Basic Information Identification Make: Gilera Model: Nexus 500 Generation: MK1 Model Year Start: 2005 Codes Chassis Codes: ZP4M400 Introduction Market Position Positioning: Premium maxi-scooter segment, known for performance and sportiness Competitive Analysis Competitors: Suzuki Burgman 400, Yamaha XMAX 500, Kymco Xciting 500 Key Features Features: Powerful 500cc engine, advanced chassis design, sporty handling, comfortable for touring Manual Value Proposition Value: Provides dealership-level technical information for DIY maintenance and repairs, saving time and money. Original Source Source: Official Gilera workshop manual, identical to what technicians use. Manual Details Coverage Areas Models Covered: All Nexus 500 MK1 models from 2005 onwards Repair Scope: A-Z, all repairs Page Count Estimated Pages: Comprehensive (exact count not specified, typical for workshop manuals of this scope) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Complete overhaul, tuning, diagnosis, fuel system, ignition system, lubrication, cooling system Transmission: Automatic transmission (CVT) service, diagnosis, and repair Chassis: Frame, suspension (front fork, rear shock absorber), steering system Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, ABS (if applicable) Electrical System: Wiring diagrams, battery, starter motor, alternator, lighting, ignition, instrumentation, ECU diagnostics Bodywork: Body panels, fairings, seat, storage, mounting hardware Procedures Included Maintenance: Routine service, oil changes, filter replacements, spark plug replacement, chain/belt adjustment Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic tool usage (if applicable) Repair: Detailed step-by-step repair instructions for all major and minor components Overhaul: Complete engine and transmission overhaul procedures Technical Adjustments: Valve clearance adjustment, throttle cable adjustment, brake lever adjustment Technical Depth Depth: Professional technician level, covering from basic maintenance to complete engine rebuilds and electrical system troubleshooting Manual Specifications File Format Format Details: Searchable PDF, designed for digital viewing and printing Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams Binding Type Binding: Not applicable (Digital PDF format) Paper Type Paper: Not applicable (Digital PDF format) Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: 492.6 cc Bore X Stroke: 93.5 mm x 73.3 mm Compression Ratio: 10.5:1 Cooling System: Liquid-cooled Performance Horsepower: Approx. 40 HP (30 kW) @ 7,500 rpm Torque: Approx. 46 Nm @ 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Ignition System: Electronic ignition Engine Oil Oil Type: SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity: Approx. 2.0 liters (with filter change) Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Clutch Type: Wet, multi-plate automatic clutch Final Drive: Gear drive Features Features: Smooth and responsive acceleration, no manual gear shifting required. Dimensions Exterior Length: Approx. 2,240 mm Width: Approx. 810 mm (at handlebars) Height: Approx. 1,380 mm (at seat) Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 215 kg (with fluids) Max Load Capacity: Approx. 150 kg Fuel Capacity Fuel Tank Capacity: 15 liters Seat Height Seat Height: Approx. 790 mm Safety Features Ratings Safety Ratings: Not applicable for motorcycles in typical automotive safety rating systems. Active Features Brakes: Hydraulic disc brakes front and rear. Optional ABS available on some models. Lighting: Halogen headlamp, LED taillight, turn signals. Passive Features Frame: High-strength steel frame for stability and rigidity. Storage: Under-seat storage compartment, lockable. Technology Features Infotainment Instrument Cluster: Analog speedometer and tachometer, digital display for fuel level, odometer, trip meter, clock, and warning lights. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on select models, providing enhanced braking stability. Connectivity Features: No advanced connectivity features typically found in modern cars. Focus is on mechanical and electrical systems. Maintenance Service Intervals Oil Change: Every 6,000 km or annually, whichever comes first. Air Filter: Inspect every 6,000 km, replace as needed. Replace every 12,000 km. Spark Plug: Replace every 12,000 km. Drive Belt: Inspect every 12,000 km, replace every 24,000 km or as indicated by wear. Valve Clearance: Check and adjust every 12,000 km. Fluid Specifications Coolant Type: Ethylene glycol-based antifreeze (e.g., Piaggio Coolant or equivalent) mixed with distilled water (50/50 ratio). Brake Fluid: DOT 4 brake fluid. Transmission Oil: Not applicable for CVT, but differential oil should be checked as per manual. Known Issues Common Problems: Occasional voltage regulator issues, wear on CVT components (belt, rollers) at higher mileage, potential fuel pump concerns. Torque Specifications Wheel Nuts: Refer to manual for specific torque values (e.g., typically around 20-30 Nm for smaller fasteners). Vehicle History Brand Heritage Heritage: Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for its sporty and innovative designs. Model Evolution Evolution: The Nexus 500 was Gilera's flagship maxi-scooter, designed to blend the comfort and practicality of a scooter with the performance and handling of a motorcycle. Production Production Period: Introduced in the early 2000s, with significant updates and revisions throughout its production run. Parent Company Ownership: Currently part of the Piaggio Group, which also owns Vespa, Aprilia,...