Instruction/ maintenance manual of the product Fuoco 500ie Gilera
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GILERA WOULD LIKE TO THANK YOU for choosing one of its products. We have prepared this manual to help you to get the very best from your scooter. Please read it carefully before riding the scooter for the first time. It contains information, tips and precautions for using your scooter.
The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; this booklet also details routine maintenance procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre .
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging the environment.
4.
INDEX VEHICLE ...................................................................................... 7 Dashboard ................................................................................ 9 Analogue instrument panel .............................
Headlight adjustment ............................................................. 64 Front direction indicators ........................................................... 67 Rear optical unit .........................................................
Fuoco 500ie Chap. 01 Vehicle 7.
01_01 8 1 Vehicle.
Dashboard (01_01) A = Ignition key-switch B = Hand brake C = Bag hook D = HAZARD button E = Horn button F = Turn indicator switch G = Rear brake lever H = Light switch + PASSING I = Analogue instrumen.
01_02 10 1 Vehicle.
Analogue instrument panel (01_02) A = Immobilizer / antitheft LED B = Speedometer with twin scale (Km/h and Mph) C = CLOCK switch D = Digital display E = Front suspension locking system warning light .
01_03 Clock (01_03) Pushing the « CLOCK » button for less than 1 second displays the following sequence: • TIME • DATE To set the clock push and hold the « CLOCK » button longer than 3 seconds. The numbers showing the hours will begin flashing.
01_05 01_06 G = Low fuel warning light H = Trip odometer gauge (B) I = Trip odometer gauge (A) L = Kilometre - mile indicator M = « SET » button N = « CLOCK » button Maintenance icons The icons signal the user that scheduled maintenance operations should be carried out.
" Kmi " represents the combination of " km " (kilometres) and " mi " (miles) " °E " represents the combination of " °C " (degrees Celsius) and " °F " (degrees Fahren- heit).
CAUTION DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING. Releasing the steering wheel Reinsert the key « B » and turn it to « KEY OFF ». CAUTION DO NOT TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING.
01_10 Horn button (01_10) Push the button « E » to sound the horn. 01_11 Light switch (01_11) When the light switch « H » is set to « 0 », the low-beam light is on. When set to « 1 », the high-beam light is activated. If the light switch « H » is pressed when set to « 2 », the high-beam light is activated.
01_13 Start-up button (01_13) To start the engine, press the starter button « R » after pulling one of the two brake levers. If the rider is not on the vehicle, the suspension lock will start the engine at idling speed.
01_16 01_17 01_18 The immobilizer system In order to enhance theft protection, the scooter is equipped with a « PIAGGIO IM- MOBILIZER » electronic engine locking device that is activated automatically when the starter key is removed.
01_19 WARNING KEEP THE "CODE CARD" AND THE RED HANDGRIP KEY IN A SAFE PLACE (NOT ON YOUR VEHICLE). Immobilizerdevice enabled indicator led (01_19) Activation of the " PIAGGIO IMMOBILIZER" system is signalled by a flashing « A » indicator.
WARNING EACH KEY HAS ITS OWN AND UNIQUE CODE, WHICH MUST BE STORED BY THE SYSTEM CONTROL UNIT. VIOLENT SHOCKS MAY AFFECT THE ELECTRONIC COMPONENTS OF THE KEY. IF THE VEHICLE IS SOLD, THE MASTER-HANDGRIP KEY (AS WELL AS THE OTHER STARTER KEYS) AND THE "CODE CARD" MUST ALSO BE TRANSFER- RED TO THE NEW OWNER.
traction of the previous key). Leave it in this position for 1 to 3 seconds and return it to the « OFF » position. CORRECT PROGRAMMING CHECK PHASE Insert the «MASTER» key, disabling the transponder (i.e., by tilting the key cap by 90°), and turn the key to « ON » position.
Remote control programming Follow these steps to program the remote controls: 1 . Insert the remote control key to be programmed in the steering lock key block. 2 . Turn the key to « ON », press the button on the remote control, release the button, turn the key back to « OFF » from the « ON » position, all within 4 seconds.
WARNING TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL RADIO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF. JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER.
01_23 Power supply socket (01_23) There is a plug socket " D " inside the helmet compartment. The plug socket may be used for external consumers (mobile phone, inspection light, etc.
01_25 01_26 01_27 WARNING OBJECTS INAPPROPRIATELY ARRANGED INSIDE THE HELMET COMPART- MENT MAY DEFORM THE SADDLE CAUSING THE COURTESY LIGHT TO RE- MAIN ON AND THIS WILL DISCHARGE THE BATTERY. IN ANY CASE, THE WARNING LIGHT "I" ON THE INSTRUMENT PANEL SIGNALS IF THE LIGHT IS ON OR OFF.
01_28 01_29 Identification (01_28, 01_29) Identification registration numbers are made up of a prefix and a number stamped on the chassis and on the engine.
Fuoco 500ie Chap. 02 Use 27.
Checks Before using the vehicle, check: 1 . There is enough fuel in the fuel tank. 2 . The correct fluid level for front and rear brakes. 3 . That tyres are properly inflated. 4 . The correct functioning of tail lights, headlamp, turn indicators, stop light and license plate light.
02_02 CAUTION PETROL DAMAGES THE PLASTIC PARTS OF THE BODYWORK. WARNING DO NOT RIDE WITH THE FUEL TANK ALMOST EMPTY, LACK OF FUEL CAN DAMAGE THE CATALYTIC CONVERTER. CAUTION USING NON-RECOMMENDED PETROL REDUCES THE EFFICIENCY OF THE EXHAUST AND FUEL SUPPLY SYSTEMS.
CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. Characteristic Fuel tank (reserve) ~ 12 l (~2 l) 02_03 Tyre pressure (02_03) Check the tyre pressure and wear periodically (roughly every 500 km). Tyres feature wear indicators; replace tyres as soon as these indicators become visible on the tyre tread.
Rear tyre Tubeless 140/70 - 14" 68S or 68P reinf TYRE INFLATION PRESSURE Front tyre pressure (with passenger) 1.6 bar (1.8 bar) Rear tyre pressure (with passenger) 2.
WARNING WE RECOMMEND WEARING GLOVES WHILE CARRYING OUT THIS OPERA- TION IN ORDER TO AVOID INJURIES. WARNING WE STRONGLY RECOMMEND NOT TO ADJUST BOTH SHOCK ABSORBERS WITH DIFFERENT PRELOADING Running in DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITS MAX.
02_06 02_07 02_08 Starting up the engine (02_06, 02_07, 02_08) The vehicle is supplied with an ignition cut-off system, activated by the emergency cut-off switch. The engine cannot be started if the ignition cut-off switch is in the OFF position A running engine automatically switches off when the ignition cut-off switch is set to OFF .
CAUTION DO NOT START-UP THE ENGINE IN CLOSED AREAS BECAUSE EXHAUST GASES ARE TOXIC. CAUTION DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CAN REACH, ALWAYS TAKE CARE, WHEN PARKING THE SCOOTER, THAT THE EXHAUST DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS, TO AVOID SERIOUS BURNS.
WARNING NEVER TRY TO START-UP THE ENGINE WITH THE THROTTLE GRIP TWISTED. THIS MAY LEAD TO LOSING CONTROL OF THE VEHICLE AND TO ROLLOVER, WITH CONSEQUENT SERIOUS OR, IN SOME CASES, LETHAL INJURIES. Precautions CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE.
02_09 Stopping the engine (02_09) Fully untwist the throttle grip, then rotate the key in the switch « A » to « KEY OFF » (extractable key). CAUTION DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONV.
02_11 Stand (02_11) Push with your foot on the centre stand's fork " F " while lifting the vehicle backward, holding onto the handlebar. Automatic transmission To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans- mission with regulator and centrifugal clutch.
of safe riding. We recommend practising riding in traffic-free zones, in order to acquire a good knowledge of your vehicle. 1 . Before riding off, remember to put on your helmet and fasten it correctly. 2. Reduce speed on rough roads and drive with care.
WARNING NEVER RIDE THE VEHICLE WITH ADDED ACCESSORIES (CASE AND/OR WINDSHIELD) FASTER THAN 120 KM/H. WITHOUT THESE ACCESSORIES THE VEHICLE MAY BE DRIVEN AT A HIGHER SPEED WITHIN THE LEGAL LIMITS.
02_12 02_13 02_14 Front suspension locking system (02_12, 02_13, 02_14, 02_15, 02_16, 02_17) The front suspension locking system simply prevents vehicle tilting when the « Q » switch is pressed. The warning light « E » starts flashing when the key switch is set to « ON ».
02_15 02_16 02_17 CAUTION THE RIDER DETECTION SENSOR IS LOCATED IN THE FRONT PART OF THE SADDLE. AVOID PLACING BAGS OR HEAVY OBJECTS ACCIDENTALLY ON THE SADDLE. NOT OBSERVING THIS RULE MAY MOVE THE VEHICLE FORWARD AND RE- LEASE THE SUSPENSION LOCKING SYSTEM EVEN IF THE RIDER IS NOT SEATED, BY SIMPLY TWISTING THE THROTTLE.
WARNING IF THE RIDER IS NOT SEATED ON THE SADDLE WHILE THE VEHICLE IS IN MOTION AND THE LOCKING SYSTEM IS ENGAGED, AVOID OPERATING THE THROTTLE CONTROL PURPOSELESSLY AS THIS MAY DAMAGE THE CATA- LYTIC CONVERTER. CAUTION DO NOT RIDE DOWNHILL WITH THE SUSPENSION LOCKING SYSTEM ENGAG- ED AND THE KEY SWITCH SET TO OFF.
THAT THE POTENTIAL MOVEMENT CAUSED BY THE SLOPE TAKES THAT WHEEL AGAINST THE SIDEWALK. WITH THE STEERING LOCK ENGAGED, MANOEUVRE SO THAT THE SIDEWALK IS TO THE RIGHT WHEN YOUR VEHI- CLE IS PARKED UPHILL AND TO THE LEFT WHEN PARKED DOWNHILL.
44 2 Use.
Fuoco 500ie Chap. 03 Maintenance 45.
03_01 03_02 03_03 Engine oil level In 4T engines, engine oil is used to lubricate the distribution elements, main bearings and thermal group. An insufficient quantity of oil can cause serious damage to the engine itself. In all four-stroke engines, a loss of efficiency in oil performance and consumption should be considered normal.
03_04 necessary to check the oil level and top it up if required. If after having topped- up the oil, the warning light still comes on while braking, at idle speed or while turning a corner, it will be necessary to take your vehicle to an Authorised Serv- ice Centre.
Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil 03_05 03_06 Hub oil level (03_05, 03_06) Check the oil in the rear hub. (oil content ~ 250 cc). To check the rear hub oil level, proceed as follows: 1) Rest the vehicle onto its centre stand, on level ground.
CAUTION AN EXCESSIVE QUANTITY OF OIL CAN LEAD TO LEAKAGE, WHICH MAY CAUSE THE ENGINE AND THE WHEEL TO GET DIRTY. CAUTION WHEN REPLACING THE HUB OIL DO NOT LET THE OIL COME INTO CONTACT WITH THE REAR BRAKE DISC.
03_07 Tyres (03_07) Check the tyre pressure and wear periodically (roughly every 500 km). Tyres feature wear indicators; replace tyres as soon as these indicators become visible on the tyre tread.
TYRE INFLATION PRESSURE Front tyre pressure (with passenger) 1.6 bar (1.8 bar) Rear tyre pressure (with passenger) 2.4 bar (2.6 bar) 03_08 03_09 Spark plug dismantlement (03_08, 03_09) This engine has two spark plugs.
N.B. THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR OF SHIELDLESS SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEM FAIL- URES. Characteristic Spark plug NGK CR7EKB Electrode gap 0.7 ÷ 0.9 mm 03_10 Removing the air filter (03_10) Proceed as follows: Unscrew the nine fixing screws « A » and remove the air filter cover « B ».
CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGING THE ENGINE. Recommended products AGIP FILTER OIL Oil for air filter .
03_13 03_14 If it is necessary to top up the coolant frequently, or if the expansion tank is completely dry, you should look for the cause in the cooling system. It is therefore essential to have the cooling system checked at an Authorised Service Centre .
Recommended products SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 03_15 03_16 Checking the brake oil level (03_15) The front and rear brake fluid reservoirs are both positioned on the handlebars. Pro- ceed as follows: 1 .
WARNING ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK . CAUTION AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. IN CASE OF CONTACT, RINSE WITH WATER.
03_17 03_18 Battery (03_17) To access the battery, proceed as follows: 1. Place the scooter on its centre stand; 2. Open the saddle, following the previously described procedure; 3. Remove the two fasteners " A " and the cover " B ".
Long periods of inactivity If the vehicle has not been used for long periods, it is necessary to periodically re- charge the battery, bearing in mind that the battery tends to go completely flat within around three months.
03_21 03_22 03_23 59 3 Maintenance.
FUSE TABLE Fuse No. 1 Capacity: 7.5 A Protected circuits: Injection ECU battery power Fuse No. 2 Capacity: 15 A Protected circuits: Battery- powered injection loads, electrical fan Fuse No.
Protected circuits: Battery- powered instrument panel Fuse No. 8 Capacity: 10A Protected circuits: Live stop, start-up and start-up enabling switch and start-up circuit. Fuse No. 9 Capacity: 7.5 A Protected circuits: live passing and horn Fuse No. 10 Capacity: 7.
L IGHT BULBS TABLE Low-beam bulb Type: HALOGEN (H8) Power: 12V - 35W Quantity: 1 RHS + 1 LHS High-beam light bulb Type: HALOGEN (H8) Power: 12V - 35W Quantity: 1 RHS + 1 LHS Helmet compartment light b.
Power: 12V - 5W Quantity: 1 Front turn indicator bulb Type: WITH BULB Power: 12V - 10W Quantity: 1 RHS + 1 LHS Front tail light bulb Type: ALL GLASS Power: 12V - 5W Quantity: 1 Instrument panel bulb T.
03_25 03_26 03_27 To replace it, disconnect the connector and insert a new bulb WARNING HIGH AND LOW BEAM LIGHT ARE OF THE HALOGEN TYPE: DO NOT TOUCH WITH YOUR FINGERS TO AVOID DAMAGING THEIR FUNCTION.
03_28 03_29 03_30 do that, remove the connector from the other bulbs so that you can adjust one head- lamp at a time. N.B. THE HEADLAMPS CAN ONLY BE LIT WHEN THE ENGINE IS ON.
03_31 03_32 03_33 66 3 Maintenance.
03_34 03_35 Front direction indicators (03_35) To access the bulb, undo the screw « A » and remove the glass « B ». To replace the bulb, hold it and then turn it clockwise.
03_36 03_37 Rear optical unit (03_36, 03_37) To access the rear light unit bulbs, undo the screw « A » and remove the glass « B ». Now tighten the screw « A » in its seat. To replace the stop light bulb « C », hold it and turn it anticlockwise.
03_39 Number plate light (03_39) Remove the screw « C », then take out the bulb holder. 03_40 Helmet compartment lighting bulb (03_40) Open the rear boot and insert a small plain slot screwdriver in the lateral notch to detach the snap-on glass " D ", then replace the bulb.
Front and rear disc brake The brake disc and pad wear is automatically compensated, therefore it has no effect on the functioning of the front and rear brakes.
ORDER TO AVOID THIS, WE RECOMMEND WASHING THE VEHICLE FRE- QUENTLY WHEN RIDING IN THESE ROAD CONDITIONS. Puncture The vehicle is equipped with tubeless tyres (without inner tube). In the event of a puncture, contrary to the situation with a tyre with inner tube, the tyre deflates more slowly, resulting in a greater steering safety.
2 . Be careful to rest the vehicle on its centre stand disabling the front suspension locking system; 3. With engine off and piston at the bottom dead centre, remove the spark plug, add 1÷2 cc of oil through the opening (adding more oil may damage the engine).
CAUTION PER IL LAVAGGIO DEL MOTORE E DEL VEICOLO É SCONSIGLIATO L'UTILIZ- ZO DELL'IDROPULITRICE; NEL CASO CHE NON SIA POSSIBILE EFFETTUARE TALE OPERAZIONE IN UN ALTRO MODO, É NECESSARIO: • USARE SOLAMENTE IL GETTO A VENTAGLIO. • NON AVVICINARE LA LANCIA A MENO DI 2 FT (60 CM).
STARTING FAILURE Emergency switch in «OFF» Set the switch back to « ON » Fuse blown Replace the blown fuse and have the vehicle checked by an Authorised Service Centre. IGNITION PROBLEM Faulty spark plug Contact an Authorised Service Centre. Faulty ignition / injection control unit.
HIGH CONSUMPTION AND LOW PERFORMANCE Air filter blocked or dirty. Clean with water and shampoo and impregnate with petrol and specific oil (section «Removing the air filter») INSUFFICIENT BRAKING Greasy disc. Worn pads. Faulty braking system. Presence of air in the front and rear brake circuit.
76 3 Maintenance.
Fuoco 500ie Chap. 04 Technical data 77.
04_01 78 4 Technical data.
ENGINE TECHNICAL DATA Type Single-cylinder, 4-stroke Cubic capacity 493 cm³ Bore x Stroke 94 x 71 mm Compression ratio 10.5 ± 0.5 : 1 Engine idle speed 1,500 ± 100 rpm Timing system Four valves, single overhead camshaft, chain driven. Valve clearance Inlet: 0.
Ignition Highly efficient electronic inductive ignition, integrated with the injection system, with variable advance, separate HV coil and double spark plug. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EKB Alternative spark plug - Fuel supply Electronic injection with electric fuel pump.
Front brake Ø 240 mm double disk with hydraulic control activated by the handlebar right-hand lever. Rear brake disc brake, diameter 240 mm, with hydraulic servo operated from the handlebar with the left-hand lever. Wheel rim type Light alloy rims. Front rim 12'' x 3.
04_02 Kit equipment (04_02) The toolkit comprises: - One box-spanner. - One twin screwdriver - One special spanner for adjusting the rear shock absorbers - One plastic clip for removing the fuses.
Fuoco 500ie Chap. 05 Spare parts and accessories 83.
05_01 Warnings (05_01) WARNING TO PREVENT ACCIDENTS AND TO GUARANTEE PROPER STABILITY, PER- FORMANCE AND SAFETY, RIDE THE VEHICLE VERY CAREFULLY WHEN IT IS FITTED WITH ACCESSORIES OR WITH UNUSUAL LOADS.
THERE ARE NOT-PIAGGO ACCESSORIES FITTED, OR AN ABNORMAL LOAD, OR IF THE VEHICLE IS NOT IN A GENERALLY GOOD CONDITION, OR WHEN- EVER WEATHER CONDITIONS DEMAND IT, SPEED SHOULD BE FURTHER REDUCED. WARNING BE EXTREMELY CAREFUL WHEN INSTALLING AND REMOVING THE MECHAN- ICAL ANTITHEFT DEVICE ON THE VEHICLE (U-SHAPED PADLOCK, DISC BLOCK, ETC.
86 5 Spare parts and accessories.
Fuoco 500ie Chap. 06 Programmed maintenance 87.
Scheduled maintenance table Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page.
Engine oil - replacement Brake pads - check condition and wear Tyre pressure and wear - check Vehicle and brake test - road test Hub oil - change Steering - Check Parking control unit software upgradi.
Coolant level - check Brake fluid level - check Engine oil - replacement Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check Vehicle an.
AFTER 20,000 KM; 40,000 KM; 60,000 KM AND 80,000 KM Spark plugs - replacement Driving belt - replacement Throttle lever - adjustment Air filter - check Engine oil - change Valve clearance - check Elec.
30,000 KM Safety locks - check Driving Belt - replacement Throttle lever - adjustment Air filter - clean Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid lev.
RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications AGIP GP 330 Grease for brake control.
94 6 Programmed maintenance.
TABLE OF CONTENTS A Air filter: 52 B Battery: 57 Brake: 55 , 70 C Clock: 12 D Disc brake: 70 Display: 12 E Engine oil: 46 , 47 Engine stop: 17 F Fuel: 23 Fuses: 58 H Headlight: 64 Horn: 16 Hub oil: 48.
The descriptions and illustrations given in this publication are not binding. While the basic features as described and illustrated in this manual remain unchanged, PIAGGIO - GILERA reserves the right.
An important point after buying a device Gilera Fuoco 500ie (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Gilera Fuoco 500ie yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Gilera Fuoco 500ie - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Gilera Fuoco 500ie you will learn all the available features of the product, as well as information on its operation. The information that you get Gilera Fuoco 500ie will certainly help you make a decision on the purchase.
If you already are a holder of Gilera Fuoco 500ie, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Gilera Fuoco 500ie.
However, one of the most important roles played by the user manual is to help in solving problems with Gilera Fuoco 500ie. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Gilera Fuoco 500ie along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
