🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500 i.e.

Vehicle Type:

Motorcycle (3-wheeled scooter)

👋 Introduction

Market Position:

The Gilera Fuoco 500 i.e. is a unique, high-performance three-wheeled scooter, often positioned as a more robust and powerful alternative in the urban mobility segment, appealing to riders seeking stability and a substantial engine. This service manual caters to owners and independent workshops looking for in-depth technical data to maintain and repair this specialized vehicle.

Target Audience:

Owners seeking to perform their own maintenance, independent repair shops, and enthusiasts with a technical inclination for this distinctive three-wheeled vehicle.

Key Features:

Provides factory-level repair information, including OEM specifications, exploded diagrams, and step-by-step instructions, enabling comprehensive servicing and troubleshooting for the Gilera Fuoco 500 i.e.

Competitive Analysis:

Competes in the premium three-wheeled scooter market, offering an alternative to models like the Piaggio MP3. Its larger displacement and Gilera badging often position it as a sportier, more potent option.

📋 Manual Details

Coverage Areas:

Comprehensive repair and maintenance for Gilera Fuoco 500 i.e., including general information, assembly/disassembly, routine maintenance, engine, fuel system, lubrication, cooling, transmission, steering, shocks, bodywork, intake/exhaust, electrical system, and advanced troubleshooting.

Manual Type:

Factory/Official Service Repair Workshop Manual

Language:

English

File Format:

PDF

Estimated Page Count:

Likely exceeds 200 pages based on typical factory service manual depth for motorcycles of this complexity.

Usage Purpose:

Primarily for repair, maintenance, diagnostics, and overhaul. Can also serve as a reference for parts identification via exploded views.

Specialized Sections:

Includes specific sections on the advanced three-wheel tilting mechanism, which requires specialized maintenance and troubleshooting.

📖 Manual Coverage

Systems Covered:

Engine (500cc liquid-cooled, single-cylinder, 4-stroke, fuel-injected), Fuel System (electronic fuel injection, throttle body, fuel pump, injectors), Lubrication System (oil pump, filter, oil type), Cooling System (liquid cooling, radiator, fan, coolant type), Transmission (CVT automatic transmission, belt drive, clutch), Braking System (front and rear hydraulic disc brakes, ABS potential), Suspension (front telescopic forks, rear dual shock absorbers, linkage), Electrical System (battery, starter, ignition, lighting, sensors, ECU), Chassis and Bodywork (frame, fairings, panels, seating).

Electrical System Details:

Includes detailed wiring diagrams, component testing procedures for ignition, lighting, starter, ECU, sensors (throttle position, coolant temperature, etc.), and charging system.

Chassis Suspension Details:

Detailed procedures for front suspension unit disassembly, inspection, and reassembly, including the tilting mechanism. Rear shock absorber removal, inspection, and adjustment.

Procedures Included:

Step-by-step repair and assembly procedures, tune-ups, lubrication, engine rebuilds, transmission service, carburetor/fuel injection adjustment, electrical diagnostics and repair, suspension overhaul, brake system maintenance, body panel removal and installation, troubleshooting guides.

Troubleshooting Scope:

Advanced troubleshooting sections with diagnostic flowcharts and fault code interpretations (if applicable) for complex issues.

Engine Rebuild Scope:

Complete engine disassembly, inspection of critical components (pistons, cylinders, crankshaft, valves), bearing replacement, seal replacement, and reassembly with specified torque sequences.

Technical Depth:

OEM specifications (torque values, compression ranges, tolerances), detailed charts, diagrams, illustrations, photos, electrical schematics, diagnostic procedures for professional mechanics and individuals with basic mechanical knowledge.

Oem Data Included:

Torque specifications for all fasteners, engine component clearances, electrical resistance values, diagnostic trouble codes (DTCs) and their meaning, fluid capacities, and recommended lubricants.

Electrical Schematics Detail:

Detailed, color-coded wiring diagrams illustrating all circuits, component locations, and wire routing.

📊 Manual Specifications

File Format:

PDF

Printable:

Yes

Compatibility:

All Windows & Mac versions, smartphones, iPads, flash drives, hard drives.

Software Requirement:

Adobe PDF Reader

Searchability:

PDF format typically allows for text searching of keywords and technical terms.

Print Quality:

Printable at original resolution, ensuring clarity of text and diagrams.

Delivery Method:

Digital download link sent via email within minutes of payment.

Support Policy:

Lifetime Protection Policy for lost or damaged downloads.

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 4-stroke, liquid-cooled, DOHC

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Fueling:

Electronic Fuel Injection (i.e.)

Horsepower:

Approx. 40 HP @ 7,000 rpm (exact figures vary by region and specific model year)

Torque:

Approx. 47 Nm @ 5,500 rpm (exact figures vary by region and specific model year)

Fuel Type:

Unleaded gasoline

Throttle Body Diameter:

Refer to manual for specific throttle body size.

Fuel Tank Capacity:

Refer to manual for specific fuel tank capacity.

Oil Type:

Refer to manual for specific API classification and viscosity grade (e.g., SAE 10W-40 semi-synthetic or synthetic motorcycle oil).

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water.

Cooling Fan Activation:

Temperature-controlled electric fan; manual provides details on testing and replacement.

Compression Ratio:

Refer to manual for specific compression ratio.

Valve Train:

Double Overhead Camshaft (DOHC), 4 valves per cylinder.

🔧 Transmission

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Final Drive:

Belt drive

Clutch Type:

Automatic centrifugal clutch

Transmission Fluid Type:

CVT transmissions typically do not have a separate user-serviceable transmission fluid; however, internal lubrication is critical. Refer to manual for specific lubrication requirements if any.

📐 Dimensions

Dry Weight:

Approx. 290 kg (639 lbs) (exact figures vary)

Gross Vehicle Weight Rating:

Refer to manual for specific GVWR.

Wheelbase:

Refer to manual for specific wheelbase measurement.

Length:

Refer to manual for specific overall length.

Width:

Refer to manual for specific overall width (typically measured at handlebars).

Height:

Refer to manual for specific overall height (typically measured at handlebars).

🛡️ Safety Features

Active Safety Features:

Potential for ABS (Anti-lock Braking System) depending on model year and market; robust three-wheel stability.

Passive Safety Features:

Integrated frame design, front and rear lighting systems, sturdy bodywork.

Front Brakes:

Dual hydraulic disc brakes (specific diameter and caliper type detailed in manual).

Rear Brakes:

Single hydraulic disc brake (specific diameter and caliper type detailed in manual).

💡 Technology Features

Driver Assistance Features:

While not typically considered 'driver assistance' in the automotive sense, the three-wheel tilting mechanism provides enhanced stability and confidence, particularly in corners and braking. The 'i.e.' designation signifies the adoption of electronic fuel injection for more precise engine control and emissions.

Infotainment Features:

Typically basic instrumentation including speedometer, tachometer, fuel gauge, coolant temperature gauge, and warning lights. No advanced infotainment systems expected.

🔧 Maintenance

Service Intervals:

Refer to manual for specific intervals for oil changes, filter replacements, valve clearance checks, spark plug replacement, and brake fluid changes. Typically, initial service around 1,000 km, followed by regular intervals (e.g., every 5,000-10,000 km or annually).

Valve Clearance Interval:

Refer to manual; typically required at initial service and then every 10,000-20,000 km or as specified.

Coolant Change Interval:

Refer to manual; typically every 2-3 years or as specified to maintain coolant effectiveness.

Engine Oil Capacity:

Refer to manual for exact capacity (typically around 1.6-1.8 liters).

Coolant Capacity:

Refer to manual for exact capacity.

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Gear Oil Spec:

Not applicable for CVT drive; refer to manual for any differential or final drive lubrication if present.

Common Issues:

Potential issues can include CVT belt wear, front suspension linkage lubrication, charging system components (stator, regulator), and occasional electrical sensor faults. Regular maintenance as per the manual is crucial.

Common Maintenance Tasks:

Regular inspection and lubrication of the front tilting mechanism, checking/replacing the CVT belt at specified intervals, ensuring proper coolant levels and radiator function.

📚 Vehicle History

Brand Heritage:

Gilera is an Italian manufacturer with a long history in motorcycle production, known for performance and innovative designs. It is part of the Piaggio Group.

Model Evolution:

The Fuoco 500 i.e. is closely related to the Piaggio MP3 500, sharing many components and design principles, but distinguished by Gilera's sportier styling and tuning. It was part of a segment exploring the potential of three-wheeled vehicles for enhanced stability and safety.

Key Innovations:

The Gilera Fuoco, like its Piaggio counterpart, pioneered the mass-market adoption of a practical three-wheeled tilting scooter, offering enhanced stability compared to traditional two-wheeled motorcycles.

Production Period:

The Gilera Fuoco 500 i.e. was produced roughly from the mid-2000s to the late 2010s.