Segment:
Performance-oriented commuter and touring maxi-scooter
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600
Unique Selling Proposition:
Sporty handling characteristics derived from motorcycle heritage, powerful single-cylinder engine.
Performance Focus:
Emphasis on sporty riding dynamics and acceleration
Design Philosophy:
Bridge the gap between scooter practicality and motorcycle performance
General Repair:
Comprehensive
Maintenance:
Tune-ups, Lubrication, Scheduled Service
Major Rebuilds:
Engine and Transmission
Estimated Pages:
N/A (as it's a digital download, page count can vary with zoom/print settings)
Type:
Factory/Official Workshop Service Repair Manual
Language:
English (Presumed, based on typical aftermarket manual offerings)
Engine:
Complete overhaul, performance tuning, diagnostics
Transmission:
Clutch, gearbox, final drive overhaul and repair
Fuel System:
Fuel injection, fuel pump, fuel pressure diagnostics
Cooling System:
Radiator, thermostat, water pump, coolant flow
Electrical System:
Ignition, lighting, charging system, wiring diagrams, connector data
Brakes:
Hydraulic system, disc brake maintenance, fluid replacement
Suspension:
Front forks, rear shock absorber, bearings
Chassis Frame:
Frame inspection, steering head bearings
Bodywork Panels:
Fairings, seat, trim removal and installation
Preventative Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable)
Troubleshooting:
Diagnostic charts, symptom-based guides
Disassembly Assembly:
Component-level step-by-step instructions
Inspections:
Wear limits, safety checks
Depth:
Comprehensive: from basic tune-ups to major engine/transmission rebuilds and diagnostics
User Level:
Professional or DIY with basic mechanical knowledge
Engine Code:
M381M (typical for 500cc Piaggio/Gilera Master engine)
Configuration:
Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1 (typical)
Horsepower:
Approx. 39 HP (29 kW) @ 7500 RPM (varies slightly by market/tuning)
Torque:
Approx. 45 Nm (33 lb-ft) @ 5500 RPM (varies slightly by market/tuning)
Induction:
Electronic Fuel Injection (EFI)
Fuel Pressure:
Refer to manual for specific OEM specifications (e.g., 3.0 - 3.5 bar)
Ignition System:
Electronic CDI
Oil Type:
API SG or higher, JASO MA certified motorcycle oil recommended (e.g., SAE 5W-40 or 10W-40)
Oil Capacity:
Approx. 1.6 - 1.8 liters (with filter change)
Coolant Capacity:
Approx. 1.0 - 1.2 liters
Minimum Compression:
Refer to manual for specific OEM value (e.g., 9.5 bar / 138 psi)
Maximum Compression Deviation Cylinders:
Refer to manual for specific OEM value (e.g., 1.0 bar / 14.5 psi)
Type:
Automatic (CVT - Continuously Variable Transmission)
Clutch Type:
Automatic centrifugal clutch
Gear Ratios:
Continuously variable, specified by belt-driven pulley ratios. Consult manual for specific ratios at different speed points.
Transmission Fluid:
No separate transmission fluid; engine oil lubricates transmission and clutch.
Length:
Approx. 2180 mm (for Mk2)
Width:
Approx. 770 mm (at handlebars)
Height:
Approx. 1370 mm (at handlebars)
Seat Height:
Approx. 785 mm
Dry Weight:
Approx. 198 kg
Wet Weight:
Approx. 212 kg (with fluids)
Maximum Load:
Refer to manual (typically ~180-200 kg including rider and luggage)
Front Tire Size:
120/70-15
Rear Tire Size:
160/60-15
Fuel Tank Capacity:
15 liters
Crash Test Ratings:
N/A for motorcycles (focus is on design and rider safety features)
Brakes:
Front: Dual discs with four-piston calipers; Rear: Single disc with two-piston caliper. Optional ABS (Anti-lock Braking System) available on some models.
Lighting:
Halogen headlights, LED taillight/indicators (model dependent)
Frame Construction:
Steel double cradle frame for rigidity and stability
Security:
Immobilizer system, steering lock
Dashboard:
Analog speedometer and tachometer, digital multi-function display (odometer, trip meter, fuel gauge, clock, temperature).
ABS:
Optional ABS system available on some variants
Charging Port:
Often equipped with a 12V accessory socket in the front storage compartment.
Engine Oil And Filter:
Every 5,000 - 7,500 km or annually (refer to manual for exact interval)
Air Filter Check:
Every 5,000 km
Spark Plug Replacement:
Every 10,000 - 15,000 km
Coolant Replacement:
Every 2 years or 30,000 km
Brake Fluid Replacement:
Every 2 years
Engine Oil:
SAE 5W-40 or 10W-40, API SG/SH/SJ or higher, JASO MA certified motorcycle oil. Specific Piaggio/Gilera branded oil often recommended.
Coolant:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 4 recommended
Final Drive Oil:
GL-4 SAE 80W-90 gear oil (capacity usually small, ~0.2L)
Common Wear Items:
CVT belt wear, voltage regulator failure, wheel bearings, exhaust system corrosion.
Electrical Gremlins:
Can occur with age; ensure clean electrical connections and battery health.
Cooling System Maintenance:
Regular coolant checks and flushes are important to prevent corrosion and overheating.
Valve Clearance Intake:
Refer to manual (e.g., 0.10 - 0.15 mm cold)
Valve Clearance Exhaust:
Refer to manual (e.g., 0.15 - 0.20 mm cold)
Spark Plug Gap:
Refer to manual (e.g., 0.7 - 0.8 mm)
Torque Cylinder Head Bolts:
Refer to manual for sequence and values (multi-stage torque application)
Torque Wheel Nuts Front:
Refer to manual (e.g., ~25 Nm)
Torque Wheel Nuts Rear:
Refer to manual (e.g., ~40 Nm)
Brand:
Piaggio & C. S.p.A.
Heritage Focus:
Pioneer in scooter manufacturing, strong Italian engineering heritage.
Model Lineup:
Gilera brand known for sporty motorcycles and scooters. Nexus line introduced as a premium maxi-scooter.
Generation:
Mk2 represents a refinement of the original Nexus 500, often incorporating Euro3 compliance and styling updates.
Year Introduction:
Original Nexus 500 introduced around 2003. Mk2 likely introduced around 2006-2007.
Manufacturing Location:
Italy
