Gilera Fuoco 500 i.e. 2006-2011 Service Repair Workshop Manual Download PDF

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Taper: Motorcycle

Distributeur:

UGS: 86159

Mots clés: 2006 2007 2008 2009 2010 2011 Fuoco Fuoco 500 i.e. Gilera Motorcycle Motorcycles

Variantes de produits

Description

The Fuoco 500 i.e., produced between 2006 and 2011, is a distinctive three-wheeled maxi-scooter renowned for its advanced tilting front suspension system. This innovative technology allows the Fuoco 500 to lean into turns, offering enhanced stability and a riding experience that blends scooter practicality with motorcycle-like agility. Sharing its platform with another model, the Fuoco 500 features a powerful liquid-cooled, four-stroke engine with electronic fuel injection and a robust triple disc brake setup for superior stopping power and control, making it a capable and engaging machine for urban commuting and longer journeys. This comprehensive Service Repair Workshop Manual provides detailed instructions and technical specifications for the Fuoco 500 i.e. It covers all essential systems, including the engine, automatic transmission, braking system, electrical components, chassis, and bodywork. Within its hundreds of pages, you will find step-by-step procedures for routine maintenance, complex repairs, and complete rebuilds, supported by hundreds of high-resolution photos and exploded diagrams. The manual is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the vehicle, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Fuoco 500 i.e.

Model Designation:

MP3 500 (shared platform with Piaggio MP3 500)

Year:

2006-2011

Codes

Engine Code Prefix:

M344M

👋 Introduction

Market Position

Vehicle Segment:

Maxi-scooter, three-wheeled scooter

Unique Selling Proposition:

Advanced tilting front suspension system providing enhanced stability and lean angle, offering a unique riding experience combining scooter practicality with motorcycle agility.

Competitive Analysis

Primary Competitors:

Piaggio MP3 500 (shared platform), Yamaha TMAX 500, Suzuki Burgman 650.

Key Features

Tilting Suspension:

Patented front suspension system allowing the scooter to lean into turns like a motorcycle.

Engine Type:

Liquid-cooled, four-stroke, single-cylinder with electronic fuel injection.

Braking System:

Triple disc brake setup for superior stopping power and control.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

PDF Download

Usability Lifetime:

Yes, for life, no expiry

Usability Devices:

Unlimited devices (computer, tablet, smartphone)

Usability Printing:

Printable (single pages or entire manual)

Usability Operating Systems:

Windows and macOS compatible

Page Count

Estimated Pages:

Hundreds of pages

📖 Manual Coverage

Systems Covered

Engine:

Full engine overhaul, fuel injection system, ignition system, cooling system, exhaust system, lubrication system, engine diagnostics and troubleshooting.

Transmission:

Automatic transmission (CVT), clutch operation, gearbox disassembly and reassembly, maintenance, troubleshooting.

Brakes:

Hydraulic braking system, front multi-wheel brake system, rear brake, brake fluid, bleeding procedure, disc and pad replacement, troubleshooting.

Electrical:

Complete wiring diagrams, battery, starting system, charging system, lighting system, instrumentation, electronic control unit (ECU), sensors, actuators, troubleshooting.

Chassis:

Frame, suspension (front and rear), steering system, wheel alignment, hub bearings, troubleshooting.

Bodywork:

Body panels, fairings, seating, storage, maintenance, repair, replacement of body components.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant checks, brake pad inspection, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common and complex issues, fault code interpretation, wiring diagnostics, component testing.

Repair:

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

Rebuild:

Complete engine and transmission rebuild procedures, including specifications for clearances and tolerances.

Technical Depth

Depth:

Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY mechanics.

Diagrams Illustrations:

Hundreds of detailed photos and exploded diagrams for clear visual guidance.

📊 Manual Specifications

File Format

Digital Format:

Print Quality

Printability:

High-resolution, printable across all pages.

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Manufacturer:

Piaggio

Engine Type:

Liquid-cooled, four-stroke, SOHC, 4-valve, single-cylinder

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.2:1

Performance

Max Power:

30.6 HP (22.5 kW) at 6,500 rpm

Max Torque:

41.3 Nm (30.5 lb-ft) at 5,250 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (Weber IWP 182 or equivalent)

Fuel Type:

Unleaded gasoline (95 RON recommended)

Fuel Tank Capacity:

12 Liters (approx. 3.17 US gallons)

🔧 Transmission

Standard

Transmission Type:

Automatic, Twist-and-go CVT (Continuously Variable Transmission)

Drive Type:

Belt drive to rear wheel

Features

Engine Management:

ECU controlled for optimal fuel mapping and transmission engagement.

📐 Dimensions

Exterior

Length:

Approx. 2,170 mm (85.4 in)

Width:

Approx. 790 mm (31.1 in)

Height:

Approx. 1,470 mm (57.9 in) to handlebar

Weights

Dry Weight:

Approx. 200 kg (441 lbs)

Curb Weight:

Approx. 215 kg (474 lbs)

🛡️ Safety Features

Active Features

Braking System Front:

Three 256 mm discs with 4-piston calipers (left side dual piston, right side single piston on each wheel), integrated braking system.

Braking System Rear:

240 mm disc with 2-piston caliper.

Suspension Lock:

Electronic suspension locking system for stability at low speeds and when stationary.

Passive Features

Lighting:

Halogen headlights, LED taillight.

Mirrors:

Integrated rear-view mirrors.

💡 Technology Features

Infotainment

Instrumentation:

Digital/analog combination instrument cluster displaying speedometer, tachometer, fuel level, coolant temperature, odometer, trip meter, and warning lights.

Driver Assistance

Traction Control:

Not typically equipped with electronic traction control systems.

Anti-lock Braking System (ABS) available on some models or as an option, particularly on later iterations or Piaggio MP3 variants.

Connectivity

Diagnostic Port:

OBD-II compliant diagnostic port (typically located under the seat or side panel) for connection to diagnostic tools.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km (3,700 miles) or annually.

Oil Filter Replacement:

Every 6,000 km (3,700 miles) or annually.

Air Filter Cleaning:

Every 6,000 km (3,700 miles).

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or every two years.

Coolant Change:

Every 24,000 km (15,000 miles) or every two years.

Fluid Specifications

Engine Oil Type:

SAE 5W-40 Synthetic, API SG/SH/SJ/SL, ACEA A3 or similar (e.g., Piaggio branded oil).

Engine Oil Capacity:

1.6 Liters (with filter change)

Coolant Type:

Ethylene glycol-based antifreeze mixture with corrosion inhibitors (e.g., Piaggio Coolant).

Brake Fluid Type:

DOT 4.

Transmission Fluid:

N/A (CVT with dedicated lubrication and cooling circuit)

Known Issues

Front Suspension Mechanism:

Potential for wear in the tilting mechanism's joints and actuators, requiring periodic inspection and lubrication. Some reports of locking mechanism issues.

Regulator Rectifier:

Occasional failures reported, affecting charging system performance. Aftermarket replacements are often more robust.

Starter Motor:

Some units may experience premature wear on the starter motor. The manual would detail testing procedures.

Wiring Harness:

Potential for chafing or corrosion in wiring harnesses, especially around the front suspension linkage. Crucial for electrical diagnostics covered in the manual.

📚 Vehicle History

Brand Heritage

Parent Company:

Gilera is an Italian motorcycle manufacturer with a long history, founded in 1909. It is currently part of the Piaggio Group.

Model Evolution

Introduction:

The Gilera Fuoco 500 i.e. was introduced in 2007 as a more performance-oriented and rugged variant of the Piaggio MP3 platform, sharing most of its mechanical components.

Shared Platform:

Shares its chassis and powertrain with the Piaggio MP3 500, but features distinct styling and tuning.