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GILERA FUOCO 500 Service Repair Workshop Manual 2007 ONWARDS
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Basic Information Identification Make: Gilera Model: Fuoco 500 Year: 2007 onwards Codes Common Model Codes: M55 Introduction Market Position Segment: High-performance maxi-scooter Target Audience: Enthusiasts and owners seeking in-depth technical...
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| Basic Information | |
| Identification | |
| Make: | Gilera |
| Model: | Fuoco 500 |
| Year: | 2007 onwards |
| Codes | |
| Common Model Codes: | M55 |
| Introduction | |
| Market Position | |
| Segment: | High-performance maxi-scooter |
| Target Audience: | Enthusiasts and owners seeking in-depth technical knowledge for self-maintenance and repair. |
| Competitive Analysis | |
| Key Competitors: | Yamaha TMAX, Suzuki Burgman 650, BMW C 650 GT (though Fuoco 500 has a distinct trike-like stability). |
| Key Features | |
| Manual Value Proposition: | Provides dealership-level repair capabilities, saving costs and ensuring correct maintenance. |
| Vehicle Uniqueness: | Trike-style front end for enhanced stability and braking. |
| Manual Details | |
| Coverage Areas | |
| Models Covered: | All Gilera Fuoco 500 models from 2007 onwards |
| Regions Covered: | Global (English language manual) |
| Page Count | |
| Estimated Page Count: | High (typically 500+ pages for comprehensive service manuals) |
| Manual Type | |
| Type: | Service Repair Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Complete engine disassembly, assembly, diagnostics, tuning, and overhaul (including cylinder head, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system, fuel injection system). |
| Transmission: | Automatic transmission (CVT) inspection, maintenance, repair, clutch, variator, torque converter, drive belts. |
| Brakes: | Front and rear brake systems (hydraulic, disc brakes), brake fluid, master cylinders, calipers, pads, rotors, bleeding procedures, parking brake. |
| Electrical: | Complete electrical system diagnostics, wiring schematics, battery, starter, alternator, lighting systems, ignition system, sensors, ECUs, fuses, relays, horn, instrumentation. |
| Suspension: | Front telescopic fork and rear shock absorber inspection, maintenance, adjustments, fork seals, spring rates, damping. |
| Chassis: | Frame inspection, steering system, wheel bearings, swingarm, maintenance and repair. |
| Fuel System: | Fuel tank, fuel pump, fuel injectors, fuel filter, fuel lines, pressure testing, emissions control systems. |
| Cooling System: | Radiator, coolant, water pump, thermostat, fan, hoses, flushing and refilling procedures. |
| Exhaust System: | Muffler, catalytic converter, exhaust pipes, gaskets, inspection and replacement. |
| Bodywork: | Fairings, body panels, seat, storage compartment, lighting, mirrors, fenders, minor body repairs and adjustments. |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, oil changes, filter replacements, fluid level checks, lubrication, tire pressure, brake pad inspection. |
| Troubleshooting: | Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, fault code interpretation (if applicable). |
| Repair: | Step-by-step instructions for all repair procedures, including component removal, installation, and adjustment. |
| Diagnostics: | Detailed diagnostic steps for electrical and mechanical issues, using factory specifications and procedures. |
| Rebuilds: | Comprehensive rebuild procedures for major components like the engine and transmission. |
| Wiring Schematics: | Full-color, detailed wiring diagrams for all electrical systems, including component identification and color coding. |
| Illustrations Diagrams: | Abundant, high-quality illustrations and diagrams to visually guide repairs and maintenance tasks. |
| Technical Depth | |
| Depth: | Factory-level, comprehensive coverage from basic maintenance to complete vehicle overhaul and advanced diagnostics. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Compatibility: | Windows (XP, Vista, 7, 8, 10), Mac, Tablets |
| Requirements: | Adobe PDF Reader |
| Print Quality | |
| Printability: | All pages are printable |
| Image Quality: | Images can be enlarged and printed |
| Binding Type | |
| Type: | Digital Download (No physical binding) |
| Paper Type | |
| Type: | N/A (Digital) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Four-stroke, single-cylinder, liquid-cooled |
| Displacement: | 492.7 cc |
| Bore X Stroke: | 94 mm x 71 mm |
| Compression Ratio: | 10.5:1 (approx.) |
| Performance | |
| Horsepower: | Approx. 40 HP @ 7,000 rpm (model dependent) |
| Torque: | Approx. 46 Nm @ 5,250 rpm (model dependent) |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (EFI) |
| Fuel Type: | Unleaded gasoline (95 RON recommended) |
| Lubrication | |
| Oil Type: | Refer to manual for specific API/JASO MA/MA2 rating and viscosity (e.g., 10W-40 or 15W-50 semi-synthetic or synthetic). |
| Cooling System | |
| Type: | Liquid-cooled |
| Coolant Type: | Ethylene glycol based coolant with anti-corrosion inhibitors (e.g., Piaggio Group specific or equivalent). |
| Transmission | |
| Standard | |
| Type: | Automatic (CVT - Continuously Variable Transmission) |
| Drive Type: | Belt drive |
| Features | |
| Gear Reduction: | Integrated planetary gear reduction |
| Clutch Type: | Automatic centrifugal dry clutch |
| Transmission Fluid: | No specific transmission fluid required for the CVT unit itself, but a gearbox oil is used for the final drive. Refer to manual for specification (e.g., SAE 80W-90 API GL-4). |
| Dimensions | |
| Exterior | |
| Length: | Approx. 2250 mm |
| Width: | Approx. 810 mm (at handlebars) |
| Height: | Approx. 1500 mm (to windscreen top) |
| Wheelbase: | Approx. 1560 mm |
| Weights | |
| Dry Weight: | Approx. 200 kg |
| Gross Vehicle Weight Rating: | Refer to VIN plate/manual |
| Fuel Tank Capacity: | 13 Liters |
| Oil Capacity: | Approx. 1.7 Liters (with filter change) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | N/A (Motorcycle/Scooter classification) |
| Active Features | |
| Braking System: | Dual front disc brakes, single rear disc brake. Often equipped with ABS as an optional feature or standard on later models. The three-wheel configuration enhances stability during braking. |
| Lighting: | Halogen headlights, LED taillight and indicators (model dependent). |
| Passive Features | |
| Frame Construction: | Steel trellis frame providing rigidity and stability. |
| Technology Features | |
| Infotainment | |
| Display: | Digital/analog instrument cluster with speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter. |
| Driver Assistance | |
| Front Suspension System: | Advanced tilting mechanism ('Roll Lock') for cornering stability, often with mechanical locking. |
| Braking Assistance: | ABS available on some models for enhanced braking control. |
| Connectivity | |
| Diagnostics Port: | On-board diagnostics (OBD) port for electronic fault diagnosis (requires compatible scanner). |
| Maintenance | |
| Service Intervals | |
| Engine Oil Change: | Every 5,000 km or annually, whichever comes first (refer to manual for precise interval). |
| Air Filter Inspection: | Every 5,000 km, replace as needed. |
| Spark Plug Replacement: | Every 10,000 - 15,000 km (refer to manual for correct type and gap). |
| Cvt Belt Inspection/Replacement: | Inspect every 10,000 km, replace as needed based on wear. |
| Brake Fluid Change: | Every 2 years (DOT 4 recommended). |
| Fluid Specifications | |
| Engine Oil Specification: | Refer to manual for API rating and SAE viscosity grade (e.g., API SG or higher, SAE 10W-40 or 15W-50). |
| Coolant Specification: | Ethylene glycol based antifreeze with corrosion inhibitors, mixture ratio 50/50 with distilled water. |
| Brake Fluid Specification: | DOT 4 |
| Final Drive Gear Oil: | SAE 80W-90 API GL-4 |
| Known Issues | |
| Common Wear Items: | CVT belt, front suspension seals, brake pads, stator/rectifier (can be prone to failure on some Piaggio group models of this era). |
| Potential Electrical Faults: | Wiring harness issues, regulator/rectifier failure, battery drain. |
| Fuel System Considerations: | Fuel pump reliability, injector clogging with prolonged storage or poor fuel quality. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Gilera (part of the Piaggio Group) |
| Model Evolution | |
| Introduction: | Introduced as a unique three-wheeled maxi-scooter, building on the success of the Piaggio MP3, but with a more powerful engine and distinct styling. |
| Key Innovations: | The 'roll lock' mechanism allowing the front wheels to tilt into corners, providing motorcycle-like handling with scooter convenience and added stability. |
| Production | |
| Manufacturing Location: | Italy (Piaggio Group plants) |
| Awards & Recognition | |
| Recognitions | |
| Segment Awards: | While specific awards for the Gilera Fuoco 500 might be limited, its innovative three-wheel design has been recognized for enhancing rider stability and confidence, particularly in the maxi-scooter segment. |