The Nexus 500 Mk1, produced from 2005 to 2009, is a maxi-scooter engineered for a blend of sporty handling and Grand Tourer comfort. Powered by the Master 500 engine, this model offers approximately 40 HP and 45 Nm of torque, making it a capable performer in its class. Its design emphasizes a powerful engine, agile chassis, and comfortable ergonomics, positioning it as a strong contender against contemporaries like the T-Max 500 and Burgman. Manufactured in Italy, the Nexus 500 is known for its robust build and performance-oriented features, including an automatic CVT transmission and optional ABS for enhanced safety. This comprehensive workshop service and repair manual provides in-depth guidance for owners, independent workshops, and mechanics. It covers all essential aspects of the Nexus 500 Mk1, including detailed procedures for engine overhaul, fuel and ignition systems, cooling, exhaust, transmission, brakes, suspension, steering, and electrical systems. The manual also includes essential information on preventive maintenance, diagnostic troubleshooting for all major systems, repair procedures, adjustment specifications, electrical component testing, critical torque values, fluid capacities and types, and detailed wiring diagrams. Its purpose is to empower users with the knowledge to perform effective DIY maintenance and repairs, ensuring the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: Mk1 Model Years Covered: 2005, 2006, 2007, 2008, 2009 Codes Engine Code Identifier: Master 500 👋 Introduction Market Position Category: Maxi-scooter Target Audience: Owners, independent workshops, mechanics Competitive Analysis Key Competitors Era: Yamaha T-Max 500, Suzuki Burgman 400/650, Honda Silver Wing 500 Key Features Vehicle Usp: Sporty handling, powerful engine, GT comfort Manual Value Proposition: Enables comprehensive DIY maintenance and repair, reducing reliance on expensive dealer services 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive workshop service and repair Page Count Estimated Page Count: 300-500 (typical for this type of manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, pistons, crankshaft, connecting rods, valve train, timing Fuel System: Fuel injection system, fuel pump, injectors, throttle body, fuel tank, fuel lines Ignition System: Ignition coil, spark plugs, ECU control Cooling System: Radiator, fan, thermostat, coolant passages, water pump Exhaust System: Exhaust manifold, catalytic converter, muffler, lambda sensors Transmission Drivetrain: CVT system (automatic transmission), clutch, variator, torque converter, final drive, belt maintenance Brakes System: Brake fluid, front and rear brake calipers, brake discs, brake lines, ABS system (if equipped), parking brake Suspension System: Front telescopic fork, rear shock absorber, swingarm, bushings, bearings Steering System: Handlebars, steering column, steering bearings Electrical System: Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), wiring diagrams, fuses, relays Instrumentation: Speedometer, tachometer, LCD display, indicator lights Bodywork Frame: Frame inspection, body panels, fairings, seat, storage compartments, trim pieces Chassis Components: Wheels, tires, footrests, stands Procedures Included Preventive Maintenance: Oil changes, filter replacements, spark plug checks, chain/belt adjustments, brake fluid flushes, coolant checks Diagnostic Troubleshooting: Step-by-step fault finding for all major systems Repair Procedures: Detailed instructions for component disassembly, inspection, repair, and reassembly Adjustment Procedures: Carburetor/throttle body synchronization, valve clearance adjustment (if applicable), brake lever adjustments Electrical Component Testing: Testing of sensors, actuators, lighting, charging system components Torque Specifications: Critical torque values for all fasteners Schematics Diagrams: Detailed electrical wiring diagrams, exploded views of components Fluid Capacities Types: Engine oil, coolant, brake fluid, transmission fluid requirements Technical Depth Depth: In-depth mechanical and electrical repair, including full engine rebuilds and complex system diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, single-cylinder, 4-valve, SOHC Displacement: 493 cc Bore X Stroke: 94 mm x 71 mm Cooling System: Liquid-cooled Performance Horsepower: Approx. 40 HP (29.4 kW) at 7,500 rpm Torque: Approx. 45 Nm (33.2 lb-ft) at 5,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (minimum 95 RON) Lubrication Oil Type Capacity: Refer to manual (typically SAE 5W-40 or 10W-40 synthetic, approx. 1.5-1.8 liters including filter) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Clutch Type: Automatic centrifugal clutch Features Drive Type: Belt drive to rear wheel Final Drive Fluid: Refer to manual (typically SAE 80W-90 gear oil, approx. 0.2 liters) 📐 Dimensions Exterior Length: Approx. 2,150 mm Width: Approx. 770 mm Height: Approx. 1,370 mm (seat height: Approx. 780 mm) Weights Dry Weight: Approx. 195 kg Fuel Tank Capacity: 15 liters Wheelbase: Approx. 1,505 mm 🛡️ Safety Features Ratings ABS Availability: Optional on some models Active Features Braking System: Combined braking system (front and rear brake activation with single lever, also separate rear brake lever) Passive Features Lighting: Halogen headlight, LED taillight and indicators 💡 Technology...