🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 Model Variant: Euro 3 Year: 2005 Onward Codes Engine Code Designation: Quasar 500 Emissions Standard: Euro 3 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, often considered a sporty and capable commuter and touring machine. Target Audience: Riders seeking a powerful, comfortable, and versatile scooter for urban commuting and longer journeys. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Atlantic 500. Key Features Engine Power: Strong performance from the 500cc Quasar engine, offering brisk acceleration and highway capability. Handling Dynamics: Sportbike-inspired chassis and suspension contribute to confident handling. Comfort Ergonomics: Spacious seating, wind protection, and comfortable rider triangle for longer distances. Storage Capacity: Under-seat storage, suitable for helmets and other items. Design Aesthetics: Aggressive styling, dual headlights, and a sporty overall appearance. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: PDF Download Page Count Estimated Page Count: Extensive (detailed coverage implies hundreds of pages, specific count not provided in product info) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the Quasar 500 engine. Fuel System: Fuel injection system diagnosis and repair, fuel pump, injectors, fuel filter replacement. Ignition System: Spark plugs, ignition coils, ECU ignition control troubleshooting. Cooling System: Radiator, cooling fan, thermostat, coolant flushing and replacement procedures. Transmission Drivetrain: CVT (Continuously Variable Transmission) maintenance, belt replacement, roller inspection, gearbox lubrication. Braking System: Hydraulic brake system inspection, pad and disc replacement, fluid bleeding, ABS system (if equipped) diagnosis. Suspension System: Front fork overhaul, rear shock absorber inspection and replacement, linkage maintenance. Electrical System: Wiring diagrams, battery maintenance, starter motor, alternator, lighting system troubleshooting. Frame Chassis: Frame inspection, steering head bearing service, body panel removal and installation. Exhaust System: Exhaust component inspection, catalytic converter maintenance (Euro 3 compliance). Procedures Included Routine Maintenance: Oil changes, filter replacements, chain/belt adjustment, tire pressure checks, spark plug replacement. Troubleshooting Diagnostics: Step-by-step guides for identifying and resolving common and uncommon issues. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement. Component Rebuilds: Detailed instructions for rebuilding carburetors/throttle bodies, brake calipers, etc. Electrical Diagnostics: Fault code interpretation, circuit testing, component testing. Bodywork Cosmetics: Panel removal, fairing repair, seat maintenance. Technical Depth Diagnostics: Advanced diagnostic procedures for complex system failures. Engine Rebuild Scope: Complete engine rebuilds including piston, rings, valves, crankshaft, and cylinder head work. Torque Specifications: Precise torque values for all critical fasteners. Clearances Tolerances: Specifications for piston-to-cylinder wall, valve clearances, bearing tolerances. Wiring Diagrams: Comprehensive and color-coded electrical wiring schematics. Special Tools: Identification and usage of specialized tools required for specific repairs. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable (standard for professional PDFs) Print Quality Image Resolution: High resolution for clear diagrams and images. Readability: Designed for clear on-screen reading and printing. Binding Type Binding Type Digital: N/A (Digital download) Paper Type Paper Type Digital: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 492.5 cc Bore X Stroke: 93.5 mm x 73.3 mm Compression Ratio: 10.5:1 Performance Peak Horsepower: Approx. 40 HP (30 kW) at 7,000 RPM (Varies slightly by region and exact model year) Peak Torque: Approx. 47 Nm (35 lb-ft) at 5,500 RPM (Varies slightly by region and exact model year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Keihin throttle body (typically 45mm) Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Tank Capacity: Approx. 15 Liters (including reserve) 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with dry clutch Final Drive: Belt drive to rear wheel via gearbox Features Cvtsystem Components: Drive pulley, driven pulley, V-belt, torque driver, centrifugal clutch. Gearbox Lubricant: Specific gear oil for gearbox, e.g., SAE 80W-90 API GL-4 📐 Dimensions Exterior Length: Approx. 2200 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1400 mm (to top of windscreen) Wheelbase: Approx. 1550 mm Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 205 kg (fully fueled) Cargo Underseat Storage: Sufficient for one full-face helmet and small items. 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle/Scooter safety ratings are typically not equivalent to automotive crash tests) Active Features Braking System Type: Front: Dual disc brakes; Rear: Single disc brake. Often equipped with ABS as an option. Lighting: Dual halogen headlights, LED taillight, integrated turn signals. Passive Features Frame Construction: High-strength steel frame providing rigidity and stability. Tires: Tubeless tires for reduced risk of sudden deflation. 💡 Technology Features Infotainment Dashboard Display: Digital and analog gauges including speedometer, tachometer, fuel gauge, temperature gauge, and odometer/trip meters. Lighting Control: Manual headlight operation, integrated turn signals. Driver Assistance ABS Availability: Optional Anti-lock Braking System (ABS) on some models for enhanced braking safety. Connectivity Diagnostic Ports: On-board diagnostic (OBD) port for connecting diagnostic tools. 🔧 Maintenance Service Intervals Engine Oil Change: Every...