The Gilera Nexus 500SP, produced between 2005 and 2007, is a maxi-scooter designed for both urban commuting and longer touring rides, offering a blend of sporty handling and practical comfort. This manufactured model emphasizes performance with its approximately 500cc, single-cylinder, 4-stroke engine, delivering robust power suitable for highway speeds. Its design focuses on a capable riding experience, positioning it as a competitor in the premium scooter market. This comprehensive factory service repair workshop manual provides detailed guidance for maintaining and repairing the Gilera Nexus 500SP Euro 3 MK2. It covers all essential systems, including the engine, fuel, cooling, electrical, braking, suspension, transmission, and chassis. The manual includes step-by-step instructions, diagnostic procedures, and technical specifications, making it an invaluable resource for owners and professional technicians alike to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Year: 2005-2007 Variant: Euro 3 MK2 Codes Engine Code: M321 (Likely, based on Piaggio Quasar engine family) 👋 Introduction Market Position Vehicle Type: Maxi-scooter / Sport scooter Target Market: Urban commuters and touring riders seeking performance and comfort Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400, Honda Silver Wing 400/600 Key Features Engine Size: 500cc class Performance Focus: Sporty handling and capable performance for highway use Manual Benefit: Cost-effective vehicle maintenance and repair 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: PDF Download Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader & WinZip Features: Instant Download, Printable Pages 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, diagnostics, and specifications Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulation Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant type and capacity Electrical System: Wiring diagrams, ignition system, lighting, charging system, starter, battery Braking System: Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications Suspension: Front telescopic fork and rear shock absorber service, adjustments, and specifications Chassis: Frame, body panels, fairings, seat, storage compartment removal and installation Transmission: CVT (Continuously Variable Transmission) removal, inspection, and maintenance Maintenance: Scheduled maintenance intervals, fluid checks and changes, filter replacements, spark plug service Troubleshooting: Diagnostic procedures for common issues, fault code interpretation (if applicable) Tooling: Special tools required for various service and repair procedures Pre Delivery: Pre-delivery inspection checklist and procedures Characteristics: General vehicle characteristics and specifications Procedures Included Engine Rebuild: Detailed step-by-step instructions for complete engine disassembly and reassembly Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams and diagnostic techniques Brake System Overhaul: Service and replacement of brake components including calipers, lines, and master cylinders Suspension Setup: Adjustments and maintenance for front forks and rear shock absorber units Fuel Injection Tuning: Information on fuel injection system servicing and potential tuning adjustments Bodywork Repair: Removal, installation, and repair of body panels and fairings Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine rebuilds) Diagrams: High-quality, detailed exploded diagrams and illustrations Instructions: Step-by-step written instructions Target Audience: Do-it-yourselfers and experienced mechanics 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text content within the PDF Print Quality Printability: All pages printable Image Quality: Top quality diagrams Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 4-stroke, liquid-cooled Displacement: 493 cc (approx.) Bore X Stroke: 94 mm x 71 mm (Likely, based on Piaggio Quasar 300/340 engines) Compression Ratio: 10.5:1 (Typical for this engine family) Performance Horsepower: Approx. 39 HP @ 7500 RPM (Estimate, based on similar engines) Torque: Approx. 45 Nm @ 5500 RPM (Estimate, based on similar engines) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with throttle body Ignition: Electronic ignition with variable advance Emission Control Emission Standard: Euro 3 compliant 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) with torque converter Optional Optional Transmission: N/A Features Drive Type: Belt drive to rear wheel 📐 Dimensions Exterior Length: Approx. 2150 mm Width: Approx. 780 mm (Handlebar width) Height: Approx. 1440 mm (Including windshield) Wheelbase: Approx. 1520 mm Weights Dry Weight: Approx. 190 kg Gross Vehicle Weight Rating: Approx. 360 kg (Estimate) Fuel Tank Capacity: Approx. 15 Liters 🛡️ Safety Features Ratings Safety Compliance: Euro 3 emissions compliance Active Features Braking System: Dual disc front brakes, single disc rear brake. ABS likely optional or not standard on all models. Lighting: Halogen headlights, LED taillight Passive Features Frame Construction: High-strength steel frame 💡 Technology Features Infotainment Dashboard: Analogue speedometer and tachometer, digital multi-function display Driver Assistance ABS: Optional Anti-lock Braking System (ABS) availability Connectivity Connectivity Features: N/A (No advanced connectivity features expected for this era) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 1 year (Typical, consult manual for exact) Air Filter Check: Every 6,000 km (Typical, consult manual for exact) Spark Plug Replacement: Every 12,000 km...