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Gilera · Overhead-cam four-stroke single, wet sump, separate gearbox oil, CVT belt drive

Nexus 500

Library entry covers 2005-2009

26 factory 51 guideline

Published source

Gilera Nexus 500 euro 3 Workshop Manual 633721 - 633728, Maintenance chart pp.MAIN-31 to MAIN-32 (ManualsLib 1347012)

Factory service manual. Covers Gilera workshop manual 633721 - 633728 for the Nexus 500 euro 3 (no year printed; earlier non-euro 3 bikes in the 2005-2009 row not confirmed).

77 items for a 2008 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Automatic or semi-automatic
Final drive: Belt CVT, scooter automatic
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2008 Gilera Nexus 500

On the road: every 300 km

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 500 km

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

Every 1,000 km

1 item

Hub oil (change)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.

Every 1,600 km or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 5,000 km or 12 months

8 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Adjust automatic / semi-automatic clutch

Primary and gearbox

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 6,500 km or 12 months

3 items

Inspect, clean and gap spark plugs

Engine

Guideline
Inspect CVT drive belt, rollers / sliders and clutch shoes

Final drive

Guideline

Typical scooter interval. Your owner's manual figure governs; check belt width against the service limit.
Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 8,000 km or 12 months

2 items

Change engine oil

Engine

Guideline

Pre-1970 machines: many owners run non-detergent or classic-spec oil with no filter, so short intervals matter. Dry sump: drain the tank and the crankcase/sump, flush the tank and clean the feed and return screens.
Replace oil filter

Engine

Guideline

Every 9,500 km or 12 months

7 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 10,000 km

21 items

Coolant level (check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Crankcase breather (empty)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Drive belt (replace)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Engine oil (change)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups); the chart lists both "Engine oil - change" and "Engine oil - replacement". Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Hub oil (check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Injection system pipework (visual check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Safety locks (check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Sliding blocks and variable speed rollers (change)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Spark plug (replace)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups); the spark plug section on the next page says check every 6,000 km and replace every 12,000 km. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Suspension (check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Valve clearance (check)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Air filter (check)

Fuel and air

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Air filter, belt compartment (check)

Fuel and air

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Electrical system and battery (check)

Ignition and electrics

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Steering (adjust at 1,000 km, then check)

Front end

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Brake fluid level (check)

Brakes

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Brake pads (check condition and wear)

Brakes

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Vehicle and brake road test

Brakes

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Tire pressure and wear (check)

Wheels and tires

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Stand control roller (replace)

Controls and cables

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Throttle lever (adjust)

Controls and cables

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 1,000 km, then every 10,000 km (listed in both the 10,000 km and 20,000 km groups). Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.

Every 13,000 km or 2 years

1 item

Check and adjust valve clearances

Engine

Guideline

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change gearbox oil

Primary and gearbox

Guideline

Every 19,500 km or 2 years

4 items

Replace air filter element

Fuel and air

Guideline
Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 19,500 km or 3 years

1 item

Replace CVT drive belt

Final drive

Guideline

Typical scooter interval, or sooner if the belt is cracked, glazed or below its width limit.

Every 20,000 km

2 items

Driven pulley bushing (service; as printed "Bushing of driven pulley")

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 20,000, 40,000, 60,000 and 80,000 km, so every 20,000 km. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Fuel filter (check)

Fuel and air

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): after 20,000, 40,000, 60,000 and 80,000 km, so every 20,000 km. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.

Every 24,000 km or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 24,000 km

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 25,500 km or 4 years

1 item

Replace spark plugs

Engine

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 38,500 km or 4 years

1 item

Replace fuel filter

Fuel and air

Guideline

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

6 items

Coolant (change)

Engine

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 2 years. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake fluid (change)

Brakes

Factory

Factory: Maintenance chart (Gilera workshop manual 633721 - 633728, Nexus 500 euro 3, printed pp.MAIN-31 to MAIN-32): every 2 years. Groups as printed: every 2 years; after 1,000 km; after 10,000, 30,000, 50,000 and 70,000 km; after 20,000, 40,000, 60,000 and 80,000 km.
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.