The Nexus 500SP Mk2, produced between 2005 and 2007, represents a commitment to the premium maxi-scooter segment, offering a blend of sporty performance and touring comfort. Known for its powerful 493cc liquid-cooled engine, agile handling, and premium features, this model stands as a capable machine in its class. An Italian manufacturer with a rich heritage in motorcycling and part of a larger group, the Nexus 500SP Mk2 was engineered to provide an engaging riding experience, competing with other prominent maxi-scooters of its era. This comprehensive Factory Service Repair Manual provides all necessary information for the maintenance and repair of the Nexus 500SP Mk2. It covers an extensive range of topics, including detailed procedures for engine mechanics, fuel injection systems, electrical systems, braking, suspension, cooling, and chassis work. The manual includes routine maintenance, troubleshooting guides with diagnostic charts, rebuilding procedures, and essential technical specifications. It is designed to empower owners, mechanics, and technicians with the factory-level knowledge needed to keep the vehicle in optimal condition. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2005-2007 Vehicle Type: Maxi-scooter Product Type: Factory Service Repair Manual 👋 Introduction Market Position Segment: Premium maxi-scooter segment, known for sportiness and touring capabilities. Competitive Analysis Competitors: Yamaha TMAX, Suzuki Burgman 400/650, BMW C650GT. Key Features Vehicle Strengths: Powerful engine, agile handling, comfortable ride, premium features for its class. Manual Value Proposition Value For Money: Provides factory-level diagnostic and repair information, enabling significant cost savings compared to dealership servicing. 📋 Manual Details Coverage Areas Primary Coverage: All repair and service procedures for the Gilera Nexus 500SP Mk2 (2005-2007) Page Count Estimated Page Count: Extensive (specific count not provided, but described as 'complete' and covering all procedures) Manual Type Type: Factory Service Repair Manual Language Language: ENGLISH Format File Format: PDF/ZIP 📖 Manual Coverage Systems Covered Engine Mechanics: Complete engine disassembly, assembly, inspection, and repair procedures Engine Management: Fuel injection system diagnosis and repair, electronic control unit (ECU) information Electrical System: Wiring diagrams, component testing, troubleshooting for all electrical systems Braking System: Front and rear brake system maintenance, repair, bleeding procedures, component replacement Suspension System: Front fork and rear shock absorber maintenance, adjustment, and overhaul Cooling System: Radiator, fan, coolant circulation system maintenance and repair Chassis And Bodywork: Frame inspection, body panel removal and installation, fairing repair Engine Components: Cylinder head, piston, crankshaft, lubrication system, valve train, timing Fuel System Components: Fuel pump, fuel injectors, throttle body, fuel pressure regulator Exhaust System: Catalytic converter, mufflers, exhaust manifold inspection and repair Wheels And Tires: Tire inspection, pressure, wheel bearing maintenance, wheel removal/installation Steering System: Handlebar, steering head bearings, fork alignment Lighting And Indicators: Headlights, taillights, brake lights, turn signals, wiring and bulbs Instrumentation And Gauges: Speedometer, tachometer, warning lights, electrical connections Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, drive belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon issues, fault code interpretation Rebuilding Procedures: Complete engine rebuild procedures, transmission overhaul (if applicable to the platform) Pre Delivery Inspection: Factory pre-delivery inspection checklist and procedures Torque Specifications: Detailed torque values for all critical fasteners throughout the vehicle Diagnostic Charts: Systematic troubleshooting charts for various operational faults Assembly Illustrations: Exploded views and step-by-step illustrations for component reassembly Timing Procedures: Engine timing procedures, valve clearance adjustments Technical Depth Depth: Comprehensive: From basic maintenance and adjustments to advanced diagnostics and complete component overhauls, suitable for professional technicians and skilled DIY enthusiasts. Diagnostic Tools: Information on required special tools and diagnostic equipment for proper service 📊 Manual Specifications File Format Compatibility: WIN/MAC/LINUX Requirement: Requires unzipper software (e.g., WinRAR) Accessibility: Instant download, accessible across multiple operating systems Print Quality Quality Description: Digital PDF format, typically high resolution suitable for clear viewing and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke Displacement: 493 cc (approximately) Bore X Stroke: Specific dimensions would be detailed in the manual Cooling System: Liquid-cooled Performance Horsepower: Approx. 40-45 HP (specific rating varies by market/tune) Torque: Specific torque figures would be detailed in the manual Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (RON 95 or higher recommended) Ignition System Ignition Type: Electronic ignition, digitally controlled 🔧 Transmission Primary Transmission Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Specific dimensions would be detailed in the manual Width: Specific dimensions would be detailed in the manual Height: Specific dimensions would be detailed in the manual Weights Dry Weight: Approx. 190-200 kg (specific weight varies by specification) Gross Vehicle Weight Rating: Specific GVWR would be detailed in the manual Capacity Fuel Tank Capacity: Approx. 15 liters (specific capacity would be detailed in the manual) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles/Scooters...