The Nexus 500sp Mk2, produced between 2005 and 2007, represents a premium maxi-scooter engineered for both spirited riding and comfortable long-distance travel. Known for its strong liquid-cooled, 4-stroke single-cylinder engine displacing approximately 460cc and featuring electronic fuel injection, it offers a performance-oriented experience within its class. Its design emphasizes sporty handling, complemented by comfort and ergonomics suitable for commuters and touring riders alike. Adhering to Euro 3 emissions standards, this model likely saw distribution in European markets, reflecting a heritage of producing stylish and capable two-wheeled vehicles. This comprehensive workshop service repair manual provides detailed information for the maintenance, repair, and troubleshooting of the Nexus 500sp Mk2. It covers all major systems, including the engine, fuel system, ignition, transmission, chassis, brakes, and electrical systems, offering factory-level technical depth. Essential procedures for routine maintenance, major repairs, component replacement, and diagnostics are thoroughly explained, complete with torque specifications and wiring diagrams. This manual serves as an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their Nexus 500sp. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500sp Model Designation: Mk2 Year: 2005-2007 Codes Emissions Standard: Euro 3 👋 Introduction Market Position Vehicle Segment: Premium maxi-scooter. Target Audience: Commuters seeking performance and comfort, touring riders. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 650, BMW C650GT (later models), Honda Silver Wing. Key Features Performance Orientation: Known for its strong single-cylinder engine and sporty handling. Comfort And Ergonomics: Designed for long-distance riding with comfortable seating and wind protection. Technological Advancements: Incorporated modern features for its time, including fuel injection and potentially ABS. 📋 Manual Details Coverage Areas Market Coverage: Likely European markets due to Euro 3 designation. Page Count Estimated Page Count: Varies, but factory service manuals of this scope typically range from 300-700 pages. Manual Type Manual Type: Workshop Service Repair Manual Language Language: Likely English, potentially with other European languages depending on the source and distribution. Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, diagnostics, and specifications. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulation, and evaporative emissions control. Ignition System: Ignition coils, spark plugs, ECU control, and timing. Transmission: Automatic transmission (CVT - Continuously Variable Transmission) operation, maintenance, and repair. Chassis: Frame, swingarm, suspension (front and rear), steering system, and wheels. Brakes: Front and rear brake systems, including hydraulic lines, calipers, discs, master cylinders, and ABS (if equipped). Electrical System: Battery, charging system (alternator/stator), starter motor, lighting, wiring diagrams, fuses, relays, and ECU interfaces. Cooling System: Radiator, cooling fan, coolant hoses, thermostat, and coolant specifications. Exhaust System: Exhaust manifold, catalytic converter (Euro 3 compliant), muffler, and lambda sensor (oxygen sensor). Bodywork: Fairings, seat, handlebars, body panels, and trim component removal and installation. Diagnostic Troubleshooting: Fault code interpretation, diagnostic procedures, and troubleshooting guides for various systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment (if applicable, though likely belt or shaft drive), brake pad inspection, tire pressure checks. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, electrical system diagnostics and repair. Component Replacement: Detailed instructions for replacing parts such as brake discs, clutch components (if applicable), bearings, seals, and electrical sensors. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Disassembly Assembly: Step-by-step instructions for complete vehicle disassembly and reassembly. Technical Depth Depth Of Coverage: Factory-level, covering all aspects from basic maintenance to complete engine and transmission overhauls. Diagnostic Capability: Advanced diagnostics, including troubleshooting guides for electronic control units (ECU) and sensor-related issues. Rebuild Procedures: Detailed procedures for rebuilding major mechanical components, including tolerances and specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text, enabling quick access to information. Print Quality Printability: All pages are printable, allowing for physical copies. Binding Type Binding: Not applicable for PDF download, but a physical copy would typically be professionally bound. Paper Type Paper Quality: Not applicable for PDF download, but a physical copy would typically be printed on durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve single-cylinder. Displacement: 460cc (exact figure may vary slightly by specific sub-model, but around this mark). Bore X Stroke: Likely around 92mm x 84mm (typical for this engine family). Compression Ratio: Typically around 10.5:1 or higher. Power Output: Around 34-36 hp (25-27 kW) at 7000-7500 RPM (estimated based on class and era). Torque Output: Around 3.9-4.1 kgf-m (approx. 38-40 Nm or 28-30 lb-ft) at 5500-6000 RPM (estimated). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded gasoline. Fuel Tank Capacity: Approximately 13-15 liters. 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission). Optional Optional Transmission: None. Features Transmission Features: Automatic clutch and variator system for seamless gear...