Segment:
Maxi-scooter, Sport-touring Scooter
Target Audience:
Owners seeking to perform their own maintenance and repairs, independent workshops.
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Piaggio X9/Xevo, Honda Silver Wing
Vehicle Attributes:
Powerful engine for its class, comfortable ride, ample storage, sporty aesthetics.
Manual Value Proposition:
Provides essential repair and maintenance information for the Gilera Nexus 500, enabling cost savings and self-sufficiency for owners.
Powertrain:
Engine disassembly, assembly, tuning, cooling system, lubrication system
Chassis:
Front suspension, rear suspension, steering system, wheel bearings, hub assemblies
Brakes:
Brake system inspection, service, hydraulic components, bleeding procedures
Fuel System:
Fuel injection system (non-electrical components), fuel pump, filter, fuel tank
Exhaust System:
Exhaust manifold, catalytic converter, muffler servicing
Bodywork:
Body panel removal and installation, fairings, seat, storage compartments
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, valve clearance adjustment
Diagnostics:
Troubleshooting common issues, identifying symptoms, diagnostic flowcharts (non-electrical)
Repair:
Component-level repair, part replacement, assembly and disassembly steps
Adjustment:
Carburetor (if applicable on specific variants), clutch, throttle cable adjustments
Depth:
Comprehensive workshop procedures, detailed component descriptions, torque specifications, clearances, timing information
Diagnostic Focus:
Mechanical diagnostics and repair; excludes electronic system diagnostics due to lack of wiring diagrams.
Engine Type:
Four-stroke, single-cylinder
Displacement:
493 cc (approx.)
Bore X Stroke:
Typically around 94 mm x 71 mm (specifics may vary, refer to manual for exact figures)
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves per cylinder
Horsepower:
Approx. 39-42 HP (at crankshaft, refer to manual for exact figures)
Torque:
Approx. 44-46 Nm (at crankshaft, refer to manual for exact figures)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (RON 95 recommended)
Oil Type:
Synthetic Motorcycle Oil, API SG or higher, JASO MA certified. Viscosity: 10W-40 recommended. (Refer to manual for precise specifications)
Oil Capacity:
Approx. 1.7 - 1.9 Liters (with filter change). (Refer to manual for exact capacity)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive Type:
Belt drive to rear wheel
Clutch Type:
Automatic centrifugal dry clutch
Gear Reduction:
Planetary gear reduction unit
Transmission Oil Type:
Specific CVT fluid or gear oil (refer to manual for exact specification and capacity, often a small quantity in the reduction gear).
Height:
Approx. 1420 mm (seat height variable)
Dry Weight:
Approx. 195 kg
Curb Weight:
Approx. 208 kg (with fluids)
Maximum Load:
Refer to manual, typically around 180-200 kg including rider and luggage.
Storage Capacity:
Underseat storage (typically fits one full-face helmet), glove box compartments.
Crash Test Data:
N/A (Motorcycle specific crash testing data not typically standardized like automobiles)
Braking System:
Front: Dual disc brakes; Rear: Single disc brake. Potential for ABS on certain trims (verify specific model VIN). Manual covers brake system servicing.
Lighting:
Halogen headlight, LED taillight, turn signals. Bulb types and replacement procedures covered.
Frame Construction:
Steel tube frame. Manual details frame inspection and minor repair procedures.
Dashboard Display:
Digital and analog instrument cluster including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, clock.
Lighting Control:
Manual light controls, ignition-controlled running lights.
ABS Availability:
Optional ABS system on some models. Manual may cover diagnostic procedures if equipped.
Diagnostic Port:
On-board diagnostics (OBD) port (likely proprietary or dealer specific for full ECU diagnostics, though manual might indicate basic checks).
Oil Change Interval:
Every 5,000 km or 12 months. (Refer to manual for precise interval based on usage)
Air Filter Replacement:
Inspect every 5,000 km, replace as needed or every 10,000-15,000 km. (Refer to manual)
Spark Plug Replacement:
Replace every 10,000-15,000 km. (Refer to manual for specific plug type and gap)
Valve Clearance Check:
Every 10,000 km or 24 months. (Crucial procedure covered in manual)
Transmission Oil Check:
Inspect at regular service intervals, change as per manual recommendations (often less frequent than engine oil).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors, 50/50 mix with distilled water. (Refer to manual for specific type/color)
Brake Fluid Type:
DOT 4 brake fluid. (Refer to manual for specific type and replacement interval)
Common Wear Items:
CVT belt wear, voltage regulator failures, front suspension seals, fuel pump longevity.
Maintenance Tips:
Regularly check coolant level, ensure proper air filter maintenance, use correct engine oil, keep battery terminals clean.
Manufacturer:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909. It is now part of the Piaggio Group.
Introduction Year:
The Gilera Nexus 500 was introduced around the mid-2000s, as a flagship maxi-scooter.
Key Updates:
Euro 3 compliant models represent an evolution to meet stricter emissions standards, often incorporating minor engine management refinements.
Production Period:
The Nexus 500 was produced roughly from 2003 to 2007/2008.
Manufacturing Location:
Italy
Automotive Press Reviews:
Generally received positive reviews for its performance, comfort, and practicality as a maxi-scooter in its era.
Reliability Reputation:
Mixed to good, dependent on maintenance history. Key components like the engine are generally robust, but ancillary systems (e.g., electrical) require diligent upkeep.
Emission Certification:
Euro 3 compliance for models covered by this manual.
