🏷️ Basic Information

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)

Emission Standard:

Euro 3

👋 Introduction

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.

Competitors:

Yamaha TMAX 500, Suzuki Burgman 650, Aprilia Scarabeo 500, BMW C 600 Sport (during its era)

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

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

Approximate Pages:

Estimated 300-500 pages (typical for comprehensive service manuals)

Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Core Systems:

Engine, Fuel System, Ignition System, Exhaust, Cooling System, Transmission, Brakes, Suspension, Steering, Electrical System, Lighting, Bodywork

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

Depth:

Comprehensive: Covers everything from basic user maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and repair.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing quick access to specific information.

Image Resolution:

High-resolution diagrams, illustrations, and photographs for clarity.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

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

Horsepower:

Approximately 40 HP (at 7,500 rpm) for the 500 SP model

Torque:

Approximately 45 Nm (at 5,500 rpm)

Fuel Delivery:

Electronic Fuel Injection (EFI) with Marelli or Keihin ECU

Fuel Type:

Unleaded Petrol (95 RON recommended)

Ignition:

Electronic CDI with variable ignition timing

Oil Type:

API SG/SH/SJ or JASO MA/MA2 specification, SAE 10W-40 or 15W-50 synthetic motorcycle oil recommended.

Coolant Type:

Ethylene glycol-based antifreeze/coolant mixture (50% water, 50% coolant)

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Optional Transmission:

N/A

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

Length:

Approx. 2,150 mm

Width:

Approx. 780 mm (at handlebars)

Height:

Approx. 1,460 mm (at windshield)

Wheelbase:

Approx. 1,520 mm

Dry Weight:

Approx. 190 kg

Wet Weight:

Approx. 203 kg (with fluids)

Max Load:

Approx. 180 kg (rider and passenger)

Storage:

Under-seat storage compartment, often accommodating one full-face helmet.

🛡️ Safety Features

Crash Safety:

N/A (Motorcycle/Scooter specific crash ratings like NCAP are not typically published)

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.

Frame Construction:

High-strength steel frame for rigidity and stability.

Tires:

Front: 120/70-15; Rear: 160/60-15 (typical)

💡 Technology Features

Dashboard:

Digital/analog combination instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meters, and warning lights.

ABS:

Anti-lock Braking System (ABS) available on certain models/trims for enhanced safety.

Diagnostic Port:

On-board diagnostic (OBD) port for electronic diagnostics and fault code retrieval.

🔧 Maintenance

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.

Brake Fluid Interval:

Replace every 2 years or as per manual, regardless of mileage.

Engine Oil Capacity:

Approx. 1.5 - 1.7 liters (with filter change)

Coolant Capacity:

Approx. 1.2 - 1.4 liters

Common Wear Items:

CVT belt wear, clutch pad wear, front fork seals, rear shock absorber longevity, fuel pump reliability, charging system components (regulator/stator).

Electrical Gremlins:

Can sometimes suffer from minor electrical connection issues or sensor faults if not maintained properly.

📚 Vehicle History

Parent Company:

Piaggio Group (acquired Gilera in 1993)

Gilera Legacy:

Gilera has a long history in motorcycle racing and production, known for performance-oriented models.

Nexus Introduction:

The Nexus series was Gilera's flagship maxi-scooter line, introduced to compete in the premium segment.

Mk2 Updates:

The Mk2 likely features refinements to the engine (Euro 3 compliance), chassis, suspension, and potentially styling updates compared to earlier versions.

Manufacturing Location:

Primarily Italy

🏆 Awards & Recognition

Performance Accolades:

While specific awards may not be widely publicized, the Nexus 500 SP was generally well-regarded in its segment for its sporty handling and performance capabilities, often earning positive reviews from motorcycle publications.