Introducing the Nexus 500SP MK2, a distinguished maxi-scooter produced from 2005 onwards. This model is engineered for performance, offering a compelling blend of sporty handling and touring comfort, setting it apart in its segment. Its robust chassis and powerful 493cc liquid-cooled engine, compliant with Euro 3 emissions standards, deliver exhilarating acceleration and stable high-speed cruising, making it an excellent choice for both daily commuting and longer journeys. The Nexus 500SP MK2 embodies a commitment to quality Italian engineering, providing a reliable and engaging riding experience. This comprehensive Factory Service Repair Workshop Manual is designed to be an indispensable resource for owners, mechanics, and technicians. It covers all essential aspects of the Nexus 500SP MK2, including detailed maintenance procedures, in-depth troubleshooting guides, critical technical specifications, and vital safety information. From routine servicing like oil changes and filter replacements to complex engine and transmission overhauls, electrical system diagnostics, and chassis repairs, this manual provides step-by-step instructions and clear diagrams. Its thorough coverage ensures that the vehicle can be maintained, repaired, and optimized for peak performance and longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Model Variant: MK2 Year Start: 2005 Year End: Ongoing (as per "Onward") Engine Code Suffix: Euro 3 Codes Emission Standard: Euro 3 👋 Introduction Market Position Segment: Maxi-scooter, performance-oriented segment. Target Audience: Commuters seeking long-distance comfort and performance, touring riders, enthusiasts who perform their own maintenance. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Scarabeo 500, Piaggio X9/X8. Key Features Performance Focus: Designed for strong acceleration and comfortable high-speed cruising, differentiating it from smaller scooters. Sporty Handling: Larger wheels and robust chassis contribute to more motorcycle-like handling characteristics. Touring Capability: Comfortable ergonomics, weather protection, and ample storage make it suitable for longer journeys. 📋 Manual Details Coverage Areas Geographical Coverage: Global (primarily European markets due to Gilera's origins and Euro 3 classification) Page Count Estimated Page Count: Likely 300-500+ pages (typical for comprehensive service manuals) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: Likely English, potentially with other European languages included. Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, tuning, valve clearance, piston, crankshaft, camshaft, timing. Fuel System: Fuel injection system (EFI), injectors, fuel pump, fuel pressure regulator, throttle body, sensors (MAP, TPS, IAT, O2). Ignition System: Ignition coil, spark plug, ECU control, timing. Exhaust System: Exhaust manifold, catalytic converter (Euro 3 specific), mufflers, Lambda sensor integration. Cooling System: Radiator, fan, coolant hoses, thermostat, water pump. Transmission Drivetrain: Automatic CVT (Continuously Variable Transmission) system, belt, variator, clutch, final drive, gearbox oil. Brakes: Hydraulic brake system (front and rear), calipers, master cylinders, brake lines, brake fluid specifications, ABS (if equipped on SP models). Suspension: Front telescopic forks (including oil type and level), rear monoshock absorber, linkage adjustment. Steering: Handlebar assembly, steering bearings, steering head adjustment. Electrical System: Wiring diagrams, battery, starter motor, alternator, lights (headlight, taillight, indicators), fuses, relays, ECU diagnostics. Bodywork Chassis: Frame, fairings, seat, storage compartments, body panel removal and installation. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, drive belt inspection/replacement, brake pad wear check. Troubleshooting: Diagnostic procedures for common issues, fault code interpretation (if applicable via diagnostics), performance problems. Engine Repair: Full engine rebuild procedures, component testing and measurement, torque specifications. Transmission Service: CVT belt and roller inspection, clutch adjustment, gearbox oil change. Brake System Repair: Brake bleeding, caliper overhaul, master cylinder replacement, pad and disc replacement. Electrical Diagnostics: Wiring harness troubleshooting, component testing, charging system checks. Suspension Fork Service: Front fork oil replacement, seal replacement, rear shock adjustment. Bodywork Refurbishment: Fairing repair and replacement, panel fitting. Technical Depth Depth: Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, electrical diagnostics, and chassis work. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High resolution, suitable for printing detailed diagrams and text. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Features Searchable Text: Likely includes searchable text for quick information retrieval. Hyperlinked Sections: Potentially includes hyperlinks for easy navigation between sections and diagrams. No Expiry: True No Extra Fees: True ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 493 cc (approximate, based on the 500 designation) Bore X Stroke: Specifications would be detailed in the manual, typically around 94 mm x 72 mm. Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder (common configuration for this engine family). Performance Horsepower Peak: Around 40 HP (approximate, actual figures vary by market and tuning) Torque Peak: Around 46 Nm (approximate, actual figures vary by market and tuning) Top Speed: Typically around 160 km/h (100 mph). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (min 95 RON recommended) Fuel Tank Capacity: Approx. 15 liters 🔧 Transmission...