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GILERA NEXUS 500 EURO 3 Service Repair PDF Manual Download 2005 ONWARD
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🏷️ Basic Information Identification Make: Gilera Model: Nexus Variant: 500 Year: 2005 onwards Emission Standard: Euro 3 Codes Manual Product Code: Likely specific to the publisher, not explicitly stated in...
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Type: Motorcycle
Vendor:
Sku: 42487
Tags:
2005
Gilera
Motorcycle
NEXUS 500
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🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus
Variant:
500
Year:
2005 onwards
Emission Standard:
Euro 3
Codes
Manual Product Code:
Likely specific to the publisher, not explicitly stated in product info.
Vehicle Chassis Codes:
Not specified in product info, but likely includes variations for different production years and regional specs.
👋 Introduction
Market Position
Segment:
Maxi-scooter, Sport-scooter
Target Audience:
Owners and independent workshops performing service and repair on the Gilera Nexus 500.
Competitive Analysis
Competitors:
Yamaha TMAX, Suzuki Burgman, Honda Silver Wing, Aprilia Atlantic, Piaggio Beverly.
Key Features Vehicle
Sporty Handling:
Designed for spirited riding with a capable chassis and suspension.
Powerful Engine:
500cc engine provides strong acceleration and high-speed cruising capability.
Comfort:
Spacious riding position and good weather protection for touring.
Key Features Manual
Value Proposition:
Empowers users to perform repairs themselves, saving time and money.
Quality:
Factory-type quality ensures accuracy and completeness.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and repair for Gilera Nexus 500 (2005 onwards)
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, component replacement
Page Count
Estimated Page Count:
Not specified, but 'highly detailed' suggests several hundred pages for a comprehensive service manual.
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
Likely English, based on product description phrasing.
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, inspection, timing, valve clearance, piston/cylinder, crankshaft, oil system.
Fuel System:
Fuel injection system (EFI), injectors, fuel pump, pressure regulator, fuel lines, throttle body.
Cooling System:
Radiator, cooling fan, coolant circulation, thermostat, hoses.
Ignition System:
Ignition coil, spark plugs, ECU control of ignition timing.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, O2 sensors.
Transmission Drivetrain:
Automatic transmission (CVT), clutch operation, belt drive, final drive.
Braking System:
Hydraulic brake system (front and rear), brake calipers, master cylinders, brake pads, brake discs, bleeding procedures.
Suspension System:
Front fork (telescopic), rear shock absorber, linkage, adjustment procedures.
Steering System:
Handlebar, steering stem, bearings, adjustment.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, indicators), horn, wiring diagrams.
Instrumentation Controls:
Dashboard, switches, levers, cables.
Chassis Frame:
Frame inspection, body panels, seat, storage compartment.
Wheels Tires:
Wheel bearing inspection, tire mounting/balancing, tire pressure.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though Nexus is belt-driven), fluid level checks.
Troubleshooting:
Diagnostic flowcharts for common issues, error code interpretation (if ECU diagnostics are covered).
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system repair.
Component Replacement:
Detailed steps for replacing parts like brake pads, bearings, cables, bulbs, etc.
Specifications Data:
Torque values, clearances, fluid capacities, electrical resistance values.
Technical Depth
Depth:
Comprehensive. Covers everything from basic checks to complete engine and transmission overhauls.
Diagnostics:
Includes diagnostic procedures and potential fault finding for various systems.
Rebuilds:
Detailed instructions for engine and transmission rebuilds.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, common for professionally produced PDF manuals.
Print Quality
Quality Description:
Professional quality, high detail.
Illustrations:
Likely includes detailed diagrams, schematics, and photographs.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, OHC
Displacement:
492.7 cc (approx.)
Bore X Stroke:
Not specified in product info, but typically around 92mm x 73mm for this engine family.
Compression Ratio:
Not specified in product info, but likely in the 10:1 to 11:1 range.
Valve Train:
Single Overhead Camshaft (SOHC), 4 valves
Performance
Horsepower:
Approx. 39-40 HP (29-30 kW) @ 7,500 rpm (for Euro 3 models)
Torque:
Approx. 45-46 Nm @ 5,500 rpm (for Euro 3 models)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with electronic throttle control.
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 15 liters
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Clutch:
Automatic centrifugal clutch
Final Drive:
Belt drive to rear wheel
Features
Smooth Operation:
CVT provides seamless acceleration and deceleration.
📐 Dimensions
Exterior
Length:
Not specified, but typical for maxi-scooters, around 2150-2250mm.
Width:
Not specified, but typically around 750-800mm.
Height:
Not specified, but typically around 1350-1450mm (seat height lower).
Weights
Dry Weight:
Approx. 190-200 kg
Curb Weight:
Not specified, but typically around 200-210 kg with fluids.
Max Load Capacity:
Not specified, but typically around 150-180 kg including rider and luggage.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle/Scooter segment typically not rated by standard automotive bodies).
Active Features
Braking System Type:
Combined braking system (optional) with ABS available on some models.
Lighting:
Multi-reflector headlight, LED taillight.
Passive Features
Frame Construction:
High-strength steel frame for rigidity and safety.
Ergonomics:
Designed for rider control and visibility.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital/analog combination display with speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature, and warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on some models, significantly enhancing safety.
Connectivity
Diagnostic Ports:
Likely includes a diagnostic port for electronic fault code reading and system analysis.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 7,500 km or annually, whichever comes first (typical for modern 4-stroke scooters).
Oil Filter Replacement:
At every engine oil change.
Air Filter Cleaning Replacement:
Every 5,000 - 10,000 km (cleaning) and 15,000 - 20,000 km (replacement), depending on operating conditions.
Spark Plug Replacement:
Every 10,000 - 15,000 km.
Cvt Belt Inspection Replacement:
Inspect belt wear every 10,000 km, replace typically between 15,000 - 25,000 km.
Coolant Change:
Every 2 years or 20,000 km.
Brake Fluid Change:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil Type:
Synthetic SAE 10W-40 or 15W-50, API SG/SH/SJ/SL or higher, JASO MA/MA2 compliant (specific recommendations in manual).
Engine Oil Capacity:
Approx. 1.4 - 1.6 liters (check dipstick/sight glass).
Coolant Type:
Ethylene glycol-based coolant, 50% mixture with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
CVT belt, brake pads, suspension bushings, voltage regulator/rectifier.
Potential Electrical Gremlins:
Can occur with age, particularly with wiring harness integrity and the rectifier/regulator.
Engine Longevity:
Generally robust if properly maintained, but issues can arise from neglected oil changes.
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera, an Italian manufacturer with a long history in motorcycle and scooter production, part of the Piaggio Group.
Model Evolution
Introduction Year:
The Nexus line was introduced in the early 2000s, with the 500cc model being a significant iteration.
Key Upgrades:
Transition to Euro 3 emissions standards in 2005, potential refinements in suspension and braking over its production run.
Production
Manufacturing Location:
Primarily Italy.
Production Period:
Produced from around 2003/2004 through to the early 2010s, with the 500cc Euro 3 variant covering 2005 onwards.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Not specifically documented for this model, but Gilera scooters have historically received accolades for design and performance.
Ratings
User Reviews:
Generally well-regarded for its sporty performance and comfortable ride, though some find it heavy for its class.
Certifications
Emission Certification:
Euro 3 compliant for emissions.