Segment:
Maxi-scooter, premium segment.
Target Audience:
Riders seeking a comfortable, powerful, and versatile scooter for urban commuting and longer-distance touring.
Competitors:
Suzuki Burgman 400/650, Yamaha TMAX, Honda Silver Wing 400/600, Aprilia Scarabeo 500.
Design:
Sporty styling, aerodynamic fairing, integrated lighting, under-seat storage.
Performance Focus:
Emphasis on comfortable ergonomics and stable handling, suitable for extended rides.
Value Proposition:
Provides comprehensive technical data enabling owners and technicians to perform all necessary maintenance and repairs.
Powertrain:
Engine disassembly, assembly, lubrication, cooling, fuel delivery, ignition, exhaust systems.
Transmission:
Automatic transmission (CVT) operation, maintenance, and repair procedures.
Chassis:
Frame, suspension (front and rear), steering system, wheels, and tires.
Brakes:
Hydraulic brake system inspection, service, bleeding, and component replacement (front and rear).
Electrical:
Wiring diagrams, battery, starter, alternator, lighting, ignition system components, instrument panel.
Bodywork:
Body panels, fairings, seat, storage, minor body repairs.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, chain/belt adjustments (if applicable).
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Rebuild Refurbish:
Detailed instructions for engine rebuild, transmission overhaul, and component refurbishment.
Restoration:
Guidance for bringing a neglected vehicle back to original specifications.
Depth:
Comprehensive, covering from basic owner maintenance to full engine and transmission overhauls, including electrical diagnostics and bodywork.
Type:
Four-stroke, liquid-cooled, single-cylinder (likely Piaggio Master 500 engine).
Bore X Stroke:
94 mm x 71 mm (typical for Master 500).
Compression Ratio:
10.5:1 (typical for Master 500).
Horsepower Max At Rpm:
Approx. 39.4 HP (29 kW) at 7,500 RPM (typical for Master 500).
Torque Max At Rpm:
Approx. 45 Nm at 5,500 RPM (typical for Master 500).
Induction:
Electronic Fuel Injection (EFI) with throttle body (likely Marelli or Keihin).
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended).
Emissions Compliance:
Euro 3
Oil Type:
Semi-synthetic or fully synthetic SAE 5W-40 API SJ/SL or higher (check manual for exact specification).
Oil Capacity With Filter:
Approx. 1.8 Liters (refer to manual for precise capacity).
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors (50/50 mix with distilled water).
Length:
Approx. 2,160 mm (specific to model year).
Width:
Approx. 790 mm (specific to model year).
Height:
Approx. 1,400 mm (specific to model year).
Dry Weight:
Approx. 190 kg (specific to model year).
Gross Vehicle Weight Rating:
Refer to vehicle compliance plate or manual.
Fuel Tank Capacity:
Approx. 15 Liters (including reserve).
Crash Test Ratings:
N/A for motorcycles/scooters in standard automotive sense. Focus is on design safety.
Braking System:
Hydraulic disc brakes front and rear, often with linked braking or ABS as an option depending on trim/market.
Lighting:
Halogen or projector headlamps, LED taillight/brake light, turn signals.
Frame Construction:
Steel tube frame for rigidity and rider safety.
Wind Protection:
Large adjustable windscreen for rider comfort and protection.
Instrument Cluster:
Analog tachometer, digital speedometer, fuel gauge, coolant temperature, odometer, trip meter, service indicator.
ABS Option:
Optional Anti-lock Braking System (ABS) available on certain models/markets.
Connectivity Features:
Basic connectivity, primarily focused on vehicle diagnostics and operation.
Engine Oil Change:
Every 5,000-7,500 km or annually, whichever comes first (refer to manual for exact mileage).
Air Filter Inspection Replacement:
Inspect every 5,000 km, replace as needed or every 10,000-15,000 km.
Spark Plug Replacement:
Every 10,000-15,000 km (specific plug type and gap to be detailed).
Transmission Oil Change:
Every 10,000-15,000 km (refer to manual for type and capacity).
Engine Oil Specification:
SAE 5W-40 API SJ/SL or higher, Semi-synthetic or Fully Synthetic.
Brake Fluid Specification:
DOT 4 Hydraulic Brake Fluid.
Coolant Specification:
50/50 mix of Ethylene Glycol based antifreeze and distilled water.
Common Wear Items:
CVT belt wear, front fork seals, brake pads, battery lifespan.
Potential Electrical Faults:
Regulator/rectifier failure, stator winding issues (common on many Piaggio engines of the era).
Engine Reliability:
Generally reliable when properly maintained, but consistent oil level checks are crucial.
Manufacturer Origin:
Gilera is an Italian manufacturer with a long history in motorcycling, now part of the Piaggio Group.
Product Line Introduction:
The Nexus line was introduced to compete in the growing maxi-scooter market, emphasizing performance and GT capabilities.
Engine Basis:
The Nexus 500 widely utilized the Piaggio Master 500 engine, known for its robust design and performance.
Production Period:
The Nexus 500 was produced in the mid-2000s, with Euro 3 variants appearing around 2006-2008.
Manufacturing Location:
Typically manufactured in Italy.
