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2005-2007 Gilera Nexus 500SP Mk2 Factory Service Repair Manual 2006

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2005-2007 Vehicle Type: Maxi-scooter Product Type: Factory Service Repair Manual 👋 Introduction Market Position Segment: Premium maxi-scooter segment, known...
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2005-2007 Gilera Nexus 500SP Mk2 Factory Service Repair Manual 20062005-2007 Gilera Nexus 500SP Mk2 Factory Service Repair Manual 20062005-2007 Gilera Nexus 500SP Mk2 Factory Service Repair Manual 20062005-2007 Gilera Nexus 500SP Mk2 Factory Service Repair Manual 2006
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Nexus 500SP Mk2
Year:
2005-2007
Vehicle Type:
Maxi-scooter
Product Type:
Factory Service Repair Manual
👋 Introduction
Market Position
Segment:
Premium maxi-scooter segment, known for sportiness and touring capabilities.
Competitive Analysis
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, BMW C650GT.
Key Features
Vehicle Strengths:
Powerful engine, agile handling, comfortable ride, premium features for its class.
Manual Value Proposition
Value For Money:
Provides factory-level diagnostic and repair information, enabling significant cost savings compared to dealership servicing.
📋 Manual Details
Coverage Areas
Primary Coverage:
All repair and service procedures for the Gilera Nexus 500SP Mk2 (2005-2007)
Page Count
Estimated Page Count:
Extensive (specific count not provided, but described as 'complete' and covering all procedures)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
ENGLISH
Format
File Format:
PDF/ZIP
📖 Manual Coverage
Systems Covered
Engine Mechanics:
Complete engine disassembly, assembly, inspection, and repair procedures
Engine Management:
Fuel injection system diagnosis and repair, electronic control unit (ECU) information
Electrical System:
Wiring diagrams, component testing, troubleshooting for all electrical systems
Braking System:
Front and rear brake system maintenance, repair, bleeding procedures, component replacement
Suspension System:
Front fork and rear shock absorber maintenance, adjustment, and overhaul
Cooling System:
Radiator, fan, coolant circulation system maintenance and repair
Chassis And Bodywork:
Frame inspection, body panel removal and installation, fairing repair
Engine Components:
Cylinder head, piston, crankshaft, lubrication system, valve train, timing
Fuel System Components:
Fuel pump, fuel injectors, throttle body, fuel pressure regulator
Exhaust System:
Catalytic converter, mufflers, exhaust manifold inspection and repair
Wheels And Tires:
Tire inspection, pressure, wheel bearing maintenance, wheel removal/installation
Steering System:
Handlebar, steering head bearings, fork alignment
Lighting And Indicators:
Headlights, taillights, brake lights, turn signals, wiring and bulbs
Instrumentation And Gauges:
Speedometer, tachometer, warning lights, electrical connections
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, drive belt inspection/replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation
Rebuilding Procedures:
Complete engine rebuild procedures, transmission overhaul (if applicable to the platform)
Pre Delivery Inspection:
Factory pre-delivery inspection checklist and procedures
Torque Specifications:
Detailed torque values for all critical fasteners throughout the vehicle
Diagnostic Charts:
Systematic troubleshooting charts for various operational faults
Assembly Illustrations:
Exploded views and step-by-step illustrations for component reassembly
Timing Procedures:
Engine timing procedures, valve clearance adjustments
Technical Depth
Depth:
Comprehensive: From basic maintenance and adjustments to advanced diagnostics and complete component overhauls, suitable for professional technicians and skilled DIY enthusiasts.
Diagnostic Tools:
Information on required special tools and diagnostic equipment for proper service
📊 Manual Specifications
File Format
Compatibility:
WIN/MAC/LINUX
Requirement:
Requires unzipper software (e.g., WinRAR)
Accessibility:
Instant download, accessible across multiple operating systems
Print Quality
Quality Description:
Digital PDF format, typically high resolution suitable for clear viewing and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, 4-stroke
Displacement:
493 cc (approximately)
Bore X Stroke:
Specific dimensions would be detailed in the manual
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 40-45 HP (specific rating varies by market/tune)
Torque:
Specific torque figures would be detailed in the manual
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (RON 95 or higher recommended)
Ignition System
Ignition Type:
Electronic ignition, digitally controlled
🔧 Transmission
Primary Transmission
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Drive Type:
Belt drive to rear wheel
Features
Clutch Type:
Automatic centrifugal clutch
📐 Dimensions
Exterior
Length:
Specific dimensions would be detailed in the manual
Width:
Specific dimensions would be detailed in the manual
Height:
Specific dimensions would be detailed in the manual
Weights
Dry Weight:
Approx. 190-200 kg (specific weight varies by specification)
Gross Vehicle Weight Rating:
Specific GVWR would be detailed in the manual
Capacity
Fuel Tank Capacity:
Approx. 15 liters (specific capacity would be detailed in the manual)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycles/Scooters typically do not undergo standardized crash testing like cars)
Active Features
Braking System Type:
Dual disc front brakes, single disc rear brake. ABS was often an optional feature on this model, detailed in the manual.
Passive Features
Lighting System:
Halogen headlights, LED taillights (typical for the era)
💡 Technology Features
Infotainment
Dashboard Features:
Digital and analog instrumentation including speedometer, tachometer, fuel gauge, temperature gauge, clock, mileage displays.
Driver Assistance
ABS Availability:
Anti-lock Braking System (ABS) was an optional feature for certain models/years, details on its operation and maintenance are in the manual.
Connectivity
Diagnostic Ports:
On-board diagnostic (OBD) port or manufacturer-specific diagnostic connectors for engine management and fault code retrieval, covered in the manual.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,000 km or annually (refer to manual for exact intervals)
Air Filter Replacement:
Inspect regularly, replace as per manual recommendations (e.g., every 10,000-15,000 km)
Spark Plug Replacement:
Typically every 10,000-12,000 km (specific plug type and gap detailed in manual)
Transmission Fluid Change:
Refer to manual for CVT fluid change intervals, often tied to mileage or time.
Fluid Specifications
Engine Oil Type:
Fully synthetic 4-stroke motorcycle oil, e.g., API SG/SH/SJ or higher, SAE 5W-40 or 10W-40 (specific viscosity and capacity detailed in manual)
Coolant Type:
Ethylene glycol-based antifreeze/coolant (specific type and mixture ratio detailed in manual)
Brake Fluid Type:
DOT 4 brake fluid (specific type and bleeding procedure detailed in manual)
Known Issues
Common Wear Items:
Drive belt, suspension components (fork seals, rear shock), braking system wear parts (pads, discs), exhaust system.
Common Issues
Electrical Gremlins:
Potential for minor electrical connection issues or sensor faults, which this manual will help diagnose.
Fuel Injection Performance:
Periodic cleaning of injectors or adjustment of fuel mapping may be required, covered in manual.
📚 Vehicle History
Brand Heritage
Heritage Summary:
Gilera is an Italian manufacturer with a long history in motorcycling, known for performance and sporty designs. Part of the Piaggio Group.
Model Evolution
Generations:
The Nexus series represented Gilera's entry into the maxi-scooter market, with the 500SP being a significant iteration.
Production
Production Period:
The Mk2 version was produced from approximately 2005 to 2007.
🏆 Awards & Recognition
Recognitions
Awards:
Specific awards for the Gilera Nexus 500SP are not widely documented, but it was generally well-regarded for its performance and handling in its class.
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