The Nexus 500 SP, produced from 2005 onwards, is a high-performance maxi-scooter engineered for sporty riding and comfortable touring. Featuring a robust 492.7 cc liquid-cooled, single-cylinder engine delivering approximately 40 HP, it offers strong acceleration and confident handling, positioning it as a premium choice in its segment. Its design emphasizes motorcycle-like ergonomics, making it suitable for enthusiasts seeking a blend of performance and practicality. The Mk2 generation likely incorporates refinements for Euro 3 compliance and overall improved performance and reliability, building on a legacy of sport-oriented vehicles. This comprehensive service repair workshop manual provides detailed information for the Nexus 500 SP (Mk2, 2005 onwards). It covers all essential systems, including the engine, automatic CVT transmission, chassis, brakes, and electrical system, with in-depth procedures for maintenance, repair, and troubleshooting. The manual includes step-by-step instructions, diagnostic flowcharts, and technical specifications such as torque values and fluid capacities. It is designed to assist owners, mechanics, and technicians in maintaining the vehicle's optimal performance and ensuring its longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 SP Generation: Mk2 Year: 2005 onwards Engine Code: M380 (likely Piaggio Quasar 300 variant with larger bore) Chassis Code: ZAPM38100 (likely) Codes Emission Standard: Euro 3 👋 Introduction Market Position Segment: High-performance maxi-scooter Target Audience: Enthusiasts and owners seeking in-depth knowledge for maintenance, repair, and customization of their Gilera Nexus 500 SP. Competitive Analysis Competitors: Yamaha TMAX 500, Suzuki Burgman 650, Aprilia Scarabeo 500, BMW C 600 Sport (during its era) Key Features Performance Focus: Designed for sportier performance compared to typical maxi-scooters, offering strong acceleration and handling. Ergonomics: Emphasis on comfortable ergonomics for longer rides, often with a motorcycle-like riding position. 📋 Manual Details Coverage Areas Engine: Complete overhaul, diagnosis, troubleshooting, performance tuning Transmission: Automatic CVT (Continuously Variable Transmission) maintenance, belt replacement, clutch inspection Chassis: Frame, suspension (front forks, rear shock), steering system, wheel bearings Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, ABS (if equipped) Electrical System: Wiring diagrams, battery, starter, alternator, lighting, ignition system, electronic control unit (ECU) Bodywork: Fairings, seat, storage compartments, panel removal and installation Cooling System: Radiator, fan, coolant flow, thermostat Fuel System: Fuel injection system, fuel pump, injectors, fuel lines, fuel tank Exhaust System: Exhaust manifold, catalytic converter, muffler Troubleshooting: Diagnostic procedures for common and uncommon faults Specifications: Torque values, clearances, fluid capacities, electrical resistance Page Count Approximate Pages: Estimated 300-500 pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Core Systems: Engine, Fuel System, Ignition System, Exhaust, Cooling System, Transmission, Brakes, Suspension, Steering, Electrical System, Lighting, Bodywork Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake pad replacement Repair: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper servicing, electrical component diagnosis and replacement, fuel injector cleaning/replacement Troubleshooting: Fault finding charts, diagnostic flowcharts, symptom-based troubleshooting Disassembly Assembly: Step-by-step instructions for disassembling and reassembling all major components and sub-assemblies Technical Depth Depth: Comprehensive: Covers everything from basic user maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and repair. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Searchability: Likely text-searchable, allowing quick access to specific information. Image Resolution: High-resolution diagrams, illustrations, and photographs for clarity. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder, SOHC, 4 valves Displacement: 492.7 cc (approximately) Bore X Stroke: Approx. 94 mm x 71 mm Performance Horsepower: Approximately 40 HP (at 7,500 rpm) for the 500 SP model Torque: Approximately 45 Nm (at 5,500 rpm) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Marelli or Keihin ECU Fuel Type: Unleaded Petrol (95 RON recommended) Ignition System Ignition: Electronic CDI with variable ignition timing Lubrication Oil Type: API SG/SH/SJ or JASO MA/MA2 specification, SAE 10W-40 or 15W-50 synthetic motorcycle oil recommended. Cooling System Coolant Type: Ethylene glycol-based antifreeze/coolant mixture (50% water, 50% coolant) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Optional Optional Transmission: N/A Features Drive System: Belt drive to rear wheel via enclosed chain/belt final drive Clutch: Automatic centrifugal dry clutch Transmission Oil: N/A (CVT system does not typically require separate transmission oil, but primary drive may have a small oil bath for clutch mechanism depending on specific Piaggio Quasar evolution) 📐 Dimensions Exterior Length: Approx. 2,150 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1,460 mm (at windshield) Wheelbase: Approx. 1,520 mm Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 203 kg (with fluids) Max Load: Approx. 180 kg (rider and passenger) Cargo Storage: Under-seat storage compartment, often accommodating one full-face helmet. 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle/Scooter specific crash ratings like NCAP are not typically published)...