🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: MK2 Year Range: 2005 onwards Variant: SP (Sport Production) Emission Standard: Euro 3 Codes Product Identifier: GILERA_NEXUS_500SP_EURO3_MK2_2005_ONWARDS_PDF 👋 Introduction Market Position Positioning: The Gilera Nexus 500SP was positioned as a high-performance, premium maxi-scooter, blending sporty handling with touring comfort, aimed at riders seeking a more engaging and powerful experience than typical urban scooters. Competitive Analysis Competitors: Competed with other large-displacement maxi-scooters of its era, such as the Suzuki Burgman 400/650, Yamaha TMAX 500, and Aprilia Atlantic 500, focusing on its Italian flair and dynamic capabilities. Key Features Features: Powerful 500cc engine, sophisticated chassis design for agile handling, premium build quality, often equipped with higher-spec components on SP models, comfortable riding position. 📋 Manual Details Coverage Areas Coverage: Comprehensive workshop, service, and repair procedures Page Count Page Count: Estimated 400-600 pages (typical for comprehensive workshop manuals) Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine disassembly, assembly, inspection, troubleshooting, performance tuning, fuel injection system (EFI), ignition system, cooling system, lubrication system, exhaust system. Transmission: Automatic transmission (CVT) maintenance, repair, component identification, fluid specifications. Chassis: Frame, suspension (front and rear), steering system, wheel bearings, swingarm. Brakes: Brake system diagnostics, component replacement (discs, pads, calipers, master cylinders, lines), bleeding procedures, ABS system (if applicable). Electrical: Wiring diagrams, battery, starter motor, alternator, lighting system, instrument cluster, ECU, sensors, fuses, relays, diagnostic codes. Bodywork: Fairings, seat, fuel tank, body panel removal and installation, trim components, lighting units. Cooling System: Radiator, coolant hoses, thermostat, coolant specifications, bleeding procedures. Fuel System: Fuel pump, fuel filter, injectors, fuel tank, pressure regulation. Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, chain/belt adjustment, brake fluid flush, coolant replacement, air filter cleaning/replacement. Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation. Repair: Detailed instructions for component removal, repair, and reinstallation for all major systems. Diagnostics: On-board diagnostics (OBD) procedures, sensor testing, ECU diagnostics. Rebuilds: Complete engine and transmission overhaul procedures, including component specifications and tolerances. Technical Depth Depth: Professional-level, covering everything from routine maintenance to full engine and transmission rebuilds, with detailed diagrams and specifications. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing all diagrams and text clearly. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, single-cylinder, liquid-cooled Displacement: 493 cc (approx.) Bore X Stroke: Approximately 94 mm x 71 mm Compression Ratio: Approximately 10.5:1 Valvetrain: SOHC, 4 valves Performance Max Power: Approximately 30-35 HP (at 7,000 rpm) Max Torque: Approximately 45-50 Nm (at 5,000 rpm) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (95 RON recommended) Lubrication Oil Type: SAE 5W-40 Synthetic Motorcycle Oil Oil Capacity: Approximately 1.7 - 1.9 Liters (with filter change) Cooling System Coolant Type: Ethylene Glycol based coolant (50% mix with distilled water) 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Features Drive System: Belt drive to rear wheel Transmission Fluid: Refer to manual for specific CVT fluid type and capacity (often proprietary or specific grades). 📐 Dimensions Exterior Length: Approx. 2220 mm Width: Approx. 770 mm Height: Approx. 1370 mm Wheelbase: Approx. 1570 mm Weights Dry Weight: Approx. 190 kg Gross Vehicle Weight: Approx. 350 kg Max Payload: Approx. 160 kg Fuel Tank Capacity: Approx. 15 Liters (including reserve) 🛡️ Safety Features Ratings Crash Safety: Motorcycle-specific safety features; no formal car-like crash test ratings. Active Features Braking System: Front: Dual disc brakes. Rear: Single disc brake. ABS may be optional or standard on certain SP models. Lighting: Halogen headlights, LED taillight, turn signals. Passive Features Frame Construction: High-strength steel frame. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog combination instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meters, and warning lights. Driver Assistance ABS: Anti-lock Braking System (ABS) available as an option or standard on some models. Connectivity ECU: Engine Control Unit (ECU) managing fuel injection and ignition timing. 🔧 Maintenance Service Intervals Oil Change Interval: Every 4,000-6,000 km or annually. Air Filter Maintenance: Inspect every 6,000 km, clean/replace as needed. Spark Plug Replacement: Every 10,000-12,000 km. Brake Fluid Replacement: Every 2 years. Coolant Replacement: Every 2-3 years. Cvt Belt Inspection: Inspect for wear and damage every 12,000 km, replace as needed. Fluid Specifications Engine Oil Spec: API SG/SH/SJ/SL or JASO MA/MA2 certified SAE 5W-40 synthetic motorcycle oil. Brake Fluid Spec: DOT 4 Coolant Spec: Ethylene Glycol based, pre-mixed 50% with distilled water. Known Issues Common Issues: Potential for stator/regulator issues, water pump leaks, throttle body cleaning requirements, variator/belt wear over time. These are general maxi-scooter considerations, specific issues would be detailed in the manual. 📚 Vehicle History Brand Heritage Heritage: Gilera, an Italian...