🏷️ Basic Information Identification Make: Gilera Model: Nexus Variant: 500 Engine Type: Scooter Emissions Standard: Euro 3 Generation Production Start Year: 2005 Codes Model Code: ZAPM35400 👋 Introduction Market Position Segment: Maxi-scooter, performance scooter Target Audience: Owners and technicians seeking in-depth maintenance and repair knowledge for the Gilera Nexus 500 Competitive Analysis Competitors: Piaggio X9 Evolution, Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing Key Features Manual Value Proposition: The 'real deal' for comprehensive A-Z repairs, offering detailed diagrams and covering all mechanical and electrical aspects. Vehicle Appeal: Sporty handling, powerful engine for its class, comfortable for touring and city use. 📋 Manual Details Coverage Areas Overall Coverage: All models and repairs A-Z Mechanical Coverage: Comprehensive mechanical repairs and maintenance Electrical Coverage: Complete electrical system diagnostics and repair Page Count Estimated Pages: Detailed page count not specified, but described as extensive Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, tuning, fuel injection, ignition, cooling, lubrication, exhaust Transmission: Automatic transmission (CVT), clutch system, drive belts Chassis: Frame, suspension (front and rear), steering, wheels, tires Brakes: Brake system (front and rear), hydraulic lines, calipers, discs, ABS (if equipped) Electrical System: Wiring diagrams, battery, charging system, lighting, starter, ignition switch, sensors, ECU Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body Bodywork: Fairings, seat, handlebars, storage compartments, body panel removal and installation Cooling System: Radiator, cooling fan, coolant hoses, thermostat Lubrication System: Oil pump, oil filter, oil passages, lubrication points Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, drive belt inspection and replacement Diagnostic Procedures: Troubleshooting common issues, reading error codes (if applicable), electrical diagnostics Repair Procedures: Engine rebuilds, transmission service, suspension overhaul, brake system repair, electrical component replacement Assembly Disassembly: Complete procedures for disassembling and reassembling all major components Technical Adjustments: Valve clearance adjustment, throttle cable adjustment, idle speed adjustment Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds Detail Level: Detailed step-by-step instructions with torque specifications, clearances, and service limits Visual Aid Quality: Tons of detailed pictures and diagrams included for clarity 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable for quick information retrieval Print Quality Printability: All pages are printable Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M354M (Quasar 4-stroke) Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Configuration: Single-cylinder, 4-stroke, 4-valve, SOHC Cooling System: Liquid-cooled Performance Horsepower: Approx. 40 HP (29.4 kW) at 7,000 RPM Torque: Approx. 45 Nm (33.2 lb-ft) at 5,500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or Magneti Marelli system Fuel Type: Unleaded gasoline, minimum 91 octane Throttle Body Diameter: Approx. 50 mm Lubrication System Oil Type: SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity With Filter Change: Approx. 1.5 Liters Ignition Ignition System: Electronic ignition, CDI (Capacitor Discharge Ignition) Spark Plug Recommended Spark Plug: NGK CR9EB or equivalent Emissions Emission Control: Catalytic converter, Lambda sensor 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive Type: Belt drive Clutch Type: Automatic centrifugal dry clutch Features Gear Ratios: Continuously variable, specific ratios not typically published for CVT systems Transmission Fluid: N/A (CVT uses dry clutch and no separate transmission fluid; drive belt and rollers are primary maintenance items) 📐 Dimensions Exterior Length: Approx. 2,150 mm (84.6 inches) Width: Approx. 780 mm (30.7 inches) Height: Approx. 1,430 mm (56.3 inches) Wheelbase: Approx. 1,505 mm (59.3 inches) Weights Dry Weight: Approx. 185 kg (407.9 lbs) Wet Weight: Approx. 198 kg (436.5 lbs) Max Load Capacity: Approx. 160 kg (353 lbs), including rider and luggage Cargo Underseat Storage: Sufficient for one full-face helmet and some smaller items Fuel Capacity Fuel Tank Capacity: 12 Liters (3.17 US gallons) 🛡️ Safety Features Ratings Crash Test Ratings: N/A for motorcycles/scooters in typical automotive crash test formats. Active Features Braking System: Dual disc front brakes, single disc rear brake ABS: Optional Anti-lock Braking System (ABS) available on some models/markets Passive Features Lighting: Halogen headlight, LED taillight and turn signals Mirrors: Large, adjustable mirrors for enhanced visibility 💡 Technology Features Infotainment Dashboard Display: Digital LCD instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meter. Driver Assistance ABS Availability: Optional ABS system significantly enhances braking safety. Connectivity Connectivity Features: N/A (Basic scooter features, no Bluetooth or advanced connectivity) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 12 months, whichever comes first Air Filter Inspection: Every 6,000 km, replace as needed Drive Belt Inspection: Every 12,000 km, replace as needed Spark Plug Replacement: Every 12,000 km Coolant Replacement: Every 24,000 km or 24 months Brake Fluid...