🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, often categorized as a sport-touring or GT (Grand Tourer) scooter. Competitive Analysis Key Competitors Mk1 Era: Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600, Aprilia Atlantic 500. Key Features Vehicle Strengths: Powerful 500cc engine for its class, sporty handling, comfortable ride for longer distances, spacious under-seat storage. Manual Value Proposition: Provides the critical technical data and procedural guidance necessary for accurate maintenance and repair, mirroring the information used by authorized service centers. 📋 Manual Details Coverage Areas Coverage Scope: All repairs covered A-Z, all models covered within the MK1 generation. Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive motorcycle service manuals, exact count not provided). Manual Type Manual Classification: Professional Workshop Service & Repair Manual Language Primary Language: English (Assumed, as typical for international market manuals and based on product description). Format Delivery Format: Instant Download PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, lubrication, cooling, fuel system (injection, carburation if applicable to MK1 variants), ignition system, exhaust system, starting system, charging system. Transmission Drivetrain: Automatic Transmission (CVT) operation, maintenance, repair, clutch, final drive (belt/chain inspection and tensioning). Chassis Suspension: Front fork (telescopic) overhaul, rear shock absorber maintenance, swingarm inspection, bearings (steering head, wheel). Braking System: Brake caliper service, brake pad replacement, brake fluid flush and bleed, master cylinder overhaul, ABS system (if equipped) diagnostics and repair. Electrical System: Wiring diagrams, lighting system, battery maintenance, fuse identification and replacement, starter motor, alternator, sensor diagnostics, ECU (Engine Control Unit) troubleshooting. Bodywork Trim: Fairing removal and installation, seat maintenance, body panel repair, plastic component repair, cosmetic trim. Procedures Included Routine Maintenance: Oil change intervals and procedures, filter replacement (oil, air), spark plug inspection and replacement, chain/belt adjustment, tire pressure checks. Diagnostic Procedures: Troubleshooting guides for common issues, fault code interpretation, step-by-step diagnostic flows for various systems. Repair Procedures: Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. Special Tool Requirements: Identification and usage instructions for specialized tools required for specific repairs and adjustments. Technical Depth Depth Of Coverage: Comprehensive, covering basic maintenance to complete engine rebuilds and advanced electrical diagnostics, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Extension: PDF Print Quality Resolution And Clarity: High-resolution scans suitable for clear viewing and printing, preserving detail in diagrams and schematics. Binding Type Digital Binding: N/A (Digital PDF format, not physically bound). Paper Type Digital Paper Equivalent: N/A (Digital PDF format, not printed on physical paper). ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC, 4 valves. Engine Displacement: 460 cc (approximate, exact may vary slightly by VIN/market). Bore X Stroke: 93.0 mm x 68.0 mm (typical for this engine family). Compression Ratio: 10.5:1 (typical). Engine Power Output: Approximately 34-39 HP (25-29 kW) at 7000-7500 RPM (actual figures vary by specific market tune). Engine Torque Output: Approximately 45-48 Nm at 5500-6000 RPM (actual figures vary by specific market tune). Performance Top Speed Estimated: Approximately 150-160 km/h (93-99 mph). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or similar system. Fuel Type Required: Unleaded Gasoline (Octane rating specified in manual, typically 91+ RON). Fuel Tank Capacity: Approximately 15 liters (3.96 US gallons). 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with wet multi-plate clutch. Optional Optional Gearbox: N/A (CVT is standard). Features Transmission Operation: Automatic, no manual clutch or gear shifting required by the rider. Final Drive: Belt drive (specific belt model and tensioning procedure detailed in manual). 📐 Dimensions Exterior Length: Approximately 2150 mm (84.6 inches). Width: Approximately 760 mm (29.9 inches). Height: Approximately 1420 mm (55.9 inches). Wheelbase: Approximately 1540 mm (60.6 inches). Weights Dry Weight: Approximately 178 kg (392 lbs). Wet Weight Estimated: Approximately 190 kg (419 lbs) (with all fluids). Seat Height: Approximately 770 mm (30.3 inches). 🛡️ Safety Features Ratings Safety Certifications: CE marking (Europe) and other regional safety standards as applicable. Active Features Braking System Features: Front: Dual 280mm discs with 4-piston calipers. Rear: 260mm disc with 2-piston caliper. Optional ABS available on some models/markets. Lighting System: Halogen headlights, LED tail light and brake light (typical for the era). Passive Features Chassis Construction: Steel frame, designed for stability and rider comfort. 💡 Technology Features Infotainment Dashboard Display: Analogue speedometer and tachometer, digital multi-function display for fuel level, odometer, trip meter, engine temperature, clock. Driver Assistance ABS Availability: Optional Anti-lock Braking System (ABS) available on certain MK1 variants. Connectivity Connectivity Features: N/A (Basic scooter technology for its era, no modern connectivity features like Bluetooth or smartphone integration). 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 6,000 km or 12 months, whichever comes first (refer to manual for precise intervals and...