The Gilera Nexus 500, produced from 2005 to 2006, is a performance-oriented maxi-scooter designed for both urban commuting and longer-distance touring. It features a robust 492.7 cc single-cylinder, four-stroke, liquid-cooled engine with electronic fuel injection, delivering approximately 39.4 HP. Known for its comfortable riding position, substantial under-seat storage, and capable handling, the Nexus 500 competed in the premium maxi-scooter segment against models from Suzuki, Yamaha, Honda, and Aprilia. Its Italian heritage, originating from a manufacturer with a history dating back to 1909 and now part of the Piaggio Group, underpins its engineering and design. This workshop service manual provides comprehensive guidance for the service, repair, and maintenance of the Gilera Nexus 500 (chassis code ZAPM35600). It covers all essential systems, including the engine, transmission, fuel system, cooling, electrical components, brakes, suspension, and chassis. The manual details routine maintenance procedures, troubleshooting diagnostics, component repair instructions, and includes full wiring diagrams. Its purpose is to equip owners, mechanics, and technicians with the in-depth knowledge required to maintain the vehicle's optimal condition, ensuring reliability and performance through proper care and timely servicing. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Year: 2005-2006 Codes Chassis Code: ZAPM35600 👋 Introduction Market Position Segment: Performance Scooter / Maxi-Scooter. Target Audience: Owners seeking to perform their own maintenance and repairs, enthusiasts, and independent workshops. Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500, Aprilia Scarabeo 500, Piaggio X8/X9 Evolution 500. Key Features Manual Benefit 1: Cost savings through DIY repairs and reduced labor costs. Manual Benefit 2: Empowerment and increased knowledge of vehicle mechanics. Manual Benefit 3: Time efficiency by having all necessary information readily available. Manual Benefit 4: Flexibility to perform repairs at one's own convenience and location (garage/workshop). Manual Benefit 5: Preservation of vehicle condition through proper and timely maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Secondary Coverage: Troubleshooting, Wiring Diagrams, Technical Specifications Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'full professional quality in depth') Manual Type Type: Workshop Service Manual (WSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, and component identification. Transmission: Clutch, variator, belt drive, and associated components. Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, and tank. Cooling System: Radiator, coolant, fan, thermostat, and water pump. Electrical System: Ignition system, lighting, starter, battery, charging system, and all wiring diagrams. Brakes: Brake system diagnosis, repair, fluid replacement, and component servicing (front and rear). Suspension: Front fork, rear shock absorber, and linkage servicing. Steering: Handlebar assembly, steering bearings, and related components. Chassis And Bodywork: Frame inspection, fairing removal and installation, seat, and storage. Exhaust System: Muffler, catalytic converter (if applicable), and exhaust pipe servicing. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, chain/belt adjustment, tire pressure, and general inspections. Troubleshooting: Diagnostic procedures for common and uncommon problems with detailed symptom analysis. Component Repair: Step-by-step instructions for the repair and replacement of all major and minor components. Rebuilds: Detailed procedures for engine and transmission rebuilds. Wiring Diagrams: Comprehensive electrical schematics for all systems, aiding in electrical fault finding. Technical Depth Depth: Comprehensive, covering everything from basic checks to complete engine overhauls and electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Quality: Professional quality, printable pages. Print Quality Printability: All pages are printable. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) Compatibility Operating Systems: Compatible with all versions of Windows & Mac. Requirements Software: Adobe PDF Reader. Delivery Method: Instant Download. ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled. Engine Code: M355M Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approximately 39.4 HP (29.4 kW) at 7500 rpm (DIN) Torque: Approximately 46.0 Nm (4.7 kgm) at 5500 rpm (DIN) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - likely Magneti Marelli system. Fuel Type: Unleaded gasoline, minimum 95 octane (RON). Fuel Tank Capacity: 12 Liters (including approx. 2-liter reserve) Lubrication Oil Type: SAE 10W-40 API SG or higher. Oil Capacity: Approximately 1.7 Liters (with filter change). 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) with dry centrifugal clutch. Optional Options: N/A (CVT is standard) Features Drive: Belt drive to rear wheel. 📐 Dimensions Exterior Length: Approx. 2160 mm Width: Approx. 760 mm Height: Approx. 1420 mm (seat height approx. 800 mm) Weights Dry Weight: Approx. 198 kg Curb Weight: Approx. 214 kg (fully fueled) 🛡️ Safety Features Ratings Crash Test Results: N/A (As this is a scooter, formal car-style crash ratings are not typically applicable or published.) Active Features Braking System: Combined braking system (linked front and rear brake operation), front dual disc brakes, rear single disc brake. ABS was an optional feature on some models. Passive...