🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Generation:

MK1

Model Year Coverage:

2005 onwards

Engine Code:

M301M (Piaggio Quasar 500)

👋 Introduction

Vehicle Segment:

Maxi-scooter, Grand Tourer Scooter

Target Audience:

Riders seeking a powerful, comfortable, and versatile scooter for commuting and touring.

Key Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600, Aprilia Scarabeo 500.

Distinguishing Features:

Sporty handling derived from Piaggio's motorcycle heritage, powerful engine, comfortable ergonomics, and robust build quality.

Engine Power:

Strong performance from the 500cc single-cylinder engine.

Handling:

Sportbike-inspired chassis and suspension for confident handling.

Comfort:

Ergonomic riding position and comfortable seat for long distances.

Practicality:

Under-seat storage and touring capability.

📋 Manual Details

Primary Coverage:

Mechanical Systems, Electrical Systems, Bodywork, Maintenance, Troubleshooting, Repair

Specific Systems:

Engine, Transmission, Fuel System, Ignition System, Cooling System, Braking System, Suspension System, Steering System, Electrical System, Lighting, Body Panels, Chassis

Estimated Page Count:

400+

Manual Type:

Service and Repair Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, assembly, and troubleshooting of the Piaggio Quasar 500 engine. Includes cylinder head, valves, piston, crankshaft, connecting rod, timing system, lubrication system, and cooling system.

Fuel System:

EFI system components, fuel pump, injectors, fuel pressure regulator, fuel tank, and filter replacement procedures.

Ignition System:

ECU diagnosis, spark plug inspection and replacement, ignition coil testing.

Transmission:

CVT (Continuously Variable Transmission) removal, inspection, belt replacement, clutch and variator servicing.

Braking System:

Front and rear brake pad replacement, caliper service, brake fluid bleeding, hydraulic system troubleshooting. Covers ABS if equipped.

Suspension System:

Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement.

Steering System:

Handlebar, steering column, and bearing inspection and maintenance.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator, regulator/rectifier), starter motor, lighting circuits, indicator circuits, and instrument panel.

Bodywork:

Fairing removal and installation, seat, luggage compartment, and cosmetic component servicing.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug service, coolant checks, brake fluid checks, drive belt inspection.

Troubleshooting:

Diagnostic procedures for common starting issues, running problems, electrical faults, and component failures. Includes symptom-based troubleshooting charts.

Major Repairs:

Engine rebuilds, transmission overhaul, suspension component replacement, electrical system diagnostics and repair.

Component Overhaul:

Detailed instructions for the overhaul of key components like the fuel injectors, throttle body, brake calipers, and suspension forks.

Scheduled Maintenance:

Specific maintenance tasks and intervals for different mileage or time periods.

Diagnostic Capabilities:

Advanced diagnostic procedures, including use of diagnostic tools (where applicable) and interpretation of error codes. Fault finding for EFI and electrical systems.

Torque Specifications:

Precise torque values for all critical fasteners, essential for proper assembly and safety.

Clearances And Tolerances:

Specifications for component clearances and wear tolerances (e.g., valve clearances, piston ring gap).

Schematics:

Detailed electrical schematics and wiring diagrams for accurate diagnosis and repair of electrical faults.

Exploded Views:

Illustrative exploded views of all major components, aiding in identification and reassembly.

📊 Manual Specifications

File Format:

PDF

Searchability:

Likely text-searchable PDF, allowing for quick location of specific topics.

Image Resolution:

High resolution, suitable for clear viewing of diagrams and images.

Printability:

Designed to be printed for workshop use.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke, liquid-cooled, SOHC

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1

Valve Train:

SOHC, 4 valves

Horsepower:

Approx. 39 HP (29 kW) at 7500 rpm

Torque:

Approx. 45 Nm (33 lb-ft) at 5500 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI) - Marelli or similar

Fuel Type:

Unleaded gasoline (95 RON recommended)

Oil Type:

SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA)

Oil Capacity:

Approx. 1.7 Liters (with filter change)

Coolant Type:

Ethylene glycol based coolant with anti-corrosion additives (50/50 mix with distilled water)

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Clutch Type:

Automatic centrifugal clutch

Drive Belt:

Reinforced drive belt

Gear Oil Type:

SAE 75W-90 GL-3 or GL-4 Gear Oil (transmission oil)

Gear Oil Capacity:

Approx. 0.2 Liters

📐 Dimensions

Length:

Approx. 2150 mm

Width:

Approx. 790 mm

Height:

Approx. 1430 mm (seat height approx. 810 mm)

Dry Weight:

Approx. 198 kg

Wet Weight:

Approx. 213 kg

Max Load Capacity:

Approx. 170 kg (rider + passenger + luggage)

Underseat Storage:

Sufficient for a full-face helmet and some smaller items.

🛡️ Safety Features

ABS:

Optional ABS (Anti-lock Braking System) available on some models.

Braking System Type:

Dual disc front brakes (e.g., 260mm), single disc rear brake (e.g., 240mm).

Lighting:

Halogen headlights, LED taillight.

Chassis Design:

High-tensile steel frame for rigidity and safety.

💡 Technology Features

Instrument Panel:

Digital/analog combination dashboard with speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature warning light, and other indicator lights.

ABS System:

Optional ABS system for enhanced braking safety.

Charging Port:

May feature a 12V accessory socket for charging devices.

🔧 Maintenance

Engine Oil Change:

Every 6,000 km or 12 months, whichever comes first.

Oil Filter Replacement:

Every 6,000 km or 12 months (coincides with oil change).

Air Filter Replacement:

Every 12,000 km or 24 months.

Spark Plug Replacement:

Every 12,000 km.

Coolant Replacement:

Every 24,000 km or 24 months.

Brake Fluid Replacement:

Every 24,000 km or 24 months.

Cvt Belt Inspection:

Inspect every 6,000 km, replace as needed (typically around 20,000-30,000 km depending on use).

Engine Oil Specification:

SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA)

Cooling System Coolant:

Ethylene glycol based coolant with anti-corrosion additives (50/50 mix with distilled water)

Brake Fluid Specification:

DOT 4 Brake Fluid

Transmission Oil Specification:

SAE 75W-90 GL-3 or GL-4 Gear Oil

Common Wear Items:

Brake pads, drive belt, suspension bushings, steering head bearings.

Potential Electrical Issues:

Occasional issues with voltage regulator/rectifier, stator output, and starter solenoid. Wiring harness integrity checks are important.

Fuel System Considerations:

Fuel injector cleaning and throttle body carbon buildup can affect performance. Regular fuel system cleaner use is recommended.

📚 Vehicle History

Brand Origin:

Gilera is an Italian manufacturer of scooters and motorcycles, with a history dating back to 1909. It is now part of the Piaggio Group.

Predecessors:

The Nexus 500 built upon the success of previous large-displacement scooters from Gilera and other Piaggio Group brands, offering a blend of performance and comfort.

Engine Platform:

Utilizes the Piaggio Quasar engine, a robust and proven powerplant shared with other models in the Piaggio Group.

Manufacturing Location:

Italy (Piaggio Group manufacturing facilities)

🏆 Awards & Recognition

Segment Recognition:

Recognized as a capable and sporty maxi-scooter within its class, often praised for its handling and engine performance.

Consumer Reviews:

Generally positive reviews for performance and comfort, with some noting the cost of parts and specialized maintenance.

Emissions Standards:

Compliant with European emissions standards for its model year.