Vehicle Segment:
Maxi-scooter, often categorized as a sport-touring or GT (Grand Tourer) scooter.
Key Competitors Mk1 Era:
Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600, Aprilia Atlantic 500.
Vehicle Strengths:
Powerful 500cc engine for its class, sporty handling, comfortable ride for longer distances, spacious under-seat storage.
Manual Value Proposition:
Provides the critical technical data and procedural guidance necessary for accurate maintenance and repair, mirroring the information used by authorized service centers.
Coverage Scope:
All repairs covered A-Z, all models covered within the MK1 generation.
Estimated Page Count:
Estimated 300-500 pages (typical for comprehensive motorcycle service manuals, exact count not provided).
Manual Classification:
Professional Workshop Service & Repair Manual
Primary Language:
English (Assumed, as typical for international market manuals and based on product description).
Delivery Format:
Instant Download PDF
Engine Systems:
Engine disassembly, assembly, lubrication, cooling, fuel system (injection, carburation if applicable to MK1 variants), ignition system, exhaust system, starting system, charging system.
Transmission Drivetrain:
Automatic Transmission (CVT) operation, maintenance, repair, clutch, final drive (belt/chain inspection and tensioning).
Chassis Suspension:
Front fork (telescopic) overhaul, rear shock absorber maintenance, swingarm inspection, bearings (steering head, wheel).
Braking System:
Brake caliper service, brake pad replacement, brake fluid flush and bleed, master cylinder overhaul, ABS system (if equipped) diagnostics and repair.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, fuse identification and replacement, starter motor, alternator, sensor diagnostics, ECU (Engine Control Unit) troubleshooting.
Bodywork Trim:
Fairing removal and installation, seat maintenance, body panel repair, plastic component repair, cosmetic trim.
Routine Maintenance:
Oil change intervals and procedures, filter replacement (oil, air), spark plug inspection and replacement, chain/belt adjustment, tire pressure checks.
Diagnostic Procedures:
Troubleshooting guides for common issues, fault code interpretation, step-by-step diagnostic flows for various systems.
Repair Procedures:
Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems.
Special Tool Requirements:
Identification and usage instructions for specialized tools required for specific repairs and adjustments.
Depth Of Coverage:
Comprehensive, covering basic maintenance to complete engine rebuilds and advanced electrical diagnostics, suitable for professional mechanics and experienced DIY enthusiasts.
Resolution And Clarity:
High-resolution scans suitable for clear viewing and printing, preserving detail in diagrams and schematics.
Digital Binding:
N/A (Digital PDF format, not physically bound).
Digital Paper Equivalent:
N/A (Digital PDF format, not printed on physical paper).
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC, 4 valves.
Engine Displacement:
460 cc (approximate, exact may vary slightly by VIN/market).
Bore X Stroke:
93.0 mm x 68.0 mm (typical for this engine family).
Compression Ratio:
10.5:1 (typical).
Engine Power Output:
Approximately 34-39 HP (25-29 kW) at 7000-7500 RPM (actual figures vary by specific market tune).
Engine Torque Output:
Approximately 45-48 Nm at 5500-6000 RPM (actual figures vary by specific market tune).
Top Speed Estimated:
Approximately 150-160 km/h (93-99 mph).
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin or similar system.
Fuel Type Required:
Unleaded Gasoline (Octane rating specified in manual, typically 91+ RON).
Fuel Tank Capacity:
Approximately 15 liters (3.96 US gallons).
Length:
Approximately 2150 mm (84.6 inches).
Width:
Approximately 760 mm (29.9 inches).
Height:
Approximately 1420 mm (55.9 inches).
Wheelbase:
Approximately 1540 mm (60.6 inches).
Dry Weight:
Approximately 178 kg (392 lbs).
Wet Weight Estimated:
Approximately 190 kg (419 lbs) (with all fluids).
Seat Height:
Approximately 770 mm (30.3 inches).
Safety Certifications:
CE marking (Europe) and other regional safety standards as applicable.
Braking System Features:
Front: Dual 280mm discs with 4-piston calipers. Rear: 260mm disc with 2-piston caliper. Optional ABS available on some models/markets.
Lighting System:
Halogen headlights, LED tail light and brake light (typical for the era).
Chassis Construction:
Steel frame, designed for stability and rider comfort.
Dashboard Display:
Analogue speedometer and tachometer, digital multi-function display for fuel level, odometer, trip meter, engine temperature, clock.
ABS Availability:
Optional Anti-lock Braking System (ABS) available on certain MK1 variants.
Connectivity Features:
N/A (Basic scooter technology for its era, no modern connectivity features like Bluetooth or smartphone integration).
Engine Oil Change Interval:
Every 6,000 km or 12 months, whichever comes first (refer to manual for precise intervals and oil type).
Air Filter Replacement Interval:
Every 12,000 km or as required by inspection (refer to manual).
Spark Plug Replacement Interval:
Every 12,000 km or as required by inspection (refer to manual for specific plug type).
Engine Oil Type:
Synthetic SAE 10W-40 or 15W-50 API SG/SH/SJ or higher (consult manual for specific grade and API rating).
Engine Oil Capacity:
Approximately 1.6 - 1.8 liters (with filter change) (refer to manual for exact capacity).
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors, pre-mixed or concentrate (50% solution) as specified by manufacturer (typically green or blue).
Brake Fluid Type:
DOT 4 (refer to manual for specific recommendations).
Final Drive Oil Type:
Gear oil SAE 80W-90 API GL-5 (refer to manual for capacity and specific recommendations).
Common Wear Items:
Brake pads, tires, drive belt, suspension bushings, stator/regulator issues (can be model dependent).
Potential Electrical Quirks:
Battery drain, intermittent electrical connections, regulator/rectifier failure (common in many liquid-cooled, high-output scooters of this era).
Cvt Component Wear:
Roller wear, clutch shoe wear, belt wear leading to performance degradation or slipping.
Manufacturer Origin:
Gilera is an Italian motorcycle manufacturer, founded in 1909. It is currently part of the Piaggio Group.
Nexus Series Introduction:
The Nexus series was Gilera's entry into the maxi-scooter market, aiming to blend scooter practicality with motorcycle performance and handling. MK1 represents the initial generation.
Production Years Mk1:
Typically from 2003 to 2007/2008, preceding the Nexus 500 'Evoluzione' models.
Motorcycle Journal Reviews:
Praised for its powerful engine and sporty dynamics, often noted as a premium maxi-scooter choice.
Customer Satisfaction General:
Generally positive, particularly for those seeking performance in a scooter platform, though maintenance costs can be higher than smaller capacity scooters.
Emission Standards:
Complies with relevant emission standards for its production period (e.g., Euro 2 or Euro 3 depending on market and year).
