🏷️ Basic Information

Make:

Piaggio

Model:

Gilera Nexus

Variant:

500 Mk1

Type:

Motorcycle

Chassis Code:

ZAPM35X (typical for 500cc variants)

👋 Introduction

Category:

Maxi-scooter, GT Scooter

Target Audience:

Motorcycle owners and independent repair shops seeking comprehensive service information.

Key Competitors:

Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600, Aprilia Atlantic 500.

Accuracy:

Factory/OEM data ensures accuracy for all repair and maintenance procedures.

Ease Of Use:

Friendly and easy-to-follow instructions, charts, and diagrams for users with basic mechanical knowledge.

Completeness:

Covers everything from basic tune-ups to major engine/transmission rebuilds.

📋 Manual Details

Primary Coverage:

Repair and maintenance of Piaggio Gilera Nexus 500 Mk1

Secondary Coverage:

Tune-ups, lubrication, major engine and transmission rebuilds, diagnostics

Estimated Pages:

Varies, typically 200-400 pages for comprehensive factory service manuals.

Type:

Workshop Factory Service Repair Manual

Language:

English (typical for officially distributed manuals)

Format:

PDF Download

📖 Manual Coverage

Engine:

Full engine overhaul, internal component diagnostics, timing, ignition system, fuel injection, cooling system, lubrication system.

Transmission:

Automatic transmission (CVT) operation, maintenance, rebuild procedures, clutch, belt, variator, and gearbox inspection.

Chassis:

Frame inspection and repair, suspension (front forks and rear shock absorber) overhaul, alignment, bearings.

Brakes:

Hydraulic brake system diagnostics, caliper and master cylinder overhaul, pad replacement, bleeding procedures, ABS system (if equipped).

Electrical:

Complete wiring diagrams, lighting system, starting system, charging system (alternator/stator, regulator/rectifier), battery, fuses, relays, electronic control unit (ECU) diagnostics, sensor testing.

Fuel System:

Fuel pump, fuel filter, injectors, fuel pressure testing, throttle body cleaning and adjustment.

Bodywork:

Fairing removal and installation, seat, panels, storage compartment, lighting components.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush, chain/belt adjustment (if applicable), lubrication points.

Repair:

Detailed step-by-step repair instructions for all major and minor components, including engine internals, transmission, suspension, brakes, and electrical systems.

Diagnostics:

Troubleshooting guides, fault code interpretation (if applicable), common problem diagnosis, testing procedures for sensors and actuators.

Rebuild:

Comprehensive engine and transmission rebuild instructions, including disassembly, inspection, component replacement, and reassembly.

Depth:

OEM specifications, including torque values, fuel pressure charts, electrical connector data, compression ranges, minimum/maximum tolerances, and critical measurements for professional-level repair and diagnostics.

Illustrations:

Exploded diagrams, detailed charts, and photographs to guide disassembly, reassembly, and component identification.

📊 Manual Specifications

Format:

PDF (Portable Document Format), allowing for digital access and searchability.

Searchability:

Text-searchable PDF, enabling quick navigation to specific topics and components.

Quality:

High-resolution digital reproduction of original factory documents, ensuring clarity of text and diagrams.

Type:

N/A (Digital PDF download)

Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Engine Type:

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

Displacement:

493 cc (typically for the 500cc model)

Bore X Stroke:

Refer to manual for specific measurements, e.g., 96 mm x 69 mm (typical for this engine family).

Compression Ratio:

Refer to manual for specific value, typically around 10.5:1 or higher.

Valve Clearance:

Intake: 0.10-0.20 mm, Exhaust: 0.15-0.25 mm (typical cold valve settings, always confirm with manual).

Horsepower:

Approx. 40-45 HP at 7,000-7,500 RPM (actual figures vary by specific model year and tuning).

Torque:

Approx. 45-50 Nm at 5,500-6,000 RPM (actual figures vary by specific model year and tuning).

Fuel Delivery:

Electronic Fuel Injection (EFI)

Throttle Body Diameter:

Refer to manual, typically 42mm or 46mm.

Fuel Pressure:

Refer to manual for specifications (e.g., 3.0-3.5 bar).

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified.

Oil Capacity:

Refer to manual, typically around 1.5 - 1.8 liters with filter change.

Type:

Liquid-cooled

Coolant Type:

Ethylene glycol based antifreeze, mixed 50/50 with distilled water.

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Drive System:

Belt drive to rear wheel

Clutch Type:

Automatic centrifugal clutch

Variator Maintenance:

Roller weight inspection and replacement, belt wear inspection and replacement, drive face and driven face inspection.

Transmission Oil:

Refer to manual for specific gearbox oil specification and change interval (often shared with engine oil or a separate gearbox oil depending on design).

📐 Dimensions

Length:

Refer to specific model year specifications, typically around 2200 mm.

Width:

Refer to specific model year specifications, typically around 780 mm.

Height:

Refer to specific model year specifications, typically around 1350 mm (seat height around 780 mm).

Dry Weight:

Refer to specific model year specifications, typically around 190-200 kg.

Gross Vehicle Weight Rating:

Refer to manual for maximum allowable weight.

Fuel Tank Capacity:

Refer to manual, typically around 15 liters.

🛡️ Safety Features

Crash Test Results:

N/A for motorcycles; safety relies on design, braking, and rider skill.

Braking System:

Front and rear disc brakes. Optional ABS (Anti-lock Braking System) may be available on certain models.

Lighting:

Halogen headlights, LED taillight and turn signals (depending on year).

Frame Construction:

Steel frame for rigidity and stability.

Bodywork:

Aerodynamic fairings designed for rider protection from wind and elements.

💡 Technology Features

Dashboard:

Digital/analog combination instrument cluster providing speed, RPM, fuel level, engine temperature, and warning lights.

Lighting Technology:

Halogen headlight for primary illumination, with LED technology often present in taillights and turn signals on later iterations.

ABS:

Optional ABS system for enhanced braking safety, particularly on earlier Mk1 models or as an upgrade.

Diagnostic Ports:

On-board diagnostic (OBD) port or proprietary diagnostic connector for electronic troubleshooting and ECU access.

🔧 Maintenance

Oil Change:

Every 5,000-7,500 km or annually. Refer to manual for precise interval.

Air Filter:

Inspect every 5,000 km, replace as needed or at manufacturer's recommended interval (e.g., 10,000-15,000 km).

Spark Plug:

Replace every 10,000-15,000 km (or per manual recommendation, depending on plug type).

Brake Fluid:

Flush and replace every 2 years or as per manual.

Coolant:

Inspect coolant level regularly, flush and replace every 2-3 years or as per manual.

Engine Oil:

SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified.

Brake Fluid:

DOT 4

Coolant:

50/50 mix of ethylene glycol antifreeze and distilled water.

Variator Wear:

Wear on variator rollers and belt can lead to decreased acceleration and performance; regular inspection is advised.

Regulator Rectifier:

Some Piaggio/Gilera models have had issues with premature failure of the regulator/rectifier, affecting charging system performance.

Fuel Injector Cleaning:

Periodic cleaning of the fuel injector can prevent rough idling and performance issues.

Suspension Seals:

Like many motorcycles, fork seals can degrade over time and may require replacement.

📚 Vehicle History

Manufacturer:

Piaggio & C. S.p.A., an Italian company with a long history in scooter and motorcycle manufacturing.

Nexus Lineage:

The Gilera Nexus was a performance-oriented maxi-scooter designed to bridge the gap between scooters and motorcycles, offering substantial power and handling.

Mk1 Introduction:

The Mk1 designation typically refers to the initial generation of the Nexus 500, introduced around 2003-2004, featuring the 493cc engine.

Manufacturing Location:

Italy

🏆 Awards & Recognition

Performance Acclaim:

While specific awards are not readily available for this particular model's manual, the Gilera Nexus 500 itself was well-regarded in its segment for its blend of performance, comfort, and practicality as a maxi-scooter.