🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Generation:

Mk1

Year:

2006

Market Segment:

Maxi-scooter / Sport-scooter

Engine Code:

M303

Chassis Code:

ZAPM30300

👋 Introduction

Positioning:

The Gilera Nexus 500 Mk1 represented a significant entry into the maxi-scooter market, aiming to blend sporty performance with touring comfort and practicality.

Target Audience:

Commuters seeking a more powerful and comfortable option than traditional scooters, sport-oriented riders, and those looking for a capable long-distance touring machine.

Competitors:

BMW C 650 GT (later models), Yamaha TMAX, Suzuki Burgman 650, Piaggio X9 Evolution.

Features:

Powerful 500cc engine, aggressive styling, comfortable ergonomics, large under-seat storage, and premium componentry.

📋 Manual Details

Primary Focus:

Repair, Maintenance, and Diagnostics

Scope:

Comprehensive factory-level service information

Estimated Pages:

~300-400

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete disassembly, assembly, inspection, and repair of the 4-stroke, single-cylinder, liquid-cooled engine.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel lines, and fuel tank maintenance and troubleshooting.

Ignition System:

Ignition coil, spark plug, ECU control, and ignition timing checks.

Cooling System:

Radiator, coolant pump, thermostat, fan, coolant lines, and fluid specifications.

Transmission:

Automatic CVT (Continuously Variable Transmission) disassembly, inspection, belt replacement, roller weights, and clutch assembly.

Chassis Frame:

Frame inspection, welding points, and structural integrity checks.

Suspension:

Front telescopic fork (fork oil type, level, seal replacement), rear monoshock absorber (spring preload adjustment, damping), and linkage system.

Brakes:

Front and rear hydraulic disc brake systems, caliper overhaul, master cylinder repair, brake pad replacement, brake fluid specifications, bleeding procedures, and ABS system (if equipped).

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, and wheel balancing.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, and fuse box.

Instrumentation:

Speedometer, tachometer, fuel gauge, warning lights, and diagnostic indicators.

Bodywork Trim:

Fairing removal and installation, seat, panels, storage compartments, and cosmetic component replacement.

Diagnostic Troubleshooting:

Fault code interpretation (OBD-II if applicable), symptom-based troubleshooting guides, and common problem diagnosis.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel), spark plug checks, coolant flushes, brake fluid changes, and lubrication points.

Disassembly Assembly:

Step-by-step instructions for component removal and reinstallation with torque specifications.

Repair:

Detailed repair procedures for worn or damaged parts, including internal engine components, transmission elements, and electrical modules.

Checks Inspections:

Visual inspections, functional tests, and performance checks for all major systems.

Adjustments:

Throttle cable adjustment, brake lever adjustment, suspension settings, and idle speed adjustments.

Depth:

In-depth, from basic owner maintenance to complete engine rebuilds and complex electrical diagnostics.

User Level:

Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable (depending on PDF creation)

Quality:

Digital PDF - quality dependent on original source; typically good for technical diagrams.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

4-stroke, single-cylinder, liquid-cooled, 4-valve per cylinder

Displacement:

492.7 cc (30.08 cu in)

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.0:1

Engine Management:

Electronic Fuel Injection (EFI)

Lubrication:

Wet sump

Horsepower:

Approx. 40 HP (29.4 kW) @ 7,000 RPM

Torque:

Approx. 45 Nm (33.2 lb-ft) @ 5,500 RPM

Fuel Type:

Unleaded gasoline (95 RON recommended)

Fuel Tank Capacity:

15 Liters (3.96 US gal)

Fuel Delivery:

Electronic Fuel Injection (EFI) with throttle body diameter approx. 40mm.

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Drive:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

Transmission Fluid:

Refer to manual for specific CVT fluid and engine oil specifications (often separate).

📐 Dimensions

Length:

Approx. 2180 mm (85.8 in)

Width:

Approx. 800 mm (31.5 in)

Height:

Approx. 1480 mm (58.3 in) (with windscreen)

Wheelbase:

Approx. 1535 mm (60.4 in)

Dry Weight:

Approx. 196 kg (432 lbs)

Wet Weight:

Approx. 208 kg (459 lbs)

Maximum Load:

Refer to manual, typically around 170-180 kg rider + luggage.

🛡️ Safety Features

Braking System:

Dual hydraulic disc front, single hydraulic disc rear. Some models may feature ABS (Anti-lock Braking System).

Lighting:

Halogen headlights, LED taillight and brake light, amber turn signals.

Frame Construction:

High-strength steel frame, designed for stability and rigidity.

Windscreen:

Aerodynamic windscreen for rider protection.

💡 Technology Features

Instrument Panel:

Digital LCD display for odometer, trip meter, fuel level, and clock; analog tachometer and speedometer.

ABS:

Optional ABS system available on some models for enhanced braking safety.

Diagnostic Port:

On-board diagnostic capabilities allowing for fault code retrieval via an OBD-II compliant port or proprietary connector.

🔧 Maintenance

Engine Oil Change:

Every 5,000 km or 1 year, whichever comes first.

Oil Filter Replacement:

Every 10,000 km or 2 years.

Air Filter Cleaning Replacement:

Check every 5,000 km, replace as needed or every 10,000 km.

Spark Plug Check Replacement:

Check every 10,000 km, replace as needed (e.g., NGK CR9EB).

Cvt Belt Inspection Replacement:

Inspect every 10,000 km, replace typically around 20,000-30,000 km depending on wear.

Brake Fluid Change:

Every 2 years.

Coolant Flush Replacement:

Every 2-3 years or 20,000 km.

Engine Oil Type:

Semi-synthetic or fully synthetic SAE 5W-40 API SG or higher.

Engine Oil Capacity:

Approx. 1.5 Liters (1.6 US qt) without filter change, 1.7 Liters (1.8 US qt) with filter change.

Brake Fluid Type:

DOT 4

Coolant Type:

Ethylene glycol-based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.

Common Problems:

Potential for voltage regulator failure (leading to battery charging issues), CVT belt wear requiring timely replacement, occasional issues with fuel pump reliability, and some electrical connector corrosion.

Maintenance Tips:

Regular cleaning of electrical connectors, keeping battery terminals clean and charged, and adhering strictly to scheduled CVT belt inspections and replacements are crucial for longevity.

📚 Vehicle History

Heritage:

Gilera, an Italian manufacturer with a long history dating back to 1909, is renowned for its sporty motorcycles and scooters, often associated with performance and innovative design. It is part of the Piaggio Group.

Evolution:

The Nexus series was Gilera's flagship maxi-scooter line, competing at the higher end of the market with a focus on performance and premium features. The 500cc model was a key offering in this segment.

Manufacturing Location:

Italy

Production Period:

The Nexus 500 was produced for several years, with the Mk1 designation referring to the initial generation and variations.

🏆 Awards & Recognition

Recognition:

While specific awards for the 2006 Mk1 may not be widely documented, the Gilera Nexus line generally received positive reviews for its performance and styling within the maxi-scooter segment.