🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Generation:

Mk1

Model Years Covered:

Primarily 2003-2006 (Mk1 generation)

Vin Prefix Common:

ZAPC357

👋 Introduction

Market Segment:

Premium Sport Scooter / Maxi-Scooter

Target Audience:

Commuters seeking performance and comfort, touring enthusiasts, riders looking for a powerful and stylish scooter.

Key Competitors Mk1:

Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600, Piaggio X9 Evolution.

Unique Selling Points:

Sporty handling derived from its motorcycle-like chassis, powerful engine for its class, distinctive Italian styling.

Engine Architecture:

Single-cylinder, four-stroke, liquid-cooled, DOHC engine.

Frame Design:

Steel double cradle frame with aluminum swingarm, contributing to excellent stability and handling.

Braking System Features:

Dual disc front brakes, single disc rear brake, often with linked braking (integral brake system) depending on market.

Suspension Features:

Large diameter front forks and a robust rear monoshock provide a comfortable and controlled ride.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Transmission (CVT), Clutch, Brakes (Front & Rear Disc), Suspension (Front Telescopic Fork, Rear Monoshock), Electrical System, Lighting, Instrumentation, Chassis, Bodywork, Wheels & Tires, General Maintenance, Troubleshooting, Diagnostic Codes

Estimated Pages:

200-300 (typical for a comprehensive workshop manual of this era)

Manual Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English (common for international markets, can vary if specified)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly of engine components including cylinder, piston, connecting rod, crankshaft, valves, camshaft, timing system.

Fuel System:

Carburetor/Fuel Injection system servicing, fuel pump, fuel filter replacement, pressure testing (if applicable).

Ignition System:

Spark plug specifications, ignition timing adjustment, CDI unit testing, coil resistance checks.

Cooling System:

Radiator inspection, coolant replacement, thermostat testing, fan operation.

Lubrication System:

Oil change procedures, oil filter replacement, oil pump inspection, oil pressure checks.

Transmission Drivetrain:

CVT (Continuously Variable Transmission) belt inspection and replacement, clutch operation, variator servicing, final drive maintenance.

Braking System:

Front and rear brake caliper servicing, brake pad replacement, brake disc inspection, brake fluid bleeding, master cylinder overhaul.

Suspension Steering:

Front fork oil level and replacement, fork seal replacement, rear shock absorber inspection and adjustment, steering head bearing maintenance.

Electrical System:

Battery testing and replacement, wiring diagrams, starter motor, alternator, lighting circuits, fuse box identification and testing.

Chassis Bodywork:

Frame inspection, fairing removal and installation, seat servicing, luggage system (if applicable).

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, chain/belt adjustment and lubrication, brake fluid checks, coolant level checks.

Troubleshooting Diagnostics:

Step-by-step diagnostic guides for common performance issues, electrical faults, and mechanical problems. Includes identification of symptoms and potential causes.

Engine Rebuild:

Comprehensive instructions for complete engine disassembly, cleaning, inspection, measurement of wear tolerances, and reassembly.

Transmission Overhaul:

Detailed guidance on servicing and replacing CVT components, clutch assembly, and final drive.

Brake System Repair:

Procedure for bleeding brakes, replacing brake pads and discs, servicing calipers and master cylinders.

Suspension Fork Rebuild:

Step-by-step instructions for front fork disassembly, seal replacement, oil change, and reassembly.

Electrical Component Testing:

Procedures for testing starter motor, alternator, ignition coils, sensors, and other electrical components using multimeters and diagnostic tools.

Wiring Diagram Interpretation:

Clear and detailed wiring diagrams for easy tracing of electrical circuits and troubleshooting of faults.

Technical Depth:

Comprehensive from basic maintenance and troubleshooting to complete engine and component overhauls. Suitable for both DIY enthusiasts and professional mechanics.

Diagnostic Codes:

Includes diagnostic trouble codes (DTCs) if applicable to the Mk1 model's ECU, along with procedures for retrieval and interpretation.

Torque Specifications:

Precise torque values for all critical fasteners to ensure proper assembly and prevent damage.

Wear Tolerances:

Detailed specifications for measuring wear on engine components like pistons, rings, cylinders, and bearings.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchable Text:

Likely includes searchable text for quick information retrieval, assuming a well-scanned and processed PDF.

Print Quality:

Designed for clear printing of text, diagrams, and illustrations. Resolution suitable for home or professional printing.

Binding Type:

Not applicable (PDF download)

Paper Type:

Not applicable (PDF download)

⚙️ Engine Specifications

Engine Type:

Four-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves

Displacement:

460 cc

Bore X Stroke:

92 mm x 69 mm (approximate, confirm with manual)

Compression Ratio:

10.5:1 (typical, confirm with manual)

Horsepower Peak:

Approx. 34 HP (25 kW) at 7,250 rpm (varies by market and tuning)

Torque Peak:

Approx. 45 Nm (33 lb-ft) at 5,750 rpm (varies by market and tuning)

Fuel Delivery:

Electronic Fuel Injection (EFI) for most models, some early markets might have had advanced carburetion. Manual will detail the specific system.

Fuel Type:

Unleaded gasoline, minimum 95 RON

Valve Clearance Intake:

0.05 - 0.10 mm (cold, confirm with manual)

Valve Clearance Exhaust:

0.10 - 0.15 mm (cold, confirm with manual)

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Clutch Type:

Automatic centrifugal clutch

Final Drive:

Belt drive to rear wheel via CVT and gearbox

Cvt Fluid Type:

Specific CVT oil (e.g., Piaggio/Gilera branded, SAE 75W/90 or similar, confirm with manual)

📐 Dimensions

Length:

Approx. 2,150 mm

Width:

Approx. 780 mm

Height:

Approx. 1,410 mm (seat height varies)

Dry Weight:

Approx. 195 kg

Gross Vehicle Weight Rating:

Approx. 395 kg

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Alloy wheels

Wheel Bolt Pattern:

N/A (Scooter wheel mounting differs from cars)

🛡️ Safety Features

Crash Test Ratings:

Not applicable (motorcycle/scooter safety is assessed differently than automobiles)

Braking System:

Front and rear disc brakes, ABS available on some models/markets.

Lighting:

Halogen headlights, LED taillight and indicators (depending on specific model year).

Chassis Strength:

Robust steel double cradle frame for rider protection in case of a mishap.

Storage Compartments:

Under-seat storage, often large enough for a helmet. Glove compartment in the front fairing.

💡 Technology Features

Instrument Cluster:

Analogue tachometer, digital speedometer, odometer, trip meter, fuel gauge, coolant temperature warning light, oil pressure warning light, engine diagnostic light.

ABS:

Anti-lock Braking System (ABS) was an optional feature on some Mk1 models, not standard across all markets.

Connectivity Features:

None directly integrated (e.g., no Bluetooth or smartphone integration as this is an older model).

Headlight Type:

Dual Halogen headlights

Taillight Type:

Incandescent bulb or early LED (confirm for specific Mk1 year)

🔧 Maintenance

First Service:

1,000 km or 6 months (whichever comes first) - typically includes oil and filter change, general inspection.

Subsequent Major Service:

Every 5,000 km or 12 months - includes engine oil, oil filter, air filter check/replacement, CVT belt inspection, brake pad check, spark plug replacement.

Valve Clearance Check:

Every 10,000 km or 24 months

Transmission Oil Change:

Every 10,000 km or 24 months

Engine Oil Type:

API SG/SH/SJ or higher, JASO MA, SAE 10W-40 (confirm specific grade with manual)

Engine Oil Capacity:

Approx. 1.7 Liters (with filter change, confirm with manual)

Coolant Type:

Ethylene glycol-based antifreeze coolant (e.g., Piaggio Coolant or equivalent)

Coolant Capacity:

Approx. 1.5 Liters (confirm with manual)

Brake Fluid Type:

DOT 4 (confirm with manual)

Common Wear Items:

CVT belt, brake pads, wheel bearings, fork seals, exhaust system.

Potential Electrical Quirks:

Some early models might experience minor electrical gremlins if not properly maintained or exposed to extreme weather.

Fuel Pump Reliability:

While generally robust, fuel pumps can be a wear item over extended mileage; regular fuel filter replacement is key.

Oil Filter Pn:

Commonly uses Gilera/Piaggio part numbers like 847228 or equivalent aftermarket filters (e.g., HiFlofiltro HF303, K&N KN303).

Air Filter Pn:

Specific to Gilera Nexus 500 Mk1 (e.g., Gilera part number 847229 or aftermarket equivalent).

📚 Vehicle History

Brand Origins:

Gilera is an Italian motorcycle manufacturer founded in 1909, known for its performance and racing heritage.

Ownership:

Currently part of the Piaggio Group, which also owns Vespa, Aprilia, and Moto Guzzi.

Nexus Introduction:

The Gilera Nexus 500 was introduced in 2003 as a premium, sporty maxi-scooter aimed at challenging established players in the market.

Mk1 Characteristics:

The Mk1 (first generation) established the Nexus's reputation for strong performance, excellent handling, and a distinctive Italian design. It was powered by a potent 460cc Piaggio Master engine.

Subsequent Generations:

The Nexus 500 underwent updates, with later models (often referred to as Mk2 or facelifted versions) featuring styling tweaks and minor mechanical revisions.

Manufacturing Location:

Italy

🏆 Awards & Recognition

Industry Reviews Mk1:

The Gilera Nexus 500 Mk1 received positive reviews for its performance, handling, and comfortable ride for a maxi-scooter, often praised for its 'motorcycle-like' feel.

Comparison Tests:

Frequently featured in comparison tests against its primary competitors, showcasing its strong performance credentials.