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Gilera Nexus 500 Euro 3 Workshop Manual
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Basic Information Identification Make: Gilera Model: Nexus 500 Engine Type: 4-stroke single-cylinder Emission Standard: Euro 3 Introduction Market Position Vehicle Segment: Maxi-scooter / Sport scooter Competitive Analysis Key Competitors: Yamaha...
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Type: Motorcycle
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Sku: 26858
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Gilera
Motorcycle
Nexus 500 Euro 3
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| Basic Information | |
| Identification | |
| Make: | Gilera |
| Model: | Nexus 500 |
| Engine Type: | 4-stroke single-cylinder |
| Emission Standard: | Euro 3 |
| Introduction | |
| Market Position | |
| Vehicle Segment: | Maxi-scooter / Sport scooter |
| Competitive Analysis | |
| Key Competitors: | Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500, Piaggio X9/MP3. |
| Key Features | |
| Performance Orientation: | The Gilera Nexus 500 was designed as a high-performance maxi-scooter, offering a blend of motorcycle-like handling and scooter practicality. |
| Handling Dynamics: | Known for its sporty chassis and suspension, providing a stable and engaging riding experience, especially on winding roads. |
| Target Audience: | Riders seeking a comfortable yet sporty option for commuting, touring, and spirited riding. |
| Manual Details | |
| Coverage Areas | |
| Coverage Scope: | All Models & Repairs A-Z |
| Mechanical Coverage: | Comprehensive |
| Electrical Coverage: | Comprehensive |
| Page Count | |
| Estimated Page Count: | Variable (typically 300-500 pages for a full workshop manual) |
| Manual Type | |
| Manual Classification: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Digital Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine overhaul, cylinder head, valve train, pistons, crankshaft, lubrication system, cooling system, timing system. |
| Fuel System: | Fuel injection system, throttle body, fuel pump, injectors, fuel pressure regulator. |
| Ignition System: | Ignition coil, spark plugs, ECU control. |
| Exhaust System: | Exhaust manifold, catalytic converter, muffler. |
| Transmission Drivetrain: | CVT (Continuously Variable Transmission) maintenance, belt replacement, roller weights, clutch assembly, final drive. |
| Brakes: | Hydraulic brake system, brake fluid replacement, caliper service, pad replacement, disc inspection, ABS (if equipped). |
| Suspension: | Front telescopic fork service, rear shock absorber inspection and replacement, linkage systems. |
| Steering: | Steering head bearing adjustment and replacement, handlebar and control lever service. |
| Electrical System: | Wiring diagrams, lighting system, battery, charging system (alternator/stator, regulator/rectifier), starter motor, instrumentation, fuses, relays. |
| Bodywork: | Fairing removal and installation, seat, panels, storage compartment, lighting assembly. |
| Diagnostic Troubleshooting: | Fault codes, diagnostic procedures for various systems. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, spark plug checks, fluid level checks, brake adjustments. |
| Component Overhaul: | Engine rebuild, transmission service, carburetor/fuel injection system cleaning and calibration. |
| Troubleshooting Guides: | Step-by-step diagnostics for common and uncommon issues. |
| Wiring Diagrams: | Detailed electrical schematics for all circuits. |
| Torque Specifications: | Precise torque values for critical fasteners. |
| Special Tool Requirements: | Identification of specialized tools needed for specific repairs. |
| Technical Depth | |
| Depth Of Information: | Comprehensive, covering from basic maintenance to complete engine rebuilds and advanced diagnostics. |
| Visual Aids: | Tons of detailed pictures and diagrams included for clear visualization of procedures. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Print Quality | |
| Printability: | All pages are printable. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Quality: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code: | Quasar (typically) |
| Engine Displacement: | 492.7 cc (approximately) |
| Engine Bore X Stroke: | 94 mm x 72 mm (typical for Quasar 500) |
| Engine Configuration: | Single-cylinder, 4-stroke |
| Valvetrain: | SOHC, 4 valves |
| Performance | |
| Bore X Stroke Ratio: | Slightly oversquare |
| Compression Ratio: | 10.5:1 (typical) |
| Horsepower: | Approximately 33.5 HP (24.6 kW) @ 6500 RPM (Euro 3 spec) |
| Torque: | Approximately 46 Nm (34 lb-ft) @ 5000 RPM (Euro 3 spec) |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (EFI) |
| Fuel Type: | Unleaded Petrol (Gasoline), minimum 95 RON |
| Lubrication | |
| Oil Capacity: | Approximately 1.6 - 1.8 Liters (check manual for exact figure) |
| Cooling | |
| Cooling System: | Liquid-cooled |
| Coolant Type: | Ethylene Glycol based coolant, 50/50 mixture with distilled water (refer to manual for specific Piaggio/Gilera recommended coolant). |
| Transmission | |
| Standard | |
| Transmission Type: | Automatic CVT (Continuously Variable Transmission) |
| Optional | |
| Optional Transmissions: | N/A (CVT is standard) |
| Features | |
| Drive System: | Belt drive to rear wheel via automatic centrifugal clutch and reduction gear. |
| Cvtf Fluid Type: | Specific CVT fluid or Automatic Transmission Fluid (ATF) as per manual recommendation (e.g., Piaggio recommends specific fluids). |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2,180 mm (varies slightly by year/spec) |
| Width: | Approx. 780 mm (at handlebars) |
| Height: | Approx. 1,470 mm (with windscreen) |
| Wheelbase: | Approx. 1,570 mm |
| Weights | |
| Dry Weight: | Approx. 191 kg |
| Wet Weight: | Approx. 204 kg (with all fluids) |
| Max Load Capacity: | Approx. 150 kg (rider + passenger + luggage) |
| Cargo | |
| Underseat Storage: | Sufficient for one full-face helmet and some smaller items. |
| Wheels Tires | |
| Front Tire Size: | 120/70-15 |
| Rear Tire Size: | 160/60-15 |
| Front Wheel Size: | 15-inch alloy |
| Rear Wheel Size: | 15-inch alloy |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | Not typically rated by official bodies like NHTSA or Euro NCAP as it is a motorcycle/scooter. |
| Active Features | |
| Braking System: | Front: Dual 260mm discs with 4-piston calipers. Rear: 240mm disc with 2-piston caliper. (ABS was often optional on earlier models, but likely standard on Euro 3 variants in some markets). |
| ABS: | Available as an option on many models, likely standard on some Euro 3 variants depending on market. |
| Passive Features | |
| Lighting: | Dual Halogen headlights, LED taillight and brake light. |
| Chassis Construction: | High-strength steel frame for rigidity and stability. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Digital/Analogue combination with speedometer, tachometer, fuel gauge, coolant temperature gauge, odometer, trip meter, and warning lights. |
| Driver Assistance | |
| ABS Availability: | Optional on some models, check specific vehicle VIN/specifications. |
| Connectivity | |
| Usb Charging Port: | Rarely standard on models of this era; check for aftermarket installation or specific market variants. |
| Maintenance | |
| Service Intervals | |
| Engine Oil Change Interval: | Typically every 6,000 - 10,000 km or annually (refer to manual for specific interval). |
| Air Filter Replacement: | Every 12,000 - 18,000 km or as needed based on conditions. |
| Spark Plug Replacement: | Every 10,000 - 12,000 km (check condition more frequently). |
| Cvtvbelt Replacement: | Typically every 20,000 - 25,000 km (crucial for performance and safety). |
| Brake Fluid Change: | Every 2 years or as per manual recommendation (critical for braking performance). |
| Fluid Specifications | |
| Engine Oil Grade: | Fully Synthetic SAE 5W-40 or 10W-40 (API SG/SH/SJ/SL or higher, JASO MA/MA2) |
| Cooling System Type: | Ethylene Glycol based, 50% distilled water mix. |
| Brake Fluid Type: | DOT 4 (ensure to check manual for specific caliper recommendations). |
| Known Issues | |
| Common Wear Items: | CVT belt, rollers, spark plugs, brake pads, fork seals (due to aggressive riding often associated with this model). |
| Potential Electrical Gremlins: | Wiring harness integrity, especially around moving parts, can be a concern on higher mileage examples. CDI/ECU issues are rare but possible. |
| Cooling System Maintenance: | Regular flushing and ensuring proper coolant levels are important to prevent overheating. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer Origin: | Gilera is an Italian manufacturer with a long history in motorcycling, founded in 1909. It is now part of the Piaggio Group. |
| Model Evolution | |
| Introduction Year: | The Nexus line was introduced in the early 2000s, with the 500cc variant becoming a flagship model. |
| Key Updates: | The Euro 3 designation signifies compliance with stricter European emissions standards, usually implemented around 2006-2007 for new models, implying a later production year or an update to meet these standards. |
| Production | |
| Manufacturing Location: | Primarily manufactured in Italy by Piaggio Group. |
| Awards & Recognition | |
| Recognitions | |
| Industry Awards: | While specific awards for the Nexus 500 might not be widely documented, it was generally well-regarded in its class for performance and handling by motorcycle journalists and enthusiasts. |
| Ratings | |
| Review Consensus: | Praised for its powerful engine, confident handling, and comfortable touring capabilities, often outperforming smaller scooters and even some entry-level motorcycles. |