Segment Placement:
The Gilera Nexus 500 MK1 was positioned as a premium maxi-scooter, offering performance and sport-touring capabilities aimed at riders seeking a comfortable yet capable machine for both urban commuting and longer journeys.
Key Competitors:
Competed with other large-displacement scooters of its era, such as the Yamaha TMAX, Suzuki Burgman 400/650, and Aprilia Atlantic 500.
Design Philosophy:
Sporty styling combined with practical touring features, including a comfortable riding position, good wind protection, and ample under-seat storage.
Performance Orientation:
Emphasized a powerful engine and agile handling, differentiating it from more comfort-focused maxi-scooters.
Engine:
Detailed coverage including disassembly, assembly, inspection, tuning, and troubleshooting of all engine components.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, pressure regulator, fuel filter, and fuel tank maintenance and diagnostics.
Cooling System:
Radiator, coolant pump, thermostat, fan, hoses, and coolant specifications and bleeding procedures.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), muffler, and lambda sensor diagnostics.
Transmission:
CVT (Continuously Variable Transmission) including variator, clutch, drive belt, and final drive servicing.
Chassis And Frame:
Frame inspection, steering head bearing service, suspension component replacement (forks, rear shock absorber).
Suspension Front:
Telescopic front fork service, seal replacement, oil level and type specifications.
Brakes Front:
Brake caliper overhaul, pad replacement, disc inspection, brake fluid type and bleeding procedures.
Electrical System:
Battery maintenance, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, and horn.
Instrumentation:
Dashboard, speedometer, tachometer, warning lights, and sensor diagnostics.
Rear Shock ABSorber:
Removal, installation, and adjustment of rear shock absorbers.
Rear Brake:
Rear brake caliper, disc, and pad service, fluid replacement, and bleeding.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical circuits.
Fairings And Panels:
Removal, installation, and repair of body panels, fairings, and trim components.
Seat And Storage:
Seat removal and latch mechanism servicing.
Routine Maintenance:
Oil changes, filter replacements (oil, air), spark plug service, chain/belt adjustment (if applicable), brake checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting.
Disassembly Assembly:
Step-by-step instructions with detailed illustrations for component removal and reinstallation.
Rebuilds:
Complete engine and transmission rebuild procedures.
Adjustments:
Valve clearance, throttle cable, brake lever adjustments.
Depth:
Comprehensive (covers everything from basic fluid changes to full engine overhauls and complex electrical diagnostics).
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, SOHC
Displacement:
460 cc (approximate)
Bore X Stroke:
Not specified, but typical for this displacement.
Horsepower:
Approximately 34-37 HP (depending on specific market tuning)
Torque:
Approximately 45-48 Nm
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body
Ignition System:
Digital electronic ignition
Oil Type:
Likely SAE 5W-40 or 10W-40 synthetic motorcycle oil meeting API SG or higher specifications (manual will confirm exact specs).
Oil Capacity:
Approximately 1.5 - 1.7 liters (including filter, manual will provide precise figure).
Safety Standards:
Designed to meet relevant European safety directives and standards for motorcycles/scooters.
Braking System:
Dual disc brakes front, single disc brake rear. ABS was an optional feature on some models.
Lighting:
Halogen headlight, LED tail light and indicators.
Frame Construction:
High-strength steel frame for stability and rigidity.
Wind Protection:
Aerodynamic fairing and windscreen for rider protection from wind and debris.
Engine Oil Change:
Typically every 5,000 - 7,500 km or annually (manual confirmation required).
Drive Belt Inspection:
Inspect every 10,000 km, replace typically every 20,000 - 30,000 km (manual confirmation required).
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (manual confirmation required).
Valve Clearance Check:
Typically every 15,000 - 20,000 km (manual confirmation required).
Brake Fluid Type:
DOT 4 (manual confirmation required).
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water (manual confirmation required).
Common Wear Items:
Drive belt, variator rollers, starter motor brushes, wheel bearings, suspension seals.
Electrical Gremlins:
Some models may experience intermittent electrical issues, often related to connectors or grounding points; thorough diagnosis is key.
