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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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类型: Motorcycle
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斯库: 44188
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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
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.