🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500

Product Name:

GILERA FUOCO 500 Workshop Repair Manual Download PDF

👋 Introduction

Description:

The Gilera Fuoco 500, also known as the Piaggio MP3 Yourban 500 in some markets, is a unique three-wheeled scooter designed for stability and comfort. This manual provides professional-grade repair and maintenance information essential for owners and technicians.

Manual Advantage:

Provides the same level of detail and accuracy as official dealer workshop manuals.

Information Access:

Thousands of pages of diagrams and detailed information for specific vehicle repair at the click of a mouse.

Manual Scope:

Covers all service and repair procedures, including electrical diagrams, torque settings, and fluid capacities.

Authenticity:

Original workshop manuals written by the manufacturers, ensuring accuracy.

Market Segment:

Maxi-scooter, three-wheel scooter segment.

Competitors:

Piaggio MP3 series (various displacements), Yamaha Tricity.

📋 Manual Details

Manual Type:

Workshop Service & Repair Manual

Language:

English

Format:

PDF Download

Compatibility:

Windows & MAC Compatible

📖 Manual Coverage

Engine:

Complete engine overhaul, rebuild, diagnostics, tuning

Transmission:

Automatic transmission (CVT) service, repair, and maintenance

Brakes:

Front and rear brake system service, including hydraulic components and ABS (if equipped)

Suspension:

Front suspension (dual-arm steering system), rear suspension (shock absorber, swingarm) service and adjustment

Electrical:

Complete wiring diagrams, electrical component diagnostics, lighting, ignition, starting, charging systems

Fuel System:

Fuel injection system, fuel pump, injectors, fuel tank service

Cooling System:

Radiator, fan, thermostat, coolant flow diagnostics

Exhaust System:

Exhaust pipe, muffler, catalytic converter inspection and replacement

Bodywork:

Body panel removal and installation, fairings, seating, storage compartment service

Chassis:

Frame integrity checks, steering system components

Instrumentation:

Speedometer, tachometer, fuel gauge, temperature gauge, warning lights diagnostics.

Lighting System:

Headlight, taillight, brake lights, turn signals, dashboard illumination.

Starting Charging System:

Battery, starter motor, alternator/stator, voltage regulator.

Exhaust Emissions:

Catalytic converter, oxygen sensors (if equipped), emissions control systems.

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, spark plug service

Troubleshooting:

Diagnostic procedures for common and uncommon faults, fault code interpretation

Repair:

Step-by-step repair instructions for all major and minor components

Diagnostics:

Factory diagnostic procedures, live data interpretation (where applicable to the era)

Technical Specifications:

Torque settings, fluid capacities, engine tolerances, electrical specifications

Component Replacement:

Detailed steps for replacing individual components like starter motor, alternator, fuel pump, brake calipers, etc.

Adjustment Procedures:

Throttle cable adjustment, parking brake adjustment, suspension pre-load adjustment.

Diagnostic Charts:

Flowcharts and guides for diagnosing specific symptoms.

Depth:

Comprehensive coverage from basic maintenance to full engine and transmission rebuilds.

Diagnostic Tools:

Information on factory diagnostic tools and procedures (may require specific hardware not included).

Engine Rebuild:

Detailed instructions for cylinder head removal/installation, piston and ring replacement, crankshaft assembly.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, multimeter testing.

📊 Manual Specifications

File Type:

Acrobat PDF

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for in-workshop use

Binding:

Not applicable (digital download)

Paper:

Not applicable (digital download)

Quality:

High-resolution, clear diagrams and text suitable for professional use.

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Cooling System:

Liquid-cooled

Horsepower Hp:

Approx. 40 HP (29.4 kW) @ 7,500 rpm

Torque Nm:

Approx. 42.5 Nm (31.3 lb-ft) @ 5,500 rpm

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Electronic Fuel Injection (EFI)

Ignition System:

Electronic ignition

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive Type:

Belt drive

📐 Dimensions

Length:

Approx. 2,170 mm (85.4 in)

Width:

Approx. 800 mm (31.5 in) (at handlebars)

Height:

Approx. 1,470 mm (57.9 in) (to top of windshield)

Wheelbase:

Approx. 1,550 mm (61.0 in)

Seat Height:

Approx. 790 mm (31.1 in)

Dry Weight:

Approx. 275 kg (606 lbs)

Gross Vehicle Weight Rating:

Not specified, but typically includes rider and cargo.

Fuel Capacity:

Approx. 12 liters (3.2 US gal)

🛡️ Safety Features

Braking System:

Combined braking system, front dual disc brakes, rear disc brake, ABS optional/standard depending on market.

Suspension System:

Patented three-wheel tilting suspension system for enhanced stability and cornering.

Lighting:

Halogen headlights, LED taillight and indicators.

Frame Construction:

Steel tube frame, providing robust support for the three-wheel configuration.

💡 Technology Features

Dashboard:

Analogue and digital instrumentation, providing speed, RPM, fuel level, engine temperature, and warning lights.

ABS:

Anti-lock Braking System (ABS) available on certain models/years for enhanced safety.

Parking Brake:

Manual parking brake lever.

Storage:

Under-seat storage compartment with potential for accessory connectivity (e.g., 12V socket).

🔧 Maintenance

Oil Change Interval:

Typically every 6,000-10,000 km (3,700-6,200 miles) or annually, refer to specific manual for exact intervals.

Air Filter Replacement:

Inspect every 6,000 km, replace as needed or at manufacturer recommended intervals.

Spark Plug Replacement:

Typically every 12,000-18,000 km (7,500-11,000 miles).

Engine Oil Type:

SAE 5W-40 Synthetic Motorcycle Oil, API SG or higher.

Engine Oil Capacity:

Approx. 1.7 liters (1.8 US qt) with filter change. Consult manual for exact capacity.

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid.

Transmission Fluid:

No separate transmission fluid, engine oil lubricates transmission components.

Final Drive Fluid:

Oil for rear differential/final drive (if applicable, consult manual), typically SAE 80W-90 GL-4.

Common Wear Items:

CVT belt wear, suspension linkage wear, brake pad and disc wear.

Potential Electrical:

Corrosion in connectors, charging system issues (regulator/stator).

Suspension Locking:

Rare instances of suspension locking mechanism issues, requiring specific diagnostic and repair procedures.

Engine Performance:

Intermittent rough idling, power loss due to injector fouling or fuel pump issues.

📚 Vehicle History

Heritage:

Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, known for performance and innovative design.

Model Introduction:

The Fuoco 500 was introduced as a more powerful and robust version of the Piaggio MP3 platform, offering a larger engine and distinct styling.

Manufacturing Location:

Italy