Market Segment:
Premium Sport Scooter / Maxi-Scooter
Target Audience:
Commuters seeking performance and comfort, touring enthusiasts, riders looking for a powerful and stylish scooter.
Key Competitors Mk1:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600, Piaggio X9 Evolution.
Unique Selling Points:
Sporty handling derived from its motorcycle-like chassis, powerful engine for its class, distinctive Italian styling.
Engine Architecture:
Single-cylinder, four-stroke, liquid-cooled, DOHC engine.
Frame Design:
Steel double cradle frame with aluminum swingarm, contributing to excellent stability and handling.
Braking System Features:
Dual disc front brakes, single disc rear brake, often with linked braking (integral brake system) depending on market.
Suspension Features:
Large diameter front forks and a robust rear monoshock provide a comfortable and controlled ride.
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Transmission (CVT), Clutch, Brakes (Front & Rear Disc), Suspension (Front Telescopic Fork, Rear Monoshock), Electrical System, Lighting, Instrumentation, Chassis, Bodywork, Wheels & Tires, General Maintenance, Troubleshooting, Diagnostic Codes
Estimated Pages:
200-300 (typical for a comprehensive workshop manual of this era)
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Language:
English (common for international markets, can vary if specified)
Engine Mechanical:
Detailed disassembly, inspection, and reassembly of engine components including cylinder, piston, connecting rod, crankshaft, valves, camshaft, timing system.
Fuel System:
Carburetor/Fuel Injection system servicing, fuel pump, fuel filter replacement, pressure testing (if applicable).
Ignition System:
Spark plug specifications, ignition timing adjustment, CDI unit testing, coil resistance checks.
Cooling System:
Radiator inspection, coolant replacement, thermostat testing, fan operation.
Lubrication System:
Oil change procedures, oil filter replacement, oil pump inspection, oil pressure checks.
Transmission Drivetrain:
CVT (Continuously Variable Transmission) belt inspection and replacement, clutch operation, variator servicing, final drive maintenance.
Braking System:
Front and rear brake caliper servicing, brake pad replacement, brake disc inspection, brake fluid bleeding, master cylinder overhaul.
Suspension Steering:
Front fork oil level and replacement, fork seal replacement, rear shock absorber inspection and adjustment, steering head bearing maintenance.
Electrical System:
Battery testing and replacement, wiring diagrams, starter motor, alternator, lighting circuits, fuse box identification and testing.
Chassis Bodywork:
Frame inspection, fairing removal and installation, seat servicing, luggage system (if applicable).
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, chain/belt adjustment and lubrication, brake fluid checks, coolant level checks.
Troubleshooting Diagnostics:
Step-by-step diagnostic guides for common performance issues, electrical faults, and mechanical problems. Includes identification of symptoms and potential causes.
Engine Rebuild:
Comprehensive instructions for complete engine disassembly, cleaning, inspection, measurement of wear tolerances, and reassembly.
Transmission Overhaul:
Detailed guidance on servicing and replacing CVT components, clutch assembly, and final drive.
Brake System Repair:
Procedure for bleeding brakes, replacing brake pads and discs, servicing calipers and master cylinders.
Suspension Fork Rebuild:
Step-by-step instructions for front fork disassembly, seal replacement, oil change, and reassembly.
Electrical Component Testing:
Procedures for testing starter motor, alternator, ignition coils, sensors, and other electrical components using multimeters and diagnostic tools.
Wiring Diagram Interpretation:
Clear and detailed wiring diagrams for easy tracing of electrical circuits and troubleshooting of faults.
Technical Depth:
Comprehensive from basic maintenance and troubleshooting to complete engine and component overhauls. Suitable for both DIY enthusiasts and professional mechanics.
Diagnostic Codes:
Includes diagnostic trouble codes (DTCs) if applicable to the Mk1 model's ECU, along with procedures for retrieval and interpretation.
Torque Specifications:
Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.
Wear Tolerances:
Detailed specifications for measuring wear on engine components like pistons, rings, cylinders, and bearings.
Engine Type:
Four-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves
Bore X Stroke:
92 mm x 69 mm (approximate, confirm with manual)
Compression Ratio:
10.5:1 (typical, confirm with manual)
Horsepower Peak:
Approx. 34 HP (25 kW) at 7,250 rpm (varies by market and tuning)
Torque Peak:
Approx. 45 Nm (33 lb-ft) at 5,750 rpm (varies by market and tuning)
Fuel Delivery:
Electronic Fuel Injection (EFI) for most models, some early markets might have had advanced carburetion. Manual will detail the specific system.
Fuel Type:
Unleaded gasoline, minimum 95 RON
Valve Clearance Intake:
0.05 - 0.10 mm (cold, confirm with manual)
Valve Clearance Exhaust:
0.10 - 0.15 mm (cold, confirm with manual)
Instrument Cluster:
Analogue tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, oil pressure warning light, engine diagnostic light.
ABS:
Anti-lock Braking System (ABS) was an optional feature on some Mk1 models, not standard across all markets.
Connectivity Features:
None directly integrated (e.g., no Bluetooth or smartphone integration as this is an older model).
Headlight Type:
Dual Halogen headlights
Taillight Type:
Incandescent bulb or early LED (confirm for specific Mk1 year)
First Service:
1,000 km or 6 months (whichever comes first) - typically includes oil and filter change, general inspection.
Subsequent Major Service:
Every 5,000 km or 12 months - includes engine oil, oil filter, air filter check/replacement, CVT belt inspection, brake pad check, spark plug replacement.
Valve Clearance Check:
Every 10,000 km or 24 months
Transmission Oil Change:
Every 10,000 km or 24 months
Engine Oil Type:
API SG/SH/SJ or higher, JASO MA, SAE 10W-40 (confirm specific grade with manual)
Engine Oil Capacity:
Approx. 1.7 Liters (with filter change, confirm with manual)
Coolant Type:
Ethylene glycol-based antifreeze coolant (e.g., Piaggio Coolant or equivalent)
Coolant Capacity:
Approx. 1.5 Liters (confirm with manual)
Brake Fluid Type:
DOT 4 (confirm with manual)
Common Wear Items:
CVT belt, brake pads, wheel bearings, fork seals, exhaust system.
Potential Electrical Quirks:
Some early models might experience minor electrical gremlins if not properly maintained or exposed to extreme weather.
Fuel Pump Reliability:
While generally robust, fuel pumps can be a wear item over extended mileage; regular fuel filter replacement is key.
Oil Filter Pn:
Commonly uses Gilera/Piaggio part numbers like 847228 or equivalent aftermarket filters (e.g., HiFlofiltro HF303, K&N KN303).
Air Filter Pn:
Specific to Gilera Nexus 500 Mk1 (e.g., Gilera part number 847229 or aftermarket equivalent).
Brand Origins:
Gilera is an Italian motorcycle manufacturer founded in 1909, known for its performance and racing heritage.
Ownership:
Currently part of the Piaggio Group, which also owns Vespa, Aprilia, and Moto Guzzi.
Nexus Introduction:
The Gilera Nexus 500 was introduced in 2003 as a premium, sporty maxi-scooter aimed at challenging established players in the market.
Mk1 Characteristics:
The Mk1 (first generation) established the Nexus's reputation for strong performance, excellent handling, and a distinctive Italian design. It was powered by a potent 460cc Piaggio Master engine.
Subsequent Generations:
The Nexus 500 underwent updates, with later models (often referred to as Mk2 or facelifted versions) featuring styling tweaks and minor mechanical revisions.
Manufacturing Location:
Italy
