gilera fuoco - [PDF Document] (2022)

  • GILERA WOULD LIKE TO THANK YOU

    for choosing one of its products. We have prepared this manualto help you to get the very best from your scooter. Please read itcarefully before ridingthe scooter for the first time. It containsinformation, tips and precautions for using your scooter. It alsodescribes features, details and devices to assureyou that you havemade the right choice. We believe that if you follow oursuggestions, you will soon get to know your new vehicle and it willserve youwell for a long time to come. This booklet forms anintegral part of the scooter; should the scooter be sold, it mustbe transferred to the new owner.

    Fuoco 500ie

    Ed. 2

  • The instructions given in this manual are intended to provide aclear, simple guide to using your scooter; this booklet alsodetails routine maintenanceprocedures and regular checks thatshould be carried out on the vehicle at an authorised Dealer orService Centre. The booklet also containsinstructions for simplerepairs. Any operations not specifically described in this manualrequire the use of special tools and/or particulartechnicalknowledge: to carry out these operations refer to anyauthorised Dealer of Service Centres.

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  • Personal safety

    Failure to completely observe these instructions will result inserious risk of personalinjury.

    Safeguarding the environment

    Sections marked with this symbol indicate the correct use of thevehicle to prevent dam-aging the environment.

    Vehicle intactness

    The incomplete or non-observance of these regulations leads tothe risk of seriousdamage to the vehicle and sometimes even theinvalidity of the guarantee.

    The signs that you see on this page are very important. They areused to highlight thoseparts of the booklet that should be readwith particular care. As you can see, each signconsists of adifferent graphic symbol, making it quick and easy to locate thevarioustopics.

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  • 4

  • INDEX

    VEHICLE......................................................................................7Dashboard................................................................................9Analogue instrumentpanel.......................................................11Clock.........................................................................................12Digital lcddisplay......................................................................12

    Maintenanceicons................................................................13*MODE*button......................................................................13

    Keyswitch.................................................................................14Locking the steeringwheel....................................................14Releasing the steeringwheel................................................ 15

    Switch directionindicators........................................................15Hornbutton...............................................................................16Lightswitch...............................................................................16Emergency flashing lightbutton................................................ 16Start-upbutton..........................................................................17Engine stopbutton....................................................................17Front suspension unlock-lockswitch........................................ 17The immobilizersystem............................................................18

    Keys......................................................................................18Immobilizerdevice enabled indicatorled...............................19Operation...............................................................................19Programming the immobilizersystem................................... 20

    Saddle opening remotecontrol................................................. 21Remotecontrol programming................................................22

    Accessing the fueltank.............................................................23Power supplysocket.................................................................24Thesaddle................................................................................24

    Opening the saddle to access the helmet compartment byremotecontrol.......................................................................24Opening thesaddle...............................................................25

    Identification..............................................................................26Bagclip.....................................................................................26

    USE..............................................................................................27

    Checks......................................................................................28Refuelling..................................................................................28Tyrepressure............................................................................30Shock absorbersadjustment....................................................31Runningin.................................................................................32Starting up theengine...............................................................33

    Precautions...........................................................................35Difficult startup.........................................................................35Stopping theengine..................................................................36anelloantifurto..........................................................................36Stand.........................................................................................37Automatictransmission.............................................................37Safedriving...............................................................................37Front suspension lockingsystem.............................................. 40

    MAINTENANCE...........................................................................45Engine oillevel..........................................................................46

    Engine oil levelcheck............................................................46Engine oiltop-up...................................................................46Warning light (insufficient oilpressure)................................. 46Engine oilchange..................................................................47

    Hub oillevel..............................................................................48Tyres.........................................................................................50Spark plugdismantlement........................................................51Removing the airfilter...............................................................52Air filtercleaning.......................................................................52Cooling fluidlevel......................................................................53Checking the brake oillevel...................................................... 55

    Braking system fluid topup...................................................55Battery.......................................................................................57

    Use of a newbattery.............................................................57Long periods ofinactivity..........................................................58Fuses........................................................................................58Front lightgroup........................................................................63

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  • Headlightadjustment.............................................................64Front directionindicators...........................................................67Rear opticalunit........................................................................68Rear turnindicators...................................................................68Number platelight.....................................................................69Helmet compartment lightingbulb............................................ 69Rear-viewmirrors......................................................................69Front and rear discbrake..........................................................70Puncture....................................................................................71Periods ofinactivity...................................................................71Cleaning thevehicle..................................................................72

    TECHNICALDATA......................................................................77Kitequipment............................................................................82

    SPARE PARTS ANDACCESSORIES........................................83Warnings...................................................................................84

    PROGRAMMEDMAINTENANCE...............................................87Scheduled maintenancetable................................................... 88

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  • Fuoco 500ie

    Chap. 01Vehicle

    7

  • 01_01

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  • 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 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

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  • 01_02

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  • 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

    F= SET switch

    G = Rpm indicator

    H = Fuel gauge

    I = Warning light for helmet compartment courtesy light on

    L = Engine control telltale light and injection system failurewarning 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

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  • 01_03

    Clock (01_03)

    Pushing the CLOCK button for less than 1 second displays thefollowing sequence: TIME DATE

    To set the clock push and hold the CLOCK button longer than 3seconds.

    The numbers showing the hours will begin flashing.

    Set the hour using the SET button. Push the CLOCK button againand the mi-nutes numbers start flashing.

    Set the minutes using the SETbutton. Push the CLOCK button againand the daynumbers start flashing.

    Set the day with the SET button. Push the CLOCK button again andthe monthnumbers start flashing.

    Set the month with the SET button. Push the CLOCK button againand the yearnumbers start flashing.

    Set the year with the SET button. Press the CLOCK button againfor 4 secondsto exit the adjustment menu.

    During the reset process, not pressing any buttons for a periodlonger than 8 secondsends the process automatically and the displayshows the modified time.

    01_04

    Digital lcd display (01_04)

    A = Total odometer gauge

    B = BELT maintenance icon

    C = SERVICE maintenance icon

    D = Engine coolant temperature indicator

    E = Trip odometer (A-B) and ambient temperature gauge (selectedwith the MODEbutton)

    F = TIME-DATE indicator

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  • 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 operationsshould be carriedout. A flashing SERVICE icon signals the need tocarry out the scheduled mainte-nance service. A flashing BELT iconsignals the driving belt needs replacing. In anycase, vehiclemaintenance must be carried out at the kilometre service intervalsrec-ommended in this booklet.

    WARNING

    REFER TO THE SCHEDULED MAINTENANCE TABLE FOR FURTHERMAIN-TENANCE OPERATIONS

    *MODE* button (01_05, 01_06)

    Pushing the ''MODE'' S button for less than a second displaysthe following se-quence of functions:

    1. Trip odometer A2. Trip odometer B3. Ambient temperature

    Push the ''MODE'' S button for longer than 3 seconds to zero setthe trip odometer.

    UNIT OF MEASUREMENT SETTING

    Press and hold the "MODE" S button for at least 3 seconds and atthe same timeturn the ignition key to "on".

    The icons "kmi" and "E" will start flashing.

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  • "Kmi" represents the combination of "km" (kilometres) and "mi"(miles)

    "E" represents the combination of "C" (degrees Celsius) and "F"(degrees Fahren-heit).

    By pushing the "MODE" S button for less than a second, the icons"km" and "mi"are selected sequentially.

    Push the "SET" button M to confirm the selection.

    Now the ambient temperature icon "C" or "F" starts flashing.

    By pushing the "MODE" S button for less than a second, the icons"C" and "F"are selected sequentially.

    Push the "SET" button M to confirm the selection.

    01_07

    01_08

    Key switch (01_07)

    The key switch A is located on the front knee-guard panel nearthe bag hook.

    SWITCH POSITIONS

    1. LOCK = Ignition disabled, extractable key, mechanicalantitheft device ena-bled. The parking brake cannot be releasedwhen engaged and can beengaged when released.

    2. OFF = Ignition disabled, extractable key, mechanicalantitheft device dis-abled and enabled/disabled parking brake.

    3. ON = Ready to start, non-extractable key, mechanicalantitheft device disa-bled.

    4. HELMET COMPARTMENT OPENING = Helmet compartmentopeningposition. Press the key when in OFF or ON and turn itanticlockwise.

    5. FUEL TANK COVER OPENING = Fuel tank cover opening position.Pressthe key when in OFF or ON and turn it clockwise.

    Locking the steering wheel (01_08)

    Turn the handlebar to the left as far as it will go; turn thekey B to LOCK andremove it.

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  • 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_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 indicatorsremain on; pushthe lever F to turn them off.

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  • 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 switchH is pressed when set to 2, thehigh-beam light is activated. Theswitch goes back to 0 automatically.

    When the ignition key is set to ON and the vehicle is notrunning, only the tail lightis on.

    When the ignition key is set to ON and the vehicle is running,the low-beam lightswill turn on two seconds after the ignition;when the high-beam lights turn on, the low-beam lights turnoff.

    01_12

    Emergency flashing light button (01_12)

    It enables the activation of the 4 turn indicatorssimultaneously. The control D canbe enabled only with the key setto ON, but once enabled, it keeps functioning evenif the key is setto OFF or LOCK. To disable this function, simply turn the keyswitchto ON.

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  • 01_13

    Start-up button (01_13)

    To start the engine, press the starter button R after pullingone of the two brakelevers.

    If the rider is not on the vehicle, the suspension lock willstart the engine at idling speed.

    01_14

    Engine stop button (01_14)

    The engine can be started when the emergency cut-off switch N isset to 1RUN; if the emergency cut-off switch N is set to 0 OFF ,the engine cannot bestarted or it shuts off if already running.

    CAUTION

    DO NOT OPERATE THE ENGINE STOP SWITCH "N" WHILE RIDINGUNLESSTHERE IS AN EMERGENCY.

    01_15

    Front suspension unlock-lock switch (01_15)

    The Q switch engages and disengages the front suspension lockingsystem.

    As the topic is so complex, find the instructions for using thiscontrol in the Use chapter.

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  • 01_16

    01_17

    01_18

    The immobilizer system

    In order to enhance theft protection, the scooter is equippedwith a PIAGGIO IM-MOBILIZER electronic engine locking device thatis activated automatically whenthe starter key is removed. Uponstart-up, the PIAGGIO IMMOBILIZER systemchecks the starter key, andonly if this key is recognised will the immobilizer systemallow thescooter to be started.

    Keys (01_16, 01_17, 01_18)

    Two types of keys come with the vehicle.

    The key A is the MASTER key.

    Only a single copy of this key is supplied, which is necessaryto program all your otherkeys and for your dealer to perform somemaintenance operations. For this reason itis advised that it beused only in exceptional circumstances.

    The key B (single copy supplied) is used for regular operationssuch as:

    - Engine start-up.

    - Remote control saddle opening.

    Together with the two keys, you will be given a CODE CARDbearing the same codeimprinted onto the two keys.

    WARNING

    LOSING THE RED KEY PREVENTS ANY REPAIRS OF THE "PIAGGIOIMMOBIL-IZER" SYSTEM AND THE ENGINE CONTROL UNIT.

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  • 01_19

    WARNING

    KEEP THE "CODE CARD" AND THE RED HANDGRIP KEY IN A SAFEPLACE(NOT ON YOUR VEHICLE).

    Immobilizerdevice enabled indicator led (01_19)

    Activation of the "PIAGGIO IMMOBILIZER" system is signalled by aflashing Aindicator. In order to reduce battery discharge, theindicator LED turns off automaticallyafter 48 hours ofuninterrupted functioning. Should the system fail, different LEDflash-ing patterns will provide the Authorised Service Centre withinformation on the typeof fault detected.

    Operation

    Each time the starter key B is removed while in the OFF, or LOCKposition,the protection system activates the engine lock. Turningthe key to "ON" disables theengine lock, provided that the safetysystem recognises the code transmitted by thekey. If the code isnot recognised, turn the key first to "OFF" and then to "ON"; iflockpersists, try again using the A MASTER key. If the enginecannot be started, contactan Authorised Service Centre, which isprovided with the electronic equipment re-quired to detect andrepair the system.

    When supplementary keys are required, remember that theprogramming must beperformed on all the keys whether they are newor existing ones.

    Contact an Authorised Service Centre and bring the A MASTER keyand allB starter keys that you own.

    The codes of keys not submitted for the new storage procedureare deleted from thememory. Any lost keys will therefore not beenabled to start the engine.

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  • WARNING

    EACH KEY HAS ITS OWN AND UNIQUE CODE, WHICH MUST BE STORED BYTHESYSTEM CONTROL UNIT.

    VIOLENT SHOCKS MAY AFFECT THE ELECTRONIC COMPONENTS OFTHEKEY.

    IF THE VEHICLE IS SOLD, THE MASTER-HANDGRIP KEY (AS WELL ASTHEOTHER STARTER KEYS) AND THE "CODE CARD" MUST ALSO BETRANSFER-RED TO THE NEW OWNER.

    Programming the immobilizer system

    Below is described the procedure to follow for programming thePIAGGIO IMMOBIL-IZER system and/or for storing other key codes. Theprogramming procedure shouldbe carried out with the engine stopswitch 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, thekey that is goingto be programmed and turn it immediately to ONposition. After 1-3 seconds, turnthe key to "OFF" again and pull itout. In this way, a maximum of 7 keys can be pro-grammed byrepeating the above procedure and keeping the indicated times.

    FINAL STAGE

    After extracting the key to be programmed, insert the MASTER keyagain and turnit to ON position (perform this operation within theten seconds following the ex-

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  • traction of the previous key). Leave it in this position for 1to 3 seconds and return itto the OFF position.

    CORRECT PROGRAMMING CHECK PHASE

    Insert the MASTER key, disabling the transponder (i.e., bytilting the key cap by90), and turn the key to ON position. Performthe engine start-up operation. Ensurethat the engine does notstart. Insert the programmed key and repeat the start-upoperation.Check that engine starts.

    WARNING

    SHOULD YOU STAR THE ENGINE WITH THE MASTER KEY (WITHTRANS-PONDER OFF) OR IN THE EVENT OF WRONG OPERATION DURINGPROGRAM-MING, REPEAT THE PROCEDURE FROM THE BEGINNING.

    01_20

    Saddle opening remote control (01_20)

    The scooter is fitted with a remote control to open the saddle.This remote control issupplied together with the keys and it hasbeen programmed to control the openingdevice control unit at themanufacturing stage. If the remote control is lost, a new onecan berequested and programmed at any Authorised Service Centre. Theremotecontrol is powered by inner batteries that get dischargedafter extended used; If thegreen LED turns on when the button ispressed, the remote control is working properly.You may need toreplace the batteries if the remote control fails or if its rangeofoperation is reduced. To separate the two halves of the remotecontrol, insert the bladeof a plain slot screwdriver at one pointon the edge and slide it all around. When theremote control isopen, remove the two batteries from the contact terminal. Installthetwo new CR1616 3V batteries with the positive pole facing thecontact terminal.

    (Video) Flutter Tutorial - Create Invoice PDF Document

    Reassemble the remote control by pressing the two clip-on halvesgently with yourfingers.

    To open the saddle without the remote control, follow theprocedure described in theEmergency Saddle Opening section.

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  • Remote control programming

    Follow these steps to program the remote controls:1. Insert theremote control key to be programmed in the steering lock keyblock.

    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.

    3 Wait 1 to 8 seconds.

    4. Repeat steps 2 and 3 for 4 times without removing thekey.

    The control unit confirms the programming has been successfullyexecuted by open-ing the saddle.

    WARNING

    TO STORE THE OTHER REMOTE CONTROLS TO MEMORY, (MAXIMUM 8),YOUNEED TO REPEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRYOUTTHESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT INTHEAUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMINGTHEREMOTE-CONTROLLED KEYS.

    WARNING

    AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHENFARAWAY FROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE RE-MOTE CONTROLAND THE RECEIVER CAN BE IMPAIRED. SHOULD THIS BETHE CASE, REPEATTHE PROGRAMMING PROCEDURE. DO NOT KEEP THEREMOTE CONTROL IN PLACESWITH TEMPERATURES EXCEEDING 60 C THEBATTERY WILL RUN DOWN TOOQUICKLY.

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  • WARNING

    TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTECONTROLRADIO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THEVEHICLEWAS 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, thenpress and turn itclockwise.

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  • 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 (mobilephone, inspection light,etc.).

    CAUTION

    PROLONGED USE OF THE PLUG SOCKET MAY RESULT IN PARTIALDIS-CHARGE OF THE BATTERY

    Electric characteristicPlug socket

    12 V - 180 W MAX

    01_24

    The saddle (01_24, 01_25)

    The saddle is supplied with a protection cover which may be usedin case of rain.

    Lift the saddle and extract the cover from its housing, thenextend it over the wholelength of the saddle, starting from thefront-end; do not over stretch the cover to avoidtearing thematerial; close the saddle.

    CAUTION

    DO NOT USE THE VEHICLE WITHOUT THE PROTECTION COVER.

    Opening the saddle to access the helmet compartment byremotecontrol (01_26)

    When the key is in LOCK or OFF position you can open the saddleusing theremote control. The saddle cannot be opened only when thekey is set to "ON".

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  • 01_25

    01_26

    01_27

    WARNING

    OBJECTS INAPPROPRIATELY ARRANGED INSIDE THE HELMET COMPART-MENTMAY DEFORM THE SADDLE CAUSING THE COURTESY LIGHT TO RE-MAIN ON ANDTHIS WILL DISCHARGE THE BATTERY. IN ANY CASE, THEWARNING LIGHT "I"ON THE INSTRUMENT PANEL SIGNALS IF THE LIGHT ISON OR OFF.

    WARNING

    THE REMOTE CONTROL OPERATES WITHIN A DISTANCE OF ABOUT 3/5ME-TRES WITH FULLY CHARGED BATTERIES. WHEN YOU ARE NEAR THESCOOTER,HANDLE THE REMOTE CONTROL CAREFULLY SO AS TO AVOIDUNINTENTIONALOPENING OF THE SADDLE. REFER TO THE OPENING THESADDLE WITH REMOTECONTROL SECTION TO REPLACE BATTERIES.

    Opening the saddle (01_27)

    With the key set to ON or OFF, press it and turn itanticlockwise.

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  • 01_28

    01_29

    Identification (01_28, 01_29)

    Identification registration numbers are made up of a prefix anda number stamped onthe chassis and on the engine. These numbersmust always be quoted when orderingspare parts. We recommendchecking that the chassis registration number stampedon the vehiclecorresponds with that on the vehicle documentation.

    CAUTION

    BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERSCANLEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THEVEHICLE,ETC.).

    Chassis number

    To read the chassis number, remove the lid A in the helmetcompartment.

    Engine number

    The engine number B is stamped near the rear left shock absorberlower support.

    01_30

    Bag clip (01_30)

    To use the bag hook C mounted on the counter shield, pull itslightly towards theback part of the vehicle.

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  • Fuoco 500ie

    Chap. 02Use

    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, turnindicators, stop light and licenseplate light.

    5. The correct functioning of front and rear brakes.

    6. The oil level in the gearcase.

    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 thecapT.

    Recommended fuel: Unleaded petrol, min octane rating of 95. Theinstrument Hindicates the fuel level and the warning light Mindicates the reserve.

    WARNING

    SWITCH OFF THE ENGINE BEFORE REFUELLING WITH PETROL.

    PETROL IS HIGHLY INFLAMMABLE.

    DO NOT SMOKE AND KEEP OPEN FLAMES AT A DISTANCE:FIRE HAZARD.

    DO NOT INHALE FUEL FUMES.

    DO NOT ALLOW PETROL TO COME INTO CONTACT WITH HOT ENGINE ORANYPLASTIC PARTS.

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  • 02_02

    CAUTION

    PETROL DAMAGES THE PLASTIC PARTS OF THE BODYWORK.

    WARNING

    DO NOT RIDE WITH THE FUEL TANK ALMOST EMPTY, LACK OF FUELCANDAMAGE THE CATALYTIC CONVERTER.

    CAUTION

    USING NON-RECOMMENDED PETROL REDUCES THE EFFICIENCY OFTHEEXHAUST AND FUEL SUPPLY SYSTEMS.

    CAUTION

    DO NOT USE THE VEHICLE TO THE COMPLETE EXHAUSTION OF THE FUEL;INTHE EVENT THAT THIS SHOULD OCCUR, DO NOT ATTEMPT TO STARTTHEENGINE. TURN THE KEY SWITCH TO OFF AND TOP-UP THE TANK AS SOONASPOSSIBLE. FAILURE TO FOLLOW THESE GUIDELINES COULD DAMAGETHE FUELPUMP AND/OR THE CATALYTIC CONVERTER.

    WARNING

    IT IS HIGHLY INADVISABLE TO REFUEL USING METHODS OTHER THANNOR-MAL FUEL PUMPS. IF PETROL IS NOT COMPLETELY CLEAN, IT CANDAMAGETHE FUEL SUPPLY SYSTEM FILTERS.

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    2 Use

  • CAUTION

    USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFEOFTHE ENGINE.

    CharacteristicFuel tank (reserve)

    ~ 12 l (~2 l)

    02_03

    Tyre pressure (02_03)

    Check the tyre pressure and wear periodically (roughly every 500km). Tyres featurewear indicators; replace tyres as soon as theseindicators become visible on the tyretread. Also check that thetyres do not show signs of splitting at the side or irregulartreadwear; if this occurs, go to an authorised workshop or at least to aworkshopequipped to perform the replacement.

    CAUTION

    TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-RECTTYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-INGDANGEROUS.

    TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITSSETFORTH BY LAW.

    TYRESFront tyre Tubeless 120/70-12" 51S or 51P

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  • Rear tyre Tubeless 140/70 - 14" 68S or 68Preinf

    TYRE INFLATION PRESSUREFront tyre pressure (withpassenger)

    1.6 bar (1.8 bar)

    Rear tyre pressure (withpassenger)

    2.4 bar (2.6 bar)

    02_04

    02_05

    Shock absorbers adjustment (02_04, 02_05)

    The preloading of the springs can be adjusted to 4 positionsusing the ring nut locatedin the lower part of the shock absorbersand the specific spanner supplied.

    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, andluggage.

    In order to carry out this operation you will need to use thespecific spanner in the kit.Spring preloading increases by turningthe ring nut towards A, but decreases if thering nut is turnedtowards B.

    CAUTION

    RIDING THE VEHICLE WITH THE SPRING PRELOADING NOT CORRECTLYSETFOR THE RIDER AND POSSIBLE PASSENGER, COULD REDUCE THE COM-FORTOF THE RIDE AND THE PRECISION OF THE STEERING.

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    2 Use

  • WARNING

    WE RECOMMEND WEARING GLOVES WHILE CARRYING OUT THIS OPERA-TIONIN ORDER TO AVOID INJURIES.

    WARNING

    WE STRONGLY RECOMMEND NOT TO ADJUST BOTH SHOCK ABSORBERSWITHDIFFERENT PRELOADING

    Running in

    DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OFITSMAX. SPEED. AVOID OPENING THE THROTTLE GRIP COMPLETELY ORKEEP-ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD. AFTERTHEFIRST 1000 KM INCREASE SPEED PROGRESSIVELY, IF POSSIBLE, UNTILTHEMAXIMUM PERFORMANCE IS OBTAINED.

    CAUTION

    IN ORDER TO AVOID DAMAGING THE VEHICLE, PLEASE COMPLY WITHTHERULES LISTED ABOVE.

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  • 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 emergencycut-off switch. The engine cannot bestarted if the ignition cut-off switch is in the OFFposition

    A running engine automatically switches off when the ignitioncut-off switch is set toOFF.

    The vehicle is equipped with automatic transmission with directdrive, so that startingis effected by turning the throttle grip toidle speed; to start-off from stationary position,progressivelytwist the throttle grip. The vehicle is equipped with an electricalfuelpump that switches on automatically as soon as the engine isstarted. The vehicle hasa front suspension locking system; a sensorplaced under the saddle will prevent thevehicle riding, but not itsstarting-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 wheelis not touching theground.

    2. Maintain the throttle grip "P" completely untwisted.

    3. Insert the key into the ignition switch A and turn it ontothe ON position.

    4. Make sure that the N switch is set to the RUN position.

    5. Pull either the front O or rear G brake lever, while pressingthe starter buttonR.

    WARNING

    THE AUTOMATIC TRANSMISSION MAKES THE REAR WHEEL TURN EVENWHENTHE THROTTLE IS SLIGHTLY TWISTED. RELEASE THE BRAKE CARE-FULLYAFTER STARTING, AND THEN ACCELERATE GRADUALLY.

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  • CAUTION

    DO NOT START-UP THE ENGINE IN CLOSED AREAS BECAUSE EXHAUSTGASESARE TOXIC.

    CAUTION

    DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CANREACH,ALWAYS TAKE CARE, WHEN PARKING THE SCOOTER, THAT THEEXHAUST DOESNOT COME INTO CONTACT WITH FLAMMABLE MATERIALS,TO AVOID SERIOUSBURNS.

    CAUTION

    DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING.UN-BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN,CAUSINGIT TO OVERHEAT AND POSSIBLY DESTROYING IT.

    CAUTION

    NEITHER PUSH THE STARTER BUTTON NOR TURN THE KEY SWITCH TOONWHEN THE TANK IS EMPTY SINCE THE START-UP SYSTEM MAY GETDAM-AGED.

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  • WARNING

    NEVER TRY TO START-UP THE ENGINE WITH THE THROTTLE GRIPTWISTED.THIS MAY LEAD TO LOSING CONTROL OF THE VEHICLE AND TOROLLOVER,WITH CONSEQUENT SERIOUS OR, IN SOME CASES, LETHALINJURIES.

    Precautions

    CAUTION

    NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TOAVOIDPOSSIBLE DAMAGE. BE CAREFUL NEVER TO EXCEED THE MAXIMUMSPEEDWHILE RUNNING DOWNHILL, IN ORDER TO AVOID DAMAGING THEENGINE.IN ANY CASE, IN ORDER TO PRESERVE THE ENGINE FROM PROLONGEDEX-CESSIVE REVOLUTIONS, THE REVOLUTION LIMITER WILL BE ACTIVATEDIFTHE ENGINE SPEED EXCEEDS THE ESTABLISHED THRESHOLD.

    WARNING

    AFTER A LONG DISTANCE COVERED AT THE MAXIMUM SPEED, DO NOTSTOPTHE ENGINE IMMEDIATELY, BUT LET IT RUN AT IDLE FOR A FEWSECONDS.

    Difficult start up

    In the rare case of flooding the engine, to facilitate start-up,it is possible to try to putthe vehicle into action with the gashand grip partially or completely open. It is howevernecessary,once the engine is started, to take your vehicle to an AuthorisedServiceCentre to determine the cause of this problem and tore-establish the vehicle properfunctioning.

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  • 02_09

    Stopping the engine (02_09)

    Fully untwist the throttle grip, then rotate the key in theswitch A to KEYOFF (extractable key).

    CAUTION

    DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CANREACH,ALWAYS TAKE CARE, WHEN PARKING THE SCOOTER, THAT THEEXHAUST DOESNOT COME INTO CONTACT WITH FLAMMABLE MATERIALS,TO AVOID SERIOUSBURNS.

    CAUTION

    DO NOT SWITCH OFF THE ENGINE WHILE THE VEHICLE IS MOVING.UN-BURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN,CAUSINGIT 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 fastenthe vehicle to an objectusing a scooter chain. Do not use the ringfor other purposes.

    WARNING

    THIS ACCESSORY IS NOT A THEFT PREVENTION GUARANTEE, IT IS ONLYADETERRENT.

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  • 02_11

    Stand (02_11)

    Push with your foot on the centre stand's fork "F" while liftingthe vehicle backward,holding onto the handlebar.

    Automatic transmission

    To ensure simple, pleasurable riding, the vehicle is equippedwith automatic trans-mission with regulator and centrifugal clutch.The system is designed to provide thebest performance (accelerationand consumption) while riding on both flat roads anduphill.

    If you have to stop on an uphill slope (traffic lights, trafficjam, etc.) use only the braketo keep the vehicle still, leaving theengine running at idle speed. Using theengine to keep the vehiclestill can cause the clutch to overheat, due to thefriction of theclutch masses against the capstan. Besides, avoid acceleratingwiththe hand brake engaged. It is therefore recommended to avoidconditions ofprolonged clutch slippage (besides those previouslyindicated) like driving uphill fullyladen on steep slopes orstarting off with driver and passenger at slopes greaterthan25%.

    Observe the following precautions if the clutch overheats:

    1. Do not continue riding in such conditions.

    2. Let the clutch cool down with the engine at idle speed for afew minutes.

    Safe driving

    Some simple tips are provided below that will enable you to useyour vehicle on a dailybasis, confidently and safely. Your skilland your mechanical knowledge are the basis

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  • of safe riding. We recommend practising riding in traffic-freezones, in order to acquirea good knowledge of your vehicle.

    1. Before riding off, remember to put on your helmet and fastenit correctly.

    2.Reduce speed on rough roads and drive with care.

    3. After riding on a long stretch of wet road without using thebrakes, braking can bepoor at the beginning. Given theseconditions, it is a good idea to operate the brakesfrom time totime.

    4. Avoid setting off by mounting the vehicle while it is restingon the support. In anycase, the rear wheel should not be turningwhen in comes into contact with the ground,in order to avoid abruptdepartures.

    5. If driving over roads affected by sand, mud, snow mixed withsalt, etc., we recom-mend cleaning the brake disc with anon-corrosive detergent frequently in order toprevent corrosiveparticles from building up in the holes, which may cause earlybreakpad wear.

    CAUTION

    ALWAYS RIDE WITHIN YOUR LIMITS RIDING UNDER THE INFLUENCE OFAL-COHOL OR OTHER DRUGS AND CERTAIN MEDICATIONS IS EXTREMELYDAN-GEROUS.

    CAUTION

    IN ORDER TO PREVENT ANY ACCIDENTS RIDE VERY CAREFULLYAFTERADDING ACCESSORIES AND WHILE CARRYING LUGGAGE. ADDINGACCES-SORIES AND LUGGAGE CAN REDUCE THE VEHICLE'S STABILITY,PERFORM-ANCE AND SAFETY DURING USE.

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  • WARNING

    NEVER RIDE THE VEHICLE WITH ADDED ACCESSORIES (CASEAND/ORWINDSHIELD) FASTER THAN 120 KM/H. WITHOUT THESE ACCESSORIESTHEVEHICLE MAY BE DRIVEN AT A HIGHER SPEED WITHIN THE LEGAL LIMITS.IFTHERE ARE NOT-PIAGGO ACCESSORIES FITTED, OR AN ABNORMAL LOAD,ORIF THE VEHICLE IS NOT IN A GENERALLY GOOD CONDITION, OR WHEN-EVERWEATHER CONDITIONS DEMAND IT, SPEED SHOULD BE FURTHERREDUCED.

    CAUTION

    DO NOT ADJUST THE MIRRORS WHILE RIDING. THIS COULD CAUSE YOUTOLOOSE CONTROL OF THE VEHICLE.

    CAUTION

    ANY CHANGES TO THE VEHICLE PERFORMANCE AS WELL AS ALTERATIONSTOORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW, ANDRENDERSTHE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPEAND DANGEROUSFOR RIDING.

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  • 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 vehicletilting when the Qswitch is pressed.

    The warning light E starts flashing when the key switch is setto ON. This meansthat the system is enabled for lockingactivation.

    When the Q switch is turned to 1, a continuous sound alarmsignals that thelocking system is engaged and, at the same time,the warning light E turns onsteadily.

    When the Q switch is turned to 2 , an intermittent sound alarmsignals that thelocking system is disengaged and, at the same time,the warning light E startsflashing again. Warning light E turns offwhen riding starts. This means that thesystem allows for vehicletilting.

    Engaging tilt locking is possible only if the followingconditions occur at the same time:

    Throttle completely untwisted Engine rpm below 2500 rpm Vehiclespeed below 10 km/h Locking system WARNING light C off (the systemhas not detected fail-

    ures)If one of these conditions is not checked, the warninglight E remains off and lockingcannot be engaged (in normal ridingconditions, the warning light E is off).

    With engine on, system locked and warning light E on, thesuspension locking sys-tem is disengaged automatically and thewarning light E turns off when the throttleis twisted to start theride.

    (Video) How to Clean Up Text Pasted into MS WORD

    For riders' safety, the vehicle has a rider detection sensor inthe saddle which ena-bles the system to prevent vehicle motion andsuspension unlocking (in case of lockedsuspension) when the rideris not properly seated in riding position: in such case, theWARNINGlight C turns on steadily

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  • 02_15

    02_16

    02_17

    CAUTION

    THE RIDER DETECTION SENSOR IS LOCATED IN THE FRONT PART OFTHESADDLE. AVOID PLACING BAGS OR HEAVY OBJECTS ACCIDENTALLY ONTHESADDLE.

    NOT OBSERVING THIS RULE MAY MOVE THE VEHICLE FORWARD ANDRE-LEASE THE SUSPENSION LOCKING SYSTEM EVEN IF THE RIDER ISNOTSEATED, BY SIMPLY TWISTING THE THROTTLE. THE VEHICLE COULDFALLACCIDENTALLY AS A CONSEQUENCE.

    WARNING

    EVERY TIME THE VEHICLE IS STOPPED, MAKE SURE THE FRONTSUSPEN-SION LOCKING SYSTEM IS ENGAGED. OTHERWISE, PLACE YOUR FEETONTHE GROUND TO KEEP THE VEHICLE UPRIGHT.

    WARNING

    AVOID USING THE LOCKING SYSTEM WHEN RIDING THE VEHICLE ALONGIR-REGULAR ROADS OR ROADS WITH OBSTACLES(E.G. ROAD HUMPS,SIDE-WALK, ETC.).

    IN CASE OF ENGINE FAILURE (DISCHARGED BATTERY) AVOID PULLINGTHEVEHICLE WITH THE LOCKING SYSTEM ENGAGED.

    WITH THE LOCKING SYSTEM ENGAGED AND THE ENGINE OFF, AVOIDMOV-ING THE VEHICLE AT SPEEDS ABOVE 5 Km/h.

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  • WARNING

    IF THE RIDER IS NOT SEATED ON THE SADDLE WHILE THE VEHICLE ISINMOTION AND THE LOCKING SYSTEM IS ENGAGED, AVOID OPERATINGTHETHROTTLE CONTROL PURPOSELESSLY AS THIS MAY DAMAGE THE CATA-LYTICCONVERTER.

    CAUTION

    DO NOT RIDE DOWNHILL WITH THE SUSPENSION LOCKING SYSTEM ENGAG-EDAND THE KEY SWITCH SET TO OFF.

    With the vehicle off and the suspension locking system engaged,it is possible to getoff the vehicle without using the stand. Forsafety reasons, it is recommended to pressthe hand brake levershown in the figure, moving it form position A to positionB.

    When the hand brake B is engaged, warning light R on theinstrument panel turnson.

    When the hand brake is set to B and the key switch is turned toposition 1, thesafety system that prevents the hand brake fromgetting released is activated. Torelease the hand brake, turn thekey switch to 2 or 3. If the switch is set to 1 ,the hand brake canalso be engaged.

    WARNING

    IT IS PREFERABLE TO USE THE STAND IF THE VEHICLE STOPS ON ASTEEPSLOPE.

    ALWAYS OBSERVE THE CUSTOMARY SAFETY PRECAUTIONS FOR CASESWHENTHE VEHICLE STOPS ON A STEEP SLOPE. TURN THE WHEELS SO

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  • THAT THE POTENTIAL MOVEMENT CAUSED BY THE SLOPE TAKES THATWHEELAGAINST THE SIDEWALK. WITH THE STEERING LOCK ENGAGED,MANOEUVRE SOTHAT THE SIDEWALK IS TO THE RIGHT WHEN YOUR VEHI-CLE IS PARKEDUPHILL AND TO THE LEFT WHEN PARKED DOWNHILL.

    If the WARNING light C turns on (flashes), it means that thereis a failure in the frontsuspension locking system. Therefore, itis necessary to contact an Authorised Serv-ice Centre. If the frontsuspension is locked , it can be unlocked by operating theQ switchtwice quickly on the unlocking position 2. Once the suspension isun-locked, the vehicle can be normally used, except for the lockingsystem which will bedisengaged.

    For some cases of failure, the vehicle speed is auto-limited to30 Km/h. This automaticprocedure is activated to enhance safetyuntil the failure is eliminated.

    Always contact an Authorised Service Centre.

    If the continuous sound alarm is activated when the WARNINGlight C turns on(steadily), try to unlock the system by operatingthe Q switch twice quickly to theunlocking position 2. If it cannotbe unlocked, contact an Authorised Service Cen-tre.

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  • Fuoco 500ie

    Chap. 03Maintenance

    45

  • 03_01

    03_02

    03_03

    Engine oil level

    In 4T engines, engine oil is used to lubricate the distributionelements, main bearingsand thermal group. An insufficient quantityof oil can cause serious damage tothe engine itself. In allfour-stroke engines, a loss of efficiency in oil performanceandconsumption should be considered normal. Consumption canparticularly reflect theconditions of use (i.e. when driving at"full acceleration" all the time, oil consumptionincreases). Thereplacement frequencies provided for by the maintenanceprogrammeare defined, depending on the total contents of oil in theengine and average con-sumption measured following standardisedmethods. In order to prevent any prob-lems, we recommend checkingoil level more frequently than indicated in theScheduledMaintenance table or before setting off on long journeys. Thevehicleis, however, equipped with an oil pressure warning light onthe instrument pan-el.

    Engine oil level check (03_01, 03_02)

    Every time the vehicle is used, visually inspect the level ofthe engine oil when theengine is cold (after completely unscrewingthe oil cap/dipstick). The oil level shouldbe somewhere between theMAX and MIN reference marks on the dipstick A; duringthe oil check,the vehicle must be resting on its centre stand on an even,horizontalsurface.

    If the check is carried out after the vehicle has been used, andtherefore with a hotengine, the level line will be lower; in orderto carry out a correct check, wait at least10 minutes after theengine has been stopped so as to get the correct level.

    Engine oil top-up

    Always check the oil level before carrying out top ups and addoil without exceedingthe MAX level. Getting an oil level betweenthe MIN and MAX levels requires ~ 400cm of oil. An oil check-up andtop-up should be carried out at any Authorised ServiceCentre, asindicated in the scheduled maintenance table.

    Warning light (insufficient oil pressure)

    The vehicle is equipped with a warning light that lights up whenthe key is turned tothe ON. However, this light should switch offonce the engine has been started. Ifthe light comes on whilebraking, at idle speed or while turning a corner, it is

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  • 03_04

    necessary to check the oil level and top it up if required. Ifafter having topped-up the oil, the warning light still comes onwhile braking, at idle speed or whileturning a corner, it will benecessary to take your vehicle to an Authorised Serv-iceCentre.

    Engine oil change (03_03, 03_04)

    The oil and the filter must be changed as indicated in thescheduled maintenance tableat an Authorised Service Centre. Theengine should be emptied by draining the oilvia the drainage tap Bof the mesh filter on the transmission side. In order tofacilitateoil drainage, loosen the cap/dipstick A. Unscrew andremove the oil cartridge filterC. Install a new oil filter takingcare to lubricate the sealing O-rings with engine oil.Since acertain quantity of oil still remains in the circuit, addapproximately 1500 cmof oil through cap A. Then start up thescooter, leave it running for a few minutesand switch it off: afterfive minutes, check the level and if necessary, top-upwithoutexceeding the MAX. level. The cartridge filter must bereplaced at every oil change.For top-ups and oil changes, use newoil of the recommended type.

    CAUTION

    RUNNING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITHINADE-QUATE LUBRICANTS ACCELERATES THE WEAR AND TEAR OF THEMOVINGPARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE.

    TOPPING UP THE ENGINE WITH AN EXCESSIVE AMOUNT OF OIL MAYCAUSEMALFUNCTION AND/OR A DROP IN PERFORMANCE OF THE VEHICLE.

    USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFEOFTHE ENGINE.

    CAUTION

    USED OILS CONTAIN SUBSTANCES HARMFUL TO THE ENVIRONMENT. FOROILREPLACEMENT, CONTACT AN AUTHORISED SERVICE CENTRE, WHICHIS EQUIPPEDTO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY FRIEND-LY AND LEGALWAY.

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  • Recommended productsAGIP CITY HI TEC 4T

    Engine oilSAE 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 checkthe rear hub oil level,proceed as follows:

    1) Rest the vehicle onto its centre stand, on level ground.

    2) Unscrew the dipstick A, dry it with a clean cloth and thenreinsert it screwing itfully into place.

    3) Pull out the dipstick to control that the oil level reachesthe second notch from thebottom, as indicated by the arrow infigure, this is the correct level and must remainconstant at alltimes.

    4) Screw the dipstick back in, checking that it is correctlylocked in place.

    CAUTION

    RIDING THE VEHICLE WITH INSUFFICIENT HUB LUBRICATION OR WITHCON-TAMINATED OR IMPROPER LUBRICANTS ACCELERATES THE WEAR ANDTEAROF THE MOVING PARTS AND CAN CAUSE SERIOUS DAMAGE.

    CAUTION

    USED OIL CAN HARM THE ENVIRONMENT. COLLECTION AND DISPOSALSHOULDBE CARRIED OUT IN COMPLIANCE WITH CURRENT REGULATIONS.

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  • CAUTION

    AN EXCESSIVE QUANTITY OF OIL CAN LEAD TO LEAKAGE, WHICH MAYCAUSETHE ENGINE AND THE WHEEL TO GET DIRTY.

    CAUTION

    WHEN REPLACING THE HUB OIL DO NOT LET THE OIL COME INTOCONTACTWITH THE REAR BRAKE DISC.

    CAUTION

    FOR OIL REPLACEMENT, CONTACT ANY AUTHORISED SERVICE CENTREASTHEY ARE EQUIPPED TO DISPOSE OF USED OILS IN ANENVIRONMENTALLYFRIENDLY AND LEGAL WAY.

    Recommended productsAGIP ROTRA 80W-90

    Rear hub oilSAE 80W/90 Oil that exceeds the requirements of APIGL3 specifications

    CharacteristicTransmission oil

    250 cm

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    3 Maintenance

  • 03_07

    Tyres (03_07)

    Check the tyre pressure and wear periodically (roughly every 500km). Tyres featurewear indicators; replace tyres as soon as theseindicators become visible on the tyretread. Also check that thetyres do not show signs of splitting at the side or irregulartreadwear; if this occurs, go to an authorised workshop or at least to aworkshopequipped to perform the replacement.

    CAUTION

    TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCOR-RECTTYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RID-INGDANGEROUS.

    TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITSSETFORTH BY LAW.

    WARNING

    THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED.RIDINGTHE VEHICLE WITH VERY LOW TYRE PRESSURE OR WITHINCORRECTLYBALANCED TYRES CAN LEAD TO DANGEROUS STEERINGVIBRATIONS.

    TYRESFront tyre Tubeless 120/70-12" 51S or 51P

    Rear tyre Tubeless 140/70 - 14" 68S or 68Preinf

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  • TYRE INFLATION PRESSUREFront tyre pressure (withpassenger)

    1.6 bar (1.8 bar)

    Rear tyre pressure (withpassenger)

    2.4 bar (2.6 bar)

    03_08

    03_09

    Spark plug dismantlement (03_08, 03_09)

    This engine has two spark plugs.

    Remove the port on the left-hand side panel of the vehicle byundoing the fixing screwA and using a small screwdriver in the rearnotch shown in the figure, then proceedas follows:

    1. Disconnect the spark plug HV wire caps B.

    2. Unscrew the spark plugs using the supplied spark plugwrench.

    3. When refitting, place the spark plugs into the hole at thedue inclination and tightenit 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. SPARKPLUGSMAINTENANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULEDMAINTENANCETABLE. USING NON-CONFORMING ELECTRONIC CENTRALUNITS AND ELECTRONICIGNITIONS OR SPARK PLUGS OTHER THAN THOSEPRESCRIBED MAY SERIOUSLYDAMAGE THE ENGINE.

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  • N.B.

    THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OROFSHIELDLESS SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEMFAIL-URES.

    CharacteristicSpark 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 coverB.

    Air filter cleaning

    1. Wash the sponge with water and neutral soap.

    2. Dry it with a clean cloth and small blasts of compressedair.

    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 refitit.

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  • CAUTION

    IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRYOUTMAINTENANCE CONTROLS OF THE AIR FILTER TO AVOID DAMAGINGTHEENGINE.

    Recommended productsAGIP FILTER OIL

    Oil for air filter spongeMineral oil with specific additives forincreased adhesiveness

    03_11

    03_12

    Cooling fluid level (03_11, 03_12, 03_13, 03_14)

    The engine cooling system operates by forcing circulation offluid. The cooling circuitcontains about 2 litres of coolantconsisting of a mixture of 50% de-ionised water andglycolethylene-based antifreeze solution with corrosion inhibitors.Recommendedcoolant: supplied with the vehicle, already mixed andready for use. For proper func-tioning of the engine, the coolanttemperature must be between the 4th and 7th litsegment, asindicated by the instrument D on the digital instrument panel.Whenthe 9th segment lights up, the icon and all the segments startflashing; stop the engine,let it cool down and check the fluidlevel; if the level is OK, contact an AuthorisedService Centre.

    Check coolant when the engine is cold as indicated in thescheduled maintenancetable.

    a) Rest the vehicle in vertical position on the stand and removethe screw of the ex-pansion tank cap shown in the photo

    b) Remove the expansion tank cover "A", turning in anticlockwisedirection.

    c) Look inside the expansion tank; the fluid level must alwaysbe between the min andthe max level

    d) If the coolant level is near the minimum mark, top up whenthe engine is cold.

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  • 03_13

    03_14

    If it is necessary to top up the coolant frequently, or if theexpansion tank is completelydry, you should look for the cause inthe cooling system. It is therefore essential tohave the coolingsystem checked at an Authorised Service Centre. Replace coolantasindicated in the scheduled maintenance table. Take your vehicle toan AuthorisedService Centre for this operation.

    CAUTION

    THE RECOMMENDED COOLANT MUST BE USED FOR TOP-UPS TOAVOIDDAMAGING THE ENGINE.

    N.B.

    SHOULD THE 9th SEGMENT OF THE COOLANT TEMPERATURE INDICATORCOMEON DURING A NON-DEMANDING RIDE, SHUT OFF THE ENGINE AND LETIT COOLDOWN. THEN CHECK THE COOLANT LEVEL; IF THE LEVEL IS OK,CONTACT ANAUTHORISED SERVICE CENTRE.

    WARNING

    IN ORDER TO AVOID BURNS, DO NOT UNSCREW THE EXPANSION TANKCAPWHILE THE ENGINE IS STILL HOT.

    WARNING

    IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RIDING, IT ISIMPORTANTTO MAKE SURE THAT THE LEVEL NEVER EXCEEDS THE MAXIMUMVALUE.

    IN ORDER TO GUARANTEE THE PROPER FUNCTION OF THE ENGINE, ITISNECESSARY TO KEEP THE RADIATOR GRILLE CLEAN.

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  • Recommended productsSPECIAL AGIP PERMANENT fluid

    coolantMonoethylene glycol-based antifreeze fluid, CUNA NC956-16

    03_15

    03_16

    Checking the brake oil level (03_15)

    The front and rear brake fluid reservoirs are both positioned onthe handlebars. Pro-ceed as follows:

    1. Place the scooter on its centre stand and make sure thehandlebar is centred;

    2. Check the fluid through the specific sight glass C.

    A certain lowering of the level is caused by wear on the pads.Should the level appearto be below the minimum mark, please contactan Authorised Service Centre orDealer in order to have brakingsystem thoroughly checked.

    Braking system fluid top up (03_16)

    Proceed as follows:Undo the screws B and remove the fuel tankcap A. Top-up using only the fluidspecified, without exceeding themaximum level.

    This procedure applies to the rear brake pump top-up operation;follow the same pro-cedure for the front brake pump.

    Under standard climatic conditions, replace fluid as indicatedin the scheduled main-tenance table.

    This operation must be carried out by trained personnel; takeyour vehicle to an au-thorised Service centre or Dealer.

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  • WARNING

    ONLY USE DOT 4 CLASS BRAKE FLUIDS. COOLING SYSTEM FLUIDSAREHIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT COME INTOCONTACTWITH THE PAINTWORK.

    CAUTION

    AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING.INCASE OF CONTACT, RINSE WITH WATER. THE BRAKING CIRCUIT FLUIDISHYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THESURROUNDINGAIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS ACERTAIN VALUE,IT WILL LEAD TO INEFFICIENT BRAKING. NEVER USEBRAKING FLUID KEPTIN CONTAINERS THAT HAVE ALREADY BEEN OPENED, ORPARTIALLY USED.

    Recommended productsAGIP BRAKE 4

    Brake fluidFMVSS DOT 4 Synthetic fluid

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  • 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 describedprocedure;

    3. Remove the two fasteners "A" and the cover "B".

    WARNING

    IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM, NEVERDISCON-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 DAMAGETOTHE ELECTRICAL SYSTEM.

    WARNING

    SPENT BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTIONANDDISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITHCURRENTREGULATIONS.

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  • Long periods of inactivity

    If the vehicle has not been used for long periods, it isnecessary to periodically re-charge the battery, bearing in mindthat the battery tends to go completely flat withinaround threemonths. The battery must be recharged with a current load equal to1/10of the battery rated capacity (~ 1A ), for a period not longerthan 8 hours. For thisoperation contact an Authorised ServiceCentre. When refitting a removed battery,make sure that allterminals 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 fuseboxes to protect the dif-ferent installation circuits. One of themis inside the battery compartment A and theother is at the internalside of the right footrest B.To have access, loosen the screwC andremove the plastic cover. The chart shows the position andcharacteristicsof the fuses in the vehicle.

    CAUTION

    BEFORE REPLACING THE BLOWN FUSE, FIND AND SOLVE THE FAILURETHATCAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANYOTHERMATERIAL (E.G., A PIECE OF ELECTRIC WIRE).

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  • 03_21

    03_22

    03_23

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    3 Maintenance

  • FUSE TABLEFuse No. 1 Capacity: 7.5 A

    Protected circuits:Injection ECUbattery power

    Fuse No. 2 Capacity: 15 A

    Protected circuits:Battery-powered injection loads,electricalfan

    Fuse No. 3 Capacity: 15 A

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    Protected circuits:Battery-powered saddle openingswitch,glove-box lighting, light switch, turnindicator switch,antitheftinstallation, 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

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  • Protected circuits:Battery-powered instrument panel

    Fuse No. 8 Capacity: 10A

    Protected circuits:Live stop,start-up and start-upenablingswitch and start-up circuit.

    Fuse No. 9 Capacity: 7.5 A

    Protected circuits:live passingand horn

    Fuse No. 10 Capacity: 7.5A

    Protected circuits:Live injectionECU, immobilizer aerial,electricfan remote control, injection loadsremote control

    Fuse No. 11 Capacity: 7.5A

    Protected circuits:Live ECUparking lever, antitheftinstallation,instrument panel, headlight remotecontrol, horn

    Fuse No. 12 Capacity: 7.5A

    Protected circuits:Live turnindicator control, saddleopeningswitch, tail lights, panel lighting

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    3 Maintenance

  • LIGHT BULBS TABLELow-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 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

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  • 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 Type: ALL GLASS

    Power: 12V - 2W

    Quantity: 4

    03_24

    Front light group (03_24, 03_25, 03_26, 03_27, 03_28, 03_29)

    To access the tail light bulb:

    - Insert a screwdriver in the notch on the side (see picture) ofthe Gilera emblem andremove it.

    - Undo the screw A and the four screws B.

    - Push the two indicated tongues to unlock the tail lights andremove the rubber bulbholder

    To replace it, slide off the bulb from the bulb holder andinsert a new bulb.

    To access the high-beam light bulbs and the low-beam lightbulbs:

    - Actuating on the inside of the front wheel housing, hold thehigh-beam light bulbholder C or the low-beam bulb holder D and thenturn it anticlockwise.

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  • 03_25

    03_26

    03_27

    To replace it, disconnect the connector and insert a newbulb

    WARNING

    HIGH AND LOW BEAM LIGHT ARE OF THE HALOGEN TYPE: DO NOTTOUCHWITH YOUR FINGERS TO AVOID DAMAGING THEIR FUNCTION.

    Headlight adjustment (03_30, 03_31, 03_32, 03_33, 03_34)

    Proceed as follows:

    - Position the unloaded vehicle, in running order and with thetyres inflated to theprescribed pressure, onto a flat surface 10 maway from a half-lit white screen; makesure the vehicle axis isperpendicular to the screen.

    - Remove the headlight assembly central cover.

    - Turn on the headlight and check that the borderline of theprojected light beam shouldbe lower than 9/10 of the distance fromthe ground to the centre of the vehicle's head-light, and higherthan 7/10.

    - Otherwise, adjust the headlight.

    N.B.

    THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDSRE-GARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TOTHESTATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THEve-hicle IS USED.

    To access the headlight adjusting screws:

    - Unscrew the four screws A (two on each side) and remove thefront cowl.

    - Unscrew the five screws B and remove the side cover.

    Each bulb has two light beam adjusting screws, one forhorizontal adjustment Cand one for the vertical adjustment D.Adjust each headlamp at a time. In order to

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  • 03_28

    03_29

    03_30

    do that, remove the connector from the other bulbs so that youcan adjust one head-lamp at a time.

    N.B.

    THE HEADLAMPS CAN ONLY BE LIT WHEN THE ENGINE IS ON. ADJUSTTHELIGHT BEAM IN A WELL VENTILATED PLACE.

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    3 Maintenance

  • 03_31

    03_32

    03_33

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  • 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.

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    3 Maintenance

  • 03_36

    03_37

    Rear optical unit (03_36, 03_37)

    To access the rear light unit bulbs, undo the screw A and removethe glass B.Now tighten the screw A in its seat.

    To replace the stop light bulb C, hold it and turn itanticlockwise.

    To replace the rear tail light bulb D, hold it and pull itoutwards.

    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.

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  • 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 inthe lateral notch todetach the snap-on glass "D", then replace thebulb.

    03_41

    Rear-view mirrors (03_41)

    The mirrors can be set to the desired position by adjusting themirror frame.

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    3 Maintenance

  • Front and rear disc brake

    The brake disc and pad wear is automatically compensated,therefore it has no effecton the functioning of the front and rearbrakes. For this reason it is not necessary toadjust the brakes. Anexcessively elastic brake lever stroke may indicate the presenceofair in the braking circuit or a failure in the braking system. Inthis case, mainly dueto the importance of brakes to guarantee saferiding conditions, the vehicle should betaken to an AuthorisedService Centre or Dealer.

    CAUTION

    THE BRAKING ACTION SHOULD BEGIN AFTER ABOUT 1/3 OF THEBRAKELEVER STROKE.

    CAUTION

    HAVE THE BRAKE PADS CHECKED BY THE DEALER ACCORDING TO THECHECKSSPECIFIED IN THE SCHEDULED MAINTENANCE TABLE. HOWEVER,IN THE EVENTOF NOISES COMING FROM THE FRONT AND/OR REAR BRAKESYSTEM DURINGOPERATION, IT IS ADVISABLE TO HAVE THE BRAKE SYS-TEM CHECKED BY APIAGGIO DEALER OR AUTHORISED SERVICE CENTRE.AFTER REPLACING THEBRAKE PADS, DO NOT USE THE SCOOTER UNTILYOU HAVE OPERATED THE BRAKELEVER SEVERAL TIMES IN ORDER TOALLOW THE PLUNGERS TO SETTLE AND THELEVER STROKE TO BE SET TOTHE CORRECT POSITION.

    CAUTION

    THE PRESENCE OF SAND, MUD, SNOW MIXED WITH SALT, ETC. ONTHEROAD, CAN DRASTICALLY REDUCE THE DURATION OF THE BRAKE PADS.IN

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  • ORDER TO AVOID THIS, WE RECOMMEND WASHING THE VEHICLEFRE-QUENTLY WHEN RIDING IN THESE ROAD CONDITIONS.

    Puncture

    The vehicle is equipped with tubeless tyres (without innertube). In the event of apuncture, contrary to the situation with atyre with inner tube, the tyre deflates moreslowly, resulting in agreater steering safety. In the event of a puncture, it isadmissibleto make an emergency repair using an "inflate and repair"spray can. For a final repair,take your vehicle to an AuthorisedService Centre or Dealer. The replacement of atyre involvesremoving the wheel in question. Take your vehicle to anAuthorisedService Centre or Dealer for these operations.

    CAUTION

    TO USE THE "INFLATE AND REPAIR" SPRAY PROPERLY FOLLOW THEIN-STRUCTIONS ON THE PACKAGING.

    WARNING

    THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED.RIDINGTHE VEHICLE WITH VERY LOW TYRE PRESSURE OR WITHINCORRECTLYBALANCED TYRES CAN LEAD TO DANGEROUS STEERINGVIBRATIONS.

    Periods of inactivity

    We recommend carrying out the following operations:

    1. Clean the scooter thoroughly and then cover it with acanvas;

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    3 Maintenance

  • 2. Be careful to rest the vehicle on its centre stand disablingthe front suspensionlocking system;

    3. With engine off and piston at the bottom dead centre, removethe spark plug, add12 cc of oil through the opening (adding moreoil may damage the engine). Operatethe starter button 1-2 times forroughly 1 second to turn the engine over slowly, theninsert thespark plug again;

    4. Empty all fuel; spread antirust grease on the unpainted metalparts; keep the wheelslifted above the ground by resting thechassis on two wooden wedges;

    5. For the battery, follow the procedures described in theBattery section.

    Recommended productsAGIP CITY HI TEC 4T

    Engine oilSAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

    Cleaning the vehicle

    In order to soften the dirt and mud deposited on the paintedsurfaces, use a low pres-sure jet of water. Once softened, mud anddirt must be removed with a soft spongefor bodywork soaked in lotsof water and "shampoo" (2-4% of car shampoo in water).Then rinseabundantly with water, and dry with a shammy cloth. For the outsideof theengine, use petroleum, a brush and clean cloths. Petroleumcan damage paintwork.Remember that any polishing with silicone waxmust always be preceded by washing

    CAUTION

    DETERGENTS CAN POLLUTE WATER. THE VEHICLE MUST BE WASHED ATAWASH STATION EQUIPPED WITH A SPECIAL WATER PURIFICATIONSYSTEM.

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  • CAUTION

    PER IL LAVAGGIO DEL MOTORE E DEL VEICOLO SCONSIGLIATOL'UTILIZ-ZO DELL'IDROPULITRICE; NEL CASO CHE NON SIA POSSIBILEEFFETTUARETALE OPERAZIONE IN UN ALTRO MODO, NECESSARIO: USARESOLAMENTE IL GETTO A VENTAGLIO.

    NON AVVICINARE LA LANCIA A MENO DI 2 FT (60 CM).

    NON USARE ACQUA A TEMPERATURE SUPERIORI A 100 F (40C).

    NON UTILIZZARE IL GETTO AD ALTA PRESSIONE.

    NON UTILIZZARE IL LAVAGGIO A VAPORE.

    NON INDIRIZZARE IL GETTO DIRETTAMENTE VERSO: IL MOTORE, ICA-BLAGGI ELETTRICI, LE FERITOIE DI RAFFREDDAMENTO DELCOPERCHIOTRASMISSIONE E DEL COPERCHIO CHIOCCIOLA.

    CAUTION

    NEVER WASH THE SCOOTER IN DIRECT SUNLIGHT, ESPECIALLY INSUMMERWHEN THE BODYWORK IS STILL HOT AS THE SHAMPOO COULD DAMAGETHEPAINTWORK IF IT DRIES BEFORE BEING RINSED OFF. NEVER USECLOTHSSOAKED IN ALCOHOL, PETROL, DIESEL OIL OR KEROSENE FORCLEANING THEPAINTED OR PLASTIC SURFACES, IN ORDER NOT TO DAM-AGE THE LUSTREFINISH OR ALTER THE MECHANICAL PROPERTIES. USINGSILICONE-BASED WAXCAN DAMAGE THE PAINTED SURFACES, DEPENDINGON THE VEHICLE COLOUR(SATIN COLOURS). FOR FURTHER INFORMATIONON THIS MATTER, CONTACT ANAUTHORISED SERVICE CENTRE .

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    3 Maintenance

  • STARTING FAILUREEmergency switch in OFF Set the switch back toON

    Fuse blown Replace the blown fuse and havethe vehicle checked byanAuthorised Service Centre.

    IGNITION PROBLEMFaulty spark plug Contact an AuthorisedService

    Centre.

    Faulty ignition / injection controlunit.

    Contact an Authorised ServiceCentre.

    Faulty coil. Due to the presence ofhigh voltage, this checkshouldonly be carried out by an expert.

    Contact an Authorised ServiceCentre.

    LACK OF COMPRESSIONLoosen spark plug. Screw in the spark plugtightly

    Cylinder head loose, piston gasrings worn.

    Contact an Authorised ServiceCentre.

    Valve stuck Contact an Authorised ServiceCentre.

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  • HIGH CONSUMPTION AND LOW PERFORMANCEAir filter blocked or dirty.Clean with water and shampoo and

    impregnate with petrol and specificoil (section Removing theairfilter)

    INSUFFICIENT BRAKINGGreasy disc. Worn pads. Faultybrakingsystem. Presence of air inthe front and rear brake circuit.

    Contact an Authorised ServiceCentre.

    INEFFICIENT SUSPENSIONSShock absorber fault, oil leak, endbufferdamaged; shock absorberpreloading incorrectly set

    Contact an Authorised ServiceCentre.

    IRREGULAR AUTOMATIC TRANSMISSIONVariator rollers and/or drivingbeltdamaged

    Contact an Authorised ServiceCentre.

    STAND DOES NOT RETURN TO POSITIONPresence of dirt Clean andgrease

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  • Fuoco 500ie

    Chap. 04Technical data

    77

  • 04_01

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  • ENGINE TECHNICAL DATAType Single-cylinder, 4-stroke

    Cubic capacity 493 cm

    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 overheadcamshaft, chaindriven.

    Valve clearance Inlet: 0.15 mm

    Outlet: 0.15 mm

    MAX. power 29.5 kW at 7,250 rpm

    MAX Power for crossover version 25 kW

    MAX torque 46.5 Nm at 5.250 rpm

    Transmission Automatic expandable pulleyvariator with torqueserver, V belt,dry self-ventilating automaticcentrifugal clutch andtransmissionhousing with forced air circulation.

    Final reduction Gear reduction unit in oil bath.

    Lubrication Engine lubrication with lobe pump(inside crankcase)controlled by achain with double filter: mesh andpaper.

    Cooling Forced coolant circulation system.

    Start-up Electric

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    4 Technical data

  • Ignition Highly efficient electronic inductiveignition,integrated with theinjection system, with variableadvance, separateHV coil anddouble spark plug.

    Ignition advance Three-dimensional map managedby controlunit

    (Video) Your First Fire Emblem

    Spark plug NGK CR7EKB

    Alternative spark plug -

    Fuel supply Electronic injection with electricfuel pump.

    Fuel Unleaded petrol (95 RON)

    exhaust muffler Absorption-type exhaust mufflerwith catalyticconverter andlambda probe.

    Emission regulations EURO 3

    VEHICLE TECHNICAL DATAChassis Tubular and sheet steel

    Front suspension The tilt mechanism is composed ofan articulatedparallelogramsuspension with die-castaluminium control arms andtwoside headstocks plus shockabsorbers with hydrauliclockingsystem.

    Rear suspension Two double-acting shockabsorbers, adjustable tofourpositions at preloading.

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  • Front brake 240 mm double disk withhydraulic control activatedby thehandlebar right-hand lever.

    Rear brake disc brake, diameter 240 mm, withhydraulic servooperated from thehandlebar with the left-hand lever.

    Wheel rim type Light alloy 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 68Preinf

    Front tyre pressure (withpassenger)

    1.6 bar (1.8 bar)

    Rear tyre pressure (withpassenger)

    2.4 bar (2.6 bar)

    Kerb weight 253 5 kg

    Maximum weight allowed 445 kg

    Battery 12 V / 14 Ah, SEALED BATTERY

    CAPACITYEngine oil 1.7 l

    Transmission oil 250 cm

    Cooling system fluid ~ 2 l

    Fuel tank (reserve) ~ 12 l (~2 l)

    81

    4 Technical data

  • 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.

    The tools are stored in the helmet compartment.

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  • Fuoco 500ie

    Chap. 05Spare 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 ITISFITTED WITH ACCESSORIES OR WITH UNUSUAL LOADS.

    WARNING

    IT IS ALSO RECOMMENDED THAT "ORIGINAL PIAGGIO SPARE PARTS"BEUSED, AS THESE ARE THE ONLY ONES OFFERING YOU THE SAMEQUALITYGUARANTEE AS THOSE INITIALLY FITTED ON THE SCOOTER. THE USEOFNON-ORIGINAL SPARE PARTS RENDERS THE WARRANTY VOID.

    WARNING

    PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG-NISEDAND GUARANTEED FOR USE. IT IS THEREFORE ESSENTIAL, IN ORDERTOCHOOSE AND MOUNT THE ACCESSORIES CORRECTLY, TO CONTACT ANAUTHORISEDDEALER OR SERVICE CENTRE. THE USE OF NON-ORIGINALACCESSORIES MAYAFFECT THE STABILITY AND OPERATION OF YOUR VE-HICLE AND REDUCESAFETY LEVELS WITH POTENTIAL RISKS FOR THERIDER.

    WARNING

    NEVER RIDE THE VEHICLE WITH ADDED ACCESSORIES (CASEAND/ORWINDSHIELD) FASTER THAN 120 KM/H. WITHOUT THESE ACCESSORIESTHEVEHICLE MAY BE DRIVEN AT A HIGHER SPEED WITHIN THE LEGAL LIMITS.IF

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  • THERE ARE NOT-PIAGGO ACCESSORIES FITTED, OR AN ABNORMAL LOAD,ORIF THE VEHICLE IS NOT IN A GENERALLY GOOD CONDITION, OR WHEN-EVERWEATHER CONDITIONS DEMAND IT, SPEED SHOULD BE FURTHERREDUCED.

    WARNING

    BE EXTREMELY CAREFUL WHEN INSTALLING AND REMOVING THEMECHAN-ICAL ANTITHEFT DEVICE ON THE VEHICLE (U-SHAPED PADLOCK,DISCBLOCK, ETC.).

    MAINLY DUE TO THE PROXIMITY TO THE BRAKE PIPES,TRANSMISSIONSAND/OR ELECTRIC CABLES, AN INCORRECT INSTALLATION ORREMOVALOF THE ANTITHEFT DEVICE AS WELL AS LEAVING IT ON BEFORESTARTINGTHE VEHICLE CAN SERIOUSLY DAMAGE ITS COMPONENTS AND AFFECTTHECORRECT FUNCTIONING OF THE VEHICLE AND HARM THE USER.

    85

    5 Spare parts and accessories

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  • Fuoco 500ie

    Chap. 06Programmedmaintenance

    87

  • Scheduled maintenance table

    Adequate maintenance is fundamental to ensuring long-lasting,optimum operationand performance of your vehicle.

    To this end, a series of checks and maintenance operations (atthe owner's expense)have been suggested, which are included in thesummary table on the following page.Any minor faults should bereported without delay to an Authorised Service Centreor Dealerwithout waiting until the next scheduled service to solve it.

    All scheduled maintenance services must be carried out at thespecified times, evenif the stated mileage has not yet beenreached. Carrying out scheduled services ontime is necessary toensure your warranty remains valid. For any furtherinformationconcerning Warranty procedures and "ScheduledMaintenance", please refer to the"Warranty Booklet".

    EVERY 2 YEARSCoolant - change

    Brake fluid - change

    Parking control unit software upgrading (if available)

    AFTER 1,000 KMSafety locks - check

    Throttle lever - adjustment

    Engine oil - change

    Electrical system and battery - check

    Coolant level - check

    Brake fluid level - check

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  • 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 upgrading (if available)

    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 KMSafety locks - check

    Driving belt - replacement

    Throttle lever - adjustment

    Air filter - clean

    Engine oil - change

    Electrical system and battery - check

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    aintenance

  • 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 and brake test - road test

    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 KMEngine oil - level check/top-up

    Brake pads - check condition and wear

    Centre stand - lubrication

    Parking control unit software upgrading (if available)

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  • AFTER 20,000 KM; 40,000 KM; 60,000 KM AND 80,000KM

    Spark plugs - replacement

    Driving belt - replacement

    Throttle lever - adjustment

    Air filter - check

    Engine oil - change

    Valve clearance - check

    Electrical system and battery - 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)

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    aintenance

  • 30,000 KMSafety 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)

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  • RECOMMENDED PRODUCTS TABLEProduct Description Specifications

    AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceedstherequirements of API GL3 specifications

    AGIP GP 330 Grease for brake control levers, throttle, standWhite calcium complex soap-based spraygrease with NLGI 2;ISO-L-XBCIB2

    AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions(throttlecontrol)

    Oil for 4-stroke engines

    AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

    SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-basedantifreeze fluid,CUNA NC 956-16

    AGIP FILTER OIL Oil for air filter sponge Mineral oil withspecific additives for increasedadhesiveness

    AUTOSOL METAL POLISH Muffler cleaning paste Specific product forcleaning and polishingstainless steel mufflers.

    AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASOMASynthetic oil

    AGIP GREASE SM 2 Grease for the tone wheel revolving ringSoap-based lithium grease containing NLGI 2Molybdenum disulphide;ISO-L-XBCHB2, DINKF2K-20

    AGIP GREASE PV2 Grease for the steering bearings, pin seatsandswinging arm

    White anhydrous-calcium based grease toprotect roller bearings;temperature rangebetween -20 C and +120 C; NLGI 2;ISO-L-XBCIB2.

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  • TABLE OF CONTENTS

    AAir filter: 52

    BBattery: 57Brake: 55, 70

    CClock: 12

    DDisc brake: 70Display: 12

    EEngine oil: 46, 47Engine stop: 17

    FFuel: 23Fuses: 58

    HHeadlight: 64Horn: 16Hub oil: 48

    IIdentification: 26Immobilizer: 18, 20Instrument panel: 11

    KKey switch: 14Keys: 18

    LLight switch: 16

    MMaintenance: 13, 45, 87, 88Mirrors: 69

    SSaddle: 21, 24, 25Scheduled maintenance: 88Shock absorbers:31Spark plug: 51Stand: 37Start-up: 17

    TTank: 23Technical Data: 77Transmission: 37Turn indicators:68

    Tyre pressure: 30Tyres: 50

    95

  • The descriptions and illustrations given in this publication arenot binding. While the basic features as described and illustratedin this manual remainunchanged, PIAGGIO - GILERA reserves theright, at any time and without being required to update thispublication beforehand, to make any changesto components, parts oraccessory supplies, which it considers necessary to improve theproduct or which are required for manufacturing orconstructionreasons.

    Not all versions shown in this publication are available in allCountries. The availability of individual versions should beconfirmed with the official Piaggio sales network.

    " Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rightsreserved. Reproduction of this publication in whole or in part isprohibited."

    PIAGGIO & C. S.p.A. - After-Sales

    V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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