Segment:
Sport Touring Scooter / Maxi-Scooter.
Target Audience:
Enthusiasts and owners seeking detailed DIY repair and maintenance capabilities for their Gilera Nexus 500SP Mk2.
Competitors:
Yamaha TMAX 500, Suzuki Burgman 650, Honda Silver Wing 600.
Vehicle Strengths:
Powerful 500cc engine, sporty handling, comfortable ergonomics for long distances, ample storage.
Manual Value:
Provides comprehensive, factory-accurate data, enabling owners to perform complex maintenance and repairs, thus saving on dealership costs and ensuring proper upkeep.
General Coverage:
Complete service and repair information for the Gilera Nexus 500SP Mk2 (2007 model year).
Specific Systems:
Engine, Fuel System, Ignition System, Cooling System, Transmission (CVT), Clutch, Brakes (ABS optional), Suspension (Front and Rear), Steering, Electrical System, Lighting, Bodywork, Chassis, Diagnostics.
Estimated Pages:
Approx. 300-400 pages (typical for comprehensive factory service manuals)
Type:
Factory Service Repair Manual (FSM)
Engine Mechanical:
Complete engine disassembly, inspection, assembly, top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), timing chain/belt, lubrication system, and cooling system.
Fuel And Ignition:
Fuel injection system (EFI), throttle body, injectors, fuel pump, fuel pressure regulator, ignition coil, spark plugs, ECU diagnostics, and sensor data.
Transmission Drivetrain:
Continuously Variable Transmission (CVT) operation, clutch (variator and torque driver) maintenance, roller weights, spring tensions, belt replacement, and final drive maintenance.
Brakes And Suspension:
Hydraulic brake system bleeding, pad and disc replacement, caliper maintenance, master cylinder servicing, front fork (telescopic) overhaul, rear shock absorber inspection and replacement, and swingarm pivot maintenance.
Electrical And Lighting:
Wiring diagrams, battery maintenance, starter motor, alternator (stator and regulator/rectifier), lighting circuits (headlights, taillights, indicators), horn, dashboard indicators, fuses, relays, and sensor troubleshooting.
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, coolant checks, brake fluid flushes, drive belt inspection, and general lubrication.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation (if applicable via diagnostic tool), and symptom-based troubleshooting guides.
Repair And Overhaul:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation for all major vehicle systems.
Adjustments And Settings:
Valve clearance adjustment, throttle cable adjustment, brake lever free play adjustment, and torque specifications for all fasteners.
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and chassis component servicing.
Type:
Four-stroke, liquid-cooled, single-cylinder, DOHC, 4 valves.
Displacement:
460 cc (typically derived from Piaggio Master 460cc engine platform).
Bore X Stroke:
92 mm x 69 mm (typical for Piaggio Master 460).
Compression Ratio:
10.5:1 (typical for Piaggio Master 460).
Horsepower:
Approx. 34-39 HP (at 7,000-7,500 rpm).
Torque:
Approx. 45-48 Nm (at 5,500-6,000 rpm).
Induction:
Electronic Fuel Injection (EFI) with Marelli or Keihin ECU.
Fuel Type:
Unleaded gasoline, minimum 95 RON.
Fuel Tank Capacity:
Approx. 15 Liters.
ABS:
Optional ABS (Anti-lock Braking System) available on SP models, significantly enhancing braking safety.
Brakes:
Dual front disc brakes (e.g., 2x 260mm), single rear disc brake (e.g., 240mm); hydraulic actuation.
Lighting:
Halogen or projector-type headlights, LED taillight, front and rear turn signals.
Chassis Design:
Steel double cradle frame for rigidity and stability.
Dashboard:
Digital and analog instrumentation including speedometer, tachometer, fuel gauge, engine temperature, clock, and indicator lights.
ABS:
Optional ABS significantly aids in preventing wheel lock-up during hard braking.
Diagnostic Port:
OBD-II or proprietary diagnostic connector for reading fault codes and live data.
Engine Oil Change:
Every 6,000 km or 6 months, whichever comes first.
Air Filter Cleaning:
Every 6,000 km; replacement as needed.
Spark Plug Inspection:
Every 12,000 km; replacement around 24,000 km (refer to manual for specific plug type).
Coolant Replacement:
Every 24,000 km or 2 years.
Brake Fluid Change:
Every 24,000 km or 2 years.
Cvt Belt Inspection:
Inspect every 12,000 km; replacement typically recommended around 20,000-24,000 km depending on wear.
Engine Oil:
SAE 10W-40 Synthetic motorcycle oil, API SG or higher, JASO MA certified (approx. 1.8-2.0 liters with filter change).
Coolant:
Ethylene glycol based coolant, 50/50 mix with distilled water.
Common Wear Items:
CVT belt wear, rear shock absorber degradation, throttle position sensor (TPS) issues, fuel pump reliability can be variable.
Electrical Connectors:
Corrosion or poor connections in some wiring harnesses can lead to intermittent issues.
Manufacturer:
Gilera is an Italian motorcycle manufacturer with a long history, now part of the Piaggio Group.
Nexus Lineage:
The Nexus series represented Gilera's foray into the premium maxi-scooter market, known for its sporty performance and handling, borrowing heavily from Piaggio's engine technology.
Manufacturing Location:
Italy (likely Piaggio Group facilities).
Model Years:
The Nexus 500 was produced across several iterations, with the Mk2 representing a refinement of the original design.
