The Gilera Nexus 500 is a sophisticated maxi-scooter designed for performance-oriented riders, offering a blend of sporty handling and practicality for touring and commuting. Produced from 2005 onward and compliant with Euro 3 emissions standards, this model features a powerful 500cc, four-stroke, single-cylinder engine with SOHC and four valves per cylinder, delivering approximately 40 HP and 45 Nm of torque. Its robust construction, utilizing a steel underbone frame, coupled with advanced features like electronic fuel injection and an automatic CVT transmission, positions it as a capable and engaging machine. The Nexus 500 was engineered to compete with established sport scooters, emphasizing a dynamic riding experience. This comprehensive Service Repair Workshop Manual provides in-depth guidance for the Gilera Nexus 500 (Euro 3). It covers all aspects of maintenance, from routine servicing like oil changes and filter replacements to complex engine overhauls, fuel system diagnostics, and transmission servicing. The manual includes detailed repair procedures, assembly and disassembly instructions, diagnostic flowcharts for troubleshooting, and essential technical specifications, including torque values. It is designed to assist owners, mechanics, and technicians in maintaining the vehicle's optimal performance, ensuring reliability and safety through clear, professional-level instructions. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: Nexus 500 (Euro 3) Year Coverage Start: 2005 Year Coverage End: Onward Codes Euro Standard: Euro 3 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, Sport scooter Target Audience: Performance-oriented riders, touring, commuting, enthusiasts Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX, Aprilia Atlantic 500, Honda Silver Wing Key Features Performance Focus: Emphasis on power and sporty handling for a scooter Engine Size: 500cc class for substantial power Euro Standard: Euro 3 compliance indicates modern emissions control 📋 Manual Details Coverage Areas Comprehensive Coverage: A-Z (All repairs covered) Model Variants Covered: All models Page Count Estimated Page Count: High (Professionals use) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English (Assumed based on common industry practice) Format File Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Full engine overhaul, diagnostics, component testing, performance tuning Fuel System: Fuel injection system, fuel pump, injectors, fuel pressure regulation, fuel tank servicing Ignition System: Spark plugs, ignition coils, ECU control, timing Cooling System: Radiator, coolant pump, thermostat, fan operation, fluid specifications Exhaust System: Catalytic converter, muffler, lambda sensors (O2 sensors), emissions control Transmission: Automatic transmission operation, fluid changes, clutch system, torque converter servicing Brakes: Hydraulic system, brake fluid, ABS components, caliper servicing, disc/pad replacement, bleeding procedures Suspension: Front forks (telescopic), rear shock absorber, linkage systems, bearing maintenance Steering: Handlebar assembly, steering head bearings, linkage Electrical System: Battery, charging system (alternator/stator), starter motor, lighting, wiring diagrams, fuses, relays, ECU diagnostics Bodywork: Panel removal and installation, fairings, seat, storage compartments Chassis: Frame inspection, welding points, component mounting Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment (if applicable), tire pressure checks, brake adjustments Troubleshooting: Diagnostic flowcharts, fault code interpretation, common problem solutions Repair Procedures: Step-by-step instructions for all major component repairs and replacements Diagnostic Procedures: Using diagnostic tools, interpreting sensor data, electrical circuit testing Assembly Disassembly: Detailed instructions for taking apart and reassembling various systems Specifications Torque: Torque values for critical fasteners and components Technical Depth Depth Level: Professional/Expert (Same type as used by mechanics) Diagnostic Capabilities: Advanced diagnostics for electronic control units (ECUs) and sensor systems Rebuild Procedures: Comprehensive instructions for complete engine and transmission rebuilds 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typical for professional PDFs) Print Quality Print Readability: High (Designed for easy reading and printing) Binding Type Binding: Not applicable (Digital download) Paper Type Paper Quality: Not applicable (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: Approximately 493cc (183MR engine family) Bore X Stroke: Specific values would be in manual (e.g., 93.5 mm x 73.2 mm) Valve Train: SOHC, 4 valves per cylinder Performance Horsepower Peak: Around 40 HP (29.4 kW) @ ~7,500 rpm (Manufacturer specific) Torque Peak: Around 45 Nm (33.2 lb-ft) @ ~5,000 rpm (Manufacturer specific) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Ignition Type: Electronic ignition, CDI controlled Emission Control: Catalytic converter, Lambda sensor (O2 sensor) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Optional Optional Transmission: N/A (CVT is standard for this model) Features Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Specific value in manual (e.g., ~2150 mm) Width: Specific value in manual (e.g., ~790 mm) Height: Specific value in manual (e.g., ~1380 mm) Wheelbase: Specific value in manual (e.g., ~1510 mm) Weights Dry Weight: Specific value in manual (e.g., ~190 kg) Wet Weight: Specific value in manual (e.g., ~205 kg) Max Load Capacity: Specific value in manual Cargo Underseat Storage: Significant storage, likely fits one full-face helmet Glove Compartment: Yes, typically with a lock 🛡️ Safety Features Ratings...