Vehicle Segment:
Maxi-scooter with advanced tilting technology.
Competitors:
Piaggio MP3 500, Yamaha TMAX 500, Suzuki Burgman 650.
Unique Selling Point:
Patented three-wheel tilting system providing motorcycle-like lean angles and stability.
Comparison To Generic Manuals:
Model-specific, in-depth coverage unlike generic Chilton or Haynes manuals.
User Friendliness:
Designed to be an 'EASY to use guide' for servicing, repairing, and diagnosing issues.
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair for the 500cc i.e. engine.
Fuel System Injection:
Detailed coverage of the electronic fuel injection (i.e.) system, including sensors, injectors, ECU, and troubleshooting.
Cooling System:
Maintenance, troubleshooting, and repair of the liquid cooling system, including radiator, water pump, and thermostat.
Suspension System:
Front and rear suspension (including the advanced tilt mechanism) inspection, maintenance, and repair. Specifications for components.
Braking System:
Front and rear brake system service, including disc and caliper maintenance, fluid bleeding, and ABS (if applicable).
Electrical System:
Comprehensive coverage of the electrical system, including wiring diagrams, component testing, battery, lighting, and ignition.
Chassis Frame:
Inspection, maintenance, and repair of the chassis and frame, including the unique tilting mechanism.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, chain adjustment, lubrication points, and pre-delivery checks.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and complex issues, including error code interpretation.
Engine Overhaul:
Detailed procedures for engine disassembly, component inspection, machining data, and reassembly.
Injection System Tuning:
Information on fuel system diagnostics and potential adjustments or component replacement for optimal performance.
Electrical Component Testing:
Methods for testing ignition coils, sensors, relays, alternators, and starter motors.
Diagnostic Capability:
Advanced diagnostic procedures suitable for professional technicians and experienced DIY mechanics.
Rebuild Complexity:
Comprehensive rebuild instructions for major components like the engine, transmission, and suspension.
Specialized Tools:
Identification of necessary specialized tooling for specific repair and maintenance tasks.
PDF Quality:
High-resolution, searchable PDF for clear viewing and printing.
Printable Pages:
Full manual can be printed, or select specific pages for targeted repairs.
Digital Format:
Downloadable PDF - no physical binding required.
Digital Medium:
Digital PDF file for viewing on computers (Win/Mac) and mobile devices.
Engine Type:
Liquid-cooled, four-stroke, four-valve, single-cylinder.
Engine Displacement:
492.7 cc
Bore X Stroke:
94 mm x 87.6 mm
Horsepower:
Approximately 39.6 HP (29.5 kW) @ 7500 rpm (subject to regional variations and specific tuning).
Torque:
Approximately 4.6 kgm (45 Nm) @ 5750 rpm (subject to regional variations and specific tuning).
Fuel Delivery:
Electronic Fuel Injection (EFI) with throttle body.
Ignition System:
Electronic ignition.
Lubrication System:
Wet sump.
Length:
Approx. 2180 mm (dependent on exact configuration).
Width:
Approx. 800 mm (at handlebars, dependent on exact configuration).
Height:
Approx. 1350 mm (seat height, dependent on exact configuration).
Dry Weight:
Approx. 235 kg.
Fuel Tank Capacity:
12 Liters (including approximately 2-liter reserve).
Braking System Type:
Dual front discs (240mm) with dual-piston calipers, single rear disc (240mm) with dual-piston caliper. Combined braking system.
ABS Availability:
ABS was an optional feature on some models.
Lighting System:
Halogen headlight, LED taillight and indicators.
Tilting Lock:
Integrated electro-hydraulic locking system for the front suspension, allowing it to be parked upright without a stand.
Instrument Cluster:
Digital-analog combination instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, and diagnostic indicators.
Tilting System Control:
The advanced tilting system is a key technological feature for stability and maneuverability.
Diagnostic Port:
OBD-II compliant diagnostic connector for electronic diagnostics and fault code reading.
Engine Oil Change:
Typically every 6,000 km or 12 months, whichever comes first (refer to manual for exact specification).
Oil Filter Replacement:
Recommended at every engine oil change.
Air Filter Cleaning:
Check and clean every 6,000 km; replace as needed. More frequent checks in dusty conditions.
Spark Plug Replacement:
Typically every 12,000 km or as specified by the manual (e.g., NGK CR9EB or equivalent).
Engine Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil meeting API SG/SH/SJ or ACEA A3 specifications (refer to manual for precise grade).
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture (50% water, 50% coolant) with corrosion inhibitors. Refer to manual for specific product recommendation.
Brake Fluid Type:
DOT 4 brake fluid.
Common Wear Items:
Front suspension pivot bearings, rear shock absorber bushings, CVT belt wear.
Tilting Mechanism:
Occasional issues with the electro-hydraulic tilting lock system may require diagnostic attention or component replacement.
Manufacturer:
Gilera is an Italian manufacturer of motorcycles, founded in 1909. It is currently part of the Piaggio Group.
Platform Basis:
The Gilera Fuoco 500 i.e. is based on the Piaggio MP3 platform, sharing much of its mechanical and electrical architecture.
Production Period:
The Fuoco was produced for a limited period, primarily in the late 2000s and early 2010s, as a performance-oriented variant of the MP3.
