Product Positioning:
Comprehensive service and repair resource for Gilera Nexus 500 owners and mechanics, emphasizing DIY and professional use
Manual Value Proposition:
Provides in-depth, illustrated repair procedures, making it a primary source for maintenance and troubleshooting, directly comparable to official factory service manuals.
Instructional Methodology:
Numbered instructions, detailed substeps, notes, cautions, and warnings ensure clarity and safety.
Visual Aid Quality:
Hundreds of photos and illustrations, including enlarged insets for detailed part examination, enhance understanding.
Ease Of Use:
Numbered table of contents, bold figure numbers, and detailed substeps facilitate quick and accurate information access.
Download Benefit:
Instant download eliminates shipping costs and waiting time.
Manual Scope:
All versions and model years from 2006 to 2010
Estimated Page Count:
Likely 400+ pages based on depth of coverage
Manual Classification:
Workshop Service Repair Manual
Searchability:
Searchable text within the PDF document for quick information retrieval.
Navigation:
Fully indexed for easy navigation with a numbered table of contents.
Compatibility:
Compatible with all Windows and Mac computers (Windows 7, Vista 32/64, XP, ME, 98, NT, 2000, etc.)
Software Requirement:
Adobe PDF Reader
Powertrain:
Engine, transmission, drivetrain (including clutch and final drive)
Chassis And Body:
Frame, suspension (front and rear), steering, wheels, brakes, body panels, seat, fuel tank
Electrical System:
Wiring diagrams, lighting, ignition, starting system, charging system, instrumentation, ECU functions
Cooling System:
Radiator, hoses, thermostat, fan operation, coolant level checks and replacement
Exhaust System:
Exhaust pipe, muffler, catalytic converter (if fitted), and associated gaskets
Fuel System:
Fuel tank, fuel pump, fuel filter, injectors, throttle body, electronic control unit (ECU)
Routine Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid checks, coolant checks, chain/belt adjustment (if applicable), tire pressure checks
Repair And Rebuild:
Engine disassembly/assembly, transmission overhaul, suspension component replacement, brake system service, electrical component diagnosis and replacement
Troubleshooting:
Diagnostic procedures for common and complex issues, guided by symptoms and electrical diagrams
Diagnostic Tools Mention:
Manual likely references diagnostic tools or procedures for ECU fault codes.
Suspension Service:
Front fork overhaul, rear shock absorber inspection and replacement, linkage lubrication (if applicable)
Wheel And Tire Service:
Tire inspection, tire pressure checks, tire replacement, wheel balancing, rim inspection
Bodywork Repair:
Panel removal and installation, fairing repairs, seat adjustment and removal
Diagnostic Capabilities:
Advanced diagnostics including troubleshooting and electrical service procedures with detailed wiring diagrams
Reconstruction Level:
Complete disassembly of the machine with step-by-step instructions and detailed illustrations
Engine Type:
Liquid-cooled, 4-stroke, single-cylinder (Piaggio Quasar engine)
Engine Displacement:
492.7 cc (approximately)
Bore X Stroke:
Approximately 94 mm x 71 mm (typical for Quasar 500)
Compression Ratio:
Typically around 10.5:1 to 11.0:1 for Quasar 500
Horsepower Output:
Approximately 33-35 HP (at 6,500-7,000 RPM)
Torque Output:
Approximately 45-47 Nm (at 5,000-5,500 RPM)
Fuel Delivery:
Electronic Fuel Injection (EFI) - likely Keihin or similar
Ignition System:
Electronic ignition with variable ignition timing
Cooling Method:
Liquid-cooled with radiator and fan
Oil Type Recommendation:
Synthetic Motorcycle Oil, SAE 5W-40 or 10W-40 (API SG/SH/SJ/SL, JASO MA)
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder
Emission Controls:
Likely includes emissions control systems such as a catalytic converter and potentially an air injection system, as per Euro regulations for the era.
Safety Certification:
Compliance with relevant European safety standards (e.g., EC Type Approval)
Braking System Front:
Dual 260 mm discs with 4-piston calipers (likely Brembo)
Braking System Rear:
Single 240 mm disc with 2-piston caliper
Optional ABS:
ABS available on certain models/years
Lighting:
Halogen headlights, LED taillight
Instrument Cluster:
Digital and analog combination dashboard with speedometer, tachometer, fuel gauge, odometer, trip meters, coolant temperature, and warning lights.
ABS Availability:
Optional Anti-lock Braking System (ABS) for enhanced safety.
Charging Port:
Likely a 12V accessory socket for charging electronic devices.
Engine Oil Change:
Every 5,000 km or 6 months (whichever comes first)
Oil Filter Replacement:
Every 10,000 km or 12 months (concurrent with oil change)
Spark Plug Replacement:
Every 10,000 km
Air Filter Cleaning/Replacement:
Inspect every 5,000 km, clean or replace as needed; replace every 10,000 km
Final Drive Oil Change:
Every 10,000 km (check manual for specific procedure and fluid type)
Engine Oil Capacity:
Approximately 1.3 Liters (with filter change)
Coolant Type:
Ethylene Glycol based coolant, pre-mixed or concentrate (typically 50/50 with distilled water)
Gearbox Oil Capacity:
Refer to manual for specific gearbox oil (if separate from engine oil)
Common Wear Items:
Front and rear brake pads, drive belt (CVT), tires, suspension bushings
Potential Electrical Issues:
Starter motor reliability, voltage regulator (common on some Piaggio platforms)
Engine Quirks:
Occasional fuel injection system cleaning might be beneficial for optimal performance, especially with varied fuel quality.
Manufacturer Origin:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909.
Nexus Development:
The Nexus 500 represented Gilera's entry into the maxi-scooter segment, known for its sporty handling and performance, often compared to motorcycles.
Manufacturing Location:
Likely manufactured in Italy
