🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500

Years Covered:

2007, 2008

Product Type:

Service Manual / Workshop Manual / Repair Manual

👋 Introduction

Vehicle Segment:

Maxi-scooter / Three-wheeled scooter

Key Competitors:

Piaggio MP3 series (especially the 400/500cc variants), Yamaha TMAX 500.

Unique Selling Proposition:

The Gilera Fuoco 500 is renowned for its distinctive three-wheel design, offering enhanced stability and a unique riding experience, coupled with a powerful 500cc engine.

Intended User:

Owners and independent repair shops seeking to perform maintenance, diagnostics, and repairs on the Gilera Fuoco 500.

📋 Manual Details

Systems Covered:

Engine, Cooling System, Power Supply, Electrical System, Chassis, Braking System, Suspensions, Bodywork, Pre-Delivery, Maintenance, Troubleshooting, Special Tools

Page Count:

330

Manual Type:

Original Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

Operating Systems:

All Versions of Windows & Mac

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for the engine, including cylinder head, pistons, crankshaft, valve train, and oil system.

Cooling System:

Diagnosis, repair, and maintenance of the radiator, coolant pump, thermostat, and cooling fan. Includes fluid capacities and specifications.

Power Supply:

Covers the fuel system, including fuel pump, injectors, fuel filter, and throttle body. Details on fuel injection system diagnostics and repair.

Electrical System:

Comprehensive wiring diagrams, component testing, troubleshooting procedures for lighting, ignition, starting, charging, and instrument cluster systems.

Chassis And Frame:

Information on the main frame, sub-frame, and associated components. Includes inspection and repair of structural elements.

Braking System:

Detailed procedures for brake pad replacement, caliper service, master cylinder overhaul, brake line maintenance, and bleeding procedures. Includes specifications for brake fluid.

Suspensions:

Front and rear suspension component diagnosis, repair, and adjustment. Covers fork seals, shock absorbers, and linkage systems. Includes specifications for suspension fluids and pressures.

Bodywork:

Information on body panels, fairings, seat removal, and related trim. Includes procedures for alignment and basic repair.

Pre Delivery Inspection:

Checklists and procedures for initial setup and inspection before customer delivery.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, spark plug checks, and lubrication schedules.

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for common issues.

Repair Operations:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Electrical Diagnostics:

Testing methods for electrical components, circuits, and sensors using multimeters and diagnostic tools.

Torque Specifications:

Detailed torque values for all critical fasteners throughout the vehicle.

Diagnostic Level:

Comprehensive, suitable for professional technicians and advanced home mechanics.

Rebuild Procedures:

Detailed instructions for complete engine and component rebuilds.

Special Tool Identification:

Identification and usage of specialized tools required for specific repair and maintenance tasks.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, designed for clear printing of text and diagrams.

Searchability:

Likely text-searchable if OCR processed, allowing quick access to specific information.

Delivery:

Digital Download

Binding Type:

N/A (Digital File)

Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Engine Type:

Four-stroke, single-cylinder, liquid-cooled, DOHC

Displacement:

493 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.5:1

Max Power:

Approximately 40 HP (29.4 kW) @ 7,000 rpm

Max Torque:

Approximately 46 Nm (34 lb-ft) @ 5,000 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (min. 95 RON recommended)

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for exact specification, e.g., API SG/SH/SJ/SL or JASO MA)

Oil Capacity:

Approximately 1.8 - 2.0 liters (including filter change, refer to manual for exact figure).

Ignition System:

Electronic ignition with variable spark advance.

Spark Plug:

NGK CR9EB or equivalent (refer to manual for specific recommendations).

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Final Drive:

Belt drive to rear wheel.

Clutch:

Automatic centrifugal clutch.

📐 Dimensions

Length:

Approx. 2,260 mm (refer to manual for exact)

Width:

Approx. 820 mm (refer to manual for exact)

Height:

Approx. 1,490 mm (refer to manual for exact)

Dry Weight:

Approx. 270 kg (refer to manual for exact)

Gross Vehicle Weight Rating:

Refer to manual for specific load limits.

Wheelbase:

Approx. 1,550 mm (refer to manual for exact)

Front Tire:

120/70-12 (check manual for specific recommendations)

Rear Tire:

140/70-14 (check manual for specific recommendations)

🛡️ Safety Features

Crash Test Results:

Not applicable to this vehicle type in the same way as cars. Focus is on stability and braking performance.

Braking System:

Dual-channel ABS (Anti-lock Braking System) is a key feature, along with front and rear disc brakes for enhanced stopping power.

Suspension System:

The advanced three-wheel tilting suspension system provides superior stability in corners and over uneven surfaces compared to two-wheeled scooters.

Lighting:

Dual headlights for improved visibility, rear brake light, and turn signals.

Ergonomics:

Comfortable seating position and hand controls designed for rider control and fatigue reduction.

💡 Technology Features

Instrument Cluster:

Digital and analog instrument cluster displaying speed, RPM, fuel level, engine temperature, and warning lights. Includes odometer and trip meter.

Braking System:

ABS (Anti-lock Braking System) is a significant technological feature for enhanced safety.

Suspension System:

The electro-hydraulic suspension locking mechanism allows the rider to lock the front suspension for stable parking or unlock it for dynamic tilting during riding. This is a key technological innovation.

Diagnostics Port:

The manual will detail access to and use of any onboard diagnostic ports for connecting advanced diagnostic tools, crucial for troubleshooting EFI systems.

🔧 Maintenance

Engine Oil Change:

Every 6,000 km or 12 months, whichever comes first. (Always consult the manual for definitive intervals).

Air Filter Check:

Inspect every 6,000 km, replace as needed. (Consult manual for replacement interval).

Spark Plug Check:

Check at 6,000 km intervals, replace as per manual schedule (e.g., 12,000 km or as needed based on condition).

Cvt Belt Inspection:

Inspect belt for wear and damage at recommended intervals (e.g., 10,000-12,000 km), replace as per manual recommendation.

Brake Fluid:

DOT 4 (refer to manual for specific type and replacement interval).

Coolant Type:

Ethylene glycol based antifreeze mixture (50% water, 50% antifreeze), specific type as per manual (e.g., Moto Guzzi/Piaggio Group recommended).

Cvt Belt Wear:

CVT belts can wear over time and may require early replacement depending on riding style and mileage. The manual will guide on inspection and replacement.

Suspension Mechanism:

The tilting mechanism for the front suspension can require periodic inspection and lubrication. Refer to the manual for specific maintenance procedures to ensure smooth operation and prevent wear.

Electrical Connections:

As with many vehicles of this era, checking and cleaning electrical connections can prevent intermittent faults. The manual's wiring diagrams are crucial here.

📚 Vehicle History

Manufacturer:

Gilera is an Italian manufacturer of scooters and motorcycles, known for its sporting heritage and innovative designs, with a history dating back to 1909. It is now part of the Piaggio Group.

Fuoco Lineage:

The Fuoco 500 is closely related to the Piaggio MP3 500, sharing many mechanical components and the innovative three-wheel front suspension system, but with Gilera's distinct styling and tuning.

Production Period:

2007-2008 for this specific model year range. Later iterations might exist under different branding or minor updates.

🏆 Awards & Recognition

Notable Features:

The Gilera Fuoco 500 was recognized for its innovative three-wheel design and powerful engine, offering a unique blend of scooter practicality and motorcycle-like performance and stability. While specific awards are not readily listed, its segment leadership in innovative design is notable.