🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500SP

Generation:

MK2

Production Years:

2005 onwards

Platform Code:

V36

Emissions Standard:

Euro 3

👋 Introduction

Vehicle Type:

Maxi-scooter / Sport Scooter

Target Audience:

Commuters, touring riders seeking performance and comfort.

Key Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 600, Aprilia Atlantic 500.

Performance Focus:

The 'SP' designation typically implies a sportier, higher-performance variant.

Design Philosophy:

Combines the practicality of a scooter with motorcycle-like performance and handling.

📋 Manual Details

Systems Covered:

Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Transmission, Clutch, Brakes (Front & Rear), Suspension (Front & Rear), Steering, Electrical System, Wiring Diagrams, Bodywork, Frame, Wheels & Tires, Diagnostic Procedures, Troubleshooting, Periodic Maintenance.

Page Count:

Hundreds of Pages (Exact number not specified, but implies comprehensive coverage)

Manual Type:

Service Repair Manual

Language:

English (Assumed, typical for such manuals)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete overhaul and repair of the 500cc engine, including cylinder head, valves, piston, crankshaft, connecting rod, timing components.

Fuel System:

EFI system diagnostics, fuel pump, injectors, throttle body, fuel pressure regulation.

Ignition System:

Ignition coil, spark plug, ECU control, diagnostic codes.

Cooling System:

Radiator, fan, thermostat, coolant, water pump, hoses.

Lubrication System:

Oil pump, oil filter, oil cooler, oil specifications, oil change procedures.

Transmission Drivetrain:

Automatic CVT transmission maintenance, belt replacement, clutch operation, final drive.

Braking System:

Front and rear disc brake systems, hydraulic lines, master cylinders, calipers, brake pad replacement, bleeding procedures.

Suspension Steering:

Front telescopic forks (likely USD), rear monoshock absorber, linkage, steering head bearings, wheel bearings.

Electrical System:

Battery, starter motor, alternator, lighting, horn, indicators, ECU, fuse box, wiring harness repair.

Bodywork Chassis:

Fairing removal and installation, seat, storage compartment, frame inspection, body panel repair.

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, brake fluid changes, coolant flushes, spark plug checks, chain/belt adjustment (if applicable to final drive).

Repair Procedures:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly.

Troubleshooting:

Diagnostic flowcharts and common issue identification for various systems.

Diagnostics:

Fault code reading (if applicable to diagnostic port), sensor testing, electrical system troubleshooting.

Torque Specifications:

All critical fasteners with precise torque values for engine, chassis, and suspension components.

Depth Of Coverage:

Comprehensive; suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capability:

Advanced, includes wiring diagrams and component testing procedures.

Rebuild Instructions:

Detailed rebuild instructions for major mechanical components.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High Resolution (Implied by 'Highly Detailed', suitable for printing)

Binding Type:

N/A (Digital Download - PDF)

Paper Type:

N/A (Digital Download - PDF)

Searchability:

Likely searchable text within the PDF for easy navigation.

⚙️ Engine Specifications

Engine Type:

Four-stroke, Single-cylinder, Liquid-cooled, DOHC

Displacement:

493 cc (approx.)

Bore X Stroke:

Typically around 94mm x 71mm (specific to this model, needs manual verification for exact figures).

Compression Ratio:

Usually around 10.0:1 to 10.5:1 (needs manual verification).

Horsepower:

Around 39-40 HP (approx. @ 7,000 RPM, needs manual verification).

Torque:

Around 45-46 Nm (approx. @ 5,500 RPM, needs manual verification).

Fuel Injection:

Electronic Fuel Injection (EFI) - likely Marelli or similar.

Fuel Type:

Unleaded Petrol (95 RON recommended)

Oil Type:

Synthetic SAE 5W-40 or 10W-40 (API SG or higher, JASO MA/MA2)

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Clutch Type:

Automatic centrifugal clutch

Drive Type:

Belt drive to rear wheel

📐 Dimensions

Length:

Approx. 2,150 mm (needs manual verification)

Width:

Approx. 790 mm (needs manual verification)

Height:

Approx. 1,430 mm (needs manual verification)

Wheelbase:

Approx. 1,575 mm (needs manual verification)

Dry Weight:

Approx. 190 kg (needs manual verification)

Gross Vehicle Weight:

Approx. 390 kg (needs manual verification)

Underseat Storage:

Ample storage for one full-face helmet and other items.

🛡️ Safety Features

Frame Construction:

High-tensile steel trellis frame for rigidity.

Braking System:

Dual front disc brakes, single rear disc brake. ABS was often an option on SP models.

Lighting:

Halogen headlights, LED tail light (depending on specific MY features).

Body Protection:

Full fairing for rider protection from elements.

💡 Technology Features

Dashboard:

Digital and analog instrument cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meters, and warning lights.

ABS Availability:

Optional ABS system on SP models.

Diagnostic Port:

On-board diagnostic connector for fault code retrieval and system analysis.

🔧 Maintenance

Oil Change Interval:

Every 6,000 - 10,000 km or annually (specific interval in manual).

Spark Plug Inspection:

Every 10,000 - 15,000 km.

Air Filter Cleaning Replacement:

Every 5,000 - 10,000 km.

Coolant Replacement:

Every 2 years or 20,000 km.

Brake Fluid:

DOT 4 (refer to manual for specific grades).

Coolant Type:

Ethylene glycol-based coolant (50/50 mix with distilled water).

Common Wear Items:

CVT belt, brake pads, tires, battery, voltage regulator (common in many scooters).

Potential Failures:

Fuel pump issues (rare), stator coil failures, suspension wear. Regular maintenance mitigates most issues.

Engine Oil Capacity:

Approx. 1.6 - 1.8 liters (with filter change, needs manual verification).

Coolant Capacity:

Approx. 1.2 - 1.5 liters (needs manual verification).

📚 Vehicle History

Manufacturer:

Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, now part of the Piaggio Group.

Nexus Series:

The Nexus series was Gilera's flagship sporty maxi-scooter line, competing in the premium segment.

Mk2 Updates:

The MK2 represents a refinement of the original Nexus, often with styling and technical updates to meet Euro 3 emissions.

Manufacturing Location:

Italy

🏆 Awards & Recognition

Industry Acclaim:

The Gilera Nexus series was generally well-received for its performance and handling in the maxi-scooter segment, earning praise in various motorcycle publications.