Segment:
Performance Scooter / Maxi-Scooter
Target Audience:
Owners and independent mechanics seeking detailed repair and maintenance information for the Gilera Nexus 500 MK1.
Differentiation:
Highly specific, make, model, and year-specific coverage, distinguishing it from generic manuals. Focus on comprehensive workshop procedures.
Documentation Style:
Easy-to-follow, detailed instructions with step-by-step diagrams.
Scope Of Coverage:
Encompasses all necessary information for repair, maintenance, and servicing.
Vehicle Systems:
Engine, Fuel System, Transmission, Clutch, Brakes, Suspension, Electrical System, Chassis, Bodywork, Lubrication, Cooling System, Ignition System, Starting System
Estimated Page Count:
Refer to product for exact count, but comprehensive coverage implies several hundred pages.
Type:
Service and Repair Manual
Searchability:
PDF format generally allows for text searching of keywords, enhancing ease of use.
Powertrain:
Engine removal/installation, cylinder head/valve servicing, cylinder/piston inspection, clutch overhaul, gearshift linkage adjustment, sub-transmission servicing, crankcase disassembly, transmission overhaul, crankshaft and primary shaft inspection.
Chassis And Suspension:
Front wheel and suspension servicing, rear wheel and suspension servicing, hydraulic brake system maintenance and repair.
Electrical System:
Battery and charging system, ignition system troubleshooting and repair, electric starter motor diagnosis, switch functionality and wiring, complete electrical diagrams.
Maintenance:
Routine maintenance checks, lubrication schedules, inspection and adjustment procedures, fluid capacity specifications.
Repair:
Step-by-step instructions for component repair and replacement, including engine rebuilds, electrical system diagnostics, and brake system overhauls.
Troubleshooting:
Comprehensive troubleshooting guides and diagnostic procedures for common and complex issues across all vehicle systems.
Calibration And Adjustment:
Specific procedures for adjusting throttle, brakes, clutch engagement points, and suspension settings as per factory specifications.
Depth:
Covers all workshop repair procedures, from basic maintenance to complete engine and electrical system rebuilds, with detailed diagrams.
Engine Rebuilds:
Detailed procedures for complete engine disassembly, inspection, component replacement (pistons, rings, valves, etc.), and reassembly.
Electrical Diagnostics:
In-depth coverage of the ignition system, charging system, starter motor, and various switches, supported by complete electrical schematics.
Compatibility:
PC and MAC compatible
Viewing Features:
Zoom in/out functionality
Delivery Method:
Instant Download via email from Tradebit System
Printing Options:
Print specific pages or the entire manual
Binding:
Not Applicable (Digital Download)
Paper:
Not Applicable (Digital Download)
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled
Displacement:
Approx. 492.7 cc (exact figures will be in the manual)
Bore X Stroke:
Refer to manual for specific dimensions.
Valvetrain:
SOHC, 4 valves (as per common 500cc Master engine configuration)
Cooling System:
Liquid-cooled, typically with a radiator and fan. Manual details servicing and coolant capacities.
Horsepower:
Typically in the range of 35-40 HP at the crankshaft (exact figures require manual reference).
Torque:
Refer to manual for specific torque figures.
Fuel Delivery:
Electronic Fuel Injection (EFI) - Specific system details will be in the manual.
Oil Type:
Requires specific motorcycle engine oil, likely a 10W-40 or 15W-50, API SG or higher, JASO MA certified. Exact specification in manual.
Oil Capacity:
Refer to manual for exact oil capacity with and without filter change.
Length:
Refer to manual for exact dimensions.
Width:
Refer to manual for exact dimensions.
Height:
Refer to manual for exact dimensions.
Dry Weight:
Typically around 190-200 kg (exact figures require manual reference).
Curb Weight:
Refer to manual for exact curb weight.
Gross Vehicle Weight Rating:
Refer to manual for GVWR.
Fuel Tank Capacity:
Typically around 15-16 liters (exact figures require manual reference).
Crash Test Results:
N/A for motorcycle-specific ratings; focus on design and engineering for safety.
Braking System:
Hydraulic disc brakes front and rear. Likely equipped with ABS as an option or standard on certain trims. Manual will detail ABS servicing.
Lighting:
Dual headlights, taillight, turn signals. Electrical diagrams will detail all lighting circuits.
Frame Construction:
Steel trellis frame (typical for this model and performance focus).
Instrument Panel:
Digital/analog combination instrument cluster, providing speed, RPM, fuel level, and warning lights. Manual details functionality.
ABS:
Optional or standard ABS system, requiring specific diagnostic and repair procedures found in the manual.
Wiring Harness:
Comprehensive electrical diagrams in the manual are key to understanding and troubleshooting the vehicle's wiring harness and electrical components.
Oil Change Interval:
Typically every 5,000-6,000 km or annually. Refer to manual for exact mileage/time recommendations.
Air Filter Cleaning Replacement:
Refer to manual for specific intervals.
Spark Plug Replacement:
Refer to manual for specific intervals.
Belt Drive Inspection Replacement:
CVT belt inspection typically every 10,000-12,000 km, replacement around 20,000-25,000 km. Manual is crucial for this.
Brake Fluid:
DOT 4 brake fluid recommended. Manual will specify exact type and bleeding procedure.
Coolant:
Ethylene glycol based coolant, pre-mixed or concentrate. Manual will specify mixture ratio and capacity.
Common Wear Items:
CVT belt, voltage regulator, suspension components, fuel pump (depending on maintenance history). Manual assists in diagnosing and replacing these.
Diagnostic Focus:
The manual's troubleshooting section is vital for identifying potential electronic or mechanical issues common to this model.
Manufacturer Origin:
Gilera is an Italian manufacturer with a long history in motorcycling, now part of the Piaggio Group.
Nexus Lineage:
The Nexus line was Gilera's flagship maxi-scooter, known for its sporty handling and performance, directly competing with models like the Yamaha TMAX.
Mk1 Introduction:
The MK1 signifies the initial generation of the Nexus 500, establishing its performance credentials.
Manufacturing Location:
Primarily Italy, under Piaggio Group ownership.
