🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: Mk2 Model Years Covered: 2005 onwards Engine Variant: 500cc SP (Specific Performance variant) Emission Standard: Euro 3 👋 Introduction Market Position Category: High-performance maxi-scooter Target Audience: Riders seeking urban commuting with touring capabilities, performance enthusiasts. Competitive Analysis Competitors: Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Forza 250/300/350, Kymco Downtown 300/500. Key Features Engine Size: Large displacement 493cc engine, offering significant power and torque for its class. Performance Variant: SP designation indicates a specific performance-oriented tuning or equipment package. Design Philosophy: Sporty styling combined with maxi-scooter practicality and comfort. 📋 Manual Details Coverage Areas Manual Type: Workshop Manual / Service & Repair Manual Language: English Format: PDF Download Completeness: Full A-Z coverage for all models and repairs Specificity: Vehicle-specific, not generic 📖 Manual Coverage Systems Covered Engine: Complete engine assembly, disassembly, overhaul, lubrication, cooling system, fuel system (injection), ignition system, exhaust system, starting system, engine management (ECU, sensors). Transmission: Automatic transmission (CVT), variator, clutch, final drive, gearbox components, lubrication. Chassis And Frame: Frame inspection, reinforcement, steering system (headset, linkage), suspension (front forks, rear shock absorber), wheel bearings, swingarm. Braking System: Front and rear brake systems (disc brakes, calipers, master cylinders, brake lines, ABS if applicable), hydraulic system, bleeding procedures, pad and disc replacement. Electrical System: Battery, charging system (alternator, regulator/rectifier), lighting (headlights, taillights, indicators), ignition switch, horn, starter motor, wiring diagrams, fuses, relays, electronic control unit (ECU) diagnostics. Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, pressure regulator, emissions control systems (EVAP). Bodywork And Trim: Fairings, panels, seat, storage compartments, mirrors, lighting fixtures, removal and installation procedures. Wheels And Tires: Tire specifications, pressure recommendations, wheel removal and installation, balancing, rim inspection. Cooling System: Radiator, coolant hoses, coolant type and capacity, water pump, thermostat, fan operation. Procedures Included General Maintenance: Routine checks, oil changes, filter replacements, spark plug replacement, air filter service, brake fluid replacement, coolant checks. Troubleshooting: Diagnostic procedures for common and uncommon issues, fault codes interpretation, symptom-based troubleshooting guides. Engine Repair: Engine rebuilds, piston and ring replacement, cylinder head service, valve adjustment, camshaft timing, gasket replacement. Transmission Repair: Variator roller replacement, clutch assembly service, gearbox disassembly and reassembly. Electrical Diagnostics: Wiring harness inspection, component testing, sensor calibration, ECU flashing and diagnostics. Brake System Service: Brake pad replacement, caliper service, master cylinder overhaul, brake line bleeding, rotor inspection and replacement. Suspension And Steering Service: Front fork seal replacement, steering head bearing adjustment and replacement, swingarm bearing service. Bodywork Repair: Fairing repair, panel replacement, minor accident damage repair. Technical Depth Depth: Comprehensive, covering detailed disassembly, assembly, repair, and diagnostic procedures, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable for physical reference. Page Count: Not specified, but typically comprehensive workshop manuals are hundreds of pages. File Size: Variable based on image quality and detail, but generally manageable for download. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled, SOHC, 4 valves Displacement: 492.7 cc Bore X Stroke: 94 mm x 88 mm (typical for this engine family) Compression Ratio: 10.0:1 (typical) Performance Horsepower: Approximately 40-43 HP at engine RPM (specific to SP variant, actual figures may vary slightly) Torque: Approximately 45-48 Nm at engine RPM (specific to SP variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Ignition System: Electronic ignition, controlled by ECU Lubrication Oil Type: SAE 5W-40 Synthetic or Semi-Synthetic Motorcycle Oil, API SG or higher, JASO MA/MA2 compliant Oil Capacity: Approx. 1.8 - 2.0 liters (with filter change) Cooling System Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Motul Motocool Expert, Shell Advance Coolant) Coolant Capacity: Approx. 1.2 liters 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) with dry centrifugal clutch Final Drive: Gear drive Features Variator System: Roller-based variator for seamless gear ratio changes. Clutch Type: Centrifugal dry clutch system. 📐 Dimensions Exterior Length: Approx. 2170 mm Width: Approx. 780 mm Height: Approx. 1450 mm (seat height variable) Weights Dry Weight: Approx. 195 kg Gross Vehicle Weight Rating: Approx. 370 kg Wheels And Tires Front Tire Size: 120/70-15 Rear Tire Size: 160/60-15 Wheel Type: Alloy wheels 🛡️ Safety Features Ratings ABS: Optional or standard on SP model (check specific variant documentation) Active Features Braking: Dual disc front brakes, single disc rear brake, high-performance calipers. Lighting: Multi-reflector headlight, LED taillight, clear lens indicators. Passive Features Frame Construction: High-strength steel frame for rigidity and stability. Ergonomics: Comfortable riding position for extended journeys. 💡 Technology Features Infotainment Dashboard: Digital/analog combination instrument cluster displaying speed, RPM, fuel level, coolant temperature, and warning lights. Driver Assistance ABS: Available as an option, enhancing braking safety. Connectivity Lighting: Halogen headlight for good night visibility. 🔧 Maintenance Service Intervals Oil Change Interval:...