Market Segment:
High-performance scooter, often positioned as a powerful and capable alternative to motorcycles for urban and touring use.
Key Competitors:
Other maxi-scooters in the 400cc+ range, such as Yamaha TMAX, Suzuki Burgman 400/650, and BMW C series.
Unique Selling Points:
Powerful 500cc engine, robust chassis, distinctive styling, and a focus on performance and comfort for longer rides.
Cost Savings:
Enables owners to perform maintenance and repairs themselves, significantly reducing dealership labor costs and extending the motorcycle's lifespan.
Ease Of Use:
Designed for clarity with detailed diagrams and step-by-step instructions, making complex procedures accessible.
Systems Covered:
Engine, Injection System, Braking System, Suspension System, Cooling System, Chassis, Electrical System, Maintenance, Troubleshooting
Estimated Page Count:
Detailed, exact page count not specified but described as comprehensive with exploded diagrams and step-by-step instructions.
Manual Type:
Service Workshop Manual / Repair Manual
File Format:
PDF Download
Engine:
Complete engine disassembly, assembly, inspection, and repair procedures for the 500cc fuel-injected engine.
Injection System:
Detailed coverage of the electronic fuel injection (IE) system, including sensor diagnostics, fuel delivery, and ECU troubleshooting.
Braking System:
Maintenance, inspection, and repair of front and rear braking systems, including hydraulic components and potential ABS integration (if applicable to the model year).
Suspensions:
Procedures for front suspension (telescopic forks) and rear suspension (shock absorbers) maintenance, adjustment, and component replacement.
Cooling System:
Maintenance, flushing, and repair of the liquid cooling system, including radiator, coolant, thermostat, and fan.
Chassis:
Inspection and maintenance of the chassis frame, steering, and related components for structural integrity and proper function.
Electrical System:
Comprehensive electrical schematics, component testing, wiring diagrams, ignition system, lighting, and starter system troubleshooting.
Maintenance:
Routine maintenance schedules, fluid changes, filter replacements, spark plug service, and general upkeep procedures.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues, often presented in a step-by-step format.
Repair:
Detailed, step-by-step repair instructions for all major components and systems of the Gilera Fuoco 500 ie.
Disassembly Assembly:
Exploded views and detailed instructions for disassembling and reassembling all major vehicle components, including the engine and transmission.
Tooling Requirements:
Details necessary specialized tools and equipment required for various maintenance and repair tasks, ensuring correct procedures are followed.
Depth Of Coverage:
High. Covers everything from basic maintenance to in-depth engine rebuilds, electrical diagnostics, and chassis repairs, suitable for professional mechanics and advanced DIY enthusiasts.
Searchability:
PDF format generally allows for text searching of keywords, making it easier to find specific information.
Print Quality:
Printable without restriction, allowing users to print specific sections or the entire manual.
Binding Type:
N/A (Digital Download - PDF)
Paper Type:
N/A (Digital Download - PDF)
Software Requirements:
Adobe PDF Reader
Operating System Compatibility:
All Versions of Windows & Mac
Engine Type:
Single-cylinder, 4-stroke, liquid-cooled, SOHC (Single Overhead Camshaft), 4 valves
Bore X Stroke:
Not explicitly stated in product info, typical for this engine class would be around 94mm x 71mm.
Horsepower:
Approximately 40 HP (29.4 kW) @ 7,500 RPM (varies slightly by region/spec).
Torque:
Approximately 42 Nm (31 lb-ft) @ 5,500 RPM (varies slightly by region/spec).
Fuel Delivery:
Electronic Fuel Injection (IE)
Ignition System:
Electronic ignition system with ECU control.
Oil Type:
Typically SAE 10W-40 or 15W-50 motorcycle specific synthetic or semi-synthetic oil.
Oil Capacity:
Approximately 1.6 - 1.8 liters (including filter, refer to manual for exact specification).
Cooling Medium:
Liquid-cooled with ethylene glycol-based antifreeze.
Wheelbase:
Approximately 1580 mm (62.2 inches)
Length:
Approximately 2235 mm (88.0 inches)
Width:
Approximately 780 mm (30.7 inches)
Seat Height:
Approximately 790 mm (31.1 inches)
Dry Weight:
Approximately 217 kg (478 lbs)
Gross Vehicle Weight Rating:
Not explicitly stated, but generally around 400-450 kg.
Fuel Capacity:
Approximately 12 liters (3.17 US gallons)
Crash Test Ratings:
N/A (Motorcycle safety is assessed differently than cars).
Braking System Type:
Disc brakes front and rear. Models may be equipped with ABS (Anti-lock Braking System).
Lighting:
Halogen headlamp, LED taillight, turn signals.
Frame Construction:
Steel frame providing rigidity and stability.
Tires:
Front: 120/70-15, Rear: 140/70-14 (typical sizes, verify with manual).
Instrument Cluster:
Digital and analog display with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, and various indicator lights.
ABS:
Optional Anti-lock Braking System (ABS) availability for enhanced braking control.
Diagnostic Port:
Likely equipped with a diagnostic port for interfacing with diagnostic tools to read fault codes and monitor engine parameters.
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first. Consult manual for precise intervals.
Air Filter Replacement:
Inspect every 5,000 km, replace as needed or every 10,000 - 15,000 km. Refer to manual for specific guidance.
Spark Plug Replacement:
Typically every 10,000 - 12,000 km. Manual will specify exact type and interval.
Belt Drive Inspection:
Inspect CVT belt wear and tension at regular intervals, typically every 10,000 - 15,000 km. Replacement interval around 20,000 km.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives. Ratio typically 50/50 with distilled water.
Brake Fluid:
DOT 4 brake fluid is typically recommended. Verify with manual.
Common Wear Items:
CVT belt, front suspension bushings, brake pads, and rear shock absorber can be common wear items due to mileage and usage.
Potential Electrical Gremlins:
As with many modern scooters, electrical connectors and battery health are crucial. The manual's electrical section will be vital for troubleshooting.
Brand Origin:
Gilera is an Italian motorcycle manufacturer founded in 1909, known for its performance-oriented scooters and motorcycles.
Fuoco Development:
The Fuoco 500 ie (also known as the Gilera GP 800 in some markets or as the Aprilia SR Max 850, which shares components) is a high-performance maxi-scooter that emerged as a more potent and aggressive offering in Gilera's lineup.
Manufacturing Location:
Italy (likely assembled within the Piaggio Group manufacturing facilities).
Production Years:
2007-2009 model years as specified.
