🏷️ Basic Information Identification Make: Gilera Model: Nexus 500sp Model Designation: Mk2 Year: 2005-2007 Codes Emissions Standard: Euro 3 👋 Introduction Market Position Vehicle Segment: Premium maxi-scooter. Target Audience: Commuters seeking performance and comfort, touring riders. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 650, BMW C650GT (later models), Honda Silver Wing. Key Features Performance Orientation: Known for its strong single-cylinder engine and sporty handling. Comfort And Ergonomics: Designed for long-distance riding with comfortable seating and wind protection. Technological Advancements: Incorporated modern features for its time, including fuel injection and potentially ABS. 📋 Manual Details Coverage Areas Market Coverage: Likely European markets due to Euro 3 designation. Page Count Estimated Page Count: Varies, but factory service manuals of this scope typically range from 300-700 pages. Manual Type Manual Type: Workshop Service Repair Manual Language Language: Likely English, potentially with other European languages depending on the source and distribution. Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, diagnostics, and specifications. Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel pressure regulation, and evaporative emissions control. Ignition System: Ignition coils, spark plugs, ECU control, and timing. Transmission: Automatic transmission (CVT - Continuously Variable Transmission) operation, maintenance, and repair. Chassis: Frame, swingarm, suspension (front and rear), steering system, and wheels. Brakes: Front and rear brake systems, including hydraulic lines, calipers, discs, master cylinders, and ABS (if equipped). Electrical System: Battery, charging system (alternator/stator), starter motor, lighting, wiring diagrams, fuses, relays, and ECU interfaces. Cooling System: Radiator, cooling fan, coolant hoses, thermostat, and coolant specifications. Exhaust System: Exhaust manifold, catalytic converter (Euro 3 compliant), muffler, and lambda sensor (oxygen sensor). Bodywork: Fairings, seat, handlebars, body panels, and trim component removal and installation. Diagnostic Troubleshooting: Fault code interpretation, diagnostic procedures, and troubleshooting guides for various systems. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment (if applicable, though likely belt or shaft drive), brake pad inspection, tire pressure checks. Major Repairs: Engine rebuilds, transmission overhaul, suspension component replacement, electrical system diagnostics and repair. Component Replacement: Detailed instructions for replacing parts such as brake discs, clutch components (if applicable), bearings, seals, and electrical sensors. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Disassembly Assembly: Step-by-step instructions for complete vehicle disassembly and reassembly. Technical Depth Depth Of Coverage: Factory-level, covering all aspects from basic maintenance to complete engine and transmission overhauls. Diagnostic Capability: Advanced diagnostics, including troubleshooting guides for electronic control units (ECU) and sensor-related issues. Rebuild Procedures: Detailed procedures for rebuilding major mechanical components, including tolerances and specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text, enabling quick access to information. Print Quality Printability: All pages are printable, allowing for physical copies. Binding Type Binding: Not applicable for PDF download, but a physical copy would typically be professionally bound. Paper Type Paper Quality: Not applicable for PDF download, but a physical copy would typically be printed on durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 4-stroke, SOHC, 4-valve single-cylinder. Displacement: 460cc (exact figure may vary slightly by specific sub-model, but around this mark). Bore X Stroke: Likely around 92mm x 84mm (typical for this engine family). Compression Ratio: Typically around 10.5:1 or higher. Power Output: Around 34-36 hp (25-27 kW) at 7000-7500 RPM (estimated based on class and era). Torque Output: Around 3.9-4.1 kgf-m (approx. 38-40 Nm or 28-30 lb-ft) at 5500-6000 RPM (estimated). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI). Fuel Type: Unleaded gasoline. Fuel Tank Capacity: Approximately 13-15 liters. 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission). Optional Optional Transmission: None. Features Transmission Features: Automatic clutch and variator system for seamless gear changes and optimal engine RPM. Final Drive: Likely belt drive or chain drive, depending on specific configuration; Belt drive is common for this class. 📐 Dimensions Exterior Length: Approximately 2150-2200 mm. Width: Approximately 760-780 mm. Height: Approximately 1380-1420 mm (seat height may vary). Wheelbase: Approximately 1530-1550 mm. Weights Dry Weight: Approximately 180-190 kg. Wet Weight: Approximately 195-205 kg (including fluids). 🛡️ Safety Features Ratings Safety Ratings: No formal crash test ratings for motorcycles/scooters in the same way as cars; relies on design and component integrity. Active Features Braking System: Disc brakes front and rear, often with a combined braking system or ABS as an option on some models. Lighting: Halogen or projector headlamps, LED tail lights (common for this era). Passive Features Chassis Design: Robust frame designed for stability and handling. Tires: Tubeless tires, typically of a sport-touring profile for good grip and stability. 💡 Technology Features Infotainment Dashboard Display: Digital and analog combination instrument cluster, likely including speedometer, tachometer, fuel gauge, temperature gauge, and indicator lights. Driver Assistance ABS Availability: Optional ABS (Anti-lock...