🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: MK 1 Codes Engine Code Prefix: M311 Generation Production Years: 2005-2007 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Commuters, touring riders, performance-oriented scooter enthusiasts Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX, Aprilia Scarabeo 500, Kymco Xciting 500 Key Features Vehicle Usp: Powerful 500cc engine, sporty handling, advanced chassis, comfortable ergonomics for long-distance riding Manual Value Proposition Benefit To Owner: Empowers owners to perform maintenance and repairs efficiently, saving costs and ensuring optimal vehicle performance. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and maintenance for the Gilera Nexus 500 MK 1 Specific Systems: Engine, Transmission, Fuel System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Cooling System, Lubrication System, Ignition System, Exhaust System Page Count Estimated Pages: Hundreds of pages Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, diagnostics, timing, valve adjustment, cylinder head service Transmission: Automatic transmission (CVT) servicing, belt inspection and replacement, clutch assembly Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulator, fuel tank servicing Electrical System: Wiring diagrams, starter motor, alternator, battery, lighting system, ignition system, electronic control unit (ECU) troubleshooting Brakes: Hydraulic brake system, front and rear disc brake service, brake pad replacement, brake fluid bleeding, ABS system (if equipped) Suspension: Front telescopic fork overhaul, rear shock absorber replacement, linkage service Bodywork: Fairing removal and installation, seat servicing, panel repair and replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug servicing, chain/belt adjustment (if applicable), tire pressure checks Troubleshooting: Diagnostic charts, common problem identification and solutions Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly Rebuilding: Engine and transmission rebuild procedures Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission overhauls 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for easy information retrieval Print Quality Quality: High-resolution for clear diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, liquid-cooled Displacement: 493cc Bore X Stroke: 94 mm x 72 mm Compression Ratio: 10.5:1 Performance Horsepower Max: 40.2 HP (29.5 kW) @ 7,500 rpm Torque Max: 45.8 Nm (33.8 lb-ft) @ 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (95 RON recommended) Lubrication Oil Type: SAE 10W-40 Synthetic Motorcycle Oil Oil Capacity With Filter: Approx. 1.6 Liters 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Features Drive Type: Belt drive to rear wheel Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Approx. 2,180 mm Width: Approx. 790 mm Height: Approx. 1,430 mm (seat height) Weights Dry Weight: Approx. 197 kg Curb Weight: Approx. 210 kg (with fluids) Max Payload: 150 kg Cargo Underseat Storage: Sufficient for one full-face helmet 🛡️ Safety Features Ratings ABS: Optional (check specific model configuration) Active Features Brakes Front: Dual 280 mm discs with 4-piston calipers Brakes Rear: 280 mm disc with 2-piston caliper Passive Features Lighting: Halogen headlights, LED taillight 💡 Technology Features Infotainment Instrument Cluster: Digital/Analog combination with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter Driver Assistance ABS: Available as an option, enhancing braking safety Connectivity Charging Port: 12V power outlet for charging accessories 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months Oil Filter Replacement: Every 6,000 km or 12 months (concurrent with oil change) Spark Plug Replacement: Every 12,000 km Air Filter Cleaning/Replacement: Every 6,000 km (inspect and clean), replace as needed Cvt Belt Inspection: Every 12,000 km (inspect for wear and cracks) Cvt Belt Replacement: Recommended every 24,000 km or as indicated by wear Fluid Specifications Engine Oil Grade: SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA/MA2) Coolant Type: Ethylene Glycol based, antifreeze coolant (50/50 mix with distilled water) Brake Fluid Type: DOT 4 Final Drive Oil Type: SAE 80W-90 Hypoid Gear Oil Known Issues Common Wear Items: CVT belt, brake pads, tires, suspension seals Common Issues Electrical Connections: Corrosion on connectors can lead to intermittent electrical faults Fuel Pump Reliability: Occasional reports of fuel pump issues, particularly with age 📚 Vehicle History Brand Heritage Parent Company: Piaggio & C. S.p.A. Model Evolution Predecessors: While the Nexus line is significant, the 500cc engine was a key component for larger, performance-oriented scooters in Piaggio's portfolio. Successors: The Nexus platform evolved into later Gilera and Aprilia models, incorporating updated technology and styling. Production Manufacturing Location: Italy 🏆 Awards & Recognition Recognitions General Reputation: Praised for its powerful engine and comfortable ride, making it a capable maxi-scooter for commuting and touring.