Gilera Fuoco 500ie Manual Download Page 92

Page: 92 / 96

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 level - check

Engine oil - replacement

Hub oil - check

Brake pads - check condition and wear

Sliding block / variable speed rollers - change

Tyre pressure and wear - check

Vehicle and brake test - road test

Suspensions - check

Steering - Check

Centre stand - lubrication

Spark plugs - replacement

Tilt locking gripper control cable - adjustment

Parking control unit software upgrading (if available)

6 Programmed maintenance

Summary of Contents for Fuoco 500ie

Page 1: ...information tips and precautions for using your scooter It also describes features details and devices to assure you that you have made the right choice We believe that if you follow our suggestions you will soon get to know your new vehicle and it will serve you well for a long time to come This booklet forms an integral part of the scooter should the scooter be sold it must be transferred to the...

Page 2: ... regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre The booklet also contains instructions for simple repairs Any operations not specifically described in this manual require the use of special tools and or particular technical knowledge to carry out these operations refer to any authorised Dealer of Service Centres 2 ...

Page 3: ...ent Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee The signs that you see on this page are very important They are used to highlight those parts of the booklet that should be read with particular care As you can see each sign consists of a different graphic symbol making ...

Page 4: ...4 ...

Page 5: ...ning the saddle to access the helmet compartment by remote control 24 Opening the saddle 25 Identification 26 Bag clip 26 USE 27 Checks 28 Refuelling 28 Tyre pressure 30 Shock absorbers adjustment 31 Running in 32 Starting up the engine 33 Precautions 35 Difficult start up 35 Stopping the engine 36 anello antifurto 36 Stand 37 Automatic transmission 37 Safe driving 37 Front suspension locking syst...

Page 6: ...mber plate light 69 Helmet compartment lighting bulb 69 Rear view mirrors 69 Front and rear disc brake 70 Puncture 71 Periods of inactivity 71 Cleaning the vehicle 72 TECHNICAL DATA 77 Kit equipment 82 SPARE PARTS AND ACCESSORIES 83 Warnings 84 PROGRAMMED MAINTENANCE 87 Scheduled maintenance table 88 6 ...

Page 7: ...Fuoco 500ie Chap 01 Vehicle 7 ...

Page 8: ...01_01 8 1 Vehicle ...

Page 9: ...utton F Turn indicator switch G Rear brake lever H Light switch PASSING I Analogue instrument panel L Digital instrument panel M Warning light unit N RUN OFF switch O Front brake lever P Throttle grip Q Front suspension locking unlocking switch R Starter button S Mode button 9 1 Vehicle ...

Page 10: ...01_02 10 1 Vehicle ...

Page 11: ...dicator H Fuel gauge I Warning light for helmet compartment courtesy light on L Engine control telltale light and injection system failure warning light M Low fuel warning light N Engine stop warning light O Turn indicator warning light P Low oil pressure warning light Q Front suspension locking system failure warning light R Warning light for parking brake engaged S High beam warning light 11 1 V...

Page 12: ...CLOCK button again and the month numbers start flashing Set the month with the SET button Push the CLOCK button again and the year numbers start flashing Set the year with the SET button Press the CLOCK button again for 4 seconds to exit the adjustment menu During the reset process not pressing any buttons for a period longer than 8 seconds ends the process automatically and the display shows the ...

Page 13: ...ntenance must be carried out at the kilometre service intervals rec ommended in this booklet WARNING REFER TO THE SCHEDULED MAINTENANCE TABLE FOR FURTHER MAIN TENANCE OPERATIONS MODE button 01_05 01_06 Pushing the MODE S button for less than a second displays the following se quence of functions 1 Trip odometer A 2 Trip odometer B 3 Ambient temperature Push the MODE S button for longer than 3 seco...

Page 14: ... panel near the bag hook SWITCH POSITIONS 1 LOCK Ignition disabled extractable key mechanical antitheft device ena bled The parking brake cannot be released when engaged and can be engaged when released 2 OFF Ignition disabled extractable key mechanical antitheft device dis abled and enabled disabled parking brake 3 ON Ready to start non extractable key mechanical antitheft device disa bled 4 HELM...

Page 15: ... OFF CAUTION DO NOT TURN THE KEY TO LOCK OR OFF WHILE RIDING 01_09 Switch direction indicators 01_09 Lever F towards 1 left turn indicators switched on Lever F towards 2 right turn indicators switched on The lever F automatically returns to 0 and the turn indicators remain on push the lever F to turn them off 15 1 Vehicle ...

Page 16: ...he vehicle is not running only the tail light is on When the ignition key is set to ON and the vehicle is running the low beam lights will turn on two seconds after the ignition when the high beam lights turn on the low beam lights turn off 01_12 Emergency flashing light button 01_12 It enables the activation of the 4 turn indicators simultaneously The control D can be enabled only with the key se...

Page 17: ...the emergency cut off switch N is set to 1 RUN if the emergency cut off switch N is set to 0 OFF the engine cannot be started or it shuts off if already running CAUTION DO NOT OPERATE THE ENGINE STOP SWITCH N WHILE RIDING UNLESS THERE IS AN EMERGENCY 01_15 Front suspension unlock lock switch 01_15 The Q switch engages and disengages the front suspension locking system As the topic is so complex fi...

Page 18: ...s come with the vehicle The key A is the MASTER key Only a single copy of this key is supplied which is necessary to program all your other keys and for your dealer to perform some maintenance operations For this reason it is advised that it be used only in exceptional circumstances The key B single copy supplied is used for regular operations such as Engine start up Remote control saddle opening ...

Page 19: ...ine lock Turning the key to ON disables the engine lock provided that the safety system recognises the code transmitted by the key If the code is not recognised turn the key first to OFF and then to ON if lock persists try again using the A MASTER key If the engine cannot be started contact an Authorised Service Centre which is provided with the electronic equipment re quired to detect and repair ...

Page 20: ...ith the engine stop switch set to RUN START PROCEDURE Insert the MASTER key into the switch in OFF position turning it to ON po sition After 1 3 seconds turn the key to OFF again and pull it out INTERMEDIATE STAGE After extracting the MASTER key insert within ten seconds the key that is going to be programmed and turn it immediately to ON position After 1 3 seconds turn the key to OFF again and pu...

Page 21: ...he opening device control unit at the manufacturing stage If the remote control is lost a new one can be requested and programmed at any Authorised Service Centre The remote control is powered by inner batteries that get discharged after extended used If the green LED turns on when the button is pressed the remote control is working properly You may need to replace the batteries if the remote cont...

Page 22: ...uted by open ing the saddle WARNING TO STORE THE OTHER REMOTE CONTROLS TO MEMORY MAXIMUM 8 YOU NEED TO REPEAT THE WHOLE PROCEDURE AGAIN FAILURE TO CARRY OUT THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE CONTROLLED KEYS WARNING AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY FROM THE SCOOTER THE ...

Page 23: ...IO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF JUST TURN THE KEY TO ON TO REACTIVATE THE RECEIVER 01_21 01_22 Accessing the fuel tank 01_21 01_22 To open the fuel tank cover set the key to OFF or ON then press and turn it clockwise 23 1 Vehicle ...

Page 24: ...with a protection cover which may be used in case of rain Lift the saddle and extract the cover from its housing then extend it over the whole length of the saddle starting from the front end do not over stretch the cover to avoid tearing the material close the saddle CAUTION DO NOT USE THE VEHICLE WITHOUT THE PROTECTION COVER Opening the saddle to access the helmet compartment by remote control 0...

Page 25: ...NEL SIGNALS IF THE LIGHT IS ON OR OFF WARNING THE REMOTE CONTROL OPERATES WITHIN A DISTANCE OF ABOUT 3 5 ME TRES WITH FULLY CHARGED BATTERIES WHEN YOU ARE NEAR THE SCOOTER HANDLE THE REMOTE CONTROL CAREFULLY SO AS TO AVOID UNINTENTIONAL OPENING OF THE SADDLE REFER TO THE OPENING THE SADDLE WITH REMOTE CONTROL SECTION TO REPLACE BATTERIES Opening the saddle 01_27 With the key set to ON or OFF press...

Page 26: ...responds with that on the vehicle documentation CAUTION BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS IMPOUNDING OF THE VEHICLE ETC Chassis number To read the chassis number remove the lid A in the helmet compartment Engine number The engine number B is stamped near the rear left shock absorber lower support 01_30 Bag clip 01_30 To use the bag ho...

Page 27: ...Fuoco 500ie Chap 02 Use 27 ...

Page 28: ...se 7 The engine oil level 8 The coolant level 02_01 Refuelling 02_01 02_02 Fuel Open the access door to the fuel tank cap and remove the cap T Recommended fuel Unleaded petrol min octane rating of 95 The instrument H indicates the fuel level and the warning light M indicates the reserve WARNING SWITCH OFF THE ENGINE BEFORE REFUELLING WITH PETROL PETROL IS HIGHLY INFLAMMABLE DO NOT SMOKE AND KEEP O...

Page 29: ...N DO NOT USE THE VEHICLE TO THE COMPLETE EXHAUSTION OF THE FUEL IN THE EVENT THAT THIS SHOULD OCCUR DO NOT ATTEMPT TO START THE ENGINE TURN THE KEY SWITCH TO OFF AND TOP UP THE TANK AS SOON AS POSSIBLE FAILURE TO FOLLOW THESE GUIDELINES COULD DAMAGE THE FUEL PUMP AND OR THE CATALYTIC CONVERTER WARNING IT IS HIGHLY INADVISABLE TO REFUEL USING METHODS OTHER THAN NOR MAL FUEL PUMPS IF PETROL IS NOT C...

Page 30: ...visible on the tyre tread Also check that the tyres do not show signs of splitting at the side or irregular tread wear if this occurs go to an authorised workshop or at least to a workshop equipped to perform the replacement CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID ING DANGEROUS TYRES MUST BE REPLACED WHEN THE TREA...

Page 31: ...ied Position 1 minimum preload driver only Position 2 medium preloading driver only Position 3 medium preloading rider and passenger Position 4 maximum preloading driver passenger and luggage In order to carry out this operation you will need to use the specific spanner in the kit Spring preloading increases by turning the ring nut towards A but decreases if the ring nut is turned towards B CAUTIO...

Page 32: ... Running in DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80 OF ITS MAX SPEED AVOID OPENING THE THROTTLE GRIP COMPLETELY OR KEEP ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD AFTER THE FIRST 1000 KM INCREASE SPEED PROGRESSIVELY IF POSSIBLE UNTIL THE MAXIMUM PERFORMANCE IS OBTAINED CAUTION IN ORDER TO AVOID DAMAGING THE VEHICLE PLEASE COMPLY WITH THE RULES LISTED ABOVE 32 2 Use ...

Page 33: ...itches on automatically as soon as the engine is started The vehicle has a front suspension locking system a sensor placed under the saddle will prevent the vehicle riding but not its starting up if the rider is not seated in riding position To start up the engine 1 Rest the vehicle on its centre stand ensuring the rear wheel is not touching the ground 2 Maintain the throttle grip P completely unt...

Page 34: ...E EXHAUST DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS TO AVOID SERIOUS BURNS CAUTION DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING UN BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN CAUSING IT TO OVERHEAT AND POSSIBLY DESTROYING IT CAUTION NEITHER PUSH THE STARTER BUTTON NOR TURN THE KEY SWITCH TO ON WHEN THE TANK IS EMPTY SINCE THE START UP SYSTEM MAY GET DAM AGED 34 2...

Page 35: ...LONGED EX CESSIVE REVOLUTIONS THE REVOLUTION LIMITER WILL BE ACTIVATED IF THE ENGINE SPEED EXCEEDS THE ESTABLISHED THRESHOLD WARNING AFTER A LONG DISTANCE COVERED AT THE MAXIMUM SPEED DO NOT STOP THE ENGINE IMMEDIATELY BUT LET IT RUN AT IDLE FOR A FEW SECONDS Difficult start up In the rare case of flooding the engine to facilitate start up it is possible to try to put the vehicle into action with ...

Page 36: ...TH FLAMMABLE MATERIALS TO AVOID SERIOUS BURNS CAUTION DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING UN BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN CAUSING IT TO OVERHEAT AND POSSIBLY DESTROYING IT 02_10 anello antifurto 02_10 The D ring on the right side of the vehicle is used to fasten the vehicle to an object using a scooter chain Do not use the ring for other purposes WA...

Page 37: ...ine to keep the vehicle still can cause the clutch to overheat due to the friction of the clutch masses against the capstan Besides avoid accelerating with the hand brake engaged It is therefore recommended to avoid conditions of prolonged clutch slippage besides those previously indicated like driving uphill fully laden on steep slopes or starting off with driver and passenger at slopes greater t...

Page 38: ...ar wheel should not be turning when in comes into contact with the ground in order to avoid abrupt departures 5 If driving over roads affected by sand mud snow mixed with salt etc we recom mend cleaning the brake disc with a non corrosive detergent frequently in order to prevent corrosive particles from building up in the holes which may cause early break pad wear CAUTION ALWAYS RIDE WITHIN YOUR L...

Page 39: ...OR IF THE VEHICLE IS NOT IN A GENERALLY GOOD CONDITION OR WHEN EVER WEATHER CONDITIONS DEMAND IT SPEED SHOULD BE FURTHER REDUCED CAUTION DO NOT ADJUST THE MIRRORS WHILE RIDING THIS COULD CAUSE YOU TO LOOSE CONTROL OF THE VEHICLE CAUTION ANY CHANGES TO THE VEHICLE PERFORMANCE AS WELL AS ALTERATIONS TO ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW AND RENDERS THE VEHICLE NO LONGER CONFORMIN...

Page 40: ...lows for vehicle tilting Engaging tilt locking is possible only if the following conditions occur at the same time Throttle completely untwisted Engine rpm below 2500 rpm Vehicle speed below 10 km h Locking system WARNING light C off the system has not detected fail ures If one of these conditions is not checked the warning light E remains off and locking cannot be engaged in normal riding conditi...

Page 41: ...CIDENTALLY AS A CONSEQUENCE WARNING EVERY TIME THE VEHICLE IS STOPPED MAKE SURE THE FRONT SUSPEN SION LOCKING SYSTEM IS ENGAGED OTHERWISE PLACE YOUR FEET ON THE GROUND TO KEEP THE VEHICLE UPRIGHT WARNING AVOID USING THE LOCKING SYSTEM WHEN RIDING THE VEHICLE ALONG IR REGULAR ROADS OR ROADS WITH OBSTACLES E G ROAD HUMPS SIDE WALK ETC IN CASE OF ENGINE FAILURE DISCHARGED BATTERY AVOID PULLING THE VE...

Page 42: ...recommended to press the hand brake lever shown in the figure moving it form position A to position B When the hand brake B is engaged warning light R on the instrument panel turns on When the hand brake is set to B and the key switch is turned to position 1 the safety system that prevents the hand brake from getting released is activated To release the hand brake turn the key switch to 2 or 3 If ...

Page 43: ...n be unlocked by operating the Q switch twice quickly on the unlocking position 2 Once the suspension is un locked the vehicle can be normally used except for the locking system which will be disengaged For some cases of failure the vehicle speed is auto limited to 30 Km h This automatic procedure is activated to enhance safety until the failure is eliminated Always contact an Authorised Service C...

Page 44: ...44 2 Use ...

Page 45: ...Fuoco 500ie Chap 03 Maintenance 45 ...

Page 46: ...s used visually inspect the level of the engine oil when the engine is cold after completely unscrewing the oil cap dipstick The oil level should be somewhere between the MAX and MIN reference marks on the dipstick A during the oil check the vehicle must be resting on its centre stand on an even horizontal surface If the check is carried out after the vehicle has been used and therefore with a hot...

Page 47: ...l remains in the circuit add approximately 1500 cm of oil through cap A Then start up the scooter leave it running for a few minutes and switch it off after five minutes check the level and if necessary top up without exceeding the MAX level The cartridge filter must be replaced at every oil change For top ups and oil changes use new oil of the recommended type CAUTION RUNNING THE ENGINE WITH INSU...

Page 48: ... Pull out the dipstick to control that the oil level reaches the second notch from the bottom as indicated by the arrow in figure this is the correct level and must remain constant at all times 4 Screw the dipstick back in checking that it is correctly locked in place CAUTION RIDING THE VEHICLE WITH INSUFFICIENT HUB LUBRICATION OR WITH CON TAMINATED OR IMPROPER LUBRICANTS ACCELERATES THE WEAR AND ...

Page 49: ...INTO CONTACT WITH THE REAR BRAKE DISC CAUTION FOR OIL REPLACEMENT CONTACT ANY AUTHORISED SERVICE CENTRE AS THEY ARE EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY Recommended products AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements of API GL3 specifications Characteristic Transmission oil 250 cm 49 3 Maintenance ...

Page 50: ...p equipped to perform the replacement CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID ING DANGEROUS TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW WARNING THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED RIDING THE VEHICLE WITH VERY LOW TYRE PRESSURE OR WITH INCORRECTLY BALANCED TYRES...

Page 51: ...Unscrew the spark plugs using the supplied spark plug wrench 3 When refitting place the spark plugs into the hole at the due inclination and tighten it by hand until it is finger tight 4 Only use the wrench to lock it in place 5 Place the B caps fully over the spark plugs 6 Refit the port making sure the rear hook is inserted CAUTION SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD SPARK PLUGS ...

Page 52: ...emoving the air filter 03_10 Proceed as follows Unscrew the nine fixing screws A and remove the air filter cover B Air filter cleaning 1 Wash the sponge with water and neutral soap 2 Dry it with a clean cloth and small blasts of compressed air 3 Impregnate the sponge with a mixture of 50 petrol and 50 specified oil 4 Gently squeeze the filter element let it drip and then refit it 52 3 Maintenance ...

Page 53: ...or use For proper func tioning of the engine the coolant temperature must be between the 4th and 7th lit segment as indicated by the instrument D on the digital instrument panel When the 9th segment lights up the icon and all the segments start flashing stop the engine let it cool down and check the fluid level if the level is OK contact an Authorised Service Centre Check coolant when the engine i...

Page 54: ...SED FOR TOP UPS TO AVOID DAMAGING THE ENGINE N B SHOULD THE 9th SEGMENT OF THE COOLANT TEMPERATURE INDICATOR COME ON DURING A NON DEMANDING RIDE SHUT OFF THE ENGINE AND LET IT COOL DOWN THEN CHECK THE COOLANT LEVEL IF THE LEVEL IS OK CONTACT AN AUTHORISED SERVICE CENTRE WARNING IN ORDER TO AVOID BURNS DO NOT UNSCREW THE EXPANSION TANK CAP WHILE THE ENGINE IS STILL HOT WARNING IN ORDER TO AVOID HAR...

Page 55: ...level appear to be below the minimum mark please contact an Authorised Service Centre or Dealer in order to have braking system thoroughly checked Braking system fluid top up 03_16 Proceed as follows Undo the screws B and remove the fuel tank cap A Top up using only the fluid specified without exceeding the maximum level This procedure applies to the rear brake pump top up operation follow the sam...

Page 56: ...ING IN CASE OF CONTACT RINSE WITH WATER THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC THAT IS IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE IT WILL LEAD TO INEFFICIENT BRAKING NEVER USE BRAKING FLUID KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED OR PARTIALLY USED Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid 56 3...

Page 57: ...ER TO AVOID DAMAGING THE ELECTRICAL SYSTEM NEVER DISCON NECT THE WIRING WHILE THE ENGINE IS RUNNING Use of a new battery 03_18 Make sure that the terminals are connected correctly CAUTION DO NOT REVERSE THE POLARITY RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELECTRICAL SYSTEM WARNING SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRE...

Page 58: ...sure that all terminals are properly connected 03_19 03_20 Fuses 03_19 03_20 03_21 03_22 03_23 The electrical system has twelve fuses divided into two fuse boxes to protect the dif ferent installation circuits One of them is inside the battery compartment A and the other is at the internal side of the right footrest B To have access loosen the screw C and remove the plastic cover The chart shows t...

Page 59: ...03_21 03_22 03_23 59 3 Maintenance ...

Page 60: ...rcuits Battery powered saddle opening switch glove box lighting light switch turn indicator switch antitheft installation fuse No 12 Fuse No 4 Capacity 20A Protected circuits battery powered ECU for parking control Fuse No 5 Capacity 20A Protected circuits battery powered fuse No 7 live fuses No 8 No 9 No 10 No 11 Fuse No 6 Capacity 15 A Protected circuits L V socket Fuse No 7 Capacity 7 5 A 60 3 ...

Page 61: ...nd horn Fuse No 10 Capacity 7 5A Protected circuits Live injection ECU immobilizer aerial electric fan remote control injection loads remote control Fuse No 11 Capacity 7 5A Protected circuits Live ECU parking lever antitheft installation instrument panel headlight remote control horn Fuse No 12 Capacity 7 5A Protected circuits Live turn indicator control saddle opening switch tail lights panel li...

Page 62: ...1 LHS Helmet compartment light bulb Type FESTOON BULB Power 12V 5W Quantity 1 Rear turn indicator light bulb Type WITH BULB Power 12V 10W Quantity 1 RHS 1 LHS Rear tail light bulb Type WITH BULB Power 12V 5W Quantity 1 RHS 1 LHS Stop light bulb Type WITH BULB Power 12V 10W Quantity 1 RHS 1 LHS License plate light bulb Type ALL GLASS 62 3 Maintenance ...

Page 63: ...screwdriver in the notch on the side see picture of the Gilera emblem and remove it Undo the screw A and the four screws B Push the two indicated tongues to unlock the tail lights and remove the rubber bulb holder To replace it slide off the bulb from the bulb holder and insert a new bulb To access the high beam light bulbs and the low beam light bulbs Actuating on the inside of the front wheel ho...

Page 64: ...ht and check that the borderline of the projected light beam should be lower than 9 10 of the distance from the ground to the centre of the vehicle s head light and higher than 7 10 Otherwise adjust the headlight N B THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS RE GARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE ve...

Page 65: ... 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 ADJUST THE LIGHT BEAM IN A WELL VENTILATED PLACE 65 3 Maintenance ...

Page 66: ...03_31 03_32 03_33 66 3 Maintenance ...

Page 67: ...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 67 3 Maintenance ...

Page 68: ...hten the screw A in its seat To replace the stop light bulb C hold it and turn it anticlockwise To replace the rear tail light bulb D hold it and pull it outwards 03_38 Rear turn indicators 03_38 To access the bulb undo the screw A and remove the glass B To replace the bulb hold it and then turn it clockwise 68 3 Maintenance ...

Page 69: ...et 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 03_41 Rear view mirrors 03_41 The mirrors can be set to the desired position by adjusting the mirror frame 69 3 Maintenance ...

Page 70: ...NG ACTION SHOULD BEGIN AFTER ABOUT 1 3 OF THE BRAKE LEVER STROKE CAUTION HAVE THE BRAKE PADS CHECKED BY THE DEALER ACCORDING TO THE CHECKS SPECIFIED IN THE SCHEDULED MAINTENANCE TABLE HOWEVER IN THE EVENT OF NOISES COMING FROM THE FRONT AND OR REAR BRAKE SYSTEM DURING OPERATION IT IS ADVISABLE TO HAVE THE BRAKE SYS TEM CHECKED BY A PIAGGIO DEALER OR AUTHORISED SERVICE CENTRE AFTER REPLACING THE BR...

Page 71: ...repair take your vehicle to an Authorised Service Centre or Dealer The replacement of a tyre involves removing the wheel in question Take your vehicle to an Authorised Service Centre or Dealer for these operations CAUTION TO USE THE INFLATE AND REPAIR SPRAY PROPERLY FOLLOW THE IN STRUCTIONS ON THE PACKAGING WARNING THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED RIDING THE VEHICLE WITH VERY...

Page 72: ...d in the Battery section Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil Cleaning the vehicle In order to soften the dirt and mud deposited on the painted surfaces use a low pres sure jet of water Once softened mud and dirt must be removed with a soft sponge for bodywork soaked in lots of water and shampoo 2 4 of car shampoo in water Then rinse ab...

Page 73: ...GGI ELETTRICI LE FERITOIE DI RAFFREDDAMENTO DEL COPERCHIO TRASMISSIONE E DEL COPERCHIO CHIOCCIOLA CAUTION NEVER WASH THE SCOOTER IN DIRECT SUNLIGHT ESPECIALLY IN SUMMER WHEN THE BODYWORK IS STILL HOT AS THE SHAMPOO COULD DAMAGE THE PAINTWORK IF IT DRIES BEFORE BEING RINSED OFF NEVER USE CLOTHS SOAKED IN ALCOHOL PETROL DIESEL OIL OR KEROSENE FOR CLEANING THE PAINTED OR PLASTIC SURFACES IN ORDER NOT...

Page 74: ...ntre Faulty ignition injection control unit Contact an Authorised Service Centre Faulty coil Due to the presence of high voltage this check should only be carried out by an expert Contact an Authorised Service Centre LACK OF COMPRESSION Loosen spark plug Screw in the spark plug tightly Cylinder head loose piston gas rings worn Contact an Authorised Service Centre Valve stuck Contact an Authorised ...

Page 75: ...esence of air in the front and rear brake circuit Contact an Authorised Service Centre INEFFICIENT SUSPENSIONS Shock absorber fault oil leak end buffer damaged shock absorber preloading incorrectly set Contact an Authorised Service Centre IRREGULAR AUTOMATIC TRANSMISSION Variator rollers and or driving belt damaged Contact an Authorised Service Centre STAND DOES NOT RETURN TO POSITION Presence of ...

Page 76: ...76 3 Maintenance ...

Page 77: ...Fuoco 500ie Chap 04 Technical data 77 ...

Page 78: ...04_01 78 4 Technical data ...

Page 79: ...pm MAX Power for crossover version 25 kW MAX torque 46 5 Nm at 5 250 rpm Transmission Automatic expandable pulley variator with torque server V belt dry self ventilating automatic centrifugal clutch and transmission housing with forced air circulation Final reduction Gear reduction unit in oil bath Lubrication Engine lubrication with lobe pump inside crankcase controlled by a chain with double fil...

Page 80: ...p Fuel Unleaded petrol 95 RON exhaust muffler Absorption type exhaust muffler with catalytic converter and lambda probe Emission regulations EURO 3 VEHICLE TECHNICAL DATA Chassis Tubular and sheet steel Front suspension The tilt mechanism is composed of an articulated parallelogram suspension with die cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking s...

Page 81: ... rims Front rim 12 x 3 00 Rear rim 14 x 4 50 Front tyre Tubeless 120 70 12 51S or 51P Rear tyre Tubeless 140 70 14 68S or 68P reinf Front tyre pressure with passenger 1 6 bar 1 8 bar Rear tyre pressure with passenger 2 4 bar 2 6 bar Kerb weight 253 5 kg Maximum weight allowed 445 kg Battery 12 V 14 Ah SEALED BATTERY CAPACITY Engine oil 1 7 l Transmission oil 250 cm Cooling system fluid 2 l Fuel ta...

Page 82: ...2 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 The tools are stored in the helmet compartment 82 4 Technical data ...

Page 83: ...Fuoco 500ie Chap 05 Spare parts and accessories 83 ...

Page 84: ...THE WARRANTY VOID WARNING PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG NISED AND GUARANTEED FOR USE IT IS THEREFORE ESSENTIAL IN ORDER TO CHOOSE AND MOUNT THE ACCESSORIES CORRECTLY TO CONTACT AN AUTHORISED DEALER OR SERVICE CENTRE THE USE OF NON ORIGINAL ACCESSORIES MAY AFFECT THE STABILITY AND OPERATION OF YOUR VE HICLE AND REDUCE SAFETY LEVELS WITH POTENTIAL RISKS FOR THE RIDER WAR...

Page 85: ...ING AND REMOVING THE MECHAN ICAL ANTITHEFT DEVICE ON THE VEHICLE U SHAPED PADLOCK DISC BLOCK ETC MAINLY DUE TO THE PROXIMITY TO THE BRAKE PIPES TRANSMISSIONS AND OR ELECTRIC CABLES AN INCORRECT INSTALLATION OR REMOVAL OF THE ANTITHEFT DEVICE AS WELL AS LEAVING IT ON BEFORE STARTING THE VEHICLE CAN SERIOUSLY DAMAGE ITS COMPONENTS AND AFFECT THE CORRECT FUNCTIONING OF THE VEHICLE AND HARM THE USER 8...

Page 86: ...86 5 Spare parts and accessories ...

Page 87: ...Fuoco 500ie Chap 06 Programmed maintenance 87 ...

Page 88: ...e to solve it All scheduled maintenance services must be carried out at the specified times even if the stated mileage has not yet been reached Carrying out scheduled services on time is necessary to ensure your warranty remains valid For any further information concerning Warranty procedures and Scheduled Maintenance please refer to the Warranty Booklet EVERY 2 YEARS Coolant change Brake fluid ch...

Page 89: ... AFTER 5 000 KM 25 000 KM 35 000 KM 55 000 KM 65 000 KM Engine oil level check top up Brake pads check condition and wear Centre stand lubrication Parking control unit software upgrading if available AFTER 10 000 KM 50 000 KM 70 000 KM Safety locks check Driving belt replacement Throttle lever adjustment Air filter clean Engine oil change Electrical system and battery check 89 6 Programmed mainten...

Page 90: ...est Hub oil check Suspensions check Steering Check Centre stand lubrication Spark plugs replacement Tilt locking gripper control cable adjustment Parking control unit software upgrading if available AFTER 15 000 KM 45 000 KM 75 000 KM Engine oil level check top up Brake pads check condition and wear Centre stand lubrication Parking control unit software upgrading if available 90 6 Programmed maint...

Page 91: ...check Coolant level check Engine oil replacement Brake pads check condition and wear Sliding block variable speed rollers change Tyre pressure and wear check Vehicle and brake test road test Hub oil change Suspensions check Steering Check Centre stand lubrication Brake fluid level check Tilt locking gripper control cable adjustment Parking control unit software upgrading if available 91 6 Programm...

Page 92: ...heck Engine oil replacement Hub oil check Brake pads check condition and wear Sliding block variable speed rollers change Tyre pressure and wear check Vehicle and brake test road test Suspensions check Steering Check Centre stand lubrication Spark plugs replacement Tilt locking gripper control cable adjustment Parking control unit software upgrading if available 92 6 Programmed maintenance ...

Page 93: ...sed antifreeze fluid CUNA NC 956 16 AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AUTOSOL METAL POLISH Muffler cleaning paste Specific product for cleaning and polishing stainless steel mufflers AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based...

Page 94: ...94 6 Programmed maintenance ...

Page 95: ...adlight 64 Horn 16 Hub oil 48 I Identification 26 Immobilizer 18 20 Instrument panel 11 K Key switch 14 Keys 18 L Light switch 16 M Maintenance 13 45 87 88 Mirrors 69 S Saddle 21 24 25 Scheduled maintenance 88 Shock absorbers 31 Spark plug 51 Stand 37 Start up 17 T Tank 23 Technical Data 77 Transmission 37 Turn indicators 68 Tyre pressure 30 Tyres 50 95 ...

Page 96: ...ts or accessory supplies which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all Countries The availability of individual versions should be confirmed with the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproduction of this pub...

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