Category:
Maxi-scooter / Sport Tourer
Target Audience:
Commuters, touring riders, and performance-oriented scooter enthusiasts.
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing.
Vehicle Design:
Sporty styling, powerful engine, comfortable ergonomics for longer distances.
Manual Purpose:
To provide comprehensive guidance for maintaining, servicing, diagnosing, and repairing the Gilera Nexus 500 (2005 model) to factory standards.
Engine:
Detailed disassembly, assembly, inspection, and repair of the 500cc engine, including top-end, bottom-end, lubrication, and cooling systems.
Fuel System:
EFI system diagnostics, fuel pump, injectors, throttle body, and emissions control.
Transmission:
CVT (Continuously Variable Transmission) servicing, belt inspection and replacement, clutch and variator maintenance.
Brakes:
Front and rear brake system maintenance, caliper service, pad replacement, hydraulic system bleeding, ABS system (if equipped) diagnostics.
Suspension:
Front fork (telescopic) and rear shock absorber maintenance, adjustments, and overhaul procedures.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), ignition system, lighting, starter system, and diagnostic connector.
Chassis And Frame:
Frame inspection, steering head bearing maintenance, and general chassis component service.
Bodywork And Trim:
Panel removal and installation, seat servicing, and other cosmetic components.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, fluid level checks, drive belt inspection.
Troubleshooting:
Diagnostic charts, common problems, and step-by-step solutions for various systems.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, and brake system repairs.
Torque Specifications:
Comprehensive list of torque values for critical fasteners across all mechanical systems.
Special Tools:
Identification and usage guidelines for specialized tools required for specific repair procedures.
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, suitable for professional technicians and advanced DIY mechanics.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1
Horsepower:
Approx. 40 HP (29.8 kW) at 7,500 rpm
Torque:
Approx. 46 Nm (33.9 lb-ft) at 5,500 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI) with digital ignition
Fuel Type:
Unleaded gasoline (95 RON recommended)
Oil Type:
Synthetic or semi-synthetic motorcycle oil, SAE 10W-40 or 15W-50
Oil Capacity:
Approx. 1.8 Liters (with filter change)
Crash Test Data:
N/A (Motorcycle/Scooter not subjected to typical automotive crash testing protocols)
Brakes:
Dual front disc brakes, single rear disc brake. ABS optional on some models/markets.
Lighting:
Halogen headlight, LED taillight, turn signals.
Frame Construction:
High-tensile steel frame for rigidity and stability.
Handling:
Designed for stable handling at high speeds and confident cornering.
Features:
Basic instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, and warning lights. No advanced infotainment systems.
Features:
Optional ABS system for enhanced braking safety.
Features:
No modern connectivity features (Bluetooth, smartphone integration).
Engine Oil Change:
Every 5,000 km (3,000 miles) or annually, whichever comes first.
Oil Filter Replacement:
Every 10,000 km (6,000 miles) or every two years.
Air Filter Cleaning:
Every 5,000 km (3,000 miles), replacement as needed.
Spark Plug Replacement:
Every 10,000 km (6,000 miles).
Drive Belt Inspection:
Every 10,000 km (6,000 miles), replacement typically around 20,000-30,000 km.
Coolant Replacement:
Every 2 years.
Engine Oil:
SAE 10W-40 or 15W-50 API SG or higher, JASO MA certified (e.g., Motul 5100 10W-40).
Coolant:
Ethylene glycol based coolant, mixed 50/50 with distilled water.
Common Problems:
Potential for stator failure, regulator/rectifier issues (leading to charging problems), and occasional CVT component wear (belt, rollers) under high mileage or aggressive use.
Preventative Measures:
Regularly checking battery voltage, ensuring proper cooling system function, and timely replacement of the drive belt are crucial.
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycle production, now part of the Piaggio Group.
Predecessors:
The Nexus 500 built upon Gilera's experience with larger displacement scooters and its sport-oriented models.
Successor:
The Nexus line was eventually succeeded by other Piaggio Group scooter models, integrating its performance characteristics.
Production Years:
The Gilera Nexus 500 was produced from the early 2000s until around 2010.
Manufacturing Location:
Primarily manufactured in Italy.
