🏷️ Basic Information

Make:

Gilera

Model:

Nexus 500SP

Generation:

Mk2

Model Years Covered:

2005 onwards

Engine Variant:

500cc SP (Specific Performance variant)

Emission Standard:

Euro 3

👋 Introduction

Category:

High-performance maxi-scooter

Target Audience:

Riders seeking urban commuting with touring capabilities, performance enthusiasts.

Competitors:

Suzuki Burgman 400/650, Yamaha TMAX 500, Honda Forza 250/300/350, Kymco Downtown 300/500.

Engine Size:

Large displacement 493cc engine, offering significant power and torque for its class.

Performance Variant:

SP designation indicates a specific performance-oriented tuning or equipment package.

Design Philosophy:

Sporty styling combined with maxi-scooter practicality and comfort.

📋 Manual Details

Manual Type:

Workshop Manual / Service & Repair Manual

Language:

English

Format:

PDF Download

Completeness:

Full A-Z coverage for all models and repairs

Specificity:

Vehicle-specific, not generic

📖 Manual Coverage

Engine:

Complete engine assembly, disassembly, overhaul, lubrication, cooling system, fuel system (injection), ignition system, exhaust system, starting system, engine management (ECU, sensors).

Transmission:

Automatic transmission (CVT), variator, clutch, final drive, gearbox components, lubrication.

Chassis And Frame:

Frame inspection, reinforcement, steering system (headset, linkage), suspension (front forks, rear shock absorber), wheel bearings, swingarm.

Braking System:

Front and rear brake systems (disc brakes, calipers, master cylinders, brake lines, ABS if applicable), hydraulic system, bleeding procedures, pad and disc replacement.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), lighting (headlights, taillights, indicators), ignition switch, horn, starter motor, wiring diagrams, fuses, relays, electronic control unit (ECU) diagnostics.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body, pressure regulator, emissions control systems (EVAP).

Bodywork And Trim:

Fairings, panels, seat, storage compartments, mirrors, lighting fixtures, removal and installation procedures.

Wheels And Tires:

Tire specifications, pressure recommendations, wheel removal and installation, balancing, rim inspection.

Cooling System:

Radiator, coolant hoses, coolant type and capacity, water pump, thermostat, fan operation.

General Maintenance:

Routine checks, oil changes, filter replacements, spark plug replacement, air filter service, brake fluid replacement, coolant checks.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault codes interpretation, symptom-based troubleshooting guides.

Engine Repair:

Engine rebuilds, piston and ring replacement, cylinder head service, valve adjustment, camshaft timing, gasket replacement.

Transmission Repair:

Variator roller replacement, clutch assembly service, gearbox disassembly and reassembly.

Electrical Diagnostics:

Wiring harness inspection, component testing, sensor calibration, ECU flashing and diagnostics.

Brake System Service:

Brake pad replacement, caliper service, master cylinder overhaul, brake line bleeding, rotor inspection and replacement.

Suspension And Steering Service:

Front fork seal replacement, steering head bearing adjustment and replacement, swingarm bearing service.

Bodywork Repair:

Fairing repair, panel replacement, minor accident damage repair.

Depth:

Comprehensive, covering detailed disassembly, assembly, repair, and diagnostic procedures, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Printability:

Printable for physical reference.

Page Count:

Not specified, but typically comprehensive workshop manuals are hundreds of pages.

File Size:

Variable based on image quality and detail, but generally manageable for download.

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, SOHC, 4 valves

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 88 mm (typical for this engine family)

Compression Ratio:

10.0:1 (typical)

Horsepower:

Approximately 40-43 HP at engine RPM (specific to SP variant, actual figures may vary slightly)

Torque:

Approximately 45-48 Nm at engine RPM (specific to SP variant)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (RON 95 or higher recommended)

Ignition System:

Electronic ignition, controlled by ECU

Oil Type:

SAE 5W-40 Synthetic or Semi-Synthetic Motorcycle Oil, API SG or higher, JASO MA/MA2 compliant

Oil Capacity:

Approx. 1.8 - 2.0 liters (with filter change)

Coolant Type:

Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Motul Motocool Expert, Shell Advance Coolant)

Coolant Capacity:

Approx. 1.2 liters

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT) with dry centrifugal clutch

Final Drive:

Gear drive

Variator System:

Roller-based variator for seamless gear ratio changes.

Clutch Type:

Centrifugal dry clutch system.

📐 Dimensions

Length:

Approx. 2170 mm

Width:

Approx. 780 mm

Height:

Approx. 1450 mm (seat height variable)

Dry Weight:

Approx. 195 kg

Gross Vehicle Weight Rating:

Approx. 370 kg

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Alloy wheels

🛡️ Safety Features

ABS:

Optional or standard on SP model (check specific variant documentation)

Braking:

Dual disc front brakes, single disc rear brake, high-performance calipers.

Lighting:

Multi-reflector headlight, LED taillight, clear lens indicators.

Frame Construction:

High-strength steel frame for rigidity and stability.

Ergonomics:

Comfortable riding position for extended journeys.

💡 Technology Features

Dashboard:

Digital/analog combination instrument cluster displaying speed, RPM, fuel level, coolant temperature, and warning lights.

ABS:

Available as an option, enhancing braking safety.

Lighting:

Halogen headlight for good night visibility.

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 6,000 km or annually, whichever comes first.

Oil Filter Replacement:

Every oil change (e.g., Piaggio/Aprilia P/N AP2574703 or equivalent).

Air Filter Service:

Every 10,000 km (clean/replace depending on condition).

Spark Plug Replacement:

Every 10,000 - 12,000 km (e.g., NGK CR9EKB or equivalent).

Coolant Replacement:

Every 2 years or 20,000 km.

Brake Fluid Replacement:

Every 2 years (DOT 4 recommended).

Variator Roller Inspection/Replacement:

Every 10,000 - 15,000 km.

Transmission Oil:

Dedicated gearbox oil (e.g., SAE 75W-90 GL-4 or GL-5, check manual for specific recommendation).

Potential Problems:

Variator wear (rollers, ramp plate), charging system issues (regulator/rectifier), coolant leaks, fuel pump reliability, rear shock absorber degradation with age.

Common Repairs:

Variator service/replacement, electrical component diagnosis, suspension overhaul.

📚 Vehicle History

Manufacturer:

Gilera, an Italian motorcycle manufacturer with a long history dating back to 1909.

Ownership:

Currently owned by Piaggio & C. S.p.A.

Introduction Year:

The Nexus line was introduced in the early 2000s, with the 500cc model being a significant step up in performance.

Mk2 Updates:

Mk2 revisions typically involve styling updates, chassis refinements, and compliance with newer emission standards like Euro 3.

Manufacturing Location:

Primarily Italy, under Piaggio Group ownership.

🏆 Awards & Recognition

Industry Standing:

The Gilera Nexus 500 was generally well-regarded for its performance and handling within the maxi-scooter segment of its era.