Gilera Nexus 500SP Euro 3 MK2 2005-Onward Service Repair Workshop Manual Download PDF

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Art.-Nr: 86805

Stichworte: 2005 Gilera Motorcycle Nexus 500SP Nexus 500SP MK2

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Beschreibung

Introducing the Nexus 500SP MK2, a distinguished maxi-scooter produced from 2005 onwards. This model is engineered for performance, offering a compelling blend of sporty handling and touring comfort, setting it apart in its segment. Its robust chassis and powerful 493cc liquid-cooled engine, compliant with Euro 3 emissions standards, deliver exhilarating acceleration and stable high-speed cruising, making it an excellent choice for both daily commuting and longer journeys. The Nexus 500SP MK2 embodies a commitment to quality Italian engineering, providing a reliable and engaging riding experience. This comprehensive Factory Service Repair Workshop Manual is designed to be an indispensable resource for owners, mechanics, and technicians. It covers all essential aspects of the Nexus 500SP MK2, including detailed maintenance procedures, in-depth troubleshooting guides, critical technical specifications, and vital safety information. From routine servicing like oil changes and filter replacements to complex engine and transmission overhauls, electrical system diagnostics, and chassis repairs, this manual provides step-by-step instructions and clear diagrams. Its thorough coverage ensures that the vehicle can be maintained, repaired, and optimized for peak performance and longevity.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500SP

Model Variant:

Year Start:

Year End:

Ongoing (as per "Onward")

Engine Code Suffix:

Euro 3

Codes

Emission Standard:

Euro 3

👋 Introduction

Market Position

Segment:

Maxi-scooter, performance-oriented segment.

Target Audience:

Commuters seeking long-distance comfort and performance, touring riders, enthusiasts who perform their own maintenance.

Competitive Analysis

Key Competitors:

Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Aprilia Scarabeo 500, Piaggio X9/X8.

Key Features

Performance Focus:

Designed for strong acceleration and comfortable high-speed cruising, differentiating it from smaller scooters.

Sporty Handling:

Larger wheels and robust chassis contribute to more motorcycle-like handling characteristics.

Touring Capability:

Comfortable ergonomics, weather protection, and ample storage make it suitable for longer journeys.

📋 Manual Details

Coverage Areas

Geographical Coverage:

Global (primarily European markets due to Gilera's origins and Euro 3 classification)

Page Count

Estimated Page Count:

Likely 300-500+ pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

Likely English, potentially with other European languages included.

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, tuning, valve clearance, piston, crankshaft, camshaft, timing.

Fuel System:

Fuel injection system (EFI), injectors, fuel pump, fuel pressure regulator, throttle body, sensors (MAP, TPS, IAT, O2).

Ignition System:

Ignition coil, spark plug, ECU control, timing.

Exhaust System:

Exhaust manifold, catalytic converter (Euro 3 specific), mufflers, Lambda sensor integration.

Cooling System:

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

Transmission Drivetrain:

Automatic CVT (Continuously Variable Transmission) system, belt, variator, clutch, final drive, gearbox oil.

Brakes:

Hydraulic brake system (front and rear), calipers, master cylinders, brake lines, brake fluid specifications, ABS (if equipped on SP models).

Suspension:

Front telescopic forks (including oil type and level), rear monoshock absorber, linkage adjustment.

Steering:

Handlebar assembly, steering bearings, steering head adjustment.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, lights (headlight, taillight, indicators), fuses, relays, ECU diagnostics.

Bodywork Chassis:

Frame, fairings, seat, storage compartments, body panel removal and installation.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, drive belt inspection/replacement, brake pad wear check.

Troubleshooting:

Diagnostic procedures for common issues, fault code interpretation (if applicable via diagnostics), performance problems.

Engine Repair:

Full engine rebuild procedures, component testing and measurement, torque specifications.

Transmission Service:

CVT belt and roller inspection, clutch adjustment, gearbox oil change.

Brake System Repair:

Brake bleeding, caliper overhaul, master cylinder replacement, pad and disc replacement.

Electrical Diagnostics:

Wiring harness troubleshooting, component testing, charging system checks.

Suspension Fork Service:

Front fork oil replacement, seal replacement, rear shock adjustment.

Bodywork Refurbishment:

Fairing repair and replacement, panel fitting.

Technical Depth

Depth:

Comprehensive; covers everything from basic maintenance to complete engine and transmission overhauls, electrical diagnostics, and chassis work.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High resolution, suitable for printing detailed diagrams and text.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

Features

Searchable Text:

Likely includes searchable text for quick information retrieval.

Hyperlinked Sections:

Potentially includes hyperlinks for easy navigation between sections and diagrams.

No Expiry:

No Extra Fees:

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder, liquid-cooled

Displacement:

493 cc (approximate, based on the 500 designation)

Bore X Stroke:

Specifications would be detailed in the manual, typically around 94 mm x 72 mm.

Valve Train:

SOHC (Single Overhead Camshaft), 4 valves per cylinder (common configuration for this engine family).

Performance

Horsepower Peak:

Around 40 HP (approximate, actual figures vary by market and tuning)

Torque Peak:

Around 46 Nm (approximate, actual figures vary by market and tuning)

Top Speed:

Typically around 160 km/h (100 mph).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (min 95 RON recommended)

Fuel Tank Capacity:

Approx. 15 liters

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Optional

Optional Transmission:

N/A (CVT is standard)

Features

Clutch Type:

Automatic centrifugal clutch

Drive Type:

Belt drive to rear wheel

Gearbox Oil Spec:

Specifications for final drive oil (e.g., SAE 80W-90) would be detailed in the manual.

📐 Dimensions

Exterior

Length:

Approx. 2170 mm

Width:

Approx. 790 mm

Height:

Approx. 1420 mm (seat height varies)

Wheelbase:

Approx. 1535 mm

Ground Clearance:

Approx. 130 mm

Weights

Dry Weight:

Approx. 198 kg

Wet Weight:

Approx. 215 kg (with fluids)

Max Load:

Specifications would be detailed in the manual.

Cargo

Storage:

Under-seat storage compartment, typically capable of fitting a full-face helmet.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle/Scooter regulations differ from cars).

Active Features

Available on 'SP' (Special Performance) models, details would be in the manual.

Braking System:

Dual front discs, single rear disc for strong stopping power.

Passive Features

Lighting:

Halogen or LED headlights, taillight, and turn signals.

Mirrors:

Large, adjustable mirrors for visibility.

💡 Technology Features

Infotainment

Display Type:

Analog speedometer and tachometer with a digital multi-function display (ODO, trip meter, clock, fuel level, engine temp).

Driver Assistance

ABS Availability:

Standard on SP models, provides enhanced braking safety.

Connectivity

Diagnostic Port:

On-board diagnostics (OBD) connector for electronic fault diagnosis.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for exact mileage).

Oil Filter Change:

Recommended at every engine oil change.

Air Filter Cleaning Replacement:

Inspect every 5,000 km, clean/replace as needed (more frequently in dusty conditions).

Spark Plug Replacement:

Every 10,000 - 15,000 km, depending on plug type.

Drive Belt Inspection Replacement:

Inspect every 10,000 km, replace around 20,000 km (refer to manual for specific intervals and condition checks).

Brake Fluid Change:

Every 2 years (hygroscopic nature of brake fluid).

Coolant Change:

Every 2-3 years or as specified.

Fluid Specifications

Engine Oil Type:

Synthetic or semi-synthetic motorcycle oil, typically SAE 10W-40 or 5W-40, API SG/SH/SJ or higher.

Engine Oil Capacity:

Approx. 1.6 - 1.8 liters (with filter change). Precise amount in manual.

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified for ABS models).

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.

Known Issues

Variator Wear:

Occasional reports of premature variator roller wear or clutch slippage if overloaded or poorly maintained.

Fuel Injector Clogging:

Can occur with poor fuel quality; regular use of quality fuel and occasional injector cleaner is beneficial.

Electrical Gremlins:

Some owners report minor electrical issues, often related to connections or the battery charging system; a good manual helps diagnose.

Regulator Rectifier:

As with many motorcycles of this era, the regulator/rectifier can be a point of failure, impacting charging system performance.

📚 Vehicle History

Brand Heritage

Parent Company:

Piaggio & C. S.p.A. (Gilera is a historic Italian brand now part of the Piaggio Group).

Model Evolution

Previous Generations:

The Nexus platform evolved from earlier Gilera maxi-scooters. The 500cc engine was a significant step up in performance.

Mk2 Updates:

MK2 typically refers to visual refreshes, potential ECU tuning updates, and minor component improvements over the initial 500SP model.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Segment Awards:

While specific awards for the 2005-onward MK2 might not be widely documented, the Nexus series was generally well-regarded for its performance and touring capabilities within the maxi-scooter market of its time.

Ratings

User Reviews:

Generally positive for performance, comfort, and handling, with common maintenance points being the focus of owner feedback.