Vehicle Segment:
High-performance three-wheeled scooter/maxi-scooter.
Target Audience:
Riders seeking a powerful, stable, and versatile urban and touring machine with a unique riding dynamic.
Key Competitors:
Piaggio MP3 (particularly the 500cc variants), Yamaha TMAX (though two-wheeled), other high-displacement maxi-scooters.
Unique Selling Proposition:
The innovative three-wheel tilting system provides enhanced stability and confidence, especially in corners and on uneven surfaces, combined with a potent 500cc engine.
Design Philosophy:
Combines the agility of a scooter with the stability and braking power of a motorcycle, offering a distinctive riding experience.
Diagnostic Procedures:
Detailed troubleshooting guides and diagnostic flowcharts for all major systems.
Electrical System:
Comprehensive wiring diagrams, component locations, and testing procedures for the entire electrical system.
Engine Mechanical:
Complete overhaul procedures, component specifications, and tolerances for the 500cc engine.
Fuel System:
In-depth coverage of the electronic fuel injection (I.E.) system, including fuel pump, injectors, sensors, and ECU diagnostics.
Suspension And Steering:
Repair and adjustment procedures for the front and rear suspension, including the unique three-wheel tilting mechanism.
Braking System:
Detailed procedures for front and rear brake systems, including hydraulic components and ABS functionality.
Body And Frame:
Information on body panel removal, installation, and repair, as well as frame inspection.
Cooling System:
Procedures for radiator, fan, thermostat, and coolant hose maintenance and replacement.
Exhaust System:
Details on exhaust manifold, catalytic converter, and muffler removal and installation.
Transmission And Drivetrain:
Information on the automatic transmission, clutch, and final drive mechanisms.
Estimated Pages:
Approximately 400-500 pages (typical for a comprehensive factory service manual of this era).
Type:
Factory Service Repair Manual
Purpose:
To provide comprehensive repair, maintenance, and diagnostic information for authorized technicians and advanced DIY users.
Searchability:
Likely to be text-searchable PDF, allowing for quick access to specific information.
Printability:
Printable pages for easy reference during workshop use.
Major Systems:
Engine, Fuel System, Ignition, Electrical System, Transmission, Braking System, Suspension, Steering, Chassis, Bodywork, Cooling System, Lubrication System, Exhaust System, Drivetrain.
Maintenance And Adjustment:
Routine maintenance checks, fluid level adjustments, belt tensioning, spark plug replacement, filter changes.
Disassembly And Assembly:
Step-by-step instructions for removing and reassembling all major components and sub-assemblies.
Repair And Rebuilding:
Detailed instructions for repairing and rebuilding internal engine components, transmission, and other assemblies.
Troubleshooting And Diagnostics:
Systematic approach to identifying and resolving problems, including fault codes (if applicable) and diagnostic tests.
Technical Specifications:
Torque values, clearances, tolerances, electrical specifications, and fluid capacities.
Depth:
Comprehensive, covering everything from basic fluid checks and tire pressure to full engine rebuilds and complex electrical system diagnostics.
User Level:
Aimed at qualified technicians and experienced DIY enthusiasts due to the complexity of the vehicle.
Engine Type:
Four-stroke, single-cylinder, liquid-cooled, DOHC.
Bore X Stroke:
94 mm x 71 mm
Compression Ratio:
10.5:1
Horsepower Peak:
Approximately 40 HP (29.4 kW) @ 7500 rpm
Torque Peak:
Approximately 43 Nm (31.7 lb-ft) @ 5250 rpm
Fuel Delivery:
Electronic Fuel Injection (I.E.) with throttle body.
Fuel Type:
Unleaded gasoline, minimum 95 RON.
Oil Type:
SAE 5W-40 Synthetic (or as specified in manual).
Oil Capacity:
Approximately 1.8 liters (with filter change) (confirm in manual).
Width:
Approx. 800 mm (at handlebars)
Height:
Approx. 1,450 mm (to windshield top)
Dry Weight:
Approx. 275 kg
Gross Vehicle Weight Rating:
Approx. 450 kg (including rider and passenger)
Fuel Tank Capacity:
12 liters (including reserve)
Crash Test Results:
N/A (Motorcycle/Scooter segment typically does not undergo standardized crash testing like automobiles).
Braking System Type:
Hydraulic disc brakes front and rear, with ABS (Anti-lock Braking System) as standard.
Front Brake Specs:
Dual 240 mm discs with three-piston calipers.
Rear Brake Specs:
240 mm disc with three-piston caliper.
Tilting Mechanism:
Hydraulic suspension lock for parking stability, active tilting system for cornering.
Lighting:
Halogen headlights, LED taillight and turn signals.
Mirrors:
Large, adjustable mirrors for good rearward visibility.
Instrument Cluster:
Digital and analog display with speedometer, tachometer, fuel gauge, temperature gauge, clock, and warning lights.
ABS System:
Standard Anti-lock Braking System on front and rear wheels for enhanced safety.
Connectivity Features:
N/A (Basic scooter technology; no advanced connectivity or Bluetooth features expected for this model year).
Oil Change Interval:
Every 5,000 km or 12 months, whichever comes first (typical for this era).
Air Filter Replacement:
Every 10,000 km or as required by inspection.
Spark Plug Replacement:
Every 15,000 - 20,000 km, depending on plug type.
Drive Belt Inspection Replacement:
Inspection every 10,000 km, replacement typically around 20,000-30,000 km (dependent on usage).
Engine Oil:
SAE 5W-40 Synthetic, API SJ/SL/SM or JASO MA/MA2.
Coolant:
Ethylene glycol based coolant with anti-corrosion additives, typically a 50/50 mix with distilled water.
Gear Oil Type:
API GL-4 or GL-5, SAE 75W-90 (for final drive).
Tilting Mechanism Wear:
Potential for wear in the tilting mechanism linkage and bearings over high mileage, requiring lubrication and adjustment.
Cvt Belt Durability:
CVT belt can wear prematurely with aggressive riding or improper maintenance.
ABS Sensor Issues:
ABS sensor ring or wiring can be susceptible to dirt or damage, leading to ABS warning lights.
Oil Filter Part Number:
Example: HiFloFiltro HF153 or OEM equivalent.
Air Filter Part Number:
Example: K&N HA-5006 or OEM equivalent.
Manufacturer Origin:
Gilera is an Italian manufacturer with a long history in motorcycle production, founded in 1909. It is now part of the Piaggio Group.
Fuoco Introduction:
The Gilera Fuoco 500 (also known as Piaggio MP3 Yourban in some markets/earlier iterations) was introduced to the market to compete in the growing three-wheeled scooter segment, offering enhanced stability and safety.
Production Period:
The first generation of the Fuoco/MP3 platform was launched in 2006, with the 500cc variant becoming a prominent model.
