The Gilera Nexus 500SP Mk2, produced in 2007, represents a compelling option in the sport touring maxi-scooter segment. Engineered with a powerful 460cc liquid-cooled, single-cylinder engine derived from the Piaggio Master platform, it delivers robust performance suitable for both urban commuting and longer journeys. Notable features include its sporty handling, comfortable ergonomics, and ample underseat storage. The Nexus 500SP Mk2 is characterized by its steel double cradle frame for enhanced stability and an optional Anti-lock Braking System (ABS) for improved safety. This comprehensive factory service repair manual provides detailed information essential for the maintenance and repair of the 2007 Gilera Nexus 500SP Mk2. It covers all major vehicle systems, including the engine mechanicals, fuel and ignition systems, transmission, brakes, suspension, and electrical components. The manual offers step-by-step instructions for routine maintenance, complex repairs, adjustments, and troubleshooting. With its in-depth technical data, this manual serves as an indispensable resource for owners, technicians, and mechanics seeking to ensure the optimal performance and longevity of their Gilera Nexus 500SP Mk2. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2007 Codes Engine Code: M354M (Common designation for the 460cc Piaggio Master engine variant) Chassis Code: GP800 / Nexus 500 variants share platform elements 👋 Introduction Market Position Segment: Sport Touring Scooter / Maxi-Scooter. Target Audience: Enthusiasts and owners seeking detailed DIY repair and maintenance capabilities for their Gilera Nexus 500SP Mk2. Competitive Analysis Competitors: Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600. Key Features Vehicle Strengths: Powerful 500cc engine, sporty handling, comfortable ergonomics for long distances, ample storage. Manual Value: Provides comprehensive, factory-accurate data, enabling owners to perform complex maintenance and repairs, thus saving on dealership costs and ensuring proper upkeep. 📋 Manual Details Coverage Areas General Coverage: Complete service and repair information for the Gilera Nexus 500SP Mk2 (2007 model year). Specific Systems: Engine, Fuel System, Ignition System, Cooling System, Transmission (CVT), Clutch, Brakes (ABS optional), Suspension (Front and Rear), Steering, Electrical System, Lighting, Bodywork, Chassis, Diagnostics. Page Count Estimated Pages: Approx. 300-400 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, assembly, top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), timing chain/belt, lubrication system, and cooling system. Fuel And Ignition: Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, ignition coil, spark plugs, ECU diagnostics, and sensor data. Transmission Drivetrain: Continuously Variable Transmission (CVT) operation, clutch (variator and torque driver) maintenance, roller weights, spring tensions, belt replacement, and final drive maintenance. Brakes And Suspension: Hydraulic brake system bleeding, pad and disc replacement, caliper maintenance, master cylinder servicing, front fork (telescopic) overhaul, rear shock absorber inspection and replacement, and swingarm pivot maintenance. Electrical And Lighting: Wiring diagrams, battery maintenance, starter motor, alternator (stator and regulator/rectifier), lighting circuits (headlights, taillights, indicators), horn, dashboard indicators, fuses, relays, and sensor troubleshooting. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug inspection/replacement, coolant checks, brake fluid flushes, drive belt inspection, and general lubrication. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable via diagnostic tool), and symptom-based troubleshooting guides. Repair And Overhaul: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major vehicle systems. Adjustments And Settings: Valve clearance adjustment, throttle cable adjustment, brake lever free play adjustment, and torque specifications for all fasteners. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and chassis component servicing. 📊 Manual Specifications File Format Quality: High-resolution PDF, typically with searchable text for easy navigation. Printability: Printable, allowing users to create hard copies for workshop use. Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves. Displacement: 460 cc (typically derived from Piaggio Master 460cc engine platform). Bore X Stroke: 92 mm x 69 mm (typical for Piaggio Master 460). Compression Ratio: 10.5:1 (typical for Piaggio Master 460). Performance Horsepower: Approx. 34-39 HP (at 7,000-7,500 rpm). Torque: Approx. 45-48 Nm (at 5,500-6,000 rpm). Fuel System Induction: Electronic Fuel Injection (EFI) with Marelli or Keihin ECU. Fuel Type: Unleaded gasoline, minimum 95 RON. Fuel Tank Capacity: Approx. 15 Liters. 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission). Clutch: Centrifugal wet clutch. Features Variator Rollers: Specific weight and profile for optimal acceleration and top speed; detailed in manual. Transmission Fluid: Specific CVT oil/transmission fluid (refer to manual for exact specification and change interval). 📐 Dimensions Exterior Length: Approx. 2150 mm. Width: Approx. 780 mm. Height: Approx. 1380 mm (seat height typically around 780-800 mm). Weights Dry Weight: Approx. 170-175 kg. Gross Vehicle Weight Rating: Approx. 330-340 kg. Cargo Underseat Storage: Ample...