🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Model Variant: 500cc 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, touring scooter Target Audience: Commuters, tourers, riders seeking performance and comfort in a scooter platform. Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500, Aprilia Scarabeo 500. Key Features Scooter Strengths: Powerful engine, comfortable ergonomics, large underseat storage, touring capability, sporty handling for its class. Manual Value Proposition: Provides comprehensive, dealer-level technical information for independent repairs and maintenance, saving time and money. 📋 Manual Details Coverage Areas Coverage Scope: All Models & All Repairs A-Z Page Count Estimated Page Count: Refer to specific manual for exact count (typically 300-600 pages for comprehensive manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanics: Complete overhaul, disassembly, assembly, timing, valve clearance, piston, cylinder, crankshaft, connecting rod. Fuel System: Fuel injection system, injectors, fuel pump, fuel filter, throttle body, sensors (MAP, IAT, TPS). Ignition System: ECU, ignition coils, spark plugs, wiring diagrams, timing. Cooling System: Radiator, coolant, water pump, thermostat, hoses, fan. Transmission Drivetrain: Automatic transmission (CVT), variator, clutch, final drive, lubrication. Brake System: Hydraulic system, brake fluid, master cylinders, calipers, brake discs, pads, bleeding procedures, ABS system (if applicable). Suspension Steering: Front forks, rear shock absorber, linkage, steering head bearings, wheel bearings. Electrical System: Battery, charging system (stator, rectifier/regulator), starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays. Chassis Bodywork: Frame inspection, body panels, seat, fairings, storage compartment, stands. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain/belt adjustments, brake checks, fluid level checks, general inspections. Troubleshooting: Diagnostic procedures for common issues, fault code interpretation (if applicable). Repair Procedures: Step-by-step instructions for component replacement and repair, including specialized tools and torque specifications. Disassembly Assembly: Detailed guidance on taking apart and reassembling various vehicle systems. Wiring Diagrams: Comprehensive electrical schematics for all systems. Technical Depth Depth: Vehicle Specific, Technician Level Coverage Level: Covers all mechanical and electrical aspects from basic maintenance to complete engine rebuilds and complex diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled, 4-valve, SOHC Engine Displacement: 493cc Bore X Stroke: 94 mm x 72 mm (approximate, verify with specific model year) Compression Ratio: 10.5:1 (approximate, verify with specific model year) Maximum Power: 32.8 HP (24.5 kW) @ 6500 rpm (approximate, verify with specific model year) Maximum Torque: 46 Nm (34 lb-ft) @ 5000 rpm (approximate, verify with specific model year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Lubrication System Oil Type: SAE 15W-40 Synthetic Motorcycle Oil (API SG or higher) Oil Capacity: Approximately 1.4 liters (1.5 US qt) with filter change (verify with manual). 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Features Clutch Type: Automatic centrifugal clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2180 mm (85.8 in) Width: Approx. 780 mm (30.7 in) Height: Approx. 1400 mm (55.1 in) Wheelbase: Approx. 1580 mm (62.2 in) Weights Dry Weight: Approx. 195 kg (430 lbs) Gross Vehicle Weight Rating: Specify from manual Cargo Underseat Storage: Sufficient for one full-face helmet and other items. 🛡️ Safety Features Ratings ABS: Optional or Standard depending on market and model year (verify specification). Active Features Braking System: Front: Dual 260 mm discs. Rear: 240 mm disc. ABS available. Passive Features Lighting: Halogen headlight, LED taillight/brake light, standard turn signals. 💡 Technology Features Infotainment Dashboard: Analog tachometer, digital speedometer, fuel gauge, odometer, trip meter, coolant temperature warning light. Driver Assistance ABS System: Optional, for enhanced braking stability. Connectivity Charging Port: Typically includes a 12V accessory socket for charging devices. 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km (3,700 miles) or 12 months, whichever comes first. Air Filter Cleaning Replacement: Inspect every 6,000 km (3,700 miles), clean or replace as needed. Spark Plug Replacement: Every 12,000 km (7,500 miles). Cv Belt Inspection Replacement: Inspect every 12,000 km (7,500 miles), replace at specified intervals (e.g., 24,000 km or 48,000 km based on usage). Valve Clearance Check: Every 18,000 km (11,200 miles). Fluid Specifications Brake Fluid: DOT 4 (verify with manual for specific type and DOT rating). Coolant Type: Ethylene glycol-based coolant, 50% mix with distilled water. Transmission Fluid: Refer to manual for specific type and procedure, often a separate oil for the final drive gearbox. Known Issues Common Wear Items: CV belt wear, variator rollers, brake pads, front fork seals, exhaust system heat shields. Common Issues Electrical Gremlins: Occasionally reported issues with wiring harnesses or starter solenoids, addressed by this manual. Engine Performance: Potential for slight performance degradation due to clogged fuel injectors or...