The Nexus 500SP Mk2, released in 2006, represents a sophisticated maxi-scooter designed for riders seeking a blend of performance, comfort, and practicality. Known for its sporty handling and robust engineering, this model offers a powerful 492.7 cc liquid-cooled engine, a continuously variable transmission (CVT) for smooth acceleration, and a chassis built for stability during both urban commuting and light touring. Its design philosophy emphasizes motorcycle-like dynamics within the convenient package of a scooter, making it a compelling option in its class. This factory service repair manual provides comprehensive guidance for the maintenance, repair, and troubleshooting of the Nexus 500SP Mk2. It covers essential areas including engine disassembly and assembly, fuel system servicing, transmission maintenance, brake system procedures, and detailed electrical system diagnostics with wiring diagrams. Additionally, the manual offers routine maintenance schedules, component testing procedures, and specific technical data such as torque specifications and fluid requirements, ensuring owners and technicians have the necessary information to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2006 Product Type: Factory Service Repair Manual Product Format: PDF Download Codes Vin Decoder Section: Likely covered in electrical or general information section 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, performance-oriented commuter/touring Target Audience: Riders seeking versatile commuting and light touring capabilities with scooter practicality Competitive Analysis Key Competitors: Yamaha TMAX 500, Suzuki Burgman 400/650, Honda Silver Wing 500/600, Kymco Xciting 500 Key Features Performance Focus: The 'SP' designation typically indicates a sport-oriented version with enhanced components or tuning. Design Philosophy: Combines motorcycle-like handling with scooter convenience, featuring a relatively large engine for the class. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive repair, maintenance, troubleshooting, and disassembly/assembly procedures Page Count Estimated Page Count: Likely 300-500 pages (typical for this level of detail) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English (assumed based on typical sales markets for this product) Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Full engine disassembly, assembly, inspection, timing, valve adjustment, lubrication, cooling system Fuel System: Fuel injection system, fuel pump, injectors, fuel pressure regulation, fuel tank and lines Transmission: Automatic transmission (CVT), variator system, clutch, belt drive, gear reduction unit Chassis And Frame: Frame inspection, steering assembly, front suspension (forks), rear suspension (shock absorber, swingarm) Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake discs, brake pad replacement Electrical System: Wiring diagrams, battery, charging system (stator, regulator/rectifier), starter motor, ignition system, lighting, instrumentation, ECU diagnostics Bodywork And Trim: Fairing removal and installation, seat, body panels, lighting covers Wheels And Tires: Wheel bearing inspection, tire replacement, wheel removal and installation Cooling System: Radiator, cooling fan, coolant levels, hoses, thermostat Exhaust System: Exhaust pipe, muffler inspection and replacement Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter service, brake fluid checks, coolant checks, chain adjustment (if applicable, though Nexus is belt-driven) Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues, fault code interpretation Disassembly And Assembly: Detailed step-by-step instructions for removing and reinstalling all major components Rebuild Procedures: Engine rebuild, transmission overhaul, suspension component replacement Adjustments: Carburetor/throttle body synchronization (if applicable), idle speed adjustment, brake lever free play Component Testing: Testing of ignition components, fuel injectors, sensors, electrical circuits Technical Depth Depth Of Information: Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts Diagnostic Capabilities: Includes fault codes, sensor data interpretation, and troubleshooting trees Specific Procedures: Torque specifications, clearances, timing marks, electrical schematics 📊 Manual Specifications File Format PDF Quality: High-resolution scans or native digital creation, ensuring clarity of text and diagrams Searchability: Likely text-searchable PDF, allowing quick access to information Print Quality Printable: Yes, designed for printing individual sections or the entire manual Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 492.7 cc (as indicated by 500 designation, actual displacement is crucial) Bore X Stroke: Specific data would be in the manual, e.g., 94 mm x 71 mm Compression Ratio: Specific data would be in the manual, e.g., 10.5:1 Performance Horsepower: Approx. 40-42 HP @ 7500 RPM (typical for this engine) Torque: Approx. 45-47 Nm @ 5500 RPM (typical for this engine) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: SAE 10W-40, API SG or higher (check manual for specific recommendations) Oil Capacity: Approx. 1.6 - 1.8 Liters (check manual for exact specification) 🔧 Transmission Standard Transmission Type: Automatic continuously variable transmission (CVT) Features Drive Type: Belt drive to rear wheel Transmission Fluid: Specific CVT fluid (refer to manual for part number and type) 📐 Dimensions Exterior Length: Approx. 2180 mm Width: Approx. 790 mm Height: Approx. 1420 mm (seat height variable) Weights Dry Weight: Approx. 190 kg...