Gilera Nexus 500SP Mk2 2005 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Gilera Model: Nexus 500SP Mk2 Year: 2005 Product Type: Factory Service Repair Manual Format: PDF Download 👋 Introduction Market Position Segment: Maxi-scooter, performance-oriented urban mobility...

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Taper: Motorcycle

Distributeur:

UGS: 54350

Mots clés: 2005 Gilera Motorcycle Motorcycles Nexus Nexus 500SP Mk2

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Nexus 500SP Mk2

Year:

Product Type:

Factory Service Repair Manual

Format:

PDF Download

👋 Introduction

Market Position

Segment:

Maxi-scooter, performance-oriented urban mobility

Combines scooter practicality with motorcycle-like performance and handling

Competitive Analysis

Key Competitors:

Yamaha TMAX, Suzuki Burgman 400/650, Aprilia Scarabeo 500

Key Features

Design:

Sporty, aerodynamic styling with motorcycle-inspired ergonomics

Performance:

Powerful 500cc engine, capable of highway speeds and brisk acceleration

Handling:

Large diameter wheels, robust suspension, and motorcycle-like chassis geometry

Practicality:

Underseat storage, comfortable seating for rider and passenger, good weather protection

📋 Manual Details

Coverage Areas

General Coverage:

Repair, maintenance, and adjustments

Target Audience:

Mechanics and DIY persons

Page Count

Estimated Pages:

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

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English (assumed based on product description)

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, assembly, inspection, and repair of engine components (cylinder, piston, crankshaft, valves, etc.)

Fuel System:

Fuel injection system, fuel pump, injectors, fuel filter, fuel tank maintenance

Ignition System:

Ignition coil, spark plug, ECU control of ignition timing

Cooling System:

Radiator, coolant circulation, thermostat, fan operation

Lubrication System:

Oil pump, oil filter, oil passages, oil change procedures

Transmission Drivetrain:

Automatic transmission (CVT), belt replacement, clutch operation, final drive maintenance

Chassis Frame:

Frame inspection, front fork assembly, rear shock absorber, swingarm maintenance

Braking System:

Brake calipers, master cylinders, brake lines, brake fluid replacement, disc and pad inspection/replacement

Electrical System:

Wiring diagrams, battery maintenance, lighting systems, starter motor, charging system (alternator/stator)

Instrumentation Controls:

Dashboard instruments, handlebar controls, electronic unit (ECU) functions

Bodywork Fairings:

Removal and installation of body panels, fairings, seat, and related components

Exhaust System:

Exhaust pipe, muffler, catalytic converter maintenance

Procedures Included

Regular Maintenance:

Oil changes, filter replacements, spark plug checks, chain/belt adjustments, tire pressure

Troubleshooting:

Diagnosis of common problems, error codes (if applicable), symptom-based troubleshooting guides

Disassembly Assembly:

Step-by-step instructions for removing and reinstalling major components and sub-assemblies

Repair Rebuild:

Detailed procedures for repairing or rebuilding specific engine, transmission, and chassis components

Inspections Checks:

Visual inspections, functional checks, torque specifications for critical fasteners

Adjustment Calibration:

Carburetor (if applicable, though likely FI for this model), throttle cable, brake lever adjustments

Wiring Diagrams:

Comprehensive electrical schematics for easy diagnosis and repair of electrical faults

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds

Diagnostic Focus:

Includes diagnostic procedures for common malfunctions and system failures

📊 Manual Specifications

File Format

Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (standard for factory PDFs), allowing for quick information retrieval

Print Quality

Resolution:

High resolution, suitable for printing individual pages or the entire manual

Layout:

Professional layout with clear diagrams, illustrations, and text formatting

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Type:

Single-cylinder, four-stroke, liquid-cooled, OHC

Displacement:

492.6 cc

Bore X Stroke:

92 mm x 95.2 mm (typical for this engine family)

Compression Ratio:

10.0:1 (typical)

Performance

Horsepower:

Approx. 40 HP (30 kW) at 7,000 RPM (manufacturer stated figures may vary slightly)

Torque:

Approx. 45 Nm (33 lb-ft) at 5,000 RPM (manufacturer stated figures may vary slightly)

Fuel System

Induction:

Electronic Fuel Injection (EFI), likely with Marelli or Piaggio ECU

Fuel Type:

Unleaded gasoline (95 RON recommended)

Lubrication

Oil Type:

SAE 10W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA)

Oil Capacity:

Approx. 1.7 liters (including filter, consult manual for precise capacity)

🔧 Transmission

Standard

Type:

Automatic Continuously Variable Transmission (CVT)

Optional

Options:

N/A (CVT is standard)

Features

Drive Belt:

Reinforced V-belt drive system

Final Drive:

Gear drive (often with a shared oil sump for transmission and final drive, consult manual)

Transmission Fluid:

Specific gear oil for final drive, consult manual for type and capacity. CVT may use specific variator fluid.

📐 Dimensions

Exterior

Length:

Approx. 2220 mm

Width:

Approx. 780 mm (at handlebars)

Height:

Approx. 1420 mm (at windshield)

Wheelbase:

Approx. 1570 mm

Weights

Dry Weight:

Approx. 198 kg

Gross Vehicle Weight Rating:

Consult manual for specific GVWR

Cargo

Storage:

Underseat storage compartment

Fuel Tank Capacity:

Approx. 15 liters

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (motorcycle/scooter safety ratings differ from automotive)

Active Features

Braking System:

Front: Dual disc brakes with multiple-piston calipers. Rear: Single disc brake. ABS was likely an optional or later feature, consult specific vehicle options.

Lighting:

Halogen headlights, LED tail light, turn signals

Passive Features

Chassis Design:

Steel frame designed for stability and rigidity

Mirrors:

Large rear-view mirrors for visibility

💡 Technology Features

Infotainment

Dashboard Display:

Analog tachometer, digital speedometer, fuel gauge, coolant temperature, clock, trip meters, warning lights.

Driver Assistance

Optional on some models/markets. The manual will detail ABS system operation and troubleshooting if equipped.

Connectivity

Connectivity Features:

Basic connectivity, primarily focused on vehicle systems. No advanced smartphone integration typical for this era.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000-7,500 km or annually (refer to manual for exact interval based on usage)

Air Filter Check:

Every 5,000 km or as needed based on operating conditions

Spark Plug Replacement:

Every 10,000-15,000 km (NGK Iridium recommended for optimal performance)

Cvt Belt Inspection:

Inspect every 10,000 km, replace typically between 15,000-25,000 km depending on wear

Brake Fluid Flush:

Every 2 years

Fluid Specifications

Engine Oil:

SAE 10W-40 Synthetic, API SG/SH/SJ/SL, JASO MA/MA2

Coolant:

Ethylene glycol-based antifreeze, mixed 50/50 with distilled water (specific type like Moto-specific coolant recommended)

Brake Fluid:

DOT 4 (or DOT 3 if specified by manufacturer, but DOT 4 preferred for higher boiling point)

Known Issues

Common Wear Items:

CVT belt, variator rollers, voltage regulator, water pump seal

Potential Problems:

Wiring harness chafing (especially near the steering head), fuel pump issues in older units, exhaust flange leaks.

Recommended Parts

Air Filter Part Number:

Refer to manual or equivalent part from reputable aftermarket suppliers (e.g., HiFloFiltro, K&N)

Oil Filter Part Number:

Refer to manual or equivalent part from reputable aftermarket suppliers (e.g., HiFloFiltro HF183, K&N KN-183)

Spark Plug Part Number:

NGK CR9EIX (Iridium)

📚 Vehicle History

Brand Heritage

Brand Origin:

Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, now part of the Piaggio Group.

Model Evolution

Nexus Lineage:

The Nexus series represented Gilera's foray into the maxi-scooter segment, focusing on performance and sporty characteristics.

Mk2 Updates:

Mk2 typically refers to an updated version, possibly with minor styling tweaks, revised suspension, or engine mapping compared to earlier models.

Production

Production Period:

Gilera Nexus 500 was produced in various iterations from the early 2000s up until the mid-2010s.

Manufacturing Location:

Italy (typically Piaggio Group manufacturing plants)

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the 2005 Nexus 500SP Mk2 are not widely publicized, Gilera scooters generally receive recognition for performance and design within their segment.

Ratings

Consumer Reviews:

Often praised for its powerful engine and sporty handling, though some reviews might point to higher maintenance costs compared to less performance-oriented scooters.

Certifications

Emissions Standards:

Meets Euro 2 or equivalent emissions standards for the 2005 model year.