The Gilera Nexus 500 Mk1 represents a significant entry into the sport maxi-scooter market, blending Italian design with capable performance. Engineered for both commuting and longer journeys, this scooter is characterized by its robust single-cylinder, four-stroke engine, delivering approximately 34-35 HP and 45-46 Nm of torque. Its liquid-cooled engine features SOHC with 4 valves and is managed by an electronic fuel injection system, ensuring efficient power delivery. The Nexus 500 is equipped with an automatic CVT transmission, dual 260 mm front discs and a 240 mm rear disc for braking, with optional ABS available. Its comfortable ergonomics, alloy wheels, and practical 15-liter fuel tank capacity make it a versatile option for discerning riders. This comprehensive workshop repair manual provides essential guidance for the maintenance and repair of your Gilera Nexus 500 Mk1. Covering a wide array of systems, including the engine, transmission, chassis, suspension, and electrical components, this manual offers detailed information on procedures such as engine removal and installation, fuel system servicing, and electrical diagnostics. It features highly detailed exploded diagrams and step-by-step instructions, enabling owners and technicians to perform routine maintenance, address common issues, and ensure the longevity and optimal performance of the vehicle. The manual includes technical specifications, troubleshooting advice, and an index for easy navigation. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Codes Engine Code Prefix: M302 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, sport scooter Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic Key Features Manual Benefit 1: Enables DIY servicing and repairs, leading to significant cost savings. Manual Benefit 2: Promotes longevity and optimal performance of the Gilera Nexus 500 Mk1. Manual Benefit 3: Provides in-depth understanding of the motorcycle's mechanics. 📋 Manual Details Coverage Areas Systems Covered: General Information, Specifications, Maintenance, Gearbox & Clutch, Engine Removal/Installation, Fuel System, Lubrication/Cooling, Combustion System, Alternator/Starter Clutch, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Transmission System, Front Wheel/Steering, Rear Wheel, Fenders/Exhaust, Periodic Checks/Adjustments, Chassis, Cooling System, Fuel Injection System, Braking System, Suspension, Electrical System, Body & Fixtures, Frame/Body Panels/Exhaust System, Wheels & Tyres, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Technical Information, Troubleshooting, Index Page Count Estimated Pages: Detailed information suggests a comprehensive manual, likely exceeding 300 pages. Manual Type Type: Workshop Repair Manual Language Language: English (Assumed based on product description, typical for international manuals) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (Fuel System, Lubrication, Cooling, Combustion, Crankcase, Piston, Cylinder, Crankshaft, Transmission, Balancer), Gearbox & Clutch, Transmission System Chassis And Suspension: Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe, Chassis, Cooling System, Braking System, Suspension, Frame/Body Panels/Exhaust System, Wheels & Tyres Electrical And Electronics: Alternator/Starter Clutch, Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Fuel Injection System Procedures Included Maintenance And Repair: Routine Maintenance, Periodic Checks & Adjustments, Engine Removal and Installation, Drivetrain Overhaul, Suspension Overhaul, Braking System Service, Electrical System Diagnostics, Fuel System Service, Cooling System Service, Troubleshooting Diagnostics: Troubleshooting section for common issues, detailed wiring diagrams for electrical diagnostics Technical Depth Depth Of Information: Comprehensive (indicated by exploded diagrams, step-by-step instructions, and detailed sections like Crankshaft/Transmission/Balancer and Fuel Injection System) 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Features Diagrams And Illustrations: Highly detailed exploded pictures and diagrams ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Engine Displacement: 460 cc (approximately) Bore X Stroke: 93.5 mm x 67.5 mm (typical for this engine family) Compression Ratio: 10.5:1 (typical) Performance Horsepower: Approx. 34-35 HP @ 6500 RPM (manufacturer dependent, check specific model year) Torque: Approx. 45-46 Nm @ 5000 RPM (manufacturer dependent, check specific model year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 95 recommended) Cooling System Cooling Method: Liquid-cooled Lubrication System Oil Type Recommendation: Synthetic SAE 10W-40 (API SG or higher, JASO MA) Engine Components Valve Train: SOHC, 4 valves 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with dry clutch Features Clutch Type: Automatic centrifugal dry clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2170 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1330 mm (at windscreen) Weights Dry Weight: Approx. 185 kg Wet Weight: Approx. 197 kg (with fluids) Max Load Capacity: Approx. 180 kg (rider + passenger + luggage) Wheels And Tires Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheel Type: Alloy wheels Fuel Capacity Fuel Tank Capacity: 15 Liters (including reserve) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle safety is primarily assessed through design and rider skill) Active Features Braking System Front: Dual 260 mm discs, hydraulic actuation Braking System Rear: 240 mm disc, hydraulic actuation ABS Availability: Optional ABS (Anti-lock Braking System) available on some...