🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Model Years Covered: 2005, 2006 Engine Variant: 500cc Single-Cylinder 👋 Introduction Market Position Vehicle Type: Maxi-scooter / Sport-scooter Target Audience Manual: DIY enthusiasts, independent repair shops, Gilera owners seeking comprehensive service information. Competitive Analysis Manual Advantage: Provides the same level of detail as used by authorized dealer technicians, ensuring accurate and efficient repairs. Key Features Manual Scope: Covers all repair procedures needed, making it a complete resource for the vehicle's lifespan. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Overhaul Page Count Estimated Page Count: High (exact number not specified, but described as 'COMPLETE FACTORY SERVICE MANUAL') Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format File Format: PDF/ZIP 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, disassembly, assembly, lubrication, cooling, and internal component inspection. Fuel And Injection System: Fuel injection system diagnosis, component testing, fuel pump, injectors, throttle body, ECU mapping. Electrical System: Wiring diagrams, lighting, ignition system, starter motor, battery, charging system, fuses, relays, sensors. Braking System: Brake fluid service, caliper maintenance, rotor inspection, brake line replacement, ABS system diagnosis (if applicable). Suspension System: Front fork service, rear shock absorber maintenance, bushing inspection, alignment specifications. Chassis And Frame: Frame inspection, steering head bearing service, subframe checks, body panel removal and installation. Cooling System: Coolant type, capacity, bleeding procedures, radiator and fan service. Procedures Included Preventive Maintenance: Scheduled maintenance checks, lubrication points, filter replacement intervals, fluid level checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair Procedures: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly. Pre Delivery Inspection: Factory procedures for new vehicle setup and initial inspection before delivery. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, including use of specialized tools and interpretation of sensor data. Rebuild Procedures: Comprehensive instructions for engine and major component rebuilds, including torque specifications and clearances. 📊 Manual Specifications File Format File Compatibility: Windows, macOS, Linux Unzipping Requirement: WinRAR or compatible unzipper required Print Quality Print Readability: Designed for clarity and ease of use, suitable for printing. Binding Type Delivery Method: Instant PDF/ZIP Download ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, 4-valve, SOHC Displacement: 493 cc Bore X Stroke: Not specified in product info, but detailed in manual Cooling System: Liquid-cooled Performance Horsepower: Approx. 39 HP (actual spec detailed in manual) Torque: Approx. 45 Nm (actual spec detailed in manual) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (specific octane rating detailed in manual) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Features Drive System: Belt drive to rear wheel 📐 Dimensions Exterior Wheelbase: Not specified in product info, but detailed in manual Weights Dry Weight: Approx. 199 kg (detailed in manual) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear (specifics detailed in manual). Passive Features Chassis Design: Robust chassis designed for stability and rider confidence. 💡 Technology Features Infotainment Dashboard Features: Digital and analog instrumentation, warning lights for engine, oil, fuel, etc. Driver Assistance ABS Availability: Optional ABS system, diagnostic procedures for which are included in the manual. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific mileage/time intervals (typically 5,000-7,500 km for synthetic oil). Spark Plug Replacement: Refer to manual for specific intervals and plug type. Belt Check Replacement: Crucial component; refer to manual for inspection and replacement intervals (e.g., 15,000-20,000 km). Fluid Specifications Engine Oil Type: High-quality synthetic motorcycle oil (e.g., SAE 5W-40 or 10W-40, API SG or higher). Specific viscosity and API rating detailed in manual. Engine Oil Capacity: Refer to manual for exact capacity (likely around 1.5 - 2.0 liters). Coolant Type: Ethylene glycol-based antifreeze, mixed with distilled water (specific ratio and type detailed in manual). Brake Fluid Type: DOT 4 (or DOT 5.1 if specified) synthetic brake fluid. Known Issues Common Wear Items: Brake pads, tires, drive belt, suspension components (normal wear and tear, addressed in manual). Potential Electrical Faults: Wiring harness integrity, stator/rectifier issues (troubleshooting covered in manual). 📚 Vehicle History Brand Heritage Manufacturer Origin: Gilera is an Italian manufacturer of scooters and motorcycles, with a history dating back to 1909. Part of the Piaggio Group. Model Evolution Nexus Lineage: The Nexus line represented Gilera's entry into the high-performance maxi-scooter segment, known for sporty handling and powerful engines. Production Manufacturing Location: Likely Italy (specifics detailed in manual) 🏆 Awards & Recognition Recognitions Manual Recognition: Considered the 'definitive guide' by mechanics and experienced DIYers for its completeness and accuracy.