🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500 ie

Year Coverage:

2007 onward

Product Type:

Service Repair Workshop Manual

👋 Introduction

Segment:

Maxi-scooter segment

Target Audience:

Owners and independent workshops seeking detailed repair and maintenance information.

Comparative Advantage:

Provides factory-level technical detail and diagnostic procedures not always available in generic repair guides.

Unique Selling Proposition:

Instant download, comprehensive coverage, professional quality, detailed diagrams and exploded views.

Cost Savings:

Enables DIY repairs, reducing dealership or independent shop labor costs.

📋 Manual Details

Overall Coverage:

Complete vehicle from front to back

Specific Areas:

Engine, Transmission, Chassis, Electrical System, Bodywork, Suspension, Brakes, Fuel System, Cooling System, Exhaust System, Lubrication System, Ignition System, Frame, Wheels, Tires, Instrumentation, Controls, Lighting, Accessories

Estimated Page Count:

Extensive (indicative of professional workshop manuals)

Type:

Factory Type PDF Service Repair Manual

Language:

English (assumed based on product description)

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, component diagnostics, rebuild procedures, timing, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod service, lubrication system maintenance.

Fuel System:

Fuel injection system (IE - Electronic Injection), fuel pump operation, injector testing, throttle body cleaning and adjustment, fuel pressure regulation, fuel tank and line service.

Ignition System:

Electronic ignition control, spark plug service, ignition coil testing, ignition timing verification.

Cooling System:

Radiator service, coolant replacement, thermostat operation, fan control, water pump inspection and replacement.

Transmission Drivetrain:

Automatic transmission operation, fluid checks and changes, belt drive system inspection and replacement, clutch assembly service.

Brakes:

Front and rear brake system maintenance, hydraulic fluid replacement, caliper and master cylinder service, brake pad and rotor inspection and replacement, ABS system diagnostics (if applicable).

Suspension Steering:

Front and rear suspension component inspection, shock absorber and spring replacement, steering linkage service, wheel bearing maintenance, front suspension geometry checks (if applicable).

Electrical System:

Battery service and testing, charging system diagnostics (alternator/stator), starter motor operation, lighting system troubleshooting, wiring diagrams, fuse and relay identification and testing, instrument cluster diagnostics.

Bodywork Frame:

Body panel removal and installation, fairing component service, seat maintenance, frame inspection and repair guidelines, accessory installation.

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant changes, belt inspection/replacement, tire pressure checks, chain lubrication (if applicable).

Diagnostics:

Systematic troubleshooting guides for common and uncommon issues, fault code interpretation (if applicable), component testing procedures.

Repair:

Step-by-step repair instructions for all major vehicle components, including detailed disassembly and reassembly sequences.

Technical Data:

Torque specifications for all fasteners, fluid capacities, electrical resistance values, diagnostic parameters.

Troubleshooting Guides:

Detailed step-by-step troubleshooting flowcharts and explanations for various symptoms and issues.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, and advanced electrical system diagnostics.

Special Tools:

Identification and use of specific tools required for certain repair procedures.

📊 Manual Specifications

Format:

PDF

Compatibility:

PC & MAC Compatible

Searchable:

Yes (PDF format allows for text search of topics and procedures)

Printability:

Printable; users can print needed pages.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, four-stroke, four-valve, liquid-cooled, EFI

Displacement:

499.5 cc (cubic centimeters)

Bore X Stroke:

94 mm x 90.9 mm (typical for this engine family)

Compression Ratio:

Approximately 10.5:1 (typical)

Horsepower:

Approximately 40 HP (at crankshaft, figures vary by region and specific tuning)

Torque:

Approximately 46 Nm (at crankshaft, figures vary by region and specific tuning)

Fuel Delivery:

Electronic Fuel Injection (IE)

Fuel Type:

Unleaded gasoline (minimum 95 RON)

Oil Type:

API SG/SH/SJ or JASO MA certified motorcycle engine oil

Oil Capacity:

Approximately 1.7 liters (with filter change, consult manual for exact figure)

Spark Plug Type:

NGK CR9EB or equivalent (consult manual for precise recommendation)

Cooling Method:

Liquid-cooled

🔧 Transmission

Transmission Type:

Automatic CVT (Continuously Variable Transmission) with torque converter

Optional Transmissions:

N/A

Drive Type:

Belt drive to rear wheel

Transmission Fluid Type:

Specific CVT fluid (consult manual for exact specification and change interval)

📐 Dimensions

Length:

Approx. 2180 mm (consult manual for exact figure)

Width:

Approx. 760 mm (at handlebars, consult manual for exact figure)

Height:

Approx. 1400 mm (at windshield, consult manual for exact figure)

Wheelbase:

Approx. 1540 mm (consult manual for exact figure)

Dry Weight:

Approx. 204 kg (consult manual for exact figure)

Gross Vehicle Weight Rating:

Consult manual

Weight Distribution:

Designed for stability at speed and maneuverability.

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycle/Scooter segment typically not subject to automotive crash testing standards)

Braking System:

Dual disc front brakes, single disc rear brake. May include ABS on some models/markets.

Lighting:

Halogen headlight, LED taillight/brake light, turn signals.

Suspension Stability:

The three-wheel front suspension design contributes to enhanced stability and confidence during cornering and braking.

Frame Construction:

High-strength steel frame for rigidity and rider safety.

💡 Technology Features

Instrument Cluster:

Digital/analog combination cluster displaying speed, RPM, fuel level, engine temperature, odometer, trip meter, and warning lights.

ABS:

Anti-lock Braking System may be present on certain variants or as an optional feature, providing enhanced braking control.

Diagnostic Port:

On-board diagnostic port for connection to specialized diagnostic tools, enabling fault code reading and system analysis.

🔧 Maintenance

Engine Oil Change:

Every 5,000 km or annually (consult manual for exact interval and conditions)

Air Filter Replacement:

Every 10,000 km or as needed based on operating conditions (consult manual)

Spark Plug Replacement:

Every 10,000 km or as per manual recommendation

Transmission Belt Inspection:

Inspect every 10,000 km, replace as needed (consult manual for specific mileage recommendations)

Brake Fluid Flush:

Every 2 years or as per manual recommendation

Engine Oil Viscosity:

10W-40 (commonly recommended, verify with manual)

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type (e.g., Piaggio Group coolant).

Brake Fluid Type:

DOT 4 (verify with manual)

Common Wear Items:

Brake pads, tires, CVT belt, spark plugs.

Potential Electrical:

Wiring harness integrity, particularly at stress points; charging system components (regulator/rectifier) can be prone to failure over time.

Engine Performance:

Can include occasional rough idle due to EFI system sensitivity; regular injector cleaning and proper maintenance are crucial.

📚 Vehicle History

Manufacturer:

Gilera is an Italian manufacturer of motorcycles and scooters, with a long history dating back to 1909. It is currently part of the Piaggio & C. S.p.A. group.

Fuoco Lineage:

The Fuoco 500 ie is a three-wheeled maxi-scooter, a segment popularized by Piaggio's own MP3. The Fuoco distinguishes itself with a more rugged, aggressive styling and a slightly different suspension setup on the twin front wheels.

Production Period:

Introduced around 2007, with this manual covering models from 2007 onward.

🏆 Awards & Recognition

Segment Awards:

N/A (Specific awards for the Gilera Fuoco 500 ie are not widely documented in general automotive press, but the three-wheeled scooter concept itself has been recognized for innovation in urban mobility.)