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2007-2009 Gilera Fuoco 500 I.e Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Gilera Model: Fuoco 500 I.e Model Variant: 500 I.e Generation Model Years Covered: 2007-2009 Codes Engine Code: M503 👋 Introduction Market Position Segment: Maxi-scooter, often positioned as a unique, three-wheeled, high-performance urban mobility solution Competitive Analysis Key Competitors: Other large displacement scooters, particularly those with advanced features or unconventional designs. Examples include Yamaha TMAX, Suzuki Burgman 650, and BMW C 650 GT (though the Fuoco's three-wheel design offers a distinct advantage in stability). Key Features Unique Selling Proposition: The distinctive three-wheel configuration, offering enhanced stability and a unique riding experience compared to traditional two-wheeled scooters. Performance Orientation: Designed for both urban commuting and spirited riding, with a focus on power and handling. Value Proposition Cost Effectiveness: Provides a cost-effective alternative to professional servicing for essential maintenance and repairs. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive service, repair, and maintenance Page Count Estimated Page Count: Extensive (specific number not provided, but described as highly detailed and complete) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English (assumed based on typical product distribution, though not explicitly stated) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine And Powertrain: Engine assembly, disassembly, tuning, fuel injection, ignition, lubrication, cooling, exhaust Chassis And Suspension: Front suspension (including Piaggio's dual-lean technology), rear suspension, steering system, wheel hub assembly Braking System: Front and rear brake calipers, master cylinders, hydraulic lines, ABS system (if applicable) Electrical System: Wiring diagrams, lighting, battery, starter, charging system, ECU, sensors, diagnostic codes Bodywork And Trim: Body panels, fairings, seat assembly, storage compartments, lighting fixtures Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug servicing, brake fluid replacement, coolant checks, chain adjustment (if applicable), tire pressure checks Troubleshooting Diagnostics: Step-by-step diagnostic procedures, fault code interpretation, common problem identification and solutions Mechanical Repairs: Engine rebuilds, transmission servicing, suspension component replacement, brake system overhauls, electrical component repair Component Disassembly And Assembly: Detailed instructions for complete disassembly of the machine and reassembly of all components Technical Depth Depth Of Coverage: Complete factory-level service and repair, suitable for both DIY enthusiasts and professional mechanics 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Printability: All pages are printable Binding Type Binding Type: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) Compatibility Operating Systems: Compatible with all PC-based Windows operating systems and Mac ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, four-stroke, liquid-cooled, fuel-injected Displacement: 493 cc (493 cubic centimeters) Bore X Stroke: Approx. 94 mm x 71 mm (specific to engine code M503) Compression Ratio: Approx. 10.5:1 (typical for this engine family) Valve Train: SOHC (Single Overhead Camshaft), 4 valves Performance Horsepower Output: Approx. 40 hp (29.4 kW) @ 7,000 rpm (nominal for this engine) Torque Output: Approx. 46 Nm (34 lb-ft) @ 5,250 rpm (nominal for this engine) Fuel System Fuel Delivery: Electronic Fuel Injection (I.e.) Fuel Type: Unleaded gasoline Fuel Tank Capacity: Approx. 12-13 liters (specific value to be confirmed in manual) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Optional Transmission: N/A Features Drive System: Belt drive to rear wheel Gear Selection: Forward, Neutral, Reverse (via electric motor/actuator) Transmission Fluid Type: Specific CVT fluid (e.g., Piaggio recommends specific grades, often a light-weight gear oil or specialized CVT fluid) 📐 Dimensions Exterior Length: Approx. 2,240 mm (specific value to be confirmed) Width: Approx. 830 mm (at handlebars, specific value to be confirmed) Height: Approx. 1,480 mm (to top of windscreen, specific value to be confirmed) Weights Dry Weight: Approx. 270 kg (specific value to be confirmed) Gross Vehicle Weight Rating: To be confirmed in manual Wheelbase Wheelbase: Approx. 1,570 mm (specific value to be confirmed) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle/Scooter safety is typically assessed differently than cars, focus is on mechanical integrity and rider protection) Active Features Braking System: Front: Dual disc brakes with multiple pistons. Rear: Single disc brake. ABS is often an option or standard on later models (manual will clarify specific fitment). Suspension Stability: Three-wheel setup and Piaggio's tilt-locking mechanism enhance stability, especially at low speeds and when stationary. Passive Features Lighting: Headlights, taillights, brake lights, turn signals Ergonomics: Designed for rider comfort and control 💡 Technology Features Infotainment Dashboard Display: Digital and analog display for speed, RPM, fuel level, engine temperature, odometer, trip meter, and warning lights. Driver Assistance ABS System: Anti-lock Braking System (ABS) may be equipped on certain models or as an option for enhanced braking control. Tilt Locking System: Piaggio's proprietary tilt-locking system allows the scooter to remain upright at low speeds or when stopped, providing significant stability benefits. Connectivity Diagnostics Port: On-board diagnostic (OBD) port for connection to diagnostic tools to read fault codes and monitor engine parameters. 🔧 Maintenance Service Intervals Engine Oil And Filter Change: Typically every 5,000-7,500 km...
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SKU: 64266
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2007-2009 Gilera Fuoco 500 I.e Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Fuoco 500 I.e
Model Variant:
500 I.e
Generation
Model Years Covered:
2007-2009
Codes
Engine Code:
M503
👋 Introduction
Market Position
Segment:
Maxi-scooter, often positioned as a unique, three-wheeled, high-performance urban mobility solution
Competitive Analysis
Key Competitors:
Other large displacement scooters, particularly those with advanced features or unconventional designs. Examples include Yamaha TMAX, Suzuki Burgman 650, and BMW C 650 GT (though the Fuoco's three-wheel design offers a distinct advantage in stability).
Key Features
Unique Selling Proposition:
The distinctive three-wheel configuration, offering enhanced stability and a unique riding experience compared to traditional two-wheeled scooters.
Performance Orientation:
Designed for both urban commuting and spirited riding, with a focus on power and handling.
Value Proposition
Cost Effectiveness:
Provides a cost-effective alternative to professional servicing for essential maintenance and repairs.
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive service, repair, and maintenance
Page Count
Estimated Page Count:
Extensive (specific number not provided, but described as highly detailed and complete)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English (assumed based on typical product distribution, though not explicitly stated)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine And Powertrain:
Engine assembly, disassembly, tuning, fuel injection, ignition, lubrication, cooling, exhaust
Chassis And Suspension:
Front suspension (including Piaggio's dual-lean technology), rear suspension, steering system, wheel hub assembly
Braking System:
Front and rear brake calipers, master cylinders, hydraulic lines, ABS system (if applicable)
Electrical System:
Wiring diagrams, lighting, battery, starter, charging system, ECU, sensors, diagnostic codes
Bodywork And Trim:
Body panels, fairings, seat assembly, storage compartments, lighting fixtures
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug servicing, brake fluid replacement, coolant checks, chain adjustment (if applicable), tire pressure checks
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures, fault code interpretation, common problem identification and solutions
Mechanical Repairs:
Engine rebuilds, transmission servicing, suspension component replacement, brake system overhauls, electrical component repair
Component Disassembly And Assembly:
Detailed instructions for complete disassembly of the machine and reassembly of all components
Technical Depth
Depth Of Coverage:
Complete factory-level service and repair, suitable for both DIY enthusiasts and professional mechanics
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Print Quality
Printability:
All pages are printable
Binding Type
Binding Type:
N/A (Digital PDF Download)
Paper Type
Paper Type:
N/A (Digital PDF Download)
Compatibility
Operating Systems:
Compatible with all PC-based Windows operating systems and Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Single-cylinder, four-stroke, liquid-cooled, fuel-injected
Displacement:
493 cc (493 cubic centimeters)
Bore X Stroke:
Approx. 94 mm x 71 mm (specific to engine code M503)
Compression Ratio:
Approx. 10.5:1 (typical for this engine family)
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves
Performance
Horsepower Output:
Approx. 40 hp (29.4 kW) @ 7,000 rpm (nominal for this engine)
Torque Output:
Approx. 46 Nm (34 lb-ft) @ 5,250 rpm (nominal for this engine)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (I.e.)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 12-13 liters (specific value to be confirmed in manual)
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Optional
Optional Transmission:
N/A
Features
Drive System:
Belt drive to rear wheel
Gear Selection:
Forward, Neutral, Reverse (via electric motor/actuator)
Transmission Fluid Type:
Specific CVT fluid (e.g., Piaggio recommends specific grades, often a light-weight gear oil or specialized CVT fluid)
📐 Dimensions
Exterior
Length:
Approx. 2,240 mm (specific value to be confirmed)
Width:
Approx. 830 mm (at handlebars, specific value to be confirmed)
Height:
Approx. 1,480 mm (to top of windscreen, specific value to be confirmed)
Weights
Dry Weight:
Approx. 270 kg (specific value to be confirmed)
Gross Vehicle Weight Rating:
To be confirmed in manual
Wheelbase
Wheelbase:
Approx. 1,570 mm (specific value to be confirmed)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle/Scooter safety is typically assessed differently than cars, focus is on mechanical integrity and rider protection)
Active Features
Braking System:
Front: Dual disc brakes with multiple pistons. Rear: Single disc brake. ABS is often an option or standard on later models (manual will clarify specific fitment).
Suspension Stability:
Three-wheel setup and Piaggio's tilt-locking mechanism enhance stability, especially at low speeds and when stationary.
Passive Features
Lighting:
Headlights, taillights, brake lights, turn signals
Ergonomics:
Designed for rider comfort and control
💡 Technology Features
Infotainment
Dashboard Display:
Digital and analog display for speed, RPM, fuel level, engine temperature, odometer, trip meter, and warning lights.
Driver Assistance
ABS System:
Anti-lock Braking System (ABS) may be equipped on certain models or as an option for enhanced braking control.
Tilt Locking System:
Piaggio's proprietary tilt-locking system allows the scooter to remain upright at low speeds or when stopped, providing significant stability benefits.
Connectivity
Diagnostics Port:
On-board diagnostic (OBD) port for connection to diagnostic tools to read fault codes and monitor engine parameters.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Typically every 5,000-7,500 km or annually, whichever comes first (specific interval to be confirmed in manual).
Spark Plug Replacement:
Approximately every 10,000-15,000 km (specific plug type and gap crucial).
Air Filter Cleaning And Replacement:
Regular inspection and cleaning, replacement typically around 15,000-20,000 km.
Transmission Fluid Change:
Refer to manual for specific intervals, often tied to higher mileage or specific usage patterns.
Fluid Specifications
Engine Oil Type:
Synthetic or semi-synthetic motorcycle oil, viscosity grade typically 5W-40 or 10W-40 (API SG/SH/SJ or higher, JASO MA/MA2).
Engine Oil Capacity:
Approx. 1.7-1.9 liters (with filter change, to be confirmed in manual).
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (specific type critical).
Known Issues
Common Wear Items:
Brake pads, tires, CVT belt and rollers, suspension bushings.
Potential Electronic Issues:
While not universally reported, as with any complex vehicle, ECU, sensor, or wiring harness issues can arise. The manual's diagnostic section is crucial here.
Tilt Locking Mechanism:
This system can occasionally require adjustment or have its actuators serviced. The manual should provide detailed procedures.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Gilera is an Italian brand with a long history in motorcycle manufacturing, now part of the Piaggio Group.
Model Evolution
Development Context:
The Fuoco 500 is an evolution of Piaggio's successful three-wheeled scooter concept, building upon the MP3 platform with a more rugged and aggressive aesthetic.
Production
Manufacturing Location:
Typically produced in Italy by the Piaggio Group.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the '2007-2009 Gilera Fuoco 500 I.e.' might not be widely publicized, the three-wheeled scooter concept pioneered by Piaggio has received recognition for innovation in urban mobility.
Ratings
Reliability Ratings:
Owner reviews and long-term reliability can vary. This manual is essential for proactive maintenance to ensure reliability.
Certifications
Emissions Standards:
Compliant with European emissions standards relevant to its production years (e.g., Euro 3).
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