GILERA NEXUS 500SP EURO 3 MK2 Workshop Repair Manual Download All 2005 ONWARDS ModelS COVERED PDF

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Generation: MK2 Engine Variant: 500SP EURO 3 Codes Emissions Standard: Euro 3 👋 Introduction Market Position Segment: Maxi-scooter Target Audience: Performance-oriented...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 30613

Stichworte: 2005 Gilera Motorcycle Motorcycles Nexus NEXUS 500SP MK2

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500SP

Generation:

Engine Variant:

500SP EURO 3

Codes

Emissions Standard:

Euro 3

👋 Introduction

Market Position

Segment:

Maxi-scooter

Target Audience:

Performance-oriented scooter riders and those seeking capable urban and light touring mobility.

Competitive Analysis

Key Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Silver Wing 500/600, Kymco Xciting 500.

Key Features

Performance Focus:

The 'SP' designation often implies a sportier tuning or higher specification than standard models.

Design Philosophy:

Combines scooter practicality with motorcycle-like ergonomics and performance, often featuring advanced suspension and braking for its class.

📋 Manual Details

Coverage Areas

Covered Model Years:

2005 onwards

Region Coverage:

Global (Euro 3 specification applies)

Page Count

Estimated Pages:

Extensive (specific count not provided, but described as comprehensive)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English (assumed based on product description)

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete disassembly, inspection, repair, and reassembly of the 500cc engine.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel filter, and tank.

Ignition System:

Ignition coil, spark plugs, CDI unit, and related wiring.

Cooling System:

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

Exhaust System:

Exhaust manifold, catalytic converter (Euro 3 compliant), mufflers, and lambda sensors.

Transmission:

Automatic transmission (CVT - Continuously Variable Transmission), including variator, clutch, and belt.

Chassis And Frame:

Frame construction, subframe, steering head, and swingarm.

Suspension Front:

Telescopic fork assembly, including oil levels, seals, and springs.

Suspension Rear:

Monoshock absorber, linkage system (if applicable), and adjustment procedures.

Braking System Front:

Dual disc brakes, calipers, master cylinder, brake lines, pads, and rotors.

Braking System Rear:

Disc brake, caliper, master cylinder, brake lines, pads, and rotor.

Wheels And Tires:

Wheel bearing replacement, tire fitting, and pressure recommendations.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, lighting system, horn, switches, and fuses.

Instrumentation:

Dashboard, indicators, speed sensor, and fuel level sender unit.

Bodywork And Fairings:

Removal, installation, and repair of body panels, seat, and storage compartments.

Cooling Fan Control:

Thermoswitch operation and fan motor testing.

Starting System:

Starter motor, starter relay, and ignition switch troubleshooting.

Lighting System:

Headlight, taillight, brake lights, turn signals, and dashboard illumination.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable, though typically belt-driven), and general inspections.

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues.

Engine Rebuild:

Complete engine disassembly, component inspection, measurement, and reassembly, including piston, rings, cylinder, crankshaft, and valve train.

Suspension Overhaul:

Front fork seal replacement, fork oil change, rear shock absorber inspection and adjustment.

Brake System Service:

Brake pad replacement, caliper service, brake fluid bleeding and replacement, rotor inspection.

Fuel System Cleaning And Testing:

Injector cleaning, fuel pressure testing, and fuel filter replacement.

Electrical Diagnostics:

Testing of charging system, starting system, ignition system, and sensor readings.

Bodywork Repair:

Fairing removal and installation, minor bodywork repairs.

Torque Specifications:

Accurate torque values for all critical fasteners.

Wiring Diagrams:

Detailed electrical schematics for all systems.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls.

Diagnostic Capability:

Includes troubleshooting guides and procedures for identifying and resolving faults.

Component Identification:

Utilizes exploded views and diagrams for easy identification and disassembly/assembly.

Adjustment Procedures:

Detailed instructions for all necessary adjustments, such as valve clearance, throttle cable, etc. (if applicable).

Special Tool Requirements:

Lists any special tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Compatibility:

PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, and later)

Print Quality

Readability:

High-quality digital reproduction ensuring clarity of text and diagrams.

Searchability:

Likely searchable text within the PDF (common for professionally created manuals).

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, four-stroke, liquid-cooled

Displacement:

493 cc (approximately)

Bore X Stroke:

Typically around 94 mm x 71 mm (specific value to be confirmed by manual)

Valve Train:

SOHC, 4 valves (typical for this engine family)

Performance

Horsepower:

Around 40-45 HP (specific figure varies by exact model year and tuning, to be confirmed by manual)

Torque:

Around 45-50 Nm (specific figure varies by exact model year and tuning, to be confirmed by manual)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (min. 95 RON recommended)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 Synthetic (API SG or higher, JASO MA recommended - specific viscosity and API rating to be confirmed by manual)

Engine Oil Capacity:

Approximately 1.6 - 1.8 Liters (with oil filter change - exact capacity to be confirmed by manual)

Coolant Type:

Ethylene Glycol based antifreeze (50% mixture with distilled water recommended)

Lubrication System

System:

Wet sump lubrication

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission)

Optional

Optional Transmission:

Features

Drive Type:

Belt drive to rear wheel

Transmission Fluid:

Specific CVT fluid (refer to manual for exact specification and change interval)

📐 Dimensions

Exterior

Length:

Approx. 2150 mm (specific dimension to be confirmed by manual)

Width:

Approx. 770 mm (handlebar width, specific dimension to be confirmed by manual)

Height:

Approx. 1400 mm (seat height and windshield, specific dimension to be confirmed by manual)

Weights

Dry Weight:

Approx. 195 kg (specific weight to be confirmed by manual)

Fuel Tank Capacity:

Approx. 15 Liters (specific capacity to be confirmed by manual)

Wheels And Tires

Front Tire Size:

120/70-15 (typical, specific size to be confirmed by manual)

Rear Tire Size:

160/60-15 (typical, specific size to be confirmed by manual)

Wheelbase:

Approx. 1560 mm (specific dimension to be confirmed by manual)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle/Scooter safety ratings differ from automobiles and are not typically published in this format.)

Active Features

Braking System:

Dual front disc brakes with radial calipers, rear disc brake. Potential for ABS on some variants (check manual for specific features).

Lighting:

Halogen or LED headlights, LED taillights and brake lights, turn signals for visibility.

Passive Features

Frame Construction:

Robust steel frame designed for stability and rider protection.

Ergonomics:

Comfortable riding position and protection from elements via fairings and windshield.

💡 Technology Features

Infotainment

Dashboard:

Digital/analog combination instrument cluster providing speed, RPM, fuel level, temperature, trip meter, and warning lights.

Driver Assistance

Optional ABS system available on certain versions; manual will cover its operation and maintenance.

Connectivity

Wiring Harness:

Comprehensive wiring diagrams for all electrical components and potential aftermarket accessory integration.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 - 7,500 km or annually (specific interval to be confirmed by manual)

Air Filter Cleaning Replacement:

Every 5,000 - 10,000 km (depending on operating conditions, specific interval to be confirmed by manual)

Spark Plug Replacement:

Every 10,000 - 15,000 km (specific interval and plug type to be confirmed by manual)

Cvt Belt Inspection Replacement:

Inspection every 10,000 km, replacement typically around 20,000 - 30,000 km (specific to be confirmed by manual)

Brake Fluid Replacement:

Every 2 years or as needed (specific interval and fluid type to be confirmed by manual)

Coolant Replacement:

Every 2 - 3 years (specific interval and type to be confirmed by manual)

Known Issues

Common Wear Items:

CVT belt wear, suspension seals, brake pad wear, electrical connections (typical for maxi-scooters of this era).

Potential Engine Issues:

While generally robust, early models might have experienced minor oil consumption or valve train adjustments. The manual will detail specific checks.

📚 Vehicle History

Brand Heritage

Brand Origin:

Gilera is an Italian motorcycle and scooter manufacturer, historically part of the Piaggio Group.

Model Evolution

Nexus Lineage:

The Nexus series was Gilera's flagship maxi-scooter, known for its sporty performance and chassis dynamics, aiming to bridge the gap between scooters and motorcycles.

Production

Manufacturing Location:

Italy (historically, under Piaggio Group ownership)

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The Gilera Nexus 500 was generally well-regarded in its segment for its performance and handling, often praised by motorcycle publications for its sporty character.