal automatic clutch Fluid Specifications Transmission Fluid Type: Refer to manual. Typically a specific CVT fluid or gear oil...