Market Position:
The Gilera Nexus 500SP Mk2 is positioned as a premium, high-performance maxi-scooter, blending sporty handling with touring comfort and significant engine power for its class. It often competed with other high-displacement scooters from European and Japanese manufacturers.
Key Competitors:
Yamaha TMAX 500, Suzuki Burgman 400/650, Piaggio X9 500, Honda Silver Wing 600.
Distinguishing Features:
Powerful 500cc Piaggio Master engine, advanced chassis design for excellent handling, comfortable ergonomics for long distances, sporty styling, robust braking system.
Intended User:
Professional motorcycle technicians, experienced DIY mechanics, and Gilera Nexus 500SP Mk2 owners seeking detailed service and repair information.
Coverage Areas:
Characteristics, Tooling, Maintenance, Electrical System, Engine (from vehicle), Engine (eng), Injection, Suspensions, Braking System, Cooling System, Chassis, Pre-Delivery, Time.
Page Count:
Estimated 300-500 pages (based on typical workshop manual depth for this category).
Manual Type:
Service and Repair Workshop Manual
Language:
Likely English (standard for international workshop manuals, specific language not explicitly stated but implied by availability).
Manual Completeness:
Covers all aspects of service and repair for the Gilera Nexus 500SP Mk2, from routine maintenance to complete engine and chassis overhauls.
Systems Covered:
Engine Mechanical, Engine Management (Injection, Ignition), Electrical System (Wiring Diagrams, Components), Fuel System, Cooling System, Lubrication System, Transmission (Clutch, Drive), Braking System (Front/Rear), Suspension System (Front Forks, Rear Shock Absorber), Chassis and Frame, Bodywork, Wheels and Tires, Steering System.
Procedures Included:
Routine Maintenance (Oil Changes, Filter Replacements, Spark Plugs), Engine Overhaul (Disassembly, Reassembly), Fuel Injection System Servicing and Diagnostics, Electrical Troubleshooting, Brake System Overhaul, Suspension Adjustments and Servicing, Cooling System Flush and Refill, Chassis Inspection, Pre-Delivery Inspections (PDI), Timing Adjustment.
Electrical System Repair:
Detailed wiring diagrams, component location, testing procedures for lights, ignition, starting, charging, and sensors.
Technical Depth:
Comprehensive, including detailed exploded views, step-by-step repair instructions, diagnostic procedures, torque specifications, and component data for professional technicians and advanced DIY enthusiasts.
Diagnostic Procedures:
Includes guided troubleshooting steps for common malfunctions, error code interpretation for the EFI system, and electrical system diagnostics.
Tooling Requirements:
Details required specialized tools for engine disassembly/assembly, suspension service, wheel bearing replacement, and specific diagnostic equipment.
Torque Specifications:
Provides detailed torque values for all critical fasteners, including engine, chassis, and suspension components.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
Horsepower:
Approximately 40-42 HP (depending on specific tuning and market regulations)
Torque:
Approximately 45-47 Nm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline (RON 95 recommended)
Oil Type:
API SG/SH/SJ or higher, SAE 15W-40 or 10W-40 (specific viscosity may vary based on ambient temperature, refer to manual for exact specification)
Oil Capacity:
Approximately 1.5 - 1.7 liters (including filter replacement)
Ignition System:
Electronic ignition system.
Transmission Type:
Automatic CVT (Continuously Variable Transmission) with wet multi-plate clutch.
Drive Type:
Belt drive to rear wheel via gearbox and chain drive.
Cvtf Fluid Type:
Specific automatic transmission fluid (refer to manual for exact specification, often a proprietary blend or equivalent)
Cvtf Fluid Capacity:
Refer to manual for exact capacity.
Braking System Front:
Dual 260 mm discs with 4-piston calipers (often with ABS as an option on SP models)
Braking System Rear:
240 mm disc with 2-piston caliper
Lighting:
Halogen headlights, LED taillight and indicators.
Frame Construction:
High-strength steel tube frame.
Instrument Cluster:
Analog speedometer and tachometer with digital display for odometer, trip meter, fuel level, coolant temperature, and clock. Warning lights for various systems.
ABS:
Optional Anti-lock Braking System (ABS) was available on SP models, providing enhanced safety during braking.
Charging Port:
Likely includes a 12V power outlet or accessory socket for charging electronic devices.
Engine Oil Change:
Every 6,000 km or 12 months, whichever comes first.
Oil Filter Replacement:
Every 12,000 km or 24 months, or at every oil change.
Air Filter Cleaning Replacement:
Inspect every 6,000 km, clean or replace as needed. Replace typically every 18,000-24,000 km.
Spark Plug Replacement:
Every 12,000 km or as per manual recommendation.
Belt Drive Inspection Replacement:
Inspect belt condition every 12,000 km, replace every 24,000 - 30,000 km or if signs of wear are present.
Clutch Adjustment:
Check and adjust as needed at 12,000 km intervals.
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Motul Motocool Factory Line, Castrol Radicool SF) mixed with distilled water (50/50 ratio).
Brake Fluid Type:
DOT 4 brake fluid.
Common Wear Items:
CVT belt wear, rear shock absorber degradation, fuel pump issues (on some units), starter motor longevity (depending on usage).
Electrical Connections:
Corrosion in electrical connectors, particularly for lighting and sensors, can be an issue in humid or salty environments.
Brand Origin:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909. It is now part of the Piaggio Group.
Nexus Series Introduction:
The Gilera Nexus was first introduced in 2003 as a sporty maxi-scooter. The 500SP Mk2 represents an updated version, likely featuring refinements in styling, engine tuning, or features compared to earlier models.
Manufacturing Location:
Primarily manufactured in Italy.
