Vehicle Segment:
High-performance maxi-scooter.
Target Audience:
Riders seeking a sporty and capable scooter for commuting, touring, and spirited riding.
Key Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500.
Vehicle Features:
Powerful 500cc engine, sporty chassis, advanced suspension, comfortable ergonomics, ample storage, Euro 3 emissions compliance.
Manual Objective:
To provide comprehensive guidance for the maintenance, repair, and restoration of the Gilera Nexus 500 Euro 3.
Engine:
Complete engine disassembly, assembly, tuning, diagnostics, and repair.
Fuel System:
Fuel injection system, fuel pump, injectors, throttle body, fuel tank, and lines.
Ignition System:
Ignition coil, spark plug, ECU control of ignition timing.
Cooling System:
Radiator, coolant flow, water pump, thermostat, fan operation.
Exhaust System:
Catalytic converter, exhaust manifold, muffler, lambda sensor (O2 sensor) function.
Transmission:
Automatic CVT transmission overhaul, maintenance, and troubleshooting.
Brakes:
Hydraulic brake system (front and rear), brake calipers, master cylinders, brake fluid, ABS (if equipped).
Suspension:
Front fork assembly (telescopic forks), rear shock absorber, swingarm, linkage (if applicable).
Steering:
Handlebar assembly, steering head bearings, steering column.
Electrical System:
Wiring diagrams, battery, alternator/stator, starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays, ECU.
Instrumentation:
Dashboard instruments, warning lights, diagnostic indicators.
Bodywork:
Fairings, seat, storage compartments, body panel removal and installation.
Wheels Tires:
Wheel bearing replacement, tire pressure, tire replacement procedures.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment (if applicable, though typically belt-driven or shaft), spark plug replacement, coolant flush.
Troubleshooting:
Diagnostic charts, fault code interpretation (if OBD-II or similar system is present), common problems and their solutions.
Repair:
Step-by-step repair instructions for all major vehicle components.
Rebuild:
Complete engine and transmission rebuild procedures with detailed specifications.
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical systems.
Disassembly Assembly:
Comprehensive instructions for removing and installing all parts and sub-assemblies.
Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostics Level:
Advanced diagnostic capabilities, including component testing and system analysis.
Torque Specifications:
Detailed torque specifications for all fasteners and critical components.
Clearances Tolerances:
Precise mechanical clearances and tolerances for engine components and other critical parts.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC.
Displacement:
492.7 cc (Approx.)
Bore X Stroke:
Refer to manual for precise dimensions.
Compression Ratio:
Refer to manual for precise ratio.
Horsepower:
Approximately 40-45 HP (at crankshaft), depending on specific model year and tune.
Torque:
Approximately 45-50 Nm (at crankshaft), depending on specific model year and tune.
Fuel Delivery:
Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded Gasoline (Petrol).
Oil Type:
Refer to manual for specific grade (e.g., SAE 10W-40 or 15W-50), typically JASO MA certified.
Oil Capacity:
Refer to manual for precise capacity (approx. 1.5 - 1.8 liters).
Coolant Type:
Ethylene glycol-based antifreeze mixture.
Coolant Capacity:
Refer to manual for precise capacity.
Instrument Panel:
Digital and analog display including speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature, and various warning lights.
ABS:
Anti-lock Braking System (ABS) available on some models, enhancing braking stability.
Diagnostic Port:
Onboard diagnostics (OBD) or proprietary diagnostic connector for electronic system analysis.
Oil Change Interval:
Refer to manual, typically every 5,000 - 7,000 km or annually.
Air Filter Replacement:
Refer to manual, typically every 10,000 - 15,000 km.
Spark Plug Replacement:
Refer to manual, typically every 15,000 - 20,000 km.
Coolant Flush Interval:
Refer to manual, typically every 2 years or 24,000 km.
Brake Fluid Type:
DOT 4 (or as specified in the manual).
Coolant Ratio:
50/50 mix of antifreeze and distilled water.
Common Wear Items:
CVT belt wear, voltage regulator/stator issues (common in many scooters of this era), steering head bearings, brake pad wear.
Diagnostic Tips:
Manual provides troubleshooting for common electrical faults (e.g., starting issues, charging system problems) and fuel system diagnostics.
