🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Generation: mk1 Year: 2005 Codes Vin Prefix: ZMP 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Commuters seeking performance, touring riders, scooter enthusiasts Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Kymco Xciting 500 Key Features Scooter Features: Sporty handling, powerful engine, comfortable ergonomics, ample under-seat storage, advanced instrumentation Manual Value Proposition Value: Essential resource for DIY maintenance, repairs, and understanding the intricate systems of the Gilera Nexus 500. 📋 Manual Details Coverage Areas Primary Coverage: Gilera Nexus 500 mk1 (2005) Secondary Coverage: Similar years and models within the Nexus 500 range Page Count Estimated Page Count: 300+ Manual Type Type: Service Repair Workshop Manual Bonus Content: Parts Catalogue Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, component inspection, timing, lubrication, cooling system Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, pressure regulator Transmission: Automatic transmission (CVT) operation, maintenance, fluid checks, belt inspection Brakes: Brake system service, hydraulic lines, brake pads, discs, bleeding procedures, ABS (if equipped) Electrical System: Wiring diagrams, battery, charging system, ignition system, lighting, starter, ECU troubleshooting Suspension: Front fork service, rear shock absorber, linkages, adjustments Chassis And Frame: Frame inspection, steering head bearings, swingarm service Bodywork: Fairing removal and installation, body panel repair, seat assembly Exhaust System: Exhaust component inspection and replacement Procedures Included Maintenance: Regular service checks, oil changes, filter replacements, spark plug service, coolant checks Troubleshooting: Diagnostic procedures for common faults, error code interpretation, electrical system troubleshooting Repair: Step-by-step repair instructions for all major components and systems Rebuilds: Detailed instructions for engine and transmission overhauls Disassembly And Assembly: Complete guide for taking apart and reassembling the entire scooter Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine rebuilds and advanced diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Text-searchable for quick information retrieval Print Quality Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: 492.6 cc Bore X Stroke: 94 mm x 71 mm Valve Train: SOHC, 4 valves Cooling System: Liquid-cooled Performance Horsepower: Approximately 40 HP (29.4 kW) at 7000 RPM Torque: Approximately 45 Nm (33.2 lb-ft) at 5500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Lubrication System Oil Type: SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity: Approximately 1.7 liters (with filter change) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Drive System: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch Transmission Fluid: Specific CVT fluid; refer to manual for exact type and capacity. 📐 Dimensions Exterior Length: Approximately 2180 mm Width: Approximately 780 mm Height: Approximately 1470 mm (seat height approx. 810 mm) Cargo Underseat Storage: Sufficient for one full-face helmet and other items Weights Dry Weight: Approximately 192 kg Gross Vehicle Weight Rating: Refer to owner's manual/compliance plate 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle/Scooter safety standards apply) Active Features Braking System: Front: Dual disc; Rear: Single disc. Optional ABS available on some models. Lighting: Halogen headlights, LED taillight, turn signals Passive Features Frame Construction: High-strength steel trellis frame Mirrors: Large, adjustable mirrors for visibility 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer and speedometer, digital display for odometer, trip meters, fuel level, coolant temperature, clock. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on some configurations. Connectivity Alarms Immobilizers: Often equipped with factory or aftermarket alarm/immobilizer systems. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 6 months, whichever comes first. Air Filter Replacement: Inspect every 6,000 km, replace as needed or every 12,000 km. Spark Plug Replacement: Replace every 12,000 km. Transmission Fluid Change: Refer to specific manual for interval and type, typically every 10,000-15,000 km. Coolant Replacement: Every 2 years or 24,000 km. Fluid Specifications Engine Oil Grade: SAE 5W-40 Synthetic (API SG/SH/SJ/SL/SM/SN, JASO MA/MA1/MA2) Coolant Type: Ethylene glycol-based antifreeze, 50% mixture with distilled water Brake Fluid: DOT 4 Known Issues Common Problems: Potential for stator failure, fuel pump issues, and occasional electrical gremlins. CVT belt wear is a standard maintenance item. Part Numbers Oil Filter Example: HIFLOFILTRO HF183 (or equivalent Piaggio/Gilera part number) Air Filter Example: HIFLOFILTRO HFA7101 (or equivalent Piaggio/Gilera part number) 📚 Vehicle History Brand Heritage Manufacturer: Gilera (an Italian brand with a long history in motorcycle racing and production, now part of the Piaggio Group) Model Evolution Development: The Nexus series was Gilera's flagship maxi-scooter, designed for performance and touring capabilities, often sharing components with Aprilia models due to the Piaggio Group ownership. Production Manufacturing Location: Italy Production Period: The Nexus 500 was produced for several years, with the mk1 designation typically referring to the initial models launched...