This document provides comprehensive service information for the Gilera Nexus 500SP Mk2, produced in 2005. As a performance-oriented maxi-scooter, the Nexus 500SP Mk2 combines the practicality of scooter design with the dynamic capabilities of a motorcycle. It features sporty, aerodynamic styling, a powerful 492.6 cc single-cylinder engine delivering approximately 40 HP, and a chassis geometry designed for stability and responsive handling. The Gilera Nexus series is recognized for its ability to offer comfortable urban mobility alongside capable performance for longer journeys, distinguishing itself within its segment through a blend of speed, agility, and distinctive Italian design. This factory service repair manual is meticulously compiled to assist mechanics and DIY enthusiasts in maintaining and repairing the Gilera Nexus 500SP Mk2. It covers a wide array of essential areas, including detailed procedures for engine mechanicals, fuel and ignition systems, cooling and lubrication, transmission, chassis, braking, and electrical systems. The manual offers step-by-step instructions for regular maintenance, troubleshooting common issues, component disassembly and assembly, and performance adjustments. With its in-depth technical specifications and clear diagnostic guidance, this resource is an indispensable tool for ensuring the optimal performance, reliability, and longevity of your vehicle. 🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2005 Product Type: Factory Service Repair Manual Format: PDF Download 👋 Introduction Market Position Segment: Maxi-scooter, performance-oriented urban mobility Usp: Combines scooter practicality with motorcycle-like performance and handling Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman 400/650, Aprilia Scarabeo 500 Key Features Design: Sporty, aerodynamic styling with motorcycle-inspired ergonomics Performance: Powerful 500cc engine, capable of highway speeds and brisk acceleration Handling: Large diameter wheels, robust suspension, and motorcycle-like chassis geometry Practicality: Underseat storage, comfortable seating for rider and passenger, good weather protection 📋 Manual Details Coverage Areas General Coverage: Repair, maintenance, and adjustments Target Audience: Mechanics and DIY persons Page Count Estimated Pages: Likely 300-500 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual Language Language: English (assumed based on product description) Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, and repair of engine components (cylinder, piston, crankshaft, valves, etc.) Fuel System: Fuel injection system, fuel pump, injectors, fuel filter, fuel tank maintenance Ignition System: Ignition coil, spark plug, ECU control of ignition timing Cooling System: Radiator, coolant circulation, thermostat, fan operation Lubrication System: Oil pump, oil filter, oil passages, oil change procedures Transmission Drivetrain: Automatic transmission (CVT), belt replacement, clutch operation, final drive maintenance Chassis Frame: Frame inspection, front fork assembly, rear shock absorber, swingarm maintenance Braking System: Brake calipers, master cylinders, brake lines, brake fluid replacement, disc and pad inspection/replacement Electrical System: Wiring diagrams, battery maintenance, lighting systems, starter motor, charging system (alternator/stator) Instrumentation Controls: Dashboard instruments, handlebar controls, electronic unit (ECU) functions Bodywork Fairings: Removal and installation of body panels, fairings, seat, and related components Exhaust System: Exhaust pipe, muffler, catalytic converter maintenance Procedures Included Regular Maintenance: Oil changes, filter replacements, spark plug checks, chain/belt adjustments, tire pressure Troubleshooting: Diagnosis of common problems, error codes (if applicable), symptom-based troubleshooting guides Disassembly Assembly: Step-by-step instructions for removing and reinstalling major components and sub-assemblies Repair Rebuild: Detailed procedures for repairing or rebuilding specific engine, transmission, and chassis components Inspections Checks: Visual inspections, functional checks, torque specifications for critical fasteners Adjustment Calibration: Carburetor (if applicable, though likely FI for this model), throttle cable, brake lever adjustments Wiring Diagrams: Comprehensive electrical schematics for easy diagnosis and repair of electrical faults Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds Diagnostic Focus: Includes diagnostic procedures for common malfunctions and system failures 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Likely text-searchable (standard for factory PDFs), allowing for quick information retrieval Print Quality Resolution: High resolution, suitable for printing individual pages or the entire manual Layout: Professional layout with clear diagrams, illustrations, and text formatting Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Type: Single-cylinder, four-stroke, liquid-cooled, OHC Displacement: 492.6 cc Bore X Stroke: 92 mm x 95.2 mm (typical for this engine family) Compression Ratio: 10.0:1 (typical) Performance Horsepower: Approx. 40 HP (30 kW) at 7,000 RPM (manufacturer stated figures may vary slightly) Torque: Approx. 45 Nm (33 lb-ft) at 5,000 RPM (manufacturer stated figures may vary slightly) Fuel System Induction: Electronic Fuel Injection (EFI), likely with Marelli or Piaggio ECU Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication Oil Type: SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity: Approx. 1.7 liters (including filter, consult manual for precise capacity) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Optional Options: N/A (CVT is standard) Features Drive Belt: Reinforced V-belt drive system Final Drive: Gear drive (often with a shared oil sump for transmission and final drive,...