Segment:
Maxi-scooter, performance scooter segment.
Target Audience:
Riders seeking a powerful, agile, and versatile scooter for urban commuting and touring.
Key Competitors:
Yamaha TMAX, Suzuki Burgman 650, BMW C 650 GT.
Unique Selling Proposition:
Motorcycle-like handling with a powerful 500cc engine, distinctive styling, and robust build quality characteristic of Piaggio's engineering.
Performance Focus:
Engineered for strong acceleration and comfortable cruising speeds.
Handling Characteristics:
Designed with a focus on stability and agility, inspired by motorcycle chassis dynamics.
Build Quality:
Represents Piaggio's commitment to durable and reliable Italian engineering.
Engine System:
Full engine disassembly, assembly, inspection, tuning, troubleshooting, and rebuild procedures for the 500cc liquid-cooled engine.
Fuel System:
Fuel injection system diagnostics, component testing (injectors, fuel pump, pressure regulator), fuel pressure charts, and maintenance.
Ignition System:
Spark plug specifications, ignition timing checks, coil and CDI unit testing, troubleshooting.
Transmission System:
Automatic transmission (CVT) operation, maintenance, fluid checks, belt inspection, roller replacement, and clutch assembly.
Braking System:
Brake caliper overhaul, pad replacement, fluid bleeding, master cylinder inspection, ABS system (if equipped) diagnostics.
Suspension System:
Front fork (telescopic) service, rear shock absorber inspection and replacement, linkage lubrication.
Electrical System:
Complete wiring diagrams, component testing (alternator, starter motor, battery), fuse and relay identification, connector data, diagnostic codes.
Cooling System:
Radiator service, coolant replacement, thermostat testing, fan operation, leak detection.
Exhaust System:
Muffler and pipe inspection, gasket replacement, catalytic converter service.
Chassis And Body:
Frame inspection, body panel removal and installation, seat assembly, storage compartment service.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, tire sizing.
Maintenance Procedures:
Routine tune-ups, lubrication schedules, oil and filter changes, spark plug replacement, air filter cleaning/replacement, battery maintenance.
Repair Procedures:
Step-by-step instructions for all major component repairs and replacements, including engine internal components, transmission, brakes, and electrical parts.
Troubleshooting Guides:
Diagnostic charts and procedures for identifying and resolving common mechanical and electrical issues.
Inspection Checklists:
Pre-ride checks, scheduled inspection points, and detailed component inspection guidelines.
Specifications Data:
OEM specifications for torque values, compression ratios, valve clearances, fluid capacities, fuel pressures, electrical resistance, and tolerances.
Depth Of Coverage:
Comprehensive, from basic maintenance and routine checks to complete engine and transmission rebuilds, including electrical system diagnostics.
User Level:
Suitable for professional mechanics and DIY enthusiasts with basic to intermediate mechanical knowledge.
Diagnostic Capabilities:
Detailed diagnostic flowcharts, electrical schematics, and component testing procedures for accurate fault finding.
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, SOHC.
Displacement:
492.7 cc (cubic centimeters)
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1 (typical for this engine)
Horsepower:
Approximately 33.3 hp @ 7000 rpm (at crankshaft)
Torque:
Approximately 37.2 Nm @ 5500 rpm (at crankshaft)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Keihin throttle body.
Fuel Type:
Unleaded gasoline, minimum 95 RON.
Oil Type:
SAE 15W-40 Synthetic Motorcycle Oil
Oil Capacity:
1.6 liters (when filter is replaced)
Oil Change Interval:
Every 6,000 km or annually, whichever comes first.
Air Filter Service:
Every 12,000 km or annually.
Spark Plug Replacement:
Every 18,000 km.
Cvt Belt Inspection:
Every 12,000 km for inspection and wear, replacement recommended every 24,000 km or as needed.
Coolant Type:
Ethylene glycol-based antifreeze, 50% mixture with distilled water.
Brake Fluid:
DOT 4 brake fluid.
Common Wear Items:
CVT belt, drive rollers, brake pads, fork seals.
Electrical Gremlins:
Some owners report occasional minor electrical issues, particularly with aging wiring or connectors, which this manual can help diagnose.
Suspension Wear:
Front fork seals and rear shock absorbers may require service or replacement over time due to the demanding nature of the vehicle.
Manufacturer:
Piaggio S.p.A., an Italian company with a long history in scooter and motorcycle manufacturing, founded in 1884.
Introduction Year:
The Gilera Fuoco 500ie was introduced around 2007, building on Piaggio's experience with their own 500cc engine platform (used in the Gilera Nexus and Piaggio MP3).
Design Philosophy:
Designed to offer a higher-performance and more 'motorcycle-like' riding experience within the maxi-scooter category, with a distinctive aggressive styling.
Manufacturing Location:
Typically manufactured in Italy by Piaggio Group.
