|
Introduction
|
|
Market Position
|
|
Segment:
|
Maxi-scooter, performance-oriented commuter/tourer
|
|
Competitive Analysis
|
|
Key Competitors:
|
Suzuki Burgman 400/650, Yamaha TMAX 500, Piaggio X8 250/X9 500, Honda Silver Wing 600
|
|
Key Features
|
|
Unique Selling Points:
|
Powerful 500cc engine for its class, agile handling for a maxi-scooter, comfortable for long distances, sporty styling.
|
|
Manual Purpose
|
|
Target Audience:
|
DIY mechanics, independent repair shops, Gilera Nexus 500 owners seeking self-sufficiency in maintenance and repair.
|
|
Manual Value Proposition
|
|
Dealer Level Information:
|
Provides the same technical data and procedures used by authorized dealer technicians.
|
|
Manual Coverage
|
|
Systems Covered
|
|
Engine:
|
Complete engine disassembly, assembly, tuning, diagnostics, internal components
|
|
Fuel System:
|
Fuel injection system, fuel pump, injectors, fuel filter, tank
|
|
Cooling System:
|
Radiator, coolant, water pump, hoses, thermostat
|
|
Ignition System:
|
Spark plug, ignition coil, ECU control
|
|
Exhaust System:
|
Catalytic converter, mufflers, lambda sensors
|
|
Transmission Clutch:
|
Automatic transmission (CVT), clutch operation, maintenance, repair
|
|
Brakes:
|
Front and rear brake systems, hydraulic lines, master cylinders, calipers, discs, bleeding procedures
|
|
Suspension:
|
Front telescopic forks, rear shock absorber, adjustment, maintenance
|
|
Steering:
|
Handlebar assembly, steering bearings, linkage
|
|
Electrical System:
|
Wiring diagrams, battery, starter, alternator, lighting, fuses, relays, ECU, diagnostic port
|
|
Bodywork:
|
Fairings, panels, seat, storage compartments, disassembly and reassembly
|
|
Procedures Included
|
|
Routine Maintenance:
|
Oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though Nexus is CVT), brake checks
|
|
Troubleshooting:
|
Diagnostic charts, common problems and solutions, fault code interpretation
|
|
Repair:
|
Component-level repair and replacement for all covered systems
|
|
Rebuilds:
|
Engine and transmission rebuild procedures
|
|
Adjustments:
|
Valve clearances, throttle cable, brake levers
|
|
Scheduled Service:
|
Factory-recommended service intervals and tasks
|
|
Technical Service Bulletins:
|
Inclusion of TSBs relevant to the covered models
|
|
Recall Information:
|
Inclusion of recall notices pertaining to the covered models
|
|
Technical Depth
|
|
Depth Level:
|
Comprehensive; covers everything from routine maintenance to complete engine and transmission overhauls.
|
|
Diagnostic Capabilities:
|
Includes ECU fault code diagnosis, sensor testing, and wiring troubleshooting.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Engine Manufacturer:
|
Piaggio (for Gilera)
|
|
Engine Code Series:
|
Quasar
|
|
Displacement:
|
493 cc
|
|
Bore X Stroke:
|
94 mm x 71 mm (typical for Quasar 500)
|
|
Compression Ratio:
|
10.5:1 (typical for Quasar 500)
|
|
Engine Cooling:
|
Liquid-cooled
|
|
Valve Train:
|
SOHC, 4 valves per cylinder
|
|
Performance
|
|
Horsepower:
|
Approx. 33.5 HP (25 kW) @ 6,500 rpm (peak figures vary slightly by source)
|
|
Torque:
|
Approx. 45 Nm (33 lb-ft) @ 5,000 rpm (peak figures vary slightly by source)
|
|
Fuel System
|
|
Fuel Delivery:
|
Electronic Fuel Injection (EFI) with Keihin throttle body
|
|
Fuel Type:
|
Unleaded gasoline, minimum 95 RON
|
|
Fuel Tank Capacity:
|
12 Liters (approx. 3.2 US gallons)
|
|
Oil Specifications
|
|
Engine Oil Type:
|
SAE 5W-40 or 10W-40 synthetic motorcycle oil meeting API SG, JASO MA specifications
|
|
Engine Oil Capacity:
|
Approx. 1.6 Liters (1.7 US quarts) with filter change
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval:
|
Every 6,000 km (3,700 miles) or annually, whichever comes first (typical for Gilera/Piaggio).
|
|
Air Filter Replacement:
|
Every 12,000 km (7,500 miles) or as needed based on operating conditions.
|
|
Spark Plug Replacement:
|
Every 12,000 km (7,500 miles).
|
|
Coolant Flush:
|
Every 2 years or 24,000 km (15,000 miles).
|
|
Brake Fluid Change:
|
Every 2 years.
|
|
Fluid Specifications
|
|
Coolant Type:
|
Ethylene glycol-based coolant, pre-mixed 50/50 with distilled water (protects to -37°C).
|
|
Brake Fluid Type:
|
DOT 4 hydraulic brake fluid.
|
|
Known Issues
|
|
Common Complaints:
|
Possible minor electrical gremlins (connectors, grounds), occasional voltage regulator issues, exhaust system rust on older models, CVT belt wear beyond specified interval.
|
|
Common Complaints Details:
|
Some owners report issues with the under-seat locking mechanism or minor fairing fitment tolerances.
|
|
Vehicle History
|
|
Brand Heritage
|
|
Manufacturer Origin:
|
Gilera is an Italian manufacturer, founded in 1909, with a strong racing heritage.
|
|
Ownership:
|
Gilera is part of the Piaggio Group, which also owns Vespa, Aprilia, and Moto Guzzi.
|
|
Model Evolution
|
|
Nexus Lineage:
|
The Nexus was Gilera's flagship maxi-scooter, introduced to compete with established players. The 500cc engine was a significant step up from smaller capacity scooters.
|
|
Mk2 Updates:
|
The 'mk2' designation often refers to minor updates or refinements over earlier versions, potentially including styling tweaks, emissions improvements (Euro 3), or chassis modifications.
|
|
Production
|
|
Manufacturing Location:
|
Likely manufactured in Italy by Piaggio.
|
