GILERA NEXUS 500 EURO 3 Service Repair PDF Manual 2005 Onward Download

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: Euro 3 Year: 2005 Onward Codes Engine Code Designation: Quasar 500 Emissions Standard: Euro 3 👋 Introduction Market Position...

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Tipo: Motorcycle

Proveedor:

SKU: 44188

Etiquetas: 2005 Gilera Motorcycle NEXUS 500 EURO 3

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Model Variant:

Euro 3

Year:

2005 Onward

Codes

Engine Code Designation:

Quasar 500

Emissions Standard:

Euro 3

👋 Introduction

Market Position

Vehicle Segment:

Maxi-scooter, often considered a sporty and capable commuter and touring machine.

Target Audience:

Riders seeking a powerful, comfortable, and versatile scooter for urban commuting and longer journeys.

Competitive Analysis

Key Competitors:

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

Key Features

Engine Power:

Strong performance from the 500cc Quasar engine, offering brisk acceleration and highway capability.

Handling Dynamics:

Sportbike-inspired chassis and suspension contribute to confident handling.

Comfort Ergonomics:

Spacious seating, wind protection, and comfortable rider triangle for longer distances.

Storage Capacity:

Under-seat storage, suitable for helmets and other items.

Design Aesthetics:

Aggressive styling, dual headlights, and a sporty overall appearance.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Extensive (detailed coverage implies hundreds of pages, specific count not provided in product info)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the Quasar 500 engine.

Fuel System:

Fuel injection system diagnosis and repair, fuel pump, injectors, fuel filter replacement.

Ignition System:

Spark plugs, ignition coils, ECU ignition control troubleshooting.

Cooling System:

Radiator, cooling fan, thermostat, coolant flushing and replacement procedures.

Transmission Drivetrain:

CVT (Continuously Variable Transmission) maintenance, belt replacement, roller inspection, gearbox lubrication.

Braking System:

Hydraulic brake system inspection, pad and disc replacement, fluid bleeding, ABS system (if equipped) diagnosis.

Suspension System:

Front fork overhaul, rear shock absorber inspection and replacement, linkage maintenance.

Electrical System:

Wiring diagrams, battery maintenance, starter motor, alternator, lighting system troubleshooting.

Frame Chassis:

Frame inspection, steering head bearing service, body panel removal and installation.

Exhaust System:

Exhaust component inspection, catalytic converter maintenance (Euro 3 compliance).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain/belt adjustment, tire pressure checks, spark plug replacement.

Troubleshooting Diagnostics:

Step-by-step guides for identifying and resolving common and uncommon issues.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement.

Component Rebuilds:

Detailed instructions for rebuilding carburetors/throttle bodies, brake calipers, etc.

Electrical Diagnostics:

Fault code interpretation, circuit testing, component testing.

Bodywork Cosmetics:

Panel removal, fairing repair, seat maintenance.

Technical Depth

Diagnostics:

Advanced diagnostic procedures for complex system failures.

Engine Rebuild Scope:

Complete engine rebuilds including piston, rings, valves, crankshaft, and cylinder head work.

Torque Specifications:

Precise torque values for all critical fasteners.

Clearances Tolerances:

Specifications for piston-to-cylinder wall, valve clearances, bearing tolerances.

Wiring Diagrams:

Comprehensive and color-coded electrical wiring schematics.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (standard for professional PDFs)

Print Quality

Image Resolution:

High resolution for clear diagrams and images.

Readability:

Designed for clear on-screen reading and printing.

Binding Type

Binding Type Digital:

N/A (Digital download)

Paper Type

Paper Type Digital:

N/A (Digital download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

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

Displacement:

492.5 cc

Bore X Stroke:

93.5 mm x 73.3 mm

Compression Ratio:

10.5:1

Performance

Peak Horsepower:

Approx. 40 HP (30 kW) at 7,000 RPM (Varies slightly by region and exact model year)

Peak Torque:

Approx. 47 Nm (35 lb-ft) at 5,500 RPM (Varies slightly by region and exact model year)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), Keihin throttle body (typically 45mm)

Fuel Type:

Unleaded gasoline, minimum 95 RON

Fuel Tank Capacity:

Approx. 15 Liters (including reserve)

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with dry clutch

Final Drive:

Belt drive to rear wheel via gearbox

Features

Cvtsystem Components:

Drive pulley, driven pulley, V-belt, torque driver, centrifugal clutch.

Gearbox Lubricant:

Specific gear oil for gearbox, e.g., SAE 80W-90 API GL-4

📐 Dimensions

Exterior

Length:

Approx. 2200 mm

Width:

Approx. 780 mm (at handlebars)

Height:

Approx. 1400 mm (to top of windscreen)

Wheelbase:

Approx. 1550 mm

Weights

Dry Weight:

Approx. 190 kg

Wet Weight:

Approx. 205 kg (fully fueled)

Cargo

Underseat Storage:

Sufficient for one full-face helmet and small items.

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle/Scooter safety ratings are typically not equivalent to automotive crash tests)

Active Features

Braking System Type:

Front: Dual disc brakes; Rear: Single disc brake. Often equipped with ABS as an option.

Lighting:

Dual halogen headlights, LED taillight, integrated turn signals.

Passive Features

Frame Construction:

High-strength steel frame providing rigidity and stability.

Tires:

Tubeless tires for reduced risk of sudden deflation.

💡 Technology Features

Infotainment

Dashboard Display:

Digital and analog gauges including speedometer, tachometer, fuel gauge, temperature gauge, and odometer/trip meters.

Lighting Control:

Manual headlight operation, integrated turn signals.

Driver Assistance

ABS Availability:

Optional Anti-lock Braking System (ABS) on some models for enhanced braking safety.

Connectivity

Diagnostic Ports:

On-board diagnostic (OBD) port for connecting diagnostic tools.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 - 10,000 km or annually (refer to manual for exact interval).

Oil Filter Replacement:

At every engine oil change.

Air Filter Cleaning Replacement:

Inspect every 6,000 km, clean or replace as needed (more frequently in dusty conditions).

Spark Plug Replacement:

Every 12,000 - 18,000 km (specific plug type and gap critical).

Cv Belt Inspection Replacement:

Inspect every 12,000 km, replace generally between 20,000 - 30,000 km (depends on usage).

Brake Fluid Replacement:

Every 2 years, regardless of mileage.

Fluid Specifications

Engine Oil Type:

Synthetic motorcycle engine oil, SAE 5W-40 or 10W-40 (API SG/SH/SJ/SL/SM, JASO MA/MA2)

Engine Oil Capacity:

Approx. 1.6 - 1.8 Liters (including filter, check dipstick/sight glass)

Coolant Type:

Ethylene glycol based antifreeze, mixture of 50% coolant and 50% distilled water.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Cvtsystem Wear:

Belt slippage or premature wear can occur with aggressive riding or high mileage without replacement.

Electrical Connections:

Corrosion in connectors can lead to intermittent electrical faults.

Cooling Fan Reliability:

Occasional reports of cooling fan failures, leading to overheating in slow traffic.

Throttle Body Cleaning:

Carbon buildup in the throttle body can affect idle and throttle response, requiring periodic cleaning.

📚 Vehicle History

Brand Heritage

Parent Company:

Piaggio & C. S.p.A.

Italian Heritage:

Gilera is a historic Italian motorcycle manufacturer with a long racing pedigree.

Model Evolution

Nexus Introduction:

The Nexus series was introduced to compete in the premium maxi-scooter segment.

Engine Development:

The Quasar engine platform is shared with other Piaggio Group brands, known for its performance and reliability.

Production

Manufacturing Location:

Primarily Italy.

Production Years:

Production ran from the early 2000s through approximately 2014, with the Euro 3 standard adopted from 2005 onwards.

🏆 Awards & Recognition

Recognitions

Segment Recognition:

Praised in reviews for its powerful engine and sporty handling within the maxi-scooter class.

Ratings

Reliability Perception:

Generally considered reliable with proper maintenance, but like any vehicle, can have specific component issues.