The Nexus 500 Euro 3, produced in 2005, represents a significant entry in the maxi-scooter segment, blending sporty performance with touring comfort. This model, part of the first generation Nexus line launched in 2003, is powered by the Master 500 engine, a robust four-stroke, single-cylinder unit displacing 493 cc. Known for its aerodynamic styling, powerful acceleration, and comfortable riding position, the Nexus 500 Euro 3 is designed for commuters, touring enthusiasts, and riders seeking a dynamic scooter experience. Its engineering quality and reliability are hallmarks of its Italian heritage, offering a premium option within its class. This comprehensive Service Repair Manual provides detailed information for the maintenance, repair, and diagnostics of the Nexus 500 Euro 3. Covering a wide array of systems including the engine, transmission, chassis, brakes, and electrical components, this 410-page manual offers step-by-step instructions, torque specifications, and troubleshooting guides. It is an essential resource for professional technicians and experienced DIY enthusiasts alike, enabling them to perform everything from routine servicing, such as oil changes and filter replacements, to complex diagnostics and component overhauls, ensuring the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Euro 3 Year: 2005 Sub Model: Euro 3 Generation Generation: First Generation (Launched 2003) Codes Engine Code Family: Master 500 👋 Introduction Market Position Segment: Maxi-scooter segment, offering a blend of touring comfort and sporty performance. Target Audience: Commuters seeking a comfortable and powerful ride, touring enthusiasts, and performance-oriented scooter riders. Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing. Key Features Performance: Powerful 500cc engine, comfortable riding position, generous storage. Design: Sporty and aerodynamic styling, premium finish. Utility: Under-seat storage, optional luggage rack, suitable for longer journeys. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance, Diagnostics, Troubleshooting Diagnostic Coverage: Includes detailed diagnostic procedures for electrical and mechanical systems. Page Count Total Pages: 410 Manual Type Type: Service Repair Manual Audience: Professional Technicians and Experienced DIY Enthusiasts Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, lubrication, cooling system, fuel injection system (MIU G3), ignition system, exhaust system, emission control systems (Euro 3). Transmission: Automatic transmission (CVT) operation, maintenance, and repair; gearbox components. Chassis: Frame, front suspension (telescopic fork), rear suspension (swingarm, shock absorber), steering system. Brakes: Front and rear brake systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, component replacement. Electrical: Battery, starting system, charging system, lighting system, instrument panel, electronic control unit (ECU), wiring diagrams, sensors, actuators. Bodywork: Body panels, fairings, seat, storage compartments, lighting fixtures. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, coolant checks, brake pad inspection. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component removal, installation, and overhaul. Diagnostics: Fault code interpretation, sensor testing, electrical system troubleshooting. Technical Depth Depth: Comprehensive, covering routine maintenance to full engine and transmission rebuilds. Detail Level: Includes torque specifications, clearance measurements, and specific tool requirements. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Quality: High resolution, suitable for printing key sections or the entire manual. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 493 cc Bore X Stroke: 94 mm x 71 mm (approximate, often cited as 93.5 x 71 mm) Compression Ratio: 10.2:1 (approximate) Valve Train: 4 valves, DOHC Performance Horsepower: Approx. 40 HP (30 kW) at 7,500 RPM Torque: Approx. 45 Nm (33 lb-ft) at 5,000 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Likely Magneti Marelli MIU G3 Fuel Type: Unleaded gasoline Lubrication Oil Capacity: Approx. 1.5 Liters (refer to manual for exact specification) Oil Type: Synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) with V-belt Optional Type: N/A (CVT is standard) Features Drive: Belt drive to rear wheel Gear Reduction: Integrated gearbox for final drive Fluid Type: Specific automatic transmission fluid (ATF) or equivalent; check manual for exact specification. 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 780 mm Height: Approx. 1430 mm (seat height varies) Wheelbase: Approx. 1570 mm Interior Seating Capacity: 1-2 persons Cargo Underseat Storage: Generous capacity, capable of storing a full-face helmet and more. Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 205 kg (with fluids) Max Load Capacity: Refer to manual for specific load limits. 🛡️ Safety Features Ratings Crash Test Ratings: Not applicable for motorcycles/scooters in the same way as cars. Active Features Brakes: Dual hydraulic disc brakes (front and rear), often with linked braking system (e.g., integral brake). Lighting: Halogen headlights, LED taillight, turn signals. Tires: Tubeless tires designed for stability and grip. Passive Features Frame: Steel...