🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Year: 2005-2007 Variant: MK2 Euro 3 Codes Engine Code Family: Quasar 👋 Introduction Market Position Category: High-performance maxi-scooter Target Audience: Commuters, touring riders, enthusiasts seeking a powerful and versatile scooter Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, BMW C series Key Features Design Philosophy: Sporty handling combined with long-distance comfort and practicality Performance Focus: Emphasis on engine power, chassis dynamics, and braking performance Manual Value Proposition: Dealer-level repair information at a fraction of the cost, empowering owners for maintenance and repairs 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for 2005-2007 Gilera Nexus 500SP MK2 Euro 3 Page Count Total Pages: 410 Manual Type Type: Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, diagnostics, fuel injection system Electrical System: Wiring diagrams, troubleshooting, component testing, battery, charging system, lighting, ignition Suspension: Front fork overhaul and adjustment, rear shock absorber, linkage systems Braking System: Front and rear brake caliper service, master cylinder, hydraulic lines, bleeding procedures, pad replacement Cooling System: Radiator, coolant hoses, thermostat, water pump, coolant specifications and replacement Chassis: Frame inspection, bodywork, fairings, seat, luggage systems Fuel System: Fuel tank, fuel pump, fuel filter, fuel injection system (EFI) components Exhaust System: Exhaust pipe, muffler, lambda sensor (oxygen sensor) Wheels And Tires: Wheel bearing service, tire pressure recommendations, wheel removal and installation Instruments And Controls: Dashboard indicators, switches, controls, throttle, brake levers Procedures Included Maintenance: Scheduled maintenance, oil change, filter replacement, spark plug replacement, chain adjustment (if applicable), fluid checks Repair: Complete step-by-step repair instructions for all major vehicle systems Troubleshooting: Diagnostic flowcharts and common problem resolution guides Disassembly Assembly: Detailed procedures for complete disassembly and reassembly of components Diagnostics: Engine diagnostics, electrical system fault finding Technical Depth Depth: In-depth technical information suitable for both DIY enthusiasts and professional mechanics Illustrations: Hundreds of detailed photos and illustrations to guide procedures Wiring Diagrams: Comprehensive electrical system wiring diagrams 📊 Manual Specifications File Format Format: PDF Compatibility: All PC based Windows operating systems and Mac Print Quality Printability: All pages are printable without restriction Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Requirements Software Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, 4-valve Displacement: 492.5 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 Performance Horsepower: Approx. 40 HP (29.4 kW) at 7,500 rpm (exact figures may vary slightly by year/market) Torque: Approx. 44 Nm (32.5 lb-ft) at 5,500 rpm (exact figures may vary slightly by year/market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body Fuel Type: Unleaded gasoline (95 RON recommended) Ignition Ignition System: Electronic ignition, digital with variable spark advance Lubrication Oil Type: SAE 5W-40 Synthetic (API SG/SH/SJ/SL) Oil Capacity: Approx. 1.4 liters (check manual for exact capacity with filter change) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Transmissions: N/A Features Clutch: Automatic centrifugal clutch Final Drive: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2,180 mm (85.8 inches) Width: Approx. 780 mm (30.7 inches) Height: Approx. 1,380 mm (54.3 inches) (seat height varies) Weights Dry Weight: Approx. 198 kg (436.5 lbs) Wet Weight: Approx. 214 kg (471.8 lbs) (with all fluids) Max Payload: Approx. 180 kg (397 lbs) (rider + passenger + luggage) Fuel Capacity Fuel Tank Capacity: 15 liters (3.96 US gallons) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle/Scooter safety is primarily through design and rider control) Active Features Braking System: Disc brakes front and rear, often with ABS as an option on some models/markets. Dual piston calipers front, single piston rear. Lighting: Halogen headlamp, LED taillight 💡 Technology Features Infotainment Dashboard Features: Digital and analog speedometer, tachometer, fuel gauge, engine temperature, clock, trip meters, warning lights. Driver Assistance ABS Availability: Optional on some models/markets. Connectivity Connectivity Features: N/A (Basic scooter technology for its era) 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 6 months (whichever comes first), refer to manual for precise details. Air Filter Replacement: Check every 5,000 km, replace as needed or at specified intervals (e.g., 10,000-15,000 km). Spark Plug Replacement: Refer to manual for specific interval, typically around 10,000-20,000 km, check condition at 5,000 km. Belt Drive Inspection: Inspect belt for wear and tension at regular intervals, replacement typically at higher mileage (e.g., 20,000-30,000 km). Fluid Specifications Coolant Type: Ethylene glycol-based coolant, suitable for mixed metal engines (refer to manual for specific mixture ratio). Brake Fluid Type: DOT 4 (low viscosity) Known Issues Common Wear Items: Drive belt wear, voltage regulator issues, starter motor solenoid, thermostat failures. Fuel Injection System: Can be sensitive to fuel quality; occasional cleaning of throttle body or injector may be beneficial. Suspension Bushings: Can...