The Gilera Nexus MK2 is a premium maxi-scooter powered by a single-cylinder, four-stroke, 492.7 cc engine, designed to meet Euro 3 emission standards. This Italian-engineered scooter, produced from approximately 2003 to 2008, offers a blend of sporty performance and comfortable touring capabilities, often featuring advanced chassis design and a powerful engine delivering around 40 HP. Its robust construction, including a high-strength steel dual-cradle frame and effective braking systems, contributes to its reputation for reliability and handling within its segment, competing with models from Suzuki, Yamaha, and Honda. This workshop manual provides comprehensive repair and maintenance information for the Gilera Nexus MK2 500 Euro 3. It covers all essential systems, including detailed engine overhaul procedures, fuel and cooling systems, transmission, brakes, suspension, frame, and bodywork. The manual includes step-by-step repair instructions, troubleshooting guides, electrical system diagnostics with wiring diagrams, and routine maintenance procedures such as fluid changes and component inspections. Its purpose is to empower owners and technicians with the knowledge needed to maintain the scooter's performance and ensure its longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus MK2 Engine Displacement: 492.7 cc Engine Type: Single-cylinder, four-stroke Emission Standard: Euro 3 Product Type: Workshop Manual Product Format: PDF Download 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Owners and independent workshops seeking detailed repair and maintenance information. Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500/530, Honda Silver Wing 600. Key Features Features: Powerful 500cc engine, advanced chassis design, comfortable touring capabilities. Manual Value Proposition Value: Enables significant cost savings on repairs and maintenance by empowering users with professional-level knowledge. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive repair and maintenance for Gilera Nexus MK2 500 Euro 3 Secondary Coverage: Troubleshooting, diagnostics, electrical systems, engine rebuilds Page Count Estimated Pages: Varies based on specific edition, typically 200-400 pages Manual Type Type: Workshop Manual / Service Manual Language Language: Likely English (based on product description) Format Digital Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, including cylinder head, cylinder, piston, crankshaft, and transmission linkage. Fuel System: Fuel injection system, fuel pump, injectors, fuel lines, and carburetor (if applicable to specific variant). Cooling System: Radiator, coolant circulation, thermostat, water pump, and associated hoses. Lubrication System: Oil pump, oil filter, oil passages, and lubrication requirements. Transmission: Clutch operation, gear shifting linkage, and transmission internal components (if applicable to service level). Frame And Body: Frame inspection, body panel removal/installation, exhaust system service. Suspension: Front fork assembly, steering system, rear shock absorber, and swingarm. Brakes: Brake system servicing, including hydraulic lines, master cylinders, calipers, and brake pads/discs. Electrical System: Charging system (alternator), ignition system, electric starter, starter clutch, lights, meters, and switches. Wiring Diagrams: Detailed wiring schematics for all electrical components and systems. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, lubrication. Repair: Step-by-step repair instructions for virtually all components and systems. Diagnostics: Troubleshooting guides, fault code identification (if applicable), and diagnostic procedures. Rebuilds: Detailed instructions for engine and component rebuilds. Disassembly Reassembly: Step-by-step procedures for removing and reinstalling major assemblies and components. Technical Depth Depth: In-depth technical information, including torque specifications, clearances, and tolerances. Illustrations: Numerous illustrations, diagrams, and exploded views to aid in understanding. Clarity: Step-by-step explanations designed for users with basic mechanical knowledge. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable for workshop use. Print Quality Quality: Digital reproduction quality of original manual, with clear diagrams and text. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Code: Likely uses Piaggio Quasar 4-valve engine, specific code may vary by sub-model. Bore X Stroke: Approx. 94 mm x 72 mm Compression Ratio: Approx. 10.5:1 Valve Train: SOHC, 4 valves per cylinder Performance Horsepower: Approx. 40 HP (29.4 kW) at 7,000 RPM Torque: Approx. 46 Nm (34 lb-ft) at 5,500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or similar system Fuel Type: Unleaded Gasoline (Octane rating typically 91 or higher) Cooling System Cooling Method: Liquid-cooled Lubrication Oil Type Spec: API SG, JASO MA certified Synthetic or Semi-Synthetic 4-stroke motorcycle oil, viscosity typically 5W-40 or 10W-40. (Refer to manual for exact specification). Oil Capacity: Approx. 1.6 - 1.8 liters (including oil filter replacement). (Refer to manual for exact capacity). 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Drive System: Belt drive to rear wheel Features Clutch: Automatic centrifugal dry clutch 📐 Dimensions Exterior Length: Approx. 2170 mm Width: Approx. 780 mm Height: Approx. 1430 mm (seat height) Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 207 kg (with fluids) Payload Capacity: Not explicitly stated, but typically designed for a single rider and moderate luggage. 🛡️ Safety Features Active Features Brakes: Front: Dual...