🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500

Generation:

Mk1

Engine Code Prefix:

M302

👋 Introduction

Vehicle Segment:

Maxi-scooter, sport scooter

Competitors:

Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic

Manual Benefit 1:

Enables DIY servicing and repairs, leading to significant cost savings.

Manual Benefit 2:

Promotes longevity and optimal performance of the Gilera Nexus 500 Mk1.

Manual Benefit 3:

Provides in-depth understanding of the motorcycle's mechanics.

📋 Manual Details

Systems Covered:

General Information, Specifications, Maintenance, Gearbox & Clutch, Engine Removal/Installation, Fuel System, Lubrication/Cooling, Combustion System, Alternator/Starter Clutch, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Transmission System, Front Wheel/Steering, Rear Wheel, Fenders/Exhaust, Periodic Checks/Adjustments, Chassis, Cooling System, Fuel Injection System, Braking System, Suspension, Electrical System, Body & Fixtures, Frame/Body Panels/Exhaust System, Wheels & Tyres, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Technical Information, Troubleshooting, Index

Estimated Pages:

Detailed information suggests a comprehensive manual, likely exceeding 300 pages.

Type:

Workshop Repair Manual

Language:

English (Assumed based on product description, typical for international manuals)

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine (Fuel System, Lubrication, Cooling, Combustion, Crankcase, Piston, Cylinder, Crankshaft, Transmission, Balancer), Gearbox & Clutch, Transmission System

Chassis And Suspension:

Front Wheel and Steering System, Rear Wheel System, Fenders and Exhaust Pipe, Chassis, Cooling System, Braking System, Suspension, Frame/Body Panels/Exhaust System, Wheels & Tyres

Electrical And Electronics:

Alternator/Starter Clutch, Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Fuel Injection System

Maintenance And Repair:

Routine Maintenance, Periodic Checks & Adjustments, Engine Removal and Installation, Drivetrain Overhaul, Suspension Overhaul, Braking System Service, Electrical System Diagnostics, Fuel System Service, Cooling System Service, Troubleshooting

Diagnostics:

Troubleshooting section for common issues, detailed wiring diagrams for electrical diagnostics

Depth Of Information:

Comprehensive (indicated by exploded diagrams, step-by-step instructions, and detailed sections like Crankshaft/Transmission/Balancer and Fuel Injection System)

📊 Manual Specifications

File Type:

PDF

Printability:

All pages are printable

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Diagrams And Illustrations:

Highly detailed exploded pictures and diagrams

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke

Engine Displacement:

460 cc (approximately)

Bore X Stroke:

93.5 mm x 67.5 mm (typical for this engine family)

Compression Ratio:

10.5:1 (typical)

Horsepower:

Approx. 34-35 HP @ 6500 RPM (manufacturer dependent, check specific model year)

Torque:

Approx. 45-46 Nm @ 5000 RPM (manufacturer dependent, check specific model year)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (RON 95 recommended)

Cooling Method:

Liquid-cooled

Oil Type Recommendation:

Synthetic SAE 10W-40 (API SG or higher, JASO MA)

Valve Train:

SOHC, 4 valves

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with dry clutch

Clutch Type:

Automatic centrifugal dry clutch

Final Drive:

Belt drive to rear wheel

📐 Dimensions

Length:

Approx. 2170 mm

Width:

Approx. 780 mm (at handlebars)

Height:

Approx. 1330 mm (at windscreen)

Dry Weight:

Approx. 185 kg

Wet Weight:

Approx. 197 kg (with fluids)

Max Load Capacity:

Approx. 180 kg (rider + passenger + luggage)

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Alloy wheels

Fuel Tank Capacity:

15 Liters (including reserve)

🛡️ Safety Features

Crash Test Data:

N/A (Motorcycle safety is primarily assessed through design and rider skill)

Braking System Front:

Dual 260 mm discs, hydraulic actuation

Braking System Rear:

240 mm disc, hydraulic actuation

ABS Availability:

Optional ABS (Anti-lock Braking System) available on some models

Lighting:

Dual headlights, LED taillight

Instrumentation:

Digital and analog display (Meters)

💡 Technology Features

Dashboard Features:

Digital LCD display for speed, fuel level, odometer, trip meter, clock, and warning lights. Analog tachometer.

ABS:

Optional ABS integration for enhanced braking safety.

Diagnostic Ports:

On-board diagnostics (OBD) port for fault code reading via dealer diagnostic tool.

🔧 Maintenance

Oil Change Interval:

Every 5,000-7,000 km or annually (refer to manual for precise interval)

Spark Plug Replacement:

Every 10,000-15,000 km

Air Filter Cleaning Replacement:

Every 7,500 km or as needed based on conditions

Gearbox Oil Change:

Every 10,000-15,000 km

Coolant Replacement:

Every 2 years or 20,000 km

Engine Oil Capacity:

Approx. 1.6 - 1.8 Liters (including filter, check manual)

Coolant Type:

Ethylene glycol-based antifreeze coolant, suitable for Piaggio Group engines

Brake Fluid Type:

DOT 4

Common Wear Items:

CVT belt wear, suspension bushings, front brake pads

Electrical Gremlins:

Occasional issues with wiring harness connectors or regulator/rectifier, especially on earlier models.

Fuel System Maintenance:

Regular cleaning of fuel injectors and throttle body recommended for optimal performance.

📚 Vehicle History

Manufacturer Origin:

Italy

Nexus Lineage:

The Nexus line represented Gilera's foray into the premium maxi-scooter market, emphasizing sportiness and comfort.

Production Years Mk1:

Likely produced from the mid-2000s (e.g., 2003-2007) until the introduction of subsequent generations.

Manufacturing Location:

Italy (under Piaggio Group ownership)

🏆 Awards & Recognition

Market Reception:

Praised for its strong performance, comfortable ride, and sporty handling within the maxi-scooter segment upon release.