Vehicle Segment:
Maxi-scooter, performance-oriented commuter/touring
Target Audience:
Riders seeking versatile commuting and light touring capabilities with scooter practicality
Key Competitors:
Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 500/600, Kymco Xciting 500
Performance Focus:
The 'SP' designation typically indicates a sport-oriented version with enhanced components or tuning.
Design Philosophy:
Combines motorcycle-like handling with scooter convenience, featuring a relatively large engine for the class.
Engine:
Full engine disassembly, assembly, inspection, timing, valve adjustment, lubrication, cooling system
Fuel System:
Fuel injection system, fuel pump, injectors, fuel pressure regulation, fuel tank and lines
Transmission:
Automatic transmission (CVT), variator system, clutch, belt drive, gear reduction unit
Chassis And Frame:
Frame inspection, steering assembly, front suspension (forks), rear suspension (shock absorber, swingarm)
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake discs, brake pad replacement
Electrical System:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, instrumentation, ECU diagnostics
Bodywork And Trim:
Fairing removal and installation, seat, body panels, lighting covers
Wheels And Tires:
Wheel bearing inspection, tire replacement, wheel removal and installation
Cooling System:
Radiator, cooling fan, coolant levels, hoses, thermostat
Exhaust System:
Exhaust pipe, muffler inspection and replacement
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter service, brake fluid checks, coolant checks, chain adjustment (if applicable, though Nexus is belt-driven)
Troubleshooting:
Diagnostic procedures for common starting, running, and electrical issues, fault code interpretation
Disassembly And Assembly:
Detailed step-by-step instructions for removing and reinstalling all major components
Rebuild Procedures:
Engine rebuild, transmission overhaul, suspension component replacement
Adjustments:
Carburetor/throttle body synchronization (if applicable), idle speed adjustment, brake lever free play
Component Testing:
Testing of ignition components, fuel injectors, sensors, electrical circuits
Depth Of Information:
Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Capabilities:
Includes fault codes, sensor data interpretation, and troubleshooting trees
Specific Procedures:
Torque specifications, clearances, timing marks, electrical schematics
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Displacement:
492.7 cc (as indicated by 500 designation, actual displacement is crucial)
Bore X Stroke:
Specific data would be in the manual, e.g., 94 mm x 71 mm
Compression Ratio:
Specific data would be in the manual, e.g., 10.5:1
Horsepower:
Approx. 40-42 HP @ 7500 RPM (typical for this engine)
Torque:
Approx. 45-47 Nm @ 5500 RPM (typical for this engine)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Oil Type:
SAE 10W-40, API SG or higher (check manual for specific recommendations)
Oil Capacity:
Approx. 1.6 - 1.8 Liters (check manual for exact specification)
Oil Change Interval:
Every 5,000 - 6,000 km or annually (refer to manual for exact interval)
Air Filter Service:
Every 10,000 - 12,000 km or annually
Spark Plug Replacement:
Every 10,000 - 15,000 km
Valve Clearance Check:
Every 15,000 - 20,000 km
Belt Replacement:
Every 20,000 - 25,000 km (critical for CVT function)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Brake Fluid:
DOT 4 (refer to manual for specific DOT rating)
Common Wear Items:
CVT belt, voltage regulator, rear shock absorber (typical for high mileage)
Potential Electrical Gremlins:
Check wiring harnesses and connectors for corrosion or damage.
Manufacturer:
Gilera, an Italian motorcycle manufacturer with a long history dating back to 1909, now part of the Piaggio Group.
Nexus Development:
The Nexus series was Gilera's flagship maxi-scooter, known for its performance and sporty handling, aiming to bridge the gap between scooters and motorcycles.
Mk2 Updates:
The Mk2 designation typically signifies a revised model with potential updates to styling, engine performance, or features over the original Mk1.
Production Period:
The Nexus 500 was produced from the early 2000s through to the late 2000s, with the Mk2 model representing a significant iteration.
