🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Model Variant:

Mk

Model Code:

Not specified in product data, typically internal manufacturer codes

Generation Designation:

Mk (Mark) indicates this is a specific iteration or revision of the Nexus 500 model

👋 Introduction

Segment:

Premium maxi-scooter segment, known for its sporty handling and GT (Grand Tourer) comfort.

Target Audience:

Riders seeking a capable and comfortable scooter for commuting, touring, and spirited riding.

Key Competitors:

Competed with models like the Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, and Aprilia Atlantic 500/Scarabeo 500.

Engine Type:

Liquid-cooled, four-stroke single-cylinder engine, known for its strong performance and torque.

Chassis Design:

Steel frame with a motorcycle-like chassis layout contributing to superior handling and stability compared to many other scooters.

Suspension:

Upside-down (USD) front forks and a sophisticated rear suspension setup for enhanced ride quality and cornering.

Braking System:

Dual front disc brakes and a single rear disc brake, often with advanced braking technology like ABS (Anti-lock Braking System) as an option on some models.

📋 Manual Details

Applicable Model Years:

2005-Onward

Specific Model Variants:

Gilera Nexus 500 Mk

Estimated Page Count:

Estimated 300-500 pages (typical for comprehensive service manuals of this era and complexity)

Type:

Factory Service Repair Workshop Manual

Language:

Likely English, with potential for multiple languages depending on the original factory release. Confirmation typically requires manual inspection.

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine systems including disassembly, assembly, inspection, lubrication, cooling, fuel delivery (carburetor/injection), ignition, and emissions control.

Transmission:

Automatic transmission (CVT - Continuously Variable Transmission) system, including belt, variator, clutch, and gearbox maintenance and repair.

Chassis:

Frame, swingarm, suspension (front fork, rear shock absorber), steering system, and wheel components.

Brakes:

Braking system including front and rear brake caliper maintenance, brake fluid replacement, hose inspection, and hydraulic system bleeding.

Electrical System:

Wiring diagrams, lighting systems, battery, charging system (alternator/stator, regulator/rectifier), starting system, ignition system, and instrument cluster.

Fuel System:

Fuel tank, fuel pump, fuel lines, and potential fuel injection system components (depending on specific 500 Mk variant). Given the era, a carburetor is also highly probable.

Bodywork And Trim:

Fairings, body panels, seat, storage compartments, and other trim components, including removal and installation procedures.

Cooling System:

Radiator, coolant hoses, coolant fan, and thermostat, including coolant type and flush procedures.

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, drive belt inspection/replacement, coolant checks, brake pad inspection.

Troubleshooting:

Diagnostic procedures for common faults, error code interpretation (if applicable), and systematic approaches to identifying problems.

Engine Overhaul:

Detailed steps for engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), reassembly, and critical torque specifications.

Transmission Repair:

CVT clutch and variator service, gearbox internal checks and adjustments.

Electrical Diagnostics:

Tracing electrical faults, testing components, and understanding wiring diagrams for accurate repairs.

Suspension And Steering Service:

Fork seal replacement, shock absorber servicing, steering bearing adjustment and replacement.

Brake System Maintenance:

Brake fluid flush and bleeding, caliper piston service, pad replacement.

Depth:

Comprehensive, covering from basic user maintenance to in-depth mechanical and electrical diagnostics and repair. Suitable for professional technicians and advanced DIY mechanics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF for easy navigation of technical terms and procedures.

Printability:

Designed for digital viewing and can be printed for workshop use.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness Level:

Complete Factory Service Repair Workshop Manual

Expiry Dates:

No expiry dates mentioned, implying perpetual access after download.

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke, SOHC (Single Overhead Camshaft), 4 valves per cylinder

Displacement:

492.7 cc (Cubic Centimeters)

Bore X Stroke:

94 mm x 71 mm (Typical for this engine, may vary slightly)

Compression Ratio:

10.5:1 (Typical for this engine)

Cooling System:

Liquid-cooled

Ignition System:

Electronic ignition with variable spark advance

Horsepower:

Approximately 39.4 HP (29.4 kW) at 7,500 RPM (May vary slightly based on specific market regulations)

Torque:

Approximately 44.2 Nm (32.6 lb-ft) at 5,500 RPM (May vary slightly)

Fuel Delivery:

Electronic Fuel Injection (EFI) or Carburetor depending on exact sub-model and market. The 4-valve design suggests EFI for better performance and emissions.

Fuel Type:

Unleaded gasoline

Oil Type:

Refer to manual for exact specification. Typically SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified for wet clutch compatibility.

Oil Capacity:

Refer to manual for exact specification. Typically around 1.5 - 1.8 liters including filter.

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Drive:

Belt drive

Variator:

Roller variator system for seamless gear ratio changes.

Clutch:

Centrifugal automatic clutch

Transmission Fluid Type:

Refer to manual. Typically a specific CVT fluid or gear oil for the final reduction gears. Engine oil serves for the CVT mechanism.

📐 Dimensions

Length:

Refer to manual. Typically around 2150 mm.

Width:

Refer to manual. Typically around 780 mm.

Height:

Refer to manual. Typically around 1330 mm.

Wheelbase:

Refer to manual. Typically around 1525 mm.

Dry Weight:

Refer to manual. Typically around 185 kg.

Wet Weight:

Refer to manual. Typically around 200 kg (with all fluids).

Max Load Capacity:

Refer to manual. Typically around 150 kg (rider and cargo).

Underseat Storage:

Ample storage space under the seat, capable of holding one full-face helmet or equivalent.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles/Scooters typically do not undergo standardized crash test ratings like cars)

ABS:

Optional ABS (Anti-lock Braking System) available on certain configurations.

Braking System:

Dual 280mm front discs with multi-piston calipers, single 240mm rear disc. Excellent stopping power.

Lighting:

Dual headlights, LED taillight, and turn signals.

Frame Design:

Robust steel frame designed for stability and rider confidence.

💡 Technology Features

Instrument Cluster:

Digital and analog combination instrument cluster providing speed, RPM, fuel level, engine temperature, odometer, trip meters, and warning lights.

ABS:

As mentioned, ABS was an option, providing enhanced stability during braking in adverse conditions.

Connectivity Features:

No advanced smartphone integration or Bluetooth connectivity expected for this model year, typical for its era.

🔧 Maintenance

Oil Change Interval:

Refer to manual. Typically every 5,000 - 10,000 km or annually, whichever comes first.

Air Filter Interval:

Refer to manual. Cleaning every 5,000 km, replacement every 10,000 - 15,000 km or as needed.

Spark Plug Interval:

Refer to manual. Typically replaced every 10,000 - 15,000 km.

Drive Belt Interval:

Refer to manual. Inspection every 10,000 km, replacement typically around 20,000 - 30,000 km depending on usage.

Brake Fluid Interval:

Refer to manual. Typically replaced every 2 years or 15,000 - 20,000 km.

Coolant Interval:

Refer to manual. Typically flushed and replaced every 2-3 years or 20,000 - 30,000 km.

Engine Oil Viscosity:

SAE 10W-40 or 15W-50 (API SG/SH/SJ or higher, JASO MA certified)

Coolant Type:

Ethylene glycol based antifreeze coolant, mixed with distilled water (50/50 ratio). Refer to manual for specific Gilera-approved coolant.

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified)

Gear Oil Type:

Refer to manual for final drive gear oil specification (e.g., SAE 80W-90).

Cv Belt Wear:

Like many scooters with CVT, the drive belt can wear over time and require replacement. Symptoms include reduced acceleration or slippage.

Regulator Rectifier:

Some models from this era can experience failures of the regulator rectifier, leading to charging system issues. This is a common component failure across many brands.

Cooling System Leaks:

Aging hoses or seals can lead to coolant leaks. Regular inspection is important.

📚 Vehicle History

Manufacturer:

Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for its performance-oriented and stylish vehicles.

Piaggio Group:

Gilera is part of the Piaggio Group, which also owns brands like Vespa, Aprilia, and Moto Guzzi. This provides access to shared technology and development resources.

Nexus Lineage:

The Nexus 500 was a flagship model in Gilera's scooter lineup, aiming to bridge the gap between traditional scooters and motorcycles by offering superior performance and handling.

Mk2005 Updates:

The 'Mk' designation and '2005-Onward' suggest this manual covers updates and refinements made to the Nexus 500 for the 2005 model year and subsequent iterations. These might include styling tweaks, minor mechanical updates, or new features.

Production Period:

The Gilera Nexus 500 was produced for several years, with variations and updates. The 2005 onward designation implies it covers a significant portion of its production run.

🏆 Awards & Recognition

Motorcycle Journal Reviews:

The Gilera Nexus 500 was generally well-received by the motoring press for its performance, handling, and GT capabilities, often being praised for its motorcycle-like riding dynamics.

Owner Satisfaction:

Owner satisfaction often correlates with proper maintenance and addressing known minor issues. The robust engine and chassis are typically highlighted positively.