🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Codes Emission Standard: Euro 3 👋 Introduction Market Position Vehicle Segment: High-performance maxi-scooter. Target Audience: Riders seeking a sporty and capable scooter for commuting, touring, and spirited riding. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500. Key Features Vehicle Features: Powerful 500cc engine, sporty chassis, advanced suspension, comfortable ergonomics, ample storage, Euro 3 emissions compliance. Manual Purpose Manual Objective: To provide comprehensive guidance for the maintenance, repair, and restoration of the Gilera Nexus 500 Euro 3. 📋 Manual Details Coverage Areas Language: English Manual Type: Digital Workshop Repair Manual Geographic Coverage: Global (Euro 3 compliant models) Page Count Estimated Page Count: Extensive (typically 500+ pages for this type of manual) Format File Format: PDF 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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. 📊 Manual Specifications File Format Searchability: Searchable text within the PDF document for quick information retrieval. Printability: Printable pages for offline use and reference during repairs. Print Quality Image Resolution: High-resolution diagrams, illustrations, and photographs for clarity. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine 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. Performance 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 System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded Gasoline (Petrol). Lubrication 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). Cooling System Coolant Type: Ethylene glycol-based antifreeze mixture. Coolant Capacity: Refer to manual for precise capacity. 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT). Drive Type: Belt drive to rear wheel. Features Transmission Fluid Type: Refer to manual for specific CVT fluid requirements. Clutch Type: Automatic centrifugal clutch. 📐 Dimensions Exterior Length: Approx. 2230 mm Width: Approx. 780 mm Height: Approx. 1420 mm (seat height varies) Wheelbase: Approx. 1535 mm Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 210 kg (including fluids and fuel) Maximum Load: Refer to manual for payload capacity. Cargo Storage Capacity: Under-seat storage compartment. 🛡️ Safety Features Ratings ABS Availability: Optional or standard depending on market/trim. Active Features Braking System: Disc brakes (front and rear), potentially with ABS. Lighting: Halogen or LED headlights, LED taillights and indicators for improved visibility. Passive Features Chassis Design: Steel frame providing rigidity and stability. 💡 Technology Features Infotainment Instrument Panel: Digital and analog display including speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature, and various warning lights. Driver Assistance ABS: Anti-lock Braking System (ABS) available on some models, enhancing braking stability. Connectivity Diagnostic Port: Onboard diagnostics (OBD) or proprietary diagnostic connector for electronic system analysis. 🔧 Maintenance Service Intervals 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...