🏷️ Basic Information Identification Make: Piaggio Model: Gilera Nexus 500SP Sub Model: Mk2 Engine Type: Euro3 Codes Manual Product Name: Piaggio Gilera Nexus 500SP Euro3 Mk2 Motorcycle Workshop Factory Service Repair Manual PDF Download 👋 Introduction Market Position Category: Maxi-scooter Segment: Performance-oriented commuter and touring maxi-scooter Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600 Unique Selling Proposition: Sporty handling characteristics derived from motorcycle heritage, powerful single-cylinder engine. Key Features Engine Size: 500cc class Performance Focus: Emphasis on sporty riding dynamics and acceleration Design Philosophy: Bridge the gap between scooter practicality and motorcycle performance 📋 Manual Details Coverage Areas General Repair: Comprehensive Maintenance: Tune-ups, Lubrication, Scheduled Service Major Rebuilds: Engine and Transmission Page Count Estimated Pages: N/A (as it's a digital download, page count can vary with zoom/print settings) Manual Type Type: Factory/Official Workshop Service Repair Manual Language Language: English (Presumed, based on typical aftermarket manual offerings) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, performance tuning, diagnostics Transmission: Clutch, gearbox, final drive overhaul and repair Fuel System: Fuel injection, fuel pump, fuel pressure diagnostics Cooling System: Radiator, thermostat, water pump, coolant flow Electrical System: Ignition, lighting, charging system, wiring diagrams, connector data Brakes: Hydraulic system, disc brake maintenance, fluid replacement Suspension: Front forks, rear shock absorber, bearings Chassis Frame: Frame inspection, steering head bearings Bodywork Panels: Fairings, seat, trim removal and installation Procedures Included Preventative Maintenance: Oil changes, filter replacements, chain adjustment (if applicable) Troubleshooting: Diagnostic charts, symptom-based guides Disassembly Assembly: Component-level step-by-step instructions Inspections: Wear limits, safety checks Technical Depth Depth: Comprehensive: from basic tune-ups to major engine/transmission rebuilds and diagnostics User Level: Professional or DIY with basic mechanical knowledge 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within PDF Print Quality Quality: High-resolution scans of original factory documentation Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: M381M (typical for 500cc Piaggio/Gilera Master engine) Configuration: Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves Displacement: 492.7 cc Bore X Stroke: 94 mm x 71 mm Compression Ratio: 10.5:1 (typical) Performance Horsepower: Approx. 39 HP (29 kW) @ 7500 RPM (varies slightly by market/tuning) Torque: Approx. 45 Nm (33 lb-ft) @ 5500 RPM (varies slightly by market/tuning) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Pressure: Refer to manual for specific OEM specifications (e.g., 3.0 - 3.5 bar) Ignition System: Electronic CDI Lubrication Oil Type: API SG or higher, JASO MA certified motorcycle oil recommended (e.g., SAE 5W-40 or 10W-40) Oil Capacity: Approx. 1.6 - 1.8 liters (with filter change) Cooling System Type: Liquid-cooled Coolant Capacity: Approx. 1.0 - 1.2 liters Compression Ranges Minimum Compression: Refer to manual for specific OEM value (e.g., 9.5 bar / 138 psi) Maximum Compression Deviation Cylinders: Refer to manual for specific OEM value (e.g., 1.0 bar / 14.5 psi) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Clutch Type: Automatic centrifugal clutch Final Drive: Gear drive Features Gear Ratios: Continuously variable, specified by belt-driven pulley ratios. Consult manual for specific ratios at different speed points. Transmission Fluid: No separate transmission fluid; engine oil lubricates transmission and clutch. 📐 Dimensions Exterior Length: Approx. 2180 mm (for Mk2) Width: Approx. 770 mm (at handlebars) Height: Approx. 1370 mm (at handlebars) Seat Height: Approx. 785 mm Weights Dry Weight: Approx. 198 kg Wet Weight: Approx. 212 kg (with fluids) Maximum Load: Refer to manual (typically ~180-200 kg including rider and luggage) Wheels Tires Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheel Type: Alloy wheels Fuel Capacity Fuel Tank Capacity: 15 liters 🛡️ Safety Features Ratings Crash Test Ratings: N/A for motorcycles (focus is on design and rider safety features) Active Features Brakes: Front: Dual discs with four-piston calipers; Rear: Single disc with two-piston caliper. Optional ABS (Anti-lock Braking System) available on some models. Lighting: Halogen headlights, LED taillight/indicators (model dependent) Passive Features Frame Construction: Steel double cradle frame for rigidity and stability Security: Immobilizer system, steering lock 💡 Technology Features Infotainment Dashboard: Analog speedometer and tachometer, digital multi-function display (odometer, trip meter, fuel gauge, clock, temperature). Driver Assistance ABS: Optional ABS system available on some variants Connectivity Charging Port: Often equipped with a 12V accessory socket in the front storage compartment. 🔧 Maintenance Service Intervals Engine Oil And Filter: Every 5,000 - 7,500 km or annually (refer to manual for exact interval) Air Filter Check: Every 5,000 km Spark Plug Replacement: Every 10,000 - 15,000 km Coolant Replacement: Every 2 years or 30,000 km Brake Fluid Replacement: Every 2 years Fluid Specifications Engine Oil: SAE 5W-40 or 10W-40, API SG/SH/SJ or higher, JASO MA certified motorcycle oil. Specific Piaggio/Gilera branded oil often recommended. Coolant: Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Brake Fluid: DOT 4 recommended Final Drive...