🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: MK2 Engine Variant: 500SP EURO 3 Codes Emissions Standard: Euro 3 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Performance-oriented scooter riders and those seeking capable urban and light touring mobility. Competitive Analysis Key Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500/600, Kymco Xciting 500. Key Features Performance Focus: The 'SP' designation often implies a sportier tuning or higher specification than standard models. Design Philosophy: Combines scooter practicality with motorcycle-like ergonomics and performance, often featuring advanced suspension and braking for its class. 📋 Manual Details Coverage Areas Covered Model Years: 2005 onwards Region Coverage: Global (Euro 3 specification applies) Page Count Estimated Pages: Extensive (specific count not provided, but described as comprehensive) Manual Type Type: Workshop Service Repair Manual Language Language: English (assumed based on product description) Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Overhaul: Complete disassembly, inspection, repair, and reassembly of the 500cc engine. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel filter, and tank. Ignition System: Ignition coil, spark plugs, CDI unit, and related wiring. Cooling System: Radiator, fan, water pump, coolant hoses, and thermostat. Exhaust System: Exhaust manifold, catalytic converter (Euro 3 compliant), mufflers, and lambda sensors. Transmission: Automatic transmission (CVT - Continuously Variable Transmission), including variator, clutch, and belt. Chassis And Frame: Frame construction, subframe, steering head, and swingarm. Suspension Front: Telescopic fork assembly, including oil levels, seals, and springs. Suspension Rear: Monoshock absorber, linkage system (if applicable), and adjustment procedures. Braking System Front: Dual disc brakes, calipers, master cylinder, brake lines, pads, and rotors. Braking System Rear: Disc brake, caliper, master cylinder, brake lines, pads, and rotor. Wheels And Tires: Wheel bearing replacement, tire fitting, and pressure recommendations. Electrical System: Wiring diagrams, battery, starter motor, alternator, lighting system, horn, switches, and fuses. Instrumentation: Dashboard, indicators, speed sensor, and fuel level sender unit. Bodywork And Fairings: Removal, installation, and repair of body panels, seat, and storage compartments. Cooling Fan Control: Thermoswitch operation and fan motor testing. Starting System: Starter motor, starter relay, and ignition switch troubleshooting. Lighting System: Headlight, taillight, brake lights, turn signals, and dashboard illumination. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable, though typically belt-driven), and general inspections. Troubleshooting: Diagnostic procedures for common starting, running, and electrical issues. Engine Rebuild: Complete engine disassembly, component inspection, measurement, and reassembly, including piston, rings, cylinder, crankshaft, and valve train. Suspension Overhaul: Front fork seal replacement, fork oil change, rear shock absorber inspection and adjustment. Brake System Service: Brake pad replacement, caliper service, brake fluid bleeding and replacement, rotor inspection. Fuel System Cleaning And Testing: Injector cleaning, fuel pressure testing, and fuel filter replacement. Electrical Diagnostics: Testing of charging system, starting system, ignition system, and sensor readings. Bodywork Repair: Fairing removal and installation, minor bodywork repairs. Torque Specifications: Accurate torque values for all critical fasteners. Wiring Diagrams: Detailed electrical schematics for all systems. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls. Diagnostic Capability: Includes troubleshooting guides and procedures for identifying and resolving faults. Component Identification: Utilizes exploded views and diagrams for easy identification and disassembly/assembly. Adjustment Procedures: Detailed instructions for all necessary adjustments, such as valve clearance, throttle cable, etc. (if applicable). Special Tool Requirements: Lists any special tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, and later) Print Quality Readability: High-quality digital reproduction ensuring clarity of text and diagrams. Searchability: Likely searchable text within the PDF (common for professionally created manuals). Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, four-stroke, liquid-cooled Displacement: 493 cc (approximately) Bore X Stroke: Typically around 94 mm x 71 mm (specific value to be confirmed by manual) Valve Train: SOHC, 4 valves (typical for this engine family) Performance Horsepower: Around 40-45 HP (specific figure varies by exact model year and tuning, to be confirmed by manual) Torque: Around 45-50 Nm (specific figure varies by exact model year and tuning, to be confirmed by manual) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (min. 95 RON recommended) Fluid Specifications Engine Oil Type: SAE 10W-40 Synthetic (API SG or higher, JASO MA recommended - specific viscosity and API rating to be confirmed by manual) Engine Oil Capacity: Approximately 1.6 - 1.8 Liters (with oil filter change - exact capacity to be confirmed by manual) Coolant Type: Ethylene Glycol based antifreeze (50% mixture with distilled water recommended) Lubrication System System: Wet sump lubrication 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Transmission: N/A Features Drive...