GILERA FUOCO 500 Workshop Repair Manual Download 2007 Onward PDF
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🏷️ Basic Information Identification Make: Gilera Model: Fuoco 500 Model Designation: Fuoco 500 ie Product Type: Workshop Repair Manual Codes Year Coverage: 2007 onwards 👋 Introduction Market Position Segment: Maxi-scooter, three-wheeled scooter segment. Competitive Analysis Key Competitors: Piaggio MP3 500 Key Features Unique Selling Points: Powerful 500cc engine, distinctive three-wheel design, advanced suspension and braking systems, robust performance for urban and touring use. Manual Value Benefit To Owner: Enables owners to perform routine maintenance, troubleshoot issues, and undertake significant repairs, saving time and money on dealership visits. Benefit To Professional: Provides comprehensive factory specifications, procedures, and wiring diagrams essential for efficient and accurate servicing and repair. 📋 Manual Details Coverage Areas Primary Region: Global Language: English Manual Type Type: Professional Workshop Service & Repair Manual Format File Format: PDF Compatibility: Windows & MAC compatible 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, performance tuning, fuel injection, ignition system, cooling system, lubrication system Transmission: Automatic transmission (CVT) servicing, fluid checks, internal component repair Chassis: Frame, suspension (front and rear), steering system, wheel bearings Brakes: Hydraulic system, caliper and master cylinder overhaul, brake pad and disc replacement, bleeding procedures, parking brake Electrical: Wiring diagrams, battery system, charging system, lighting, starting system, instrument panel, electronic control unit (ECU) diagnostics Bodywork: Fairings, panels, seat, storage, lighting assemblies, instrumentation Fuel System: Fuel tank, fuel pump, fuel filter, fuel injectors, throttle body Cooling System: Radiator, fan, coolant, hoses, thermostat Exhaust System: Muffler, catalytic converter, exhaust pipes Procedures Included Maintenance: Oil change, filter replacement, spark plug replacement, air filter cleaning/replacement, brake fluid flush, coolant flush, valve clearance adjustment, drive belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, fault code interpretation, electrical system diagnosis Repair: Engine rebuild, transmission overhaul, suspension component replacement, brake system repair, electrical component repair, body panel repair/replacement Diagnostics: ECU fault code reading and clearing, sensor testing, actuator testing Adjustments: Throttle cable adjustment, brake lever free play adjustment, suspension preload adjustment Technical Depth Depth: Comprehensive factory-level repair and diagnostic information, suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Quality: High-resolution scans, clear text, searchable content within PDF. Print Quality Printability: Printable pages for convenient workshop use. Binding Type Format: Digital Download (PDF) Paper Type Digital Medium: Electronic Acrobat Reader format ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, single-cylinder, fuel-injected Displacement: 492.7 cc Bore X Stroke: 92 mm x 115.2 mm Compression Ratio: 10.0:1 (approx.) Performance Horsepower: 40 hp (29.4 kW) @ 7,500 rpm Torque: 43 Nm (31.7 lb-ft) @ 5,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with 55mm throttle body Fuel Type: Unleaded Petrol (Gasoline) Ignition Ignition System: Electronic ignition Lubrication Oil Type: Refer to manual for specific API rating (e.g., API SG, SH, SJ or higher; JASO MA recommended) Oil Capacity: Approx. 1.7 Liters (with filter change) Cooling System Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (e.g., Piaggio Piaggio Coolant). Coolant Capacity: Approx. 1.2 Liters 🔧 Transmission Standard Transmission Type: Automatic Continuously Variable Transmission (CVT) Drive Type: Belt drive to rear wheel Features Clutch Type: Automatic centrifugal clutch Fluid Specifications Transmission Fluid: Refer to manual for specific CVT fluid requirements (often a specialized, non-automotive type). Typically requires regular replacement. 📐 Dimensions Exterior Length: Approx. 2,150 mm Width: Approx. 780 mm Height: Approx. 1,400 mm (to handlebars) Weights Dry Weight: Approx. 200 kg Gross Vehicle Weight Rating: Refer to VIN plate/manual Fuel Tank Capacity: Approx. 12 Liters (including 2-liter reserve) 🛡️ Safety Features Ratings Stability System: Three-wheel configuration with tilting mechanism for stability during cornering. Active Features Braking System: Triple disc brakes (front and rear). ABS available on some models, refer to specific vehicle configuration. Lighting: Halogen headlights, LED taillights/indicators (depending on year). Passive Features Frame Construction: Steel frame construction providing robust chassis support. 💡 Technology Features Infotainment Instrumentation: Digital and analog display including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, and warning lights. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) available on certain configurations, providing enhanced braking stability. Connectivity ECU: Electronic Control Unit (ECU) manages engine functions, fuel injection, and ignition timing, with diagnostic capabilities via specific tools. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000 - 10,000 km or annually, whichever comes first (refer to specific manual recommendation). Spark Plug Replacement: Approximately every 10,000 - 20,000 km (specific type and gap crucial, consult manual). Air Filter Cleaning: Every 5,000 km or as needed in dusty conditions. Drive Belt Inspection: Inspect every 10,000 km, replace typically between 20,000 - 30,000 km. Brake Fluid Change: Every 2 years. Coolant Change: Every 2 - 3 years. Fluid Specifications Engine Oil Viscosity: SAE 5W-40 or 10W-40, depending on climate and specific manual recommendations (API SG or higher, JASO MA). Brake Fluid Type: DOT 4. Known Issues Common Complaints: Potential for stator/generator issues, occasional CVT belt wear concerns, suspension locking...
Refer to manual for specific CVT fluid requirements (often a specialized, non-automotive type). Typically requires regular replacement.
📐 Dimensions
Exterior
Length:
Approx. 2,150 mm
Width:
Approx. 780 mm
Height:
Approx. 1,400 mm (to handlebars)
Weights
Dry Weight:
Approx. 200 kg
Gross Vehicle Weight Rating:
Refer to VIN plate/manual
Fuel Tank Capacity:
Approx. 12 Liters (including 2-liter reserve)
🛡️ Safety Features
Ratings
Stability System:
Three-wheel configuration with tilting mechanism for stability during cornering.
Active Features
Braking System:
Triple disc brakes (front and rear). ABS available on some models, refer to specific vehicle configuration.
Lighting:
Halogen headlights, LED taillights/indicators (depending on year).
Passive Features
Frame Construction:
Steel frame construction providing robust chassis support.
💡 Technology Features
Infotainment
Instrumentation:
Digital and analog display including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meter, and warning lights.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) available on certain configurations, providing enhanced braking stability.
Connectivity
ECU:
Electronic Control Unit (ECU) manages engine functions, fuel injection, and ignition timing, with diagnostic capabilities via specific tools.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 - 10,000 km or annually, whichever comes first (refer to specific manual recommendation).
Spark Plug Replacement:
Approximately every 10,000 - 20,000 km (specific type and gap crucial, consult manual).
Air Filter Cleaning:
Every 5,000 km or as needed in dusty conditions.
Drive Belt Inspection:
Inspect every 10,000 km, replace typically between 20,000 - 30,000 km.
Brake Fluid Change:
Every 2 years.
Coolant Change:
Every 2 - 3 years.
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-40 or 10W-40, depending on climate and specific manual recommendations (API SG or higher, JASO MA).
Brake Fluid Type:
DOT 4.
Known Issues
Common Complaints:
Potential for stator/generator issues, occasional CVT belt wear concerns, suspension locking mechanism reliability (early models), water ingress into electrical connectors.
Gilera is an Italian manufacturer of scooters and motorcycles, founded in 1909. It is now part of the Piaggio Group.
Model Evolution
Development:
The Fuoco 500 was developed by Gilera, sharing its platform and powertrain with the highly successful Piaggio MP3 500. It was positioned as a sportier and more aggressive variant.
Production
Production Period:
Introduced around 2007.
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