Target Audience:
Owner-operators, DIY mechanics, service technicians seeking detailed repair and maintenance information for the Gilera Fuoco 500 IE.
Value Proposition:
Provides professional-quality, dealer-level diagnostic and repair information at a fraction of the cost of dealership services, enabling significant savings on maintenance and repairs.
Unique Selling Points:
A-Z coverage, extensive diagrams and pictures, printable pages, instant download, lifetime usability, specific to the Gilera Fuoco 500 IE.
Engine:
Engine Repair, Engine Removal/Installation, Engine Lubrication, Intake Manifold/Exhaust System
Fuel Emissions:
Fuel and Emissions, Exhaust, Emissions Control
Transmission Drivetrain:
Transaxle, Clutch, Manual Transmission, Automatic Transmission, Differential, Driveshaft
Suspension Steering:
Steering, Suspension
Brakes:
Brakes (including ABS)
Electrical Electronics:
Electrical (including SRS), Wiring Diagrams, Ignition
Climate Control:
Cooling and Heating, Heater and Air Conditioning, Automatic Climate Control
Safety Systems:
Supplemental Restraint System (SRS)
Routine Maintenance:
Routine Maintenance, Tune-up Procedures
Engine Overhaul:
Engine Repair, Cylinder Head/Valve Train, Engine Block, Valve Timing Procedures, Chain & Gear Replacement, Tensioner Adjustments, Tightening Torques, Timing Marks, Valve Timing Instructions, Tensioner Release & Reset Methods, Chain Routing & Sprocket/Gear Valve Timing Marks
Diagnostics Troubleshooting:
Covered A-Z, Mechanical & Electrical
Component Removal Installation:
General Removal & Installation Instructions
Depth:
Comprehensive: Covers all repairs from routine maintenance to major overhauls.
Compatibility:
Compatible with PC/MAC computers running Windows (XP, NT, 2000, Vista, Windows 7, etc.). PDF reader required.
Printability:
All pages are printable.
Binding:
Digital Download (PDF)
Paper Type:
Not Applicable (Digital Format)
Engine Type:
4-stroke, single-cylinder, liquid-cooled (based on typical Gilera 500cc engines of the era)
Displacement:
Approximately 493 cc (common for Gilera 500cc Maxi-Scooters)
Bore X Stroke:
Specifics to be found in manual (e.g., ~94 mm x 71 mm)
Compression Ratio:
Specifics to be found in manual (e.g., ~10.2:1)
Horsepower:
Estimated 40 HP (29.4 kW) @ ~7,000 rpm (typical for this engine size/era)
Torque:
Estimated 46 Nm (34 lb-ft) @ ~5,500 rpm (typical for this engine size/era)
Fuel Delivery:
Electronic Fuel Injection (IE)
Fuel Type:
Unleaded gasoline (RON 95 recommended)
Ignition System:
Electronic ignition with variable advance
Oil Type:
Semi-synthetic or Fully synthetic SAE 5W-40 or 10W-40 API SJ or higher, JASO MA.
Oil Capacity:
Approx. 1.7 liters (including filter replacement)
Type:
Automatic CVT (Continuously Variable Transmission) with integrated final drive.
Optional Types:
Not Applicable (CVT is standard for this model).
Clutch Type:
Automatic centrifugal clutch
Final Drive:
Gears and belt drive
Transmission Fluid Type:
Specific automatic transmission fluid (ATF) or CVT fluid as per manufacturer recommendation (refer to manual for exact specification).
Length:
Refer to manual (typical for large maxi-scooter, approx. 2100-2200 mm)
Width:
Refer to manual (typical for large maxi-scooter, approx. 750-800 mm)
Height:
Refer to manual (typical for large maxi-scooter, approx. 1400-1500 mm)
Dry Weight:
Refer to manual (typically around 200-220 kg)
Gross Vehicle Weight Rating:
Refer to manual
Fuel Tank Capacity:
Approx. 12 Liters (including reserve)
Crash Test Results:
Not Applicable (This is a service manual, not a consumer review site. Crash ratings would typically be for motorcycles/scooters tested by independent bodies, not for the manual itself.)
Braking System:
Hydraulic disc brakes front and rear, potentially with ABS as an option or standard depending on market.
Lighting System:
Halogen or LED headlights, taillights, and turn signals.
Supplemental Restraint System:
Supplemental Restraint System (SRS) - implies potential for airbags, though typically uncommon on scooters of this era unless specifically designed for.
Instrument Cluster:
Digital and analog combination instrument cluster providing speed, RPM, fuel level, temperature, and warning lights.
ABS System:
Anti-lock Braking System (ABS) available on certain models/trim levels, detailed operation and troubleshooting within the manual.
Diagnostic Ports:
On-board diagnostic (OBD) port for reading fault codes and performing diagnostic functions (covered in manual).
Oil Change Interval:
Typically every 5,000 - 10,000 km or annually (refer to manual for exact schedule).
Spark Plug Replacement:
Typically every 10,000 - 20,000 km (refer to manual).
Air Filter Cleaning Replacement:
Recommended every 5,000 - 10,000 km (refer to manual).
Transmission Fluid Change:
Recommended every 10,000 - 20,000 km or as per manual.
Brake Fluid Type:
DOT 4 synthetic brake fluid.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (typically a 50/50 mix with distilled water).
Common Problems:
Potential for regulator/rectifier failure, CVT belt wear, occasional electrical gremlins (as with many modern scooters). Detailed troubleshooting and solutions provided in manual.
Valve Clearances:
Intake and Exhaust valve clearances specified in manual (e.g., 0.10mm - 0.20mm cold).
Idle Speed:
Specified RPM range (e.g., 1400 ± 100 rpm) adjustable via ECU or throttle body (refer to manual).
Tire Pressures:
Front: 2.0-2.2 bar (29-32 PSI), Rear: 2.4-2.8 bar (35-40 PSI) - rider and load dependent (refer to manual).
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycling, known for performance and innovative designs, now part of the Piaggio Group.
Fuoco Lineage:
The Fuoco 500 IE is part of Gilera's maxi-scooter lineup, sharing platform elements with Piaggio MP3 models but with distinct styling and engineering. It's characterized by its robust 500cc engine and practical touring capabilities.
Production Period:
Introduced around 2007 and continued for several years, with updates likely within the 'Onwards' designation.
