GILERA NEXUS 500 EURO 3 Workshop Repair Manual Download All 2005 ONWARDS ModelS COVERED PDF

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Sub Model: Euro 3 Generation Model Years Covered: 2005 onwards Codes Emission Standard: Euro 3 👋 Introduction Market Position Segment: Premium...

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标签: 2005 Gilera Motorcycle Motorcycles Nexus NEXUS 500

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Description

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500

Sub Model:

Euro 3

Generation

Model Years Covered:

2005 onwards

Codes

Emission Standard:

Euro 3

👋 Introduction

Market Position

Segment:

Premium maxi-scooter segment, offering performance and touring capabilities.

Competitive Analysis

Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600, Aprilia Atlantic 500.

Key Features

Unique Selling Points:

Powerful 500cc engine, comfortable ride, sporty handling, premium Italian styling.

Target Audience

User Profile:

Commuters seeking performance, touring riders, and enthusiasts performing their own maintenance.

Manual Value Proposition

Benefit To Owner:

Empowers owners to maintain and repair their Nexus 500 confidently, saving time and money.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Scope:

All Nexus 500 Euro 3 models from 2005 onwards

Page Count

Estimated Pages:

Detailed (Exact count not provided, but extensive)

Manual Type

Type:

Workshop Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Full disassembly, assembly, tuning, diagnostics, and repair of the 500cc engine.

Fuel System:

Fuel injection system, fuel pump, injectors, sensors, and related components.

Ignition System:

Ignition coil, spark plug, CDI unit, and timing.

Cooling System:

Radiator, coolant, water pump, thermostat, and fan operation.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, and emissions control.

Transmission Drivetrain:

Automatic CVT transmission overhaul, belt replacement, clutch, and final drive.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, discs, master cylinders, and ABS troubleshooting (if applicable).

Suspension:

Front telescopic forks, rear shock absorber, linkages, and adjustments.

Steering:

Handlebars, steering stem, bearings, and fork assembly.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, lighting, fuses, relays, and ECUs.

Bodywork Chassis:

Frame, fairings, seat, storage, lighting, and body panel removal/installation.

Instrumentation:

Dashboard indicators, speedometer, tachometer, and warning lights.

Procedures Included

Maintenance:

Oil changes, filter replacements, spark plug checks, fluid level checks, brake pad replacement, tire pressure checks, drive belt inspection/replacement.

Troubleshooting:

Diagnostic procedures for common problems, fault code interpretation, and systematic problem-solving.

Repair:

Detailed step-by-step instructions for all major and minor repair tasks.

Overhaul:

Complete engine and transmission rebuild procedures.

Disassembly Assembly:

Comprehensive guides for taking apart and reassembling all vehicle components.

Adjustments:

Carburetor (if applicable), clutch, throttle, and suspension adjustments.

Technical Specifications:

Torque specifications, clearances, fluid capacities, and critical measurements.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capabilities:

Advanced diagnostic procedures and troubleshooting guides for electrical and mechanical issues.

Diagrams Illustrations:

High-quality exploded views, wiring diagrams, and detailed illustrations for clarity.

📊 Manual Specifications

File Format

Compatibility:

PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)

Searchability:

Likely searchable PDF text, enhancing ease of use.

Print Quality

Clarity:

Designed for easy reading and clear identification of parts and procedures.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, single-cylinder, liquid-cooled

Displacement:

492.7 cc

Bore X Stroke:

Not specified, but typical for the displacement range.

Valve Train:

SOHC, 4 valves

Performance

Horsepower:

Approx. 40 HP (varies slightly by market and year)

Torque:

Approx. 45 Nm (varies slightly by market and year)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Lubrication

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil, viscosity typically 10W-40 or 15W-50 (refer to manual for specific grade).

Oil Capacity:

Approx. 1.8 - 2.0 liters (with filter change) - manual to confirm exact.

Cooling System

Coolant Type:

Ethylene glycol-based antifreeze mixture (e.g., 50/50 with distilled water).

Starting System

Starter:

Electric starter

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Optional

Type:

N/A (CVT is standard)

Features

Drive Belt:

Reinforced drive belt, clutch assembly.

Gear Reduction:

Integrated gear reduction for final drive.

Fluid Specifications

Transmission Fluid:

Specific automatic transmission fluid (ATF) or scooter oil required – manual to confirm exact specification.

📐 Dimensions

Exterior

Length:

Approx. 2180 mm

Width:

Approx. 770 mm (at handlebars)

Height:

Approx. 1400 mm (seat height approx. 800 mm)

Weights

Dry Weight:

Approx. 202 kg

Wet Weight:

Approx. 215 kg (with fluids)

Max Load Capacity:

Not specified, but typically around 180-200 kg including rider and cargo.

Wheels Tires

Front Tire:

120/70-15

Rear Tire:

160/60-15

Wheel Type:

Alloy wheels

Fuel Capacity

Fuel Tank Capacity:

15 liters

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle safety is typically assessed differently than cars)

Active Features

Braking System:

Optional ABS (Anti-lock Braking System) on some models; otherwise, powerful dual disc front and single disc rear brakes.

Lighting:

Dual headlights, LED taillight and indicators for increased visibility.

Passive Features

Chassis Design:

Sturdy steel frame for stability.

Ergonomics:

Comfortable seating position and handgrips designed for rider control.

💡 Technology Features

Infotainment

Dashboard:

Analog tachometer and speedometer, digital display for odometer, trip meter, fuel level, clock, and warning lights.

Driver Assistance

Optional ABS system available on some configurations for enhanced braking control.

Connectivity

Diagnostic Port:

On-board diagnostic (OBD) port for engine management system diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 km or annually, whichever comes first (refer to manual).

Air Filter Replacement:

Inspect every 5,000 km, replace as needed or every 10,000 km (refer to manual).

Spark Plug Replacement:

Inspect every 10,000 km, replace as needed (refer to manual for type and gap).

Drive Belt Replacement:

Inspect every 10,000 km, replace typically every 20,000 - 30,000 km (refer to manual).

Brake Fluid Replacement:

Every 2 years (refer to manual for fluid type, typically DOT 4).

Fluid Specifications

Coolant Capacity:

Approx. 1.5 - 1.7 liters (refer to manual for exact capacity).

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

Drive belt, voltage regulator, starter motor solenoid can be common wear items on higher mileage examples.

Electrical Gremlins:

Some owners report minor electrical gremlins, often related to connectors or grounding points.

Preventative Maintenance

Importance Of Manual:

Adhering to the maintenance schedule in this manual is crucial for the longevity and optimal performance of the Nexus 500.

📚 Vehicle History

Brand Heritage

Parent Company:

Piaggio & C. S.p.A. (Italian manufacturer)

Gilera Legacy:

Gilera has a long history of producing performance motorcycles and scooters.

Model Evolution

Introduction Of Nexus:

The Nexus series was introduced to cater to the growing maxi-scooter market with a blend of performance and comfort.

Euro 3 Compliance:

The 'Euro 3' designation indicates compliance with European emissions standards implemented around 2006, requiring improved engine management and exhaust systems.

Production

Manufacturing Location:

Primarily Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Generally well-received by motorcycle publications for its performance and comfort, though some noted the price point.

Ratings

Owner Satisfaction:

Owner satisfaction is generally high, particularly among those who appreciate its sporty performance and touring capabilities.

Certifications

Emission Standards:

Euro 3 compliant