🏷️ Basic Information Identification Make: Gilera Model: Nexus 500 SP Generation: Mk2 Year: 2005 onwards Engine Code: M380 (likely Piaggio Quasar 300 variant with larger bore) Chassis Code: ZAPM38100 (likely) Codes Emission Standard: Euro 3 👋 Introduction Market Position Segment: High-performance maxi-scooter Target Audience: Enthusiasts and owners seeking in-depth knowledge for maintenance, repair, and customization of their Gilera Nexus 500 SP. Competitive Analysis Competitors: Yamaha TMAX 500, Suzuki Burgman 650, Aprilia Scarabeo 500, BMW C 600 Sport (during its era) Key Features Performance Focus: Designed for sportier performance compared to typical maxi-scooters, offering strong acceleration and handling. Ergonomics: Emphasis on comfortable ergonomics for longer rides, often with a motorcycle-like riding position. 📋 Manual Details Coverage Areas Engine: Complete overhaul, diagnosis, troubleshooting, performance tuning Transmission: Automatic CVT (Continuously Variable Transmission) maintenance, belt replacement, clutch inspection Chassis: Frame, suspension (front forks, rear shock), steering system, wheel bearings Brakes: Front and rear brake systems, hydraulic lines, calipers, master cylinders, ABS (if equipped) Electrical System: Wiring diagrams, battery, starter, alternator, lighting, ignition system, electronic control unit (ECU) Bodywork: Fairings, seat, storage compartments, panel removal and installation Cooling System: Radiator, fan, coolant flow, thermostat Fuel System: Fuel injection system, fuel pump, injectors, fuel lines, fuel tank Exhaust System: Exhaust manifold, catalytic converter, muffler Troubleshooting: Diagnostic procedures for common and uncommon faults Specifications: Torque values, clearances, fluid capacities, electrical resistance Page Count Approximate Pages: Estimated 300-500 pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Core Systems: Engine, Fuel System, Ignition System, Exhaust, Cooling System, Transmission, Brakes, Suspension, Steering, Electrical System, Lighting, Bodywork Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake pad replacement Repair: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper servicing, electrical component diagnosis and replacement, fuel injector cleaning/replacement Troubleshooting: Fault finding charts, diagnostic flowcharts, symptom-based troubleshooting Disassembly Assembly: Step-by-step instructions for disassembling and reassembling all major components and sub-assemblies Technical Depth Depth: Comprehensive: Covers everything from basic user maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and repair. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Searchability: Likely text-searchable, allowing quick access to specific information. Image Resolution: High-resolution diagrams, illustrations, and photographs for clarity. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder, SOHC, 4 valves Displacement: 492.7 cc (approximately) Bore X Stroke: Approx. 94 mm x 71 mm Performance Horsepower: Approximately 40 HP (at 7,500 rpm) for the 500 SP model Torque: Approximately 45 Nm (at 5,500 rpm) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Marelli or Keihin ECU Fuel Type: Unleaded Petrol (95 RON recommended) Ignition System Ignition: Electronic CDI with variable ignition timing Lubrication Oil Type: API SG/SH/SJ or JASO MA/MA2 specification, SAE 10W-40 or 15W-50 synthetic motorcycle oil recommended. Cooling System Coolant Type: Ethylene glycol-based antifreeze/coolant mixture (50% water, 50% coolant) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Optional Optional Transmission: N/A Features Drive System: Belt drive to rear wheel via enclosed chain/belt final drive Clutch: Automatic centrifugal dry clutch Transmission Oil: N/A (CVT system does not typically require separate transmission oil, but primary drive may have a small oil bath for clutch mechanism depending on specific Piaggio Quasar evolution) 📐 Dimensions Exterior Length: Approx. 2,150 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1,460 mm (at windshield) Wheelbase: Approx. 1,520 mm Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 203 kg (with fluids) Max Load: Approx. 180 kg (rider and passenger) Cargo Storage: Under-seat storage compartment, often accommodating one full-face helmet. 🛡️ Safety Features Ratings Crash Safety: N/A (Motorcycle/Scooter specific crash ratings like NCAP are not typically published) Active Features Braking System: Front: Dual 280mm discs with 4-piston calipers; Rear: 280mm disc with 2-piston caliper. ABS (Anti-lock Braking System) often optional or standard on SP models. Lighting: Dual Halogen headlights, LED taillight and brake light. Passive Features Frame Construction: High-strength steel frame for rigidity and stability. Tires: Front: 120/70-15; Rear: 160/60-15 (typical) 💡 Technology Features Infotainment Dashboard: Digital/analog combination instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meters, and warning lights. Driver Assistance ABS: Anti-lock Braking System (ABS) available on certain models/trims for enhanced safety. Connectivity Diagnostic Port: On-board diagnostic (OBD) port for electronic diagnostics and fault code retrieval. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or annually, whichever comes first. Air Filter Interval: Inspect every 12,000 km, replace as needed. Spark Plug Interval: Replace every 12,000 km or as per manufacturer recommendation (check manual for specific type and gap). Transmission Belt Interval: Inspect every 12,000 km, replace between 18,000-24,000 km or as per wear indicators....