🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: MK2 Engine Code: M321M Platform: Nexus Emissions Standard: Euro 3 Applicable Model Years: 2005 onwards 👋 Introduction Market Position Segment: Premium Maxi-scooter Target Audience: Commuters, touring riders, performance-oriented scooter enthusiasts Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Forza, Aprilia Atlantic, Piaggio X9/X10 Key Features Sporty Handling: Known for its sporty chassis and agile handling, distinguishing it from many competitors. Powerful Engine: 500cc engine provides strong acceleration and comfortable highway cruising. Premium Features: Often equipped with higher-spec components and a more aggressive styling than standard models. Manual Utility: Provides in-depth technical information essential for maintaining this performance scooter. 📋 Manual Details Coverage Areas Coverage: Complete workshop and repair procedures Page Count Estimated Pages: High (typically 300-500+ pages for this type of manual) Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, tuning, troubleshooting, diagnostics Fuel System: Fuel injection, fuel pump, injectors, fuel lines, fuel tank Ignition System: Spark plugs, ignition coils, ECU control Cooling System: Radiator, water pump, thermostat, coolant flow, fan operation Lubrication System: Oil pump, oil filter, oil passages, oil specifications Exhaust System: Exhaust manifold, catalytic converter, muffler, lambda sensors Transmission: CVT (Continuously Variable Transmission) overhaul, belt replacement, roller weights, clutch operation Chassis: Frame inspection, alignment, fork assembly, rear shock absorber replacement Brakes: Brake system diagnostics, caliper overhaul, master cylinder replacement, brake fluid specifications, ABS (if equipped) Wheels And Tires: Tire pressure, tire replacement, wheel balancing, wheel bearing service Electrical System: Wiring diagrams, battery, starter motor, alternator, lighting system, fuses, relays, ECU diagnostics Instrumentation: Dashboard layout, gauge functions, indicator lights Bodywork: Fairing removal and installation, seat replacement, cosmetic repairs Diagnostics: Troubleshooting guides, error codes, fault finding procedures Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant flush Repair: Engine rebuild, transmission repair, suspension overhaul, electrical component replacement, body panel repair Rebuild: Complete engine and transmission rebuild procedures Refurbish: Procedures for restoring worn components Restoration: Guidance for bringing the vehicle back to original specifications Troubleshooting: Step-by-step guides for diagnosing and resolving common and uncommon issues Technical Depth Depth: Comprehensive (from basic maintenance to advanced diagnostics and full rebuilds) 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF Print Quality Printability: Printable for hard copy reference Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Valvetrain: SOHC, 4 valves Cooling System: Liquid-cooled Performance Horsepower: Approx. 40 HP (29.4 kW) @ 7,500 rpm (specifications can vary slightly by year/region) Torque: Approx. 46 Nm (34 lb-ft) @ 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Petrol (Gasoline) Fuel Capacity: Approx. 15 Liters 🔧 Transmission Standard Type: Automatic CVT (Continuously Variable Transmission) Drive: Belt drive to rear wheel Features Clutch: Automatic centrifugal clutch Fluid Type: Specific CVT oil (refer to manual for exact specification, e.g., SAE 75W/90 or similar gearbox oil) 📐 Dimensions Exterior Length: Approx. 2,170 mm Width: Approx. 800 mm (at handlebars) Height: Approx. 1,420 mm (seat height) Weights Dry Weight: Approx. 193 kg Curb Weight: Approx. 205 kg (with fluids) Wheels And Tires Front Tire: 120/70-15 Rear Tire: 160/60-15 🛡️ Safety Features Active Features Brakes: Disc brakes front and rear, ABS optional on some versions Lighting: Halogen headlights, LED taillights (typical for MK2) Passive Features Frame: High-tensile steel frame for rigidity Windscreen: Adjustable windscreen for rider comfort and protection 💡 Technology Features Infotainment Instrument Cluster: Digital LCD display with analog tachometer, speed indicator, fuel gauge, coolant temperature, clock, and diagnostic indicators. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on some models, enhancing braking safety. Connectivity Diagnostics Port: Likely features a diagnostic connector for electronic fault finding and ECU communication. 🔧 Maintenance Service Intervals Oil Change: Typically every 5,000-7,000 km or annually, whichever comes first (refer to manual for exact) Air Filter: Inspect every 5,000 km, replace as needed or at higher mileage intervals (e.g., 10,000-15,000 km) Spark Plug: Replace typically every 10,000-15,000 km Transmission Belt: Inspect at higher mileage intervals (e.g., 15,000-20,000 km), replace based on wear Fluid Specifications Engine Oil: Synthetic 5W-40 or 10W-40 (API SG or higher, JASO MA) Engine Oil Capacity: Approx. 1.6 - 1.8 Liters (including filter, refer to manual) Coolant: Ethylene glycol based antifreeze mixture (50/50 with distilled water) Brake Fluid: DOT 4 (for both front and rear systems) Final Drive Oil: SAE 75W/90 GL-5 (check manual for specific type and capacity) Known Issues Variator Rollers: Wear on variator rollers can lead to poor acceleration or vibration. Replacement is straightforward with the correct tools. Fuel Pump: Occasional issues with the fuel pump or its regulator...