Segment:
Maxi-scooter / Urban Commuter
Competitors:
Yamaha TMAX, Suzuki Burgman 400/650, Honda Silver Wing, Kymco Xciting 500
Unique Selling Points:
Powerful 500cc engine, distinctive styling, advanced suspension for its class, Piaggio Group engineering.
Benefit To Owner:
Enables DIY servicing, reduces repair costs, extends motorcycle lifespan, enhances understanding of vehicle systems.
Primary Coverage:
Complete Workshop Repair and Service
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Reassembly
Estimated Page Count:
High (Detailed, likely 300+ pages based on depth of coverage)
Type:
Workshop Repair Manual
Language:
English (Assumed, based on product description language)
Powertrain:
Engine, Fuel System (Injection), Lubrication, Cooling, Gearbox, Clutch, Transmission
Chassis And Suspension:
Front Wheel and Steering, Rear Wheel System, Chassis, Suspension, Fenders, Exhaust Pipe
Electrical:
Electrical System, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams
Body And Fixtures:
Body & Fixtures, Frame/Body Panels/Exhaust System
Maintenance:
Periodic checks & Adjustments, General Maintenance, Fluid Changes
Repair And Rebuild:
Engine Removal and Installation, Crankcase/Piston/Cylinder, Crankshaft/Transmission/Balancer, Cylinder Head/Valves, Gearbox & Clutch Overhaul
Diagnostics And Troubleshooting:
Troubleshooting guides for various systems
Inspections:
Visual inspections, torque checks, fluid level checks, tire pressure checks.
Adjustments:
Carburetor (if applicable, though likely FI), throttle cable, brake levers, suspension settings.
Depth:
Comprehensive: From routine maintenance to complete engine rebuilds and electrical system diagnostics.
Visuals:
Highly detailed exploded pictures and diagrams
Rebuild Procedures:
Detailed steps for engine disassembly, component inspection, part replacement, and reassembly including piston, rings, valves, crankshaft.
Electrical Diagrams:
Comprehensive wiring diagrams for all electrical systems, aiding in troubleshooting.
Torque Specifications:
Precise torque values for all critical fasteners.
Type:
Four-stroke, Single-cylinder, Liquid-cooled, DOHC
Displacement:
493 cc (Approximate)
Horsepower Estimated:
Approx. 40-45 HP (Varies by market and specific tuning)
Torque Estimated:
Approx. 45-50 Nm (Varies by market and specific tuning)
System:
Electronic Fuel Injection (IE - 'iniezione elettronica')
Type:
Wet Sump (Typically)
System Details:
Details on combustion chamber design, valve timing, spark plug specifications.
Length:
Approx. 2250 mm (Estimate)
Width:
Approx. 800 mm (Estimate)
Height:
Approx. 1490 mm (Estimate)
Dry Weight:
Approx. 210 kg (Estimate)
Gross Vehicle Weight:
Refer to manual for specific GVWR
Crash Test Results:
N/A (Motorcycle specific testing varies)
Braking System:
Dual front disc brakes, Single rear disc brake. ABS likely optional or standard on later models.
Lighting:
Halogen headlights, LED taillight (likely on later models)
Frame Construction:
Steel frame, designed for stability.
Dashboard:
Digital/Analog combination instrument cluster displaying speed, RPM, fuel level, coolant temperature, and warning lights.
ABS:
Anti-lock Braking System (ABS) - availability depends on model year and specific trim.
Diagnostic Port:
Likely has a diagnostic port for electronic fault code retrieval using specialized tools.
Oil Change:
Typically every 5,000 - 10,000 km or annually, depending on usage (refer to manual for precise intervals).
Spark Plug Replacement:
Typically every 10,000 - 20,000 km (refer to manual for specific type and interval).
Air Filter Cleaning Replacement:
Check at regular intervals, replace as needed based on operating conditions.
Transmission Fluid Change:
Refer to manual for specific interval and procedure.
Engine Oil:
Specific viscosity and API rating required (e.g., 10W-40, API SG or higher - consult manual for exact spec).
Coolant:
Ethylene glycol-based, with anti-corrosion additives (e.g., Piaggio Group specific coolant or equivalent).
Brake Fluid:
DOT 4 (Recommended for most hydraulic braking systems of this era).
Common Problems:
Potential for stator/regulator issues, occasional fuel pump problems, wear on CVT components, electrical connector corrosion.
Troubleshooting Assistance:
Manual provides detailed diagnostic procedures for addressing common and uncommon issues.
Manufacturer Origin:
Gilera is an Italian motorcycle manufacturer, now part of the Piaggio Group.
Development Context:
The Fuoco 500 ie (also known as the Gilera GP 800 in some markets, though that was a different model) represents Gilera's foray into the larger displacement maxi-scooter segment, leveraging Piaggio's engine technology.
Production Years:
Mid-2000s to early 2010s (Exact years vary by market)
