Category:
Maxi-scooter, GT Scooter
Target Audience:
Motorcycle owners and independent repair shops seeking comprehensive service information.
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600, Aprilia Atlantic 500.
Accuracy:
Factory/OEM data ensures accuracy for all repair and maintenance procedures.
Ease Of Use:
Friendly and easy-to-follow instructions, charts, and diagrams for users with basic mechanical knowledge.
Completeness:
Covers everything from basic tune-ups to major engine/transmission rebuilds.
Primary Coverage:
Repair and maintenance of Piaggio Gilera Nexus 500 Mk1
Secondary Coverage:
Tune-ups, lubrication, major engine and transmission rebuilds, diagnostics
Estimated Pages:
Varies, typically 200-400 pages for comprehensive factory service manuals.
Type:
Workshop Factory Service Repair Manual
Language:
English (typical for officially distributed manuals)
Engine:
Full engine overhaul, internal component diagnostics, timing, ignition system, fuel injection, cooling system, lubrication system.
Transmission:
Automatic transmission (CVT) operation, maintenance, rebuild procedures, clutch, belt, variator, and gearbox inspection.
Chassis:
Frame inspection and repair, suspension (front forks and rear shock absorber) overhaul, alignment, bearings.
Brakes:
Hydraulic brake system diagnostics, caliper and master cylinder overhaul, pad replacement, bleeding procedures, ABS system (if equipped).
Electrical:
Complete wiring diagrams, lighting system, starting system, charging system (alternator/stator, regulator/rectifier), battery, fuses, relays, electronic control unit (ECU) diagnostics, sensor testing.
Fuel System:
Fuel pump, fuel filter, injectors, fuel pressure testing, throttle body cleaning and adjustment.
Bodywork:
Fairing removal and installation, seat, panels, storage compartment, lighting components.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, chain/belt adjustment (if applicable), lubrication points.
Repair:
Detailed step-by-step repair instructions for all major and minor components, including engine internals, transmission, suspension, brakes, and electrical systems.
Diagnostics:
Troubleshooting guides, fault code interpretation (if applicable), common problem diagnosis, testing procedures for sensors and actuators.
Rebuild:
Comprehensive engine and transmission rebuild instructions, including disassembly, inspection, component replacement, and reassembly.
Depth:
OEM specifications, including torque values, fuel pressure charts, electrical connector data, compression ranges, minimum/maximum tolerances, and critical measurements for professional-level repair and diagnostics.
Illustrations:
Exploded diagrams, detailed charts, and photographs to guide disassembly, reassembly, and component identification.
Format:
PDF (Portable Document Format), allowing for digital access and searchability.
Searchability:
Text-searchable PDF, enabling quick navigation to specific topics and components.
Quality:
High-resolution digital reproduction of original factory documents, ensuring clarity of text and diagrams.
Type:
N/A (Digital PDF download)
Type:
N/A (Digital PDF download)
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Displacement:
493 cc (typically for the 500cc model)
Bore X Stroke:
Refer to manual for specific measurements, e.g., 96 mm x 69 mm (typical for this engine family).
Compression Ratio:
Refer to manual for specific value, typically around 10.5:1 or higher.
Valve Clearance:
Intake: 0.10-0.20 mm, Exhaust: 0.15-0.25 mm (typical cold valve settings, always confirm with manual).
Horsepower:
Approx. 40-45 HP at 7,000-7,500 RPM (actual figures vary by specific model year and tuning).
Torque:
Approx. 45-50 Nm at 5,500-6,000 RPM (actual figures vary by specific model year and tuning).
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Diameter:
Refer to manual, typically 42mm or 46mm.
Fuel Pressure:
Refer to manual for specifications (e.g., 3.0-3.5 bar).
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified.
Oil Capacity:
Refer to manual, typically around 1.5 - 1.8 liters with filter change.
Coolant Type:
Ethylene glycol based antifreeze, mixed 50/50 with distilled water.
Length:
Refer to specific model year specifications, typically around 2200 mm.
Width:
Refer to specific model year specifications, typically around 780 mm.
Height:
Refer to specific model year specifications, typically around 1350 mm (seat height around 780 mm).
Dry Weight:
Refer to specific model year specifications, typically around 190-200 kg.
Gross Vehicle Weight Rating:
Refer to manual for maximum allowable weight.
Fuel Tank Capacity:
Refer to manual, typically around 15 liters.
Crash Test Results:
N/A for motorcycles; safety relies on design, braking, and rider skill.
Braking System:
Front and rear disc brakes. Optional ABS (Anti-lock Braking System) may be available on certain models.
Lighting:
Halogen headlights, LED taillight and turn signals (depending on year).
Frame Construction:
Steel frame for rigidity and stability.
Bodywork:
Aerodynamic fairings designed for rider protection from wind and elements.
Dashboard:
Digital/analog combination instrument cluster providing speed, RPM, fuel level, engine temperature, and warning lights.
Lighting Technology:
Halogen headlight for primary illumination, with LED technology often present in taillights and turn signals on later iterations.
ABS:
Optional ABS system for enhanced braking safety, particularly on earlier Mk1 models or as an upgrade.
Diagnostic Ports:
On-board diagnostic (OBD) port or proprietary diagnostic connector for electronic troubleshooting and ECU access.
Oil Change:
Every 5,000-7,500 km or annually. Refer to manual for precise interval.
Air Filter:
Inspect every 5,000 km, replace as needed or at manufacturer's recommended interval (e.g., 10,000-15,000 km).
Spark Plug:
Replace every 10,000-15,000 km (or per manual recommendation, depending on plug type).
Brake Fluid:
Flush and replace every 2 years or as per manual.
Coolant:
Inspect coolant level regularly, flush and replace every 2-3 years or as per manual.
Engine Oil:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified.
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water.
Variator Wear:
Wear on variator rollers and belt can lead to decreased acceleration and performance; regular inspection is advised.
Regulator Rectifier:
Some Piaggio/Gilera models have had issues with premature failure of the regulator/rectifier, affecting charging system performance.
Fuel Injector Cleaning:
Periodic cleaning of the fuel injector can prevent rough idling and performance issues.
Suspension Seals:
Like many motorcycles, fork seals can degrade over time and may require replacement.
Manufacturer:
Piaggio & C. S.p.A., an Italian company with a long history in scooter and motorcycle manufacturing.
Nexus Lineage:
The Gilera Nexus was a performance-oriented maxi-scooter designed to bridge the gap between scooters and motorcycles, offering substantial power and handling.
Mk1 Introduction:
The Mk1 designation typically refers to the initial generation of the Nexus 500, introduced around 2003-2004, featuring the 493cc engine.
Manufacturing Location:
Italy
