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.
Systems Covered:
Engine, Cooling System, Power Supply, Electrical System, Chassis, Braking System, Suspensions, Bodywork, Pre-Delivery, Maintenance, Troubleshooting, Special Tools
Manual Type:
Original Factory Service Repair Workshop Manual
Operating Systems:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
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.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC
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).
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)
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.
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.
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.
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.
