The Nexus 500SP Mk2 is a distinguished maxi-scooter, celebrated for its potent 493cc liquid-cooled engine, advanced chassis design, and comfortable ergonomics. This model, a product of rich Italian heritage, offers a compelling blend of sporty performance and touring capability, making it suitable for both daily commuting and extended journeys. Key features include its powerful engine, robust braking systems, and a high-strength steel frame, all contributing to its reputation for engineering quality and engaging riding experience. This comprehensive service and repair workshop manual is designed to guide owners, mechanics, and technicians through all aspects of the Nexus 500SP Mk2. It covers a wide array of topics, including detailed maintenance procedures, engine overhauls, electrical system diagnostics, suspension servicing, and troubleshooting common issues. With in-depth technical data, torque specifications, and exploded views, this manual serves as an essential resource for ensuring the optimal performance, reliability, and longevity of your vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: Mk2 Product Type: Motorcycle Workshop Manual Download 👋 Introduction Market Market Position: The Gilera Nexus 500SP Mk2 is positioned as a premium, high-performance maxi-scooter, blending sporty handling with touring comfort and significant engine power for its class. It often competed with other high-displacement scooters from European and Japanese manufacturers. Competitive Analysis Key Competitors: Yamaha TMAX 500, Suzuki Burgman 400/650, Piaggio X9 500, Honda Silver Wing 600. Key Features Distinguishing Features: Powerful 500cc Piaggio Master engine, advanced chassis design for excellent handling, comfortable ergonomics for long distances, sporty styling, robust braking system. Target Audience Intended User: Professional motorcycle technicians, experienced DIY mechanics, and Gilera Nexus 500SP Mk2 owners seeking detailed service and repair information. 📋 Manual Details Coverage Coverage Areas: Characteristics, Tooling, Maintenance, Electrical System, Engine (from vehicle), Engine (eng), Injection, Suspensions, Braking System, Cooling System, Chassis, Pre-Delivery, Time. Page Count Page Count: Estimated 300-500 pages (based on typical workshop manual depth for this category). Type Manual Type: Service and Repair Workshop Manual Language Language: Likely English (standard for international workshop manuals, specific language not explicitly stated but implied by availability). Format Format: PDF Download Completeness Manual Completeness: Covers all aspects of service and repair for the Gilera Nexus 500SP Mk2, from routine maintenance to complete engine and chassis overhauls. 📖 Manual Coverage Systems Systems Covered: Engine Mechanical, Engine Management (Injection, Ignition), Electrical System (Wiring Diagrams, Components), Fuel System, Cooling System, Lubrication System, Transmission (Clutch, Drive), Braking System (Front/Rear), Suspension System (Front Forks, Rear Shock Absorber), Chassis and Frame, Bodywork, Wheels and Tires, Steering System. Procedures Procedures Included: Routine Maintenance (Oil Changes, Filter Replacements, Spark Plugs), Engine Overhaul (Disassembly, Reassembly), Fuel Injection System Servicing and Diagnostics, Electrical Troubleshooting, Brake System Overhaul, Suspension Adjustments and Servicing, Cooling System Flush and Refill, Chassis Inspection, Pre-Delivery Inspections (PDI), Timing Adjustment. Electrical System Repair: Detailed wiring diagrams, component location, testing procedures for lights, ignition, starting, charging, and sensors. Depth Technical Depth: Comprehensive, including detailed exploded views, step-by-step repair instructions, diagnostic procedures, torque specifications, and component data for professional technicians and advanced DIY enthusiasts. Troubleshooting Diagnostic Procedures: Includes guided troubleshooting steps for common malfunctions, error code interpretation for the EFI system, and electrical system diagnostics. Special Tools Tooling Requirements: Details required specialized tools for engine disassembly/assembly, suspension service, wheel bearing replacement, and specific diagnostic equipment. Technical Data Torque Specifications: Provides detailed torque values for all critical fasteners, including engine, chassis, and suspension components. 📊 Manual Specifications File File Format: PDF Print Print Quality: High-resolution, suitable for printing with clear diagrams and text. Binding Binding Type: N/A (Digital Download) Paper Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, DOHC Displacement: 493 cc Performance Horsepower: Approximately 40-42 HP (depending on specific tuning and market regulations) Torque: Approximately 45-47 Nm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 95 recommended) Lubrication Oil Type: API SG/SH/SJ or higher, SAE 15W-40 or 10W-40 (specific viscosity may vary based on ambient temperature, refer to manual for exact specification) Oil Capacity: Approximately 1.5 - 1.7 liters (including filter replacement) Engine Management Ignition System: Electronic ignition system. 🔧 Transmission Features Transmission Type: Automatic CVT (Continuously Variable Transmission) with wet multi-plate clutch. Drive Type: Belt drive to rear wheel via gearbox and chain drive. Fluid Cvtf Fluid Type: Specific automatic transmission fluid (refer to manual for exact specification, often a proprietary blend or equivalent) Cvtf Fluid Capacity: Refer to manual for exact capacity. 📐 Dimensions Exterior Length: Approximately 2240 mm Width: Approximately 800 mm (at handlebars) Height: Approximately 1420 mm (seat height) Weights Dry Weight: Approximately 190 kg Gross Vehicle Weight Rating: Refer to vehicle registration or manual for specific GVWR. Wheels Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheelbase: Approximately 1535 mm Fuel Capacity Fuel Tank Capacity: Approximately 15 liters 🛡️ Safety Features Active Features Braking System Front: Dual 260 mm discs with 4-piston...