Segment:
Maxi-scooter, performance-oriented urban mobility
Usp:
Combines scooter practicality with motorcycle-like performance and handling
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Aprilia Scarabeo 500
Design:
Sporty, aerodynamic styling with motorcycle-inspired ergonomics
Performance:
Powerful 500cc engine, capable of highway speeds and brisk acceleration
Handling:
Large diameter wheels, robust suspension, and motorcycle-like chassis geometry
Practicality:
Underseat storage, comfortable seating for rider and passenger, good weather protection
Engine Mechanical:
Disassembly, assembly, inspection, and repair of engine components (cylinder, piston, crankshaft, valves, etc.)
Fuel System:
Fuel injection system, fuel pump, injectors, fuel filter, fuel tank maintenance
Ignition System:
Ignition coil, spark plug, ECU control of ignition timing
Cooling System:
Radiator, coolant circulation, thermostat, fan operation
Lubrication System:
Oil pump, oil filter, oil passages, oil change procedures
Transmission Drivetrain:
Automatic transmission (CVT), belt replacement, clutch operation, final drive maintenance
Chassis Frame:
Frame inspection, front fork assembly, rear shock absorber, swingarm maintenance
Braking System:
Brake calipers, master cylinders, brake lines, brake fluid replacement, disc and pad inspection/replacement
Electrical System:
Wiring diagrams, battery maintenance, lighting systems, starter motor, charging system (alternator/stator)
Instrumentation Controls:
Dashboard instruments, handlebar controls, electronic unit (ECU) functions
Bodywork Fairings:
Removal and installation of body panels, fairings, seat, and related components
Exhaust System:
Exhaust pipe, muffler, catalytic converter maintenance
Regular Maintenance:
Oil changes, filter replacements, spark plug checks, chain/belt adjustments, tire pressure
Troubleshooting:
Diagnosis of common problems, error codes (if applicable), symptom-based troubleshooting guides
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling major components and sub-assemblies
Repair Rebuild:
Detailed procedures for repairing or rebuilding specific engine, transmission, and chassis components
Inspections Checks:
Visual inspections, functional checks, torque specifications for critical fasteners
Adjustment Calibration:
Carburetor (if applicable, though likely FI for this model), throttle cable, brake lever adjustments
Wiring Diagrams:
Comprehensive electrical schematics for easy diagnosis and repair of electrical faults
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds
Diagnostic Focus:
Includes diagnostic procedures for common malfunctions and system failures
Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (standard for factory PDFs), allowing for quick information retrieval
Resolution:
High resolution, suitable for printing individual pages or the entire manual
Layout:
Professional layout with clear diagrams, illustrations, and text formatting
Binding:
N/A (Digital PDF Download)
Paper:
N/A (Digital PDF Download)
Type:
Single-cylinder, four-stroke, liquid-cooled, OHC
Bore X Stroke:
92 mm x 95.2 mm (typical for this engine family)
Compression Ratio:
10.0:1 (typical)
Horsepower:
Approx. 40 HP (30 kW) at 7,000 RPM (manufacturer stated figures may vary slightly)
Torque:
Approx. 45 Nm (33 lb-ft) at 5,000 RPM (manufacturer stated figures may vary slightly)
Induction:
Electronic Fuel Injection (EFI), likely with Marelli or Piaggio ECU
Fuel Type:
Unleaded gasoline (95 RON recommended)
Oil Type:
SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA)
Oil Capacity:
Approx. 1.7 liters (including filter, consult manual for precise capacity)
Crash Test Data:
N/A (motorcycle/scooter safety ratings differ from automotive)
Braking System:
Front: Dual disc brakes with multiple-piston calipers. Rear: Single disc brake. ABS was likely an optional or later feature, consult specific vehicle options.
Lighting:
Halogen headlights, LED tail light, turn signals
Chassis Design:
Steel frame designed for stability and rigidity
Mirrors:
Large rear-view mirrors for visibility
Dashboard Display:
Analog tachometer, digital speedometer, fuel gauge, coolant temperature, clock, trip meters, warning lights.
ABS:
Optional on some models/markets. The manual will detail ABS system operation and troubleshooting if equipped.
Connectivity Features:
Basic connectivity, primarily focused on vehicle systems. No advanced smartphone integration typical for this era.
Oil Change:
Every 5,000-7,500 km or annually (refer to manual for exact interval based on usage)
Air Filter Check:
Every 5,000 km or as needed based on operating conditions
Spark Plug Replacement:
Every 10,000-15,000 km (NGK Iridium recommended for optimal performance)
Cvt Belt Inspection:
Inspect every 10,000 km, replace typically between 15,000-25,000 km depending on wear
Brake Fluid Flush:
Every 2 years
Engine Oil:
SAE 10W-40 Synthetic, API SG/SH/SJ/SL, JASO MA/MA2
Coolant:
Ethylene glycol-based antifreeze, mixed 50/50 with distilled water (specific type like Moto-specific coolant recommended)
Brake Fluid:
DOT 4 (or DOT 3 if specified by manufacturer, but DOT 4 preferred for higher boiling point)
Common Wear Items:
CVT belt, variator rollers, voltage regulator, water pump seal
Potential Problems:
Wiring harness chafing (especially near the steering head), fuel pump issues in older units, exhaust flange leaks.
Air Filter Part Number:
Refer to manual or equivalent part from reputable aftermarket suppliers (e.g., HiFloFiltro, K&N)
Oil Filter Part Number:
Refer to manual or equivalent part from reputable aftermarket suppliers (e.g., HiFloFiltro HF183, K&N KN-183)
Spark Plug Part Number:
NGK CR9EIX (Iridium)
Brand Origin:
Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, now part of the Piaggio Group.
Nexus Lineage:
The Nexus series represented Gilera's foray into the maxi-scooter segment, focusing on performance and sporty characteristics.
Mk2 Updates:
Mk2 typically refers to an updated version, possibly with minor styling tweaks, revised suspension, or engine mapping compared to earlier models.
Production Period:
Gilera Nexus 500 was produced in various iterations from the early 2000s up until the mid-2010s.
Manufacturing Location:
Italy (typically Piaggio Group manufacturing plants)
