🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Years: 2005, 2006, 2007, 2008, 2009, 2010 Codes Product Code: GIL-NEX500-MK1-WSM-PDF 👋 Introduction Market Position Vehicle Segment: Maxi-scooter / Sport Scooter Target Audience: Commuters, touring riders, performance-oriented scooter enthusiasts Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500 Key Features Performance Orientation: Known for its powerful 500cc engine and sporty handling compared to many competitors Touring Capability: Comfortable riding position, ample storage (under-seat), and stability at higher speeds 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive A-Z coverage for all models and repairs Mechanical Coverage: Complete mechanical repair and maintenance procedures Electrical Coverage: Complete electrical system diagnostics and repair Page Count Estimated Pages: Likely 500+ pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Engine disassembly, assembly, diagnosis, tuning, internal components, cooling system, lubrication system, fuel system, ignition system Transmission System: Automatic transmission (CVT) operation, diagnosis, maintenance, and repair Chassis And Suspension: Front fork, rear shock absorber, swingarm, steering system, wheel bearings, hub maintenance Braking System: Hydraulic brake system diagnosis, caliper overhaul, master cylinder, brake lines, ABS (if equipped) operation and maintenance Electrical System: Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), starter system, battery maintenance, ECU diagnosis, sensors, and actuators Fuel System: Fuel injection system, fuel pump, injectors, throttle body, fuel filter replacement Exhaust System: Exhaust pipe, muffler, catalytic converter maintenance and replacement Bodywork And Trim: Panel removal, fairing installation, seat, storage compartment access Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, valve clearance checks, coolant replacement, brake fluid flush, chain adjustment (if applicable), tire pressure checks Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults Repair Procedures: Step-by-step instructions for component overhaul and replacement Disassembly And Assembly: Detailed procedures for engine, transmission, suspension, and body component removal and installation Electrical Diagnostics: Component testing, wiring harness continuity checks, fault code reading (if applicable) Technical Depth Depth: Full workshop level, suitable for professional technicians and experienced DIY enthusiasts Diagnostic Information: Includes torque specifications, clearances, fluid capacities, electrical values, and diagnostic flowcharts Rebuild Information: Detailed procedures for complete engine and transmission rebuilds 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF (as per standard practice for modern manuals) Print Quality Printability: All pages are printable Image Quality: High-quality, includes tons of detailed pictures & diagrams Binding Type Binding: N/A (PDF Download) Paper Type Paper Quality: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 493 cc (approx.) Bore X Stroke: Not explicitly stated, but typical for 500cc class Compression Ratio: Not explicitly stated, but typical for 500cc class Performance Horsepower: Approx. 39-40 HP (at crankshaft) Torque: Approx. 45-46 Nm (at crankshaft) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Lubrication Oil Type: Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA) Oil Capacity: Approx. 1.6 - 1.7 Liters (with filter change) Cooling System Coolant Type: Ethylene glycol based antifreeze coolant with corrosion inhibitors (50% mixture with distilled water recommended) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive: Belt drive Features Transmission Fluid: Specific CVT fluid or gear oil (refer to manual for exact specification, often SAE 75W-90 or similar for final drive) 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 770 mm Height: Approx. 1350 mm (seat height approx. 790 mm) Weights Dry Weight: Approx. 185 kg Curb Weight: Approx. 195 kg (with fluids) Max Load Capacity: Approx. 160 kg (rider + passenger + luggage) Cargo Under Seat Storage: Sufficient for one full-face helmet plus other items 🛡️ Safety Features Ratings Crash Test Information: N/A (Motorcycles/Scooters typically not rated by standard automotive crash test agencies) Active Features Braking System Type: Dual disc front, single disc rear (typically Brembo or similar quality components) ABS Availability: Optional on some models/markets Passive Features Lighting: Halogen headlights, LED taillight Mirrors: Large, adjustable mirrors for good rear visibility 💡 Technology Features Infotainment Dashboard: Digital and analog display with speedometer, tachometer, fuel gauge, odometer, trip meters, coolant temperature warning, oil pressure warning, and indicator lights. Lighting System: Multi-reflector halogen headlight, LED taillight and brake light. Driver Assistance ABS: Available as an option on certain models, providing anti-lock braking for enhanced safety. Connectivity Diagnostics Port: On-board diagnostic (OBD) port for electronic fault diagnosis (manual will detail access and basic procedures). 🔧 Maintenance Service Intervals First Service: Typically 1,000 km or 1 month Regular Service: Every 6,000 km or 6 months (whichever comes first), including oil and filter changes. Major Service: At higher mileages (e.g., 12,000 km, 24,000 km), involving more in-depth checks like valve adjustments, coolant flush, and...