The Gilera Nexus 500 Euro 3, produced from 2005 onward, is a premium maxi-scooter designed for riders seeking a blend of sporty performance and everyday versatility. Powered by the robust Quasar 500 engine, this model offers strong acceleration and comfortable cruising capabilities, making it suitable for both urban commuting and longer journeys. Its design emphasizes rider comfort with a spacious seating position and effective wind protection, complemented by a capable chassis that provides confident handling. The Gilera Nexus 500 Euro 3 stands out with its aggressive styling and a powerful engine platform that positions it competitively within the maxi-scooter market. This comprehensive Service Repair Workshop Manual provides detailed guidance for the maintenance and repair of the Gilera Nexus 500 Euro 3. It covers all essential systems, including complete engine overhaul procedures for the Quasar 500, fuel and ignition systems, cooling, transmission, braking, suspension, and electrical systems. The manual includes step-by-step troubleshooting, routine maintenance schedules, major repair instructions, and specific technical data such as torque specifications and clearances. It is an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance, reliability, and longevity of their Gilera Nexus 500 Euro 3. 🏷️ 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...