Piaggio Gilera Nexus 500SP Euro3 Mk2 Motorcycle Workshop Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Piaggio Model: Gilera Nexus 500SP Sub Model: Mk2 Engine Type: Euro3 Codes Manual Product Name: Piaggio Gilera Nexus 500SP Euro3 Mk2 Motorcycle Workshop Factory Service...

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Mots clés: Gilera Gilera Nexus 500SP Mk2 Motorcycle Motorcycles Piaggio Zip

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Piaggio

Model:

Gilera Nexus 500SP

Sub Model:

Engine Type:

Euro3

Codes

Manual Product Name:

Piaggio Gilera Nexus 500SP Euro3 Mk2 Motorcycle Workshop Factory Service Repair Manual PDF Download

👋 Introduction

Market Position

Category:

Maxi-scooter

Segment:

Performance-oriented commuter and touring maxi-scooter

Competitive Analysis

Competitors:

Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing 600

Unique Selling Proposition:

Sporty handling characteristics derived from motorcycle heritage, powerful single-cylinder engine.

Key Features

Engine Size:

500cc class

Performance Focus:

Emphasis on sporty riding dynamics and acceleration

Design Philosophy:

Bridge the gap between scooter practicality and motorcycle performance

📋 Manual Details

Coverage Areas

General Repair:

Comprehensive

Maintenance:

Tune-ups, Lubrication, Scheduled Service

Major Rebuilds:

Engine and Transmission

Page Count

Estimated Pages:

N/A (as it's a digital download, page count can vary with zoom/print settings)

Manual Type

Type:

Factory/Official Workshop Service Repair Manual

Language

Language:

English (Presumed, based on typical aftermarket manual offerings)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, performance tuning, diagnostics

Transmission:

Clutch, gearbox, final drive overhaul and repair

Fuel System:

Fuel injection, fuel pump, fuel pressure diagnostics

Cooling System:

Radiator, thermostat, water pump, coolant flow

Electrical System:

Ignition, lighting, charging system, wiring diagrams, connector data

Brakes:

Hydraulic system, disc brake maintenance, fluid replacement

Suspension:

Front forks, rear shock absorber, bearings

Chassis Frame:

Frame inspection, steering head bearings

Bodywork Panels:

Fairings, seat, trim removal and installation

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable)

Troubleshooting:

Diagnostic charts, symptom-based guides

Disassembly Assembly:

Component-level step-by-step instructions

Inspections:

Wear limits, safety checks

Technical Depth

Depth:

Comprehensive: from basic tune-ups to major engine/transmission rebuilds and diagnostics

User Level:

Professional or DIY with basic mechanical knowledge

📊 Manual Specifications

File Format

Format:

Searchability:

Typically searchable text within PDF

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M381M (typical for 500cc Piaggio/Gilera Master engine)

Configuration:

Single-cylinder, four-stroke, liquid-cooled, DOHC, 4 valves

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1 (typical)

Performance

Horsepower:

Approx. 39 HP (29 kW) @ 7500 RPM (varies slightly by market/tuning)

Torque:

Approx. 45 Nm (33 lb-ft) @ 5500 RPM (varies slightly by market/tuning)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Pressure:

Refer to manual for specific OEM specifications (e.g., 3.0 - 3.5 bar)

Ignition System:

Electronic CDI

Lubrication

Oil Type:

API SG or higher, JASO MA certified motorcycle oil recommended (e.g., SAE 5W-40 or 10W-40)

Oil Capacity:

Approx. 1.6 - 1.8 liters (with filter change)

Cooling System

Type:

Liquid-cooled

Coolant Capacity:

Approx. 1.0 - 1.2 liters

Compression Ranges

Minimum Compression:

Refer to manual for specific OEM value (e.g., 9.5 bar / 138 psi)

Maximum Compression Deviation Cylinders:

Refer to manual for specific OEM value (e.g., 1.0 bar / 14.5 psi)

🔧 Transmission

Standard

Type:

Automatic (CVT - Continuously Variable Transmission)

Clutch Type:

Automatic centrifugal clutch

Final Drive:

Gear drive

Features

Gear Ratios:

Continuously variable, specified by belt-driven pulley ratios. Consult manual for specific ratios at different speed points.

Transmission Fluid:

No separate transmission fluid; engine oil lubricates transmission and clutch.

📐 Dimensions

Exterior

Length:

Approx. 2180 mm (for Mk2)

Width:

Approx. 770 mm (at handlebars)

Height:

Approx. 1370 mm (at handlebars)

Seat Height:

Approx. 785 mm

Weights

Dry Weight:

Approx. 198 kg

Wet Weight:

Approx. 212 kg (with fluids)

Maximum Load:

Refer to manual (typically ~180-200 kg including rider and luggage)

Wheels Tires

Front Tire Size:

120/70-15

Rear Tire Size:

160/60-15

Wheel Type:

Alloy wheels

Fuel Capacity

Fuel Tank Capacity:

15 liters

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A for motorcycles (focus is on design and rider safety features)

Active Features

Brakes:

Front: Dual discs with four-piston calipers; Rear: Single disc with two-piston caliper. Optional ABS (Anti-lock Braking System) available on some models.

Lighting:

Halogen headlights, LED taillight/indicators (model dependent)

Passive Features

Frame Construction:

Steel double cradle frame for rigidity and stability

Security:

Immobilizer system, steering lock

💡 Technology Features

Infotainment

Dashboard:

Analog speedometer and tachometer, digital multi-function display (odometer, trip meter, fuel gauge, clock, temperature).

Driver Assistance

Optional ABS system available on some variants

Connectivity

Charging Port:

Often equipped with a 12V accessory socket in the front storage compartment.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

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

Air Filter Check:

Every 5,000 km

Spark Plug Replacement:

Every 10,000 - 15,000 km

Coolant Replacement:

Every 2 years or 30,000 km

Brake Fluid Replacement:

Every 2 years

Fluid Specifications

Engine Oil:

SAE 5W-40 or 10W-40, API SG/SH/SJ or higher, JASO MA certified motorcycle oil. Specific Piaggio/Gilera branded oil often recommended.

Coolant:

Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 recommended

Final Drive Oil:

GL-4 SAE 80W-90 gear oil (capacity usually small, ~0.2L)

Known Issues

Common Wear Items:

CVT belt wear, voltage regulator failure, wheel bearings, exhaust system corrosion.

Electrical Gremlins:

Can occur with age; ensure clean electrical connections and battery health.

Cooling System Maintenance:

Regular coolant checks and flushes are important to prevent corrosion and overheating.

Technical Specifications

Valve Clearance Intake:

Refer to manual (e.g., 0.10 - 0.15 mm cold)

Valve Clearance Exhaust:

Refer to manual (e.g., 0.15 - 0.20 mm cold)

Spark Plug Gap:

Refer to manual (e.g., 0.7 - 0.8 mm)

Torque Cylinder Head Bolts:

Refer to manual for sequence and values (multi-stage torque application)

Torque Wheel Nuts Front:

Refer to manual (e.g., ~25 Nm)

Torque Wheel Nuts Rear:

Refer to manual (e.g., ~40 Nm)

📚 Vehicle History

Brand Heritage

Brand:

Piaggio & C. S.p.A.

Heritage Focus:

Pioneer in scooter manufacturing, strong Italian engineering heritage.

Model Evolution

Model Lineup:

Gilera brand known for sporty motorcycles and scooters. Nexus line introduced as a premium maxi-scooter.

Generation:

Mk2 represents a refinement of the original Nexus 500, often incorporating Euro3 compliance and styling updates.

Year Introduction:

Original Nexus 500 introduced around 2003. Mk2 likely introduced around 2006-2007.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Of The Year:

N/A (specific model awards not readily available in general product info)

Ratings

Reliability Studies:

Customer reviews and owner feedback generally indicate reliability when properly maintained. Refer to specialized forums for detailed user experiences.

Certifications

Emissions:

Euro3 compliant