Target Audience:
Owners and independent workshops seeking detailed repair and maintenance information.
Competitors:
Suzuki Burgman 400/650, Yamaha TMAX 500/530, Honda Silver Wing 600.
Features:
Powerful 500cc engine, advanced chassis design, comfortable touring capabilities.
Value:
Enables significant cost savings on repairs and maintenance by empowering users with professional-level knowledge.
Primary Coverage:
Comprehensive repair and maintenance for Gilera Nexus MK2 500 Euro 3
Secondary Coverage:
Troubleshooting, diagnostics, electrical systems, engine rebuilds
Estimated Pages:
Varies based on specific edition, typically 200-400 pages
Type:
Workshop Manual / Service Manual
Language:
Likely English (based on product description)
Digital Format:
PDF (Portable Document Format)
Engine:
Complete engine overhaul, including cylinder head, cylinder, piston, crankshaft, and transmission linkage.
Fuel System:
Fuel injection system, fuel pump, injectors, fuel lines, and carburetor (if applicable to specific variant).
Cooling System:
Radiator, coolant circulation, thermostat, water pump, and associated hoses.
Lubrication System:
Oil pump, oil filter, oil passages, and lubrication requirements.
Transmission:
Clutch operation, gear shifting linkage, and transmission internal components (if applicable to service level).
Frame And Body:
Frame inspection, body panel removal/installation, exhaust system service.
Suspension:
Front fork assembly, steering system, rear shock absorber, and swingarm.
Brakes:
Brake system servicing, including hydraulic lines, master cylinders, calipers, and brake pads/discs.
Electrical System:
Charging system (alternator), ignition system, electric starter, starter clutch, lights, meters, and switches.
Wiring Diagrams:
Detailed wiring schematics for all electrical components and systems.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, lubrication.
Repair:
Step-by-step repair instructions for virtually all components and systems.
Diagnostics:
Troubleshooting guides, fault code identification (if applicable), and diagnostic procedures.
Rebuilds:
Detailed instructions for engine and component rebuilds.
Disassembly Reassembly:
Step-by-step procedures for removing and reinstalling major assemblies and components.
Depth:
In-depth technical information, including torque specifications, clearances, and tolerances.
Illustrations:
Numerous illustrations, diagrams, and exploded views to aid in understanding.
Clarity:
Step-by-step explanations designed for users with basic mechanical knowledge.
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Printability:
Printable for workshop use.
Quality:
Digital reproduction quality of original manual, with clear diagrams and text.
Binding:
N/A (Digital PDF Download)
Paper:
N/A (Digital PDF Download)
Engine Code:
Likely uses Piaggio Quasar 4-valve engine, specific code may vary by sub-model.
Bore X Stroke:
Approx. 94 mm x 72 mm
Compression Ratio:
Approx. 10.5:1
Valve Train:
SOHC, 4 valves per cylinder
Horsepower:
Approx. 40 HP (29.4 kW) at 7,000 RPM
Torque:
Approx. 46 Nm (34 lb-ft) at 5,500 RPM
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin or similar system
Fuel Type:
Unleaded Gasoline (Octane rating typically 91 or higher)
Cooling Method:
Liquid-cooled
Oil Type Spec:
API SG, JASO MA certified Synthetic or Semi-Synthetic 4-stroke motorcycle oil, viscosity typically 5W-40 or 10W-40. (Refer to manual for exact specification).
Oil Capacity:
Approx. 1.6 - 1.8 liters (including oil filter replacement). (Refer to manual for exact capacity).
Brakes:
Front: Dual 280mm discs with 4-piston calipers. Rear: 240mm disc with 2-piston caliper. Integral braking system (CBS) likely present.
Lighting:
Dual Halogen Headlights, LED Taillight, standard turn signals.
Frame Construction:
High-strength steel dual-cradle frame.
Tires:
Front: 120/70-15. Rear: 160/60-15.
Anti Theft:
Immobilizer system (standard on most later models).
Instrument Cluster:
Digital-analog combination instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature gauge, clock, and indicator lights.
ABS Option:
ABS (Anti-lock Braking System) was likely an optional feature on some MK2 models. (Manual will clarify if present).
Charging Port:
12V power outlet (cigarette lighter style) often present for accessory charging.
Oil Change:
Every 6,000 km or 12 months, whichever comes first. (Refer to manual for exact intervals).
Air Filter:
Inspect every 6,000 km, replace as needed. Clean at 12,000 km.
Spark Plug:
Replace every 12,000 km or as per manual recommendation.
Coolant Change:
Every 24,000 km or 24 months. Flush system and refill with specified coolant.
Belt Check Cvt:
Inspect CVT belt wear and condition every 12,000 km. Replacement typically recommended between 20,000 - 30,000 km or if wear is significant.
Brake Fluid:
DOT 4 (Refer to manual for specific type and replacement intervals).
Coolant:
Ethylene glycol based antifreeze, mixed 50/50 with distilled water. (Refer to manual for specific formulation).
Common Problems:
Potential issues can include voltage regulator failure, stator coil degradation, water pump seal leaks, and occasional CVT belt wear beyond expected limits. Fuel system cleanliness is also crucial. (Manual provides detailed troubleshooting).
Maintenance Recommendation:
Adherence to the scheduled maintenance outlined in the manual is critical for long-term reliability and performance.
Brand Origin:
Gilera is an Italian manufacturer founded in 1909, known for its performance motorcycles and scooters. It is now part of the Piaggio Group.
First Generation:
The Nexus line was introduced in the early 2000s as a premium, sporty maxi-scooter.
Mk2 Introduction:
The MK2 generation saw updates to styling, chassis, and engine tuning to meet Euro 3 emissions standards.
Production Period:
The Nexus 500 was produced from approximately 2003 to 2007/2008, with the MK2 designation covering later Euro 3 compliant models.
Manufacturing Location:
Italy
