Segment:
Maxi-scooter, performance-oriented, touring and commuting focused.
Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500/530, Honda Silver Wing 600, Kymco Xciting 500.
Vehicle Highlights:
Powerful 500cc engine, comfortable ergonomics for longer rides, substantial under-seat storage, sporty handling for its class, Euro 3 emissions compliant.
Engine And Fuel:
Detailed coverage of the 500cc engine, including disassembly, assembly, torque specifications, valve clearance, timing chain, piston, cylinder, crankshaft, and the complete fuel injection system (ECU, injectors, sensors, fuel pump, fuel pressure regulator).
Cooling And Lubrication:
Instructions for the cooling system (radiator, coolant, water pump, thermostat) and lubrication system (oil pump, oil filter, oil type and capacity).
Braking And Suspension:
Comprehensive guide to the braking system (disc brakes, calipers, brake fluid, master cylinder, hydraulic lines) and suspension components (front fork, rear shock absorber, linkage, bearings, seals).
Chassis And Bodywork:
Information on the chassis frame, body panels, fairings, seat, storage, and related fasteners and trim.
Electrical System:
Detailed wiring diagrams, component identification, troubleshooting procedures, battery, ignition system, lighting, starter motor, and instrumentation.
Maintenance And Servicing:
Routine maintenance tasks, scheduled service intervals, fluid changes (oil, coolant, brake fluid), filter replacement, and inspection points.
Diagnostics And Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable), and troubleshooting flowcharts.
Repair And Rebuild:
Detailed instructions for disassembly, inspection, repair, and reassembly of all major mechanical and electrical components.
Pre Delivery And Setup:
Guidance on initial setup and preparation of the vehicle before delivery to the customer.
Tooling And Special Tools:
Identification and usage instructions for specialized tools required for specific maintenance and repair tasks.
Depth:
Comprehensive, covering routine maintenance to complete engine and component overhauls. Suitable for professional technicians and advanced DIY mechanics.
Engine Type:
Single-cylinder, four-stroke
Displacement:
493 cc (approximate, based on Nexus 500)
Bore X Stroke:
Refer to manual (typical for 500cc singles would be around 94mm x 71mm, but specific Gilera data needed)
Cooling System:
Liquid-cooled
Valve Train:
SOHC, 4 valves (typical for this engine architecture)
Compression Ratio:
Refer to manual (likely around 10.0:1 to 11.5:1)
Horsepower:
Approximately 40-45 HP (refer to manual for exact figures)
Torque:
Approximately 45-50 Nm (refer to manual for exact figures)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Oil Type:
Refer to manual (e.g., SAE 5W-40 or 10W-40 synthetic motorcycle oil meeting API SG/SH/SJ or JASO MA/MA2 specifications)
Oil Capacity:
Refer to manual (typically around 1.5 - 2.0 liters including filter)
Length:
Refer to manual (typical for maxi-scooter: ~2200 mm)
Width:
Refer to manual (typical for maxi-scooter: ~770 mm)
Height:
Refer to manual (typical for maxi-scooter: ~1400 mm)
Wheelbase:
Refer to manual (typical for maxi-scooter: ~1550 mm)
Dry Weight:
Refer to manual (typical for 500cc maxi-scooters: ~190-200 kg)
Wet Weight:
Refer to manual (including fluids)
Payload Capacity:
Refer to manual
Crash Test Results:
N/A (Motorcycles/scooters are not typically rated by agencies like NHTSA or Euro NCAP in the same way as cars).
Braking System:
Dual disc front brakes, single disc rear brake. ABS might be optional or standard on SP models (refer to manual).
Lighting:
Halogen or LED headlights and taillights, turn signals.
Frame Construction:
Steel frame designed for rigidity and stability.
Storage:
Under-seat storage compartment, glove box.
Instrument Cluster:
Digital and analog display with speedometer, tachometer, fuel gauge, engine temperature, odometer, trip meters, and warning lights.
ABS:
Optional or standard on SP models, consult manual for specific vehicle configuration.
Charging Port:
May include a 12V accessory socket for charging devices (refer to manual).
Oil Change Interval:
Refer to manual (typically 5,000-7,500 km or annually, whichever comes first)
Air Filter Replacement:
Refer to manual (e.g., every 10,000-15,000 km or as needed)
Spark Plug Replacement:
Refer to manual (e.g., every 15,000-20,000 km)
Coolant Replacement:
Refer to manual (e.g., every 2-4 years or 20,000-40,000 km)
Brake Fluid Replacement:
Refer to manual (typically every 2 years)
Coolant Type:
Refer to manual (typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water)
Brake Fluid Type:
Refer to manual (typically DOT 4)
Cv Belt Inspection:
Refer to manual (inspection and replacement intervals critical for CVT performance and longevity)
Common Wear Items:
CVT belt wear, stator/regulator issues, front fork seal leaks, rear shock absorber wear are common on many maxi-scooters of this era.
Electrical Gremlins:
Can sometimes experience minor electrical issues if not maintained, wiring harness integrity is important.
Manufacturer:
Gilera, an Italian motorcycle manufacturer with a long history, now part of the Piaggio Group.
Nexus Lineage:
The Nexus series was Gilera's flagship maxi-scooter line, known for its sporty performance and premium features, evolving from earlier models.
Production Period:
The Nexus 500 was produced roughly from the mid-2000s to the early 2010s. The MK2 designation typically refers to a later iteration within that period.
Manufacturing Location:
Italy
