Positioning:
The Gilera Nexus 500SP was positioned as a high-performance, premium maxi-scooter, blending sporty handling with touring comfort, aimed at riders seeking a more engaging and powerful experience than typical urban scooters.
Competitors:
Competed with other large-displacement maxi-scooters of its era, such as the Suzuki Burgman 400/650, Yamaha TMAX 500, and Aprilia Atlantic 500, focusing on its Italian flair and dynamic capabilities.
Features:
Powerful 500cc engine, sophisticated chassis design for agile handling, premium build quality, often equipped with higher-spec components on SP models, comfortable riding position.
Engine:
Engine disassembly, assembly, inspection, troubleshooting, performance tuning, fuel injection system (EFI), ignition system, cooling system, lubrication system, exhaust system.
Transmission:
Automatic transmission (CVT) maintenance, repair, component identification, fluid specifications.
Chassis:
Frame, suspension (front and rear), steering system, wheel bearings, swingarm.
Brakes:
Brake system diagnostics, component replacement (discs, pads, calipers, master cylinders, lines), bleeding procedures, ABS system (if applicable).
Electrical:
Wiring diagrams, battery, starter motor, alternator, lighting system, instrument cluster, ECU, sensors, fuses, relays, diagnostic codes.
Bodywork:
Fairings, seat, fuel tank, body panel removal and installation, trim components, lighting units.
Cooling System:
Radiator, coolant hoses, thermostat, coolant specifications, bleeding procedures.
Fuel System:
Fuel pump, fuel filter, injectors, fuel tank, pressure regulation.
Maintenance:
Oil changes, filter replacements, spark plug replacement, chain/belt adjustment, brake fluid flush, coolant replacement, air filter cleaning/replacement.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation.
Repair:
Detailed instructions for component removal, repair, and reinstallation for all major systems.
Diagnostics:
On-board diagnostics (OBD) procedures, sensor testing, ECU diagnostics.
Rebuilds:
Complete engine and transmission overhaul procedures, including component specifications and tolerances.
Depth:
Professional-level, covering everything from routine maintenance to full engine and transmission rebuilds, with detailed diagrams and specifications.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled
Displacement:
493 cc (approx.)
Bore X Stroke:
Approximately 94 mm x 71 mm
Compression Ratio:
Approximately 10.5:1
Valvetrain:
SOHC, 4 valves
Max Power:
Approximately 30-35 HP (at 7,000 rpm)
Max Torque:
Approximately 45-50 Nm (at 5,000 rpm)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil
Oil Capacity:
Approximately 1.7 - 1.9 Liters (with filter change)
Coolant Type:
Ethylene Glycol based coolant (50% mix with distilled water)
Instrument Cluster:
Digital and analog combination instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meters, and warning lights.
ABS:
Anti-lock Braking System (ABS) available as an option or standard on some models.
ECU:
Engine Control Unit (ECU) managing fuel injection and ignition timing.
Oil Change Interval:
Every 4,000-6,000 km or annually.
Air Filter Maintenance:
Inspect every 6,000 km, clean/replace as needed.
Spark Plug Replacement:
Every 10,000-12,000 km.
Brake Fluid Replacement:
Every 2 years.
Coolant Replacement:
Every 2-3 years.
Cvt Belt Inspection:
Inspect for wear and damage every 12,000 km, replace as needed.
Engine Oil Spec:
API SG/SH/SJ/SL or JASO MA/MA2 certified SAE 5W-40 synthetic motorcycle oil.
Coolant Spec:
Ethylene Glycol based, pre-mixed 50% with distilled water.
Common Issues:
Potential for stator/regulator issues, water pump leaks, throttle body cleaning requirements, variator/belt wear over time. These are general maxi-scooter considerations, specific issues would be detailed in the manual.
Heritage:
Gilera, an Italian manufacturer with a long history dating back to 1909, is known for its performance-oriented motorcycles and scooters. It is part of the Piaggio Group.
Evolution:
The Nexus series represented Gilera's premium maxi-scooter offering, evolving from earlier models. The MK2 iteration and SP (Sport Production) variants focused on enhanced performance and sportier aesthetics.
Production Years:
The Nexus 500 was produced roughly from 2003 to 2007, with the MK2 and SP variants being part of this range.
Manufacturing Location:
Italy
