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Gilera Nexus 500 Euro 3 Workshop Manual 2005 Onwards
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🏷️ 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...
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类型: Motorcycle
厂商:
斯库: 34684
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🏷️ 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 Replacement:
Every 24 months, regardless of mileage
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Known Issues
Common Wear Items:
Drive belt, rollers, battery, front suspension bushings, brake pads
Potential Electrical Issues:
Starter motor solenoid, rectifier/regulator issues reported on some models
Fuel System Maintenance:
Periodic cleaning of fuel injectors and throttle body recommended for optimal performance
📚 Vehicle History
Brand Heritage
Brand Origin:
Gilera is an Italian motorcycle manufacturer founded in 1909, now part of the Piaggio Group.
Model Evolution
Introduction Year:
The Gilera Nexus series was introduced in the early 2000s as a sporty maxi-scooter.
Engine Development:
The 500cc model utilizes the Piaggio Quasar engine, known for its performance and reliability.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Performance Awards:
Recognized for its sporty performance and handling within the maxi-scooter segment.
Ratings
Consumer Satisfaction:
Generally positive reviews for its power and ride comfort, though some maintenance complexity exists.
Certifications
Emissions Certification:
Euro 3 compliant, indicating adherence to European emission standards for motor vehicles.