🏷️ Basic Information

Make:

Gilera

Model:

Fuoco 500

Model Variant:

500ie

Year:

2007 onwards

Engine Code Family:

M307

👋 Introduction

Segment:

Maxi-scooter, urban mobility, touring.

Target Audience:

Owners and technicians seeking in-depth knowledge for maintenance, repair, and restoration of the Gilera Fuoco 500.

Competitors:

Piaggio MP3 500, Yamaha TMAX 500, Suzuki Burgman 650.

Unique Selling Points:

Three-wheel stability (with tilting front axle), powerful 500cc engine, comfortable for long-distance travel, versatile urban and touring capabilities.

Value:

Essential for DIY maintenance, professional repairs, and maintaining the longevity and performance of the Gilera Fuoco 500. Offers significant cost savings compared to dealership servicing.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

Page Count:

Hundreds (specific count not provided but described as comprehensive)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, piston, crankshaft, camshaft, valve train, lubrication system, cooling system.

Fuel System:

Fuel injection system (throttle body, injectors, fuel pump, fuel pressure regulator), fuel tank, fuel lines, emissions control system.

Ignition System:

Ignition coils, spark plugs, ECU controlled ignition timing.

Transmission Drivetrain:

Automatic transmission (CVT - continuously variable transmission) operation, maintenance, and repair, clutch assembly, belt drive, final drive.

Brakes:

Hydraulic brake system, brake calipers, brake discs, brake pads, brake lines, ABS system (if equipped), parking brake.

Suspension:

Front suspension (telescopic forks), rear suspension (monoshock absorber, swingarm), linkage systems, adjustments, replacement of components.

Steering:

Handlebar assembly, steering column, steering bearings, adjustments.

Electrical System:

Battery, charging system (alternator, regulator), starter motor, lighting system (headlights, taillights, indicators), horn, wiring diagrams, fuses, relays, sensors.

Frame Bodywork:

Chassis inspection, frame repair (if applicable), body panel removal and installation, seat, fairings, storage compartment.

Instruments Controls:

Instrument cluster (speedometer, tachometer, fuel gauge, warning lights), controls (throttle, brake levers, switches).

Troubleshooting:

Diagnostic procedures, common problems and solutions, fault codes (if applicable).

Routine Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable, though this is belt-driven), tire pressure checks, brake fluid checks, coolant checks.

Rebuilds Overhauls:

Complete engine rebuilds, transmission overhauls, suspension rebuilds, brake system overhauls.

Component Replacement:

Step-by-step guides for replacing major components like cylinder head, piston, starter motor, alternator, fuel injectors, brake calipers, shock absorbers, etc.

Diagnostic Testing:

Procedures for testing electrical components, fuel system pressure, ignition system components, and sensor functionality.

Wiring Diagrams:

Detailed electrical system wiring diagrams for accurate troubleshooting and repair.

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and component rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchable:

Likely searchable text-based PDF, enabling quick information retrieval.

Printable:

Designed for printing, allowing users to have physical copies for workshop use.

Quality:

High-resolution, ensuring clarity of text, diagrams, and illustrations.

Binding:

Not applicable (digital PDF download).

Paper:

Not applicable (digital PDF download).

⚙️ Engine Specifications

Make:

Piaggio

Model:

Quasar 500

Type:

4-stroke, liquid-cooled, SOHC, 4-valve

Displacement:

492.7 cc

Bore X Stroke:

94 mm x 71 mm

Compression Ratio:

10.0:1

Horsepower Max:

40.0 hp @ 7,500 rpm (approx.)

Torque Max:

43 Nm @ 5,750 rpm (approx.)

Fuel Delivery:

Electronic fuel injection (EFI) with Marelli 7SM ECU

Fuel Type:

Unleaded gasoline (min. 95 octane recommended)

Fuel Tank Capacity:

12 Liters (approx.)

Oil Type:

SAE 5W-40 Synthetic (specific part number would be in manual)

Oil Capacity:

Approximately 1.8 Liters (check manual for exact capacity with filter change)

Coolant Type:

Ethylene glycol-based coolant with anticorrosion additives (e.g., Piaggio Coolant P2).

🔧 Transmission

Type:

Automatic CVT (Continuously Variable Transmission) with torque converter

Transmission Options:

N/A (CVT is standard)

Drive Type:

Belt drive to rear wheel

Transmission Fluid:

Specific CVT fluid recommended (check manual for type and capacity)

📐 Dimensions

Length:

Approx. 2235 mm

Width:

Approx. 815 mm

Height:

Approx. 1470 mm

Wheelbase:

Approx. 1600 mm

Dry Weight:

Approx. 275 kg

Gross Vehicle Weight Rating:

Approx. 470 kg (includes rider and cargo)

Payload Capacity:

Approx. 195 kg

🛡️ Safety Features

Crash Test Results:

Not applicable for this vehicle type in traditional automotive terms. Focus is on stability and braking.

ABS:

Anti-lock Braking System (ABS) typically standard or optional on this model.

Tilting Mechanism:

Patented front suspension system allowing the vehicle to lean into corners for stability and maneuverability, similar to a motorcycle.

Lighting:

Effective headlight, taillight, and indicator system for visibility.

Braking Performance:

Dual front disc brakes and single rear disc brake for strong stopping power.

💡 Technology Features

Instrument Panel:

Digital/analog combination dashboard with speedometer, tachometer, fuel level indicator, coolant temperature gauge, clock, and various warning lights (engine, oil, battery, ABS, etc.).

ABS:

Standard or optional ABS system for enhanced braking safety.

Suspension Locking:

Hydraulic locking mechanism for the front suspension to keep the two front wheels parallel at low speeds or when stationary, allowing it to stand upright without a kickstand.

Wiring Harness:

Comprehensive wiring harness for all electronic systems, including ECU, sensors, lighting, and accessories.

🔧 Maintenance

Engine Oil Change:

Every 7,500 km or annually, whichever comes first (check manual for exact interval and oil type).

Air Filter Replacement:

Inspect every 7,500 km, replace as needed or according to manual recommendations.

Spark Plug Replacement:

Typically at 15,000 km or as specified in manual.

Transmission Belt Inspection:

Inspect at 7,500 km intervals, replace at recommended mileage (e.g., 15,000-20,000 km, or sooner if wear is evident).

Brake Fluid Change:

Every 2 years or as recommended.

Coolant Change:

Every 3-4 years or as recommended.

Valve Clearance Check:

Typically at higher mileage intervals (e.g., 20,000 km), consult manual.

Engine Oil Specification:

SAE 5W-40 Synthetic (e.g., Piaggio's recommended API SL/JASO MA specification).

Brake Fluid Specification:

DOT 4 Hydraulic Brake Fluid.

Coolant Specification:

Ethylene Glycol based, permanent coolant (e.g., Piaggio P2, or equivalent meeting relevant standards).

Common Problems:

Possible wear on CVT components (belt, rollers), occasional electrical gremlins (related to sensors or connections), potential for front suspension locking mechanism issues if not properly maintained. Overheating under prolonged stress.

Preventative Measures:

Adherence to strict maintenance schedules, regular cleaning of components, checking all electrical connections, and proper maintenance of the front suspension locking mechanism are crucial.

📚 Vehicle History

Manufacturer:

Gilera is an Italian manufacturer of motorcycles and scooters, founded in 1909. It is now part of the Piaggio Group.

Development:

The Fuoco 500 (also known as the Gilera Fuoco 500ie and in some markets as the Piaggio MP3 500) is an evolution of Piaggio's three-wheeled scooter concept, offering more power and a distinct design.

Introduction Year:

The three-wheel concept was pioneered by the Piaggio MP3 in 2006; the Fuoco 500 followed shortly after, offering a more 'rugged' aesthetic and a larger engine.

Manufacturing Location:

Italy (primarily Piaggio Group facilities)

🏆 Awards & Recognition

Awards:

While specific awards for the Fuoco 500 might not be widely publicized, the three-wheel scooter concept pioneered by Piaggio (and shared by Gilera) has been recognized for its innovation in urban mobility.

User Reviews:

Often praised for its stability, comfort, and performance, particularly for longer commutes and touring, though sometimes criticized for weight and complexity.