Gilera Fuoco 500ie LT, Manual

Page 1: ...ation tips and precautions for using your vehicle 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 scooter and it will serve you well for a long time to come This booklet forms an integral part of the vehicle should the vehicle be sold it must be transferred to the new o...

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 booklet require the use of special tools and or particular technical knowledge to carry out these operations refer to any authorised Dealer or Service Centres 2 ...

Page 3: ...ging the environment 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 parts of the booklet that should be read with particular care The different symbols are used to make each topic in the man...

Page 4: ...4 ...

Page 5: ...addle to access the helmet compartment by remote control 27 Opening the saddle 28 Identification 28 Bag clip 29 USE 31 Checks 32 Refuelling 32 Tyre pressure 34 Shock absorbers adjustment 36 Running in 37 Starting up the engine 37 Precautions 39 Difficult start up 40 Stopping the engine 40 Anti theft ring 41 Stand 41 Automatic transmission 42 Safe driving 42 Front suspension locking system 44 Parki...

Page 6: ... indicators 77 Number plate light 78 Helmet compartment lighting bulb 78 Rear view mirrors 79 Front and rear disc brake 79 Puncture 80 Inactivity of the vehicle 81 Cleaning the vehicle 82 TECHNICAL DATA 87 Tool kit 92 SPARE PARTS AND ACCESSORIES 93 Warnings 94 SCHEDULED MAINTENANCE 97 Scheduled servicing table 98 6 ...

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

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

Page 9: ...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 Analogue instrument panel 01_02 A Immobilizer anti theft LED 9 1 Vehicle ...

Page 10: ... 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 10 1 Vehicle ...

Page 11: ...01_02 11 1 Vehicle ...

Page 12: ...g the SET button Push the CLOCK button again and the day numbers start flashing Set the day with the SET button Push the 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 proc...

Page 13: ...L Kilometre mile indicator M SET button N CLOCK button Maintenance icons The icons signal the user that scheduled maintenance operations should be carried out A flashing SERVICE icon signals the need to carry out the scheduled mainte nance service A flashing BELT icon signals the drive belt needs replacing In any case vehicle maintenance must be carried out at the kilometre service intervals rec o...

Page 14: ...e time turn the ignition key to on The icons kmi and E will start flashing 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 sta...

Page 15: ... brake 3 ON Ready to start non extractable key mechanical antitheft device disa bled 4 HELMET COMPARTMENT OPENING Helmet compartment opening position Press the key when in OFF or ON and turn it anticlockwise 5 FUEL TANK COVER OPENING Fuel tank cover opening position Press the key when in OFF or ON and turn it clockwise 01_08 Locking the steering wheel 01_08 Turn the handlebar to the left as far as...

Page 16: ... 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 01_10 Horn button 01_10 Push the button E to sound the horn 16 1 Vehicle ...

Page 17: ... 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 set to ON but once enabled it ke...

Page 18: ...lock will start the engine at idling speed 01_14 Engine stop button 01_14 The engine can be started when 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 18 1 Vehicle ...

Page 19: ... Upon start up the PIAGGIO IMMOBILIZER system checks the starter key and only if this key is recognised will the Immobiliser system allow the vehicle to be started 01_16 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 necessary to program all your other keys and for your dealer to perform some maintenanc...

Page 20: ...D HANDGRIP KEY IN A SAFE PLACE NOT ON YOUR VEHICLE 01_19 Immobilizer device enabled indicator led 01_19 Activation of the PIAGGIO IMMOBILIZER system is signalled by a flashing A indicator In order to reduce battery discharge the indicator LED turns off automatically after 48 hours of uninterrupted functioning Should the system fail different LED flash ing patterns will provide the Authorised Servi...

Page 21: ... the system When supplementary keys are required remember that the programming must be performed on all the keys whether they are new or existing ones Contact an Authorised Service Centre and bring the A MASTER key and all B starter keys that you own The codes of keys not submitted for the new storage procedure are deleted from the memory Any lost keys will therefore not be enabled to start the en...

Page 22: ...1 3 seconds turn the key to OFF again and pull it out In this way a maximum of 7 keys can be pro grammed by repeating the above procedure and keeping the indicated times FINAL STAGE After extracting the key to be programmed insert the MASTER key again and turn it to ON position perform this operation within the ten seconds following the ex traction of the previous key Leave it in this position for...

Page 23: ...the button is pressed the remote control is working properly You may need to replace the batteries if the remote control fails or if its range of operation is reduced To separate the two halves of the remote control insert the blade of a plain slot screwdriver at one point on the edge and slide it all around Once the remote control is open remove the two batteries from the contact terminal Install...

Page 24: ...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 SYNCHRONISM BETWEEN THE RE MOTE CONTROL AND THE RECEIVER CAN BE IMPAIRED SHOULD THIS BE THE CASE REPEAT THE PROGRAMMING PROCEDURE DO NOT KEEP THE REMOTE CONT...

Page 25: ...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 25 1 Vehicle ...

Page 26: ...ERY Electric characteristic Plug 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 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 DON T RIDE THE V...

Page 27: ...JECTS INAPPROPRIATELY ARRANGED INSIDE THE HELMET COMPART MENT MAY DEFORM THE SADDLE CAUSING THE COURTESY LIGHT TO RE MAIN ON AND THIS WILL DISCHARGE THE BATTERY IN ANY CASE THE WARNING LIGHT I ON THE INSTRUMENT PANEL SIGNALS IF THE LIGHT IS ON OR OFF 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 REMO...

Page 28: ...ation registration numbers are made up of a prefix and a number stamped on the chassis and on the engine These numbers must always be quoted when ordering spare parts We recommend checking that the chassis registration number stamped on the vehicle corresponds with that on the vehicle documentation CAUTION PLEASE REMIND THAT ALTERING IDENTIFICATION REGISTRATION NUM BERS CAN LEAD TO SERIOUS PENAL S...

Page 29: ... in the helmet compartment 01_29 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 hook C mounted on the counter shield pull it slightly towards the back part of the vehicle 29 1 Vehicle ...

Page 30: ...30 1 Vehicle ...

Page 31: ...Fuoco 500ie LT Chap 02 Use 31 ...

Page 32: ...ning of front and rear brakes 6 The oil level in the gearcase 7 Engine oil level 8 The coolant level 02_02 Refuelling 02_02 02_03 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 PETR...

Page 33: ...THE CATALYTIC CONVERTER CAUTION USING NON RECOMMENDED PETROL REDUCES THE EFFICIENCY OF THE EXHAUST AND FUEL SUPPLY SYSTEMS CAUTION DO NOT USE THE VEHICLE TO THE COMPLETE EXHAUSTION OF THE FUEL SHOULD THIS OCCUR DO NOT ATTEMPT TO START THE ENGINE TURN THE IGNITION 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...

Page 34: ...ENGINE Characteristic Fuel tank reserve 12 l 1 8 l 02_04 Tyre pressure 02_04 Check tyre pressure and wear periodically roughly every 500 km Tyres feature wear indicators replace tyres as soon as these indicators become visible on the tyre tread Also check that the tyres do not show signs of splitting at the sides or irregular tread wear if this occurs go to an authorised workshop or at least to a ...

Page 35: ...ORMAL TYRE WEAR AND MAKES RID ING DANGEROUS TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW TYRE INFLATION PRESSURE Front tyre pressure 1 6 bar Rear tyre pressure 2 5 bar TYRES Front tyre Tubeless 120 70 12 51S or 51P Rear tyre Tubeless 140 70 14 68S or 68P 35 2 Use ...

Page 36: ...d 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 CAUTION RIDING THE VEHICLE WITH THE SPRING PRELOADING NOT CORRECTLY SET FOR THE RIDER AND POSSIBLE PASSENGER COULD REDUCE THE COM FORT OF THE RIDE AND THE PRECISION OF THE STEERING WARNING...

Page 37: ...n the OFF position A running engine automatically switches off when the ignition cut off switch is set to OFF The vehicle is equipped with automatic transmission with direct drive so that starting is effected by turning the throttle grip to idle speed to start off from stationary position progressively twist the throttle grip The vehicle is equipped with an electrical fuel pump that switches on au...

Page 38: ...E BRAKE CARE FULLY AFTER STARTING AND THEN ACCELERATE GRADUALLY CAUTION DO NOT START UP THE ENGINE IN CLOSED AREAS BECAUSE EXHAUST GASES ARE TOXIC CAUTION DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CAN REACH ALWAYS TAKE CARE WHEN PARKING THE VEHICLE THAT THE SI LENCER DOES NOT COME INTO CONTACT WITH FLAMMABLE MATERIALS TO AVOID SERIOUS BURNS CAUTION DO NOT SHUT OFF THE ENGINE WHILE THE V...

Page 39: ...CLE AND TO ROLLOVER WITH CONSEQUENT SERIOUS OR IN SOME CASES LETHAL INJURIES Precautions CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE BE CAREFUL NEVER TO EXCEED THE MAXIMUM SPEED WHILE RUNNING DOWNHILL IN ORDER TO AVOID DAMAGING THE ENGINE IN ANY CASE IN ORDER TO PRESERVE THE ENGINE FROM PROLONGED OVERREVVING THE REVOLUTION LIMITER WILL BE ACTIVATED IF THE ...

Page 40: ...wever necessary once the engine is started to take your vehicle to an Authorised Service Centre to determine the cause of this problem and to re establish the vehicle proper functioning 02_11 Stopping the engine 02_11 Fully untwist the throttle grip then rotate the key in the switch A to KEY OFF extractable key CAUTION DUE TO THE HIGH TEMPERATURES THE CATALYTIC CONVERTER CAN REACH ALWAYS TAKE CARE...

Page 41: ... Anti theft ring 02_12 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 WARNING THIS ACCESSORY IS NOT A THEFT PREVENTION GUARANTEE IT IS ONLY A DETERRENT 02_13 Stand 02_13 Push with your foot on the centre stand s fork F while lifting the vehicle backward holding onto the handlebar 41 2 Use ...

Page 42: ...ted like driving up a steep hill fully loaded or starting off with rider and passenger on a slope with a gradient greater than 25 Take 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 a few minutes 02_15 Safe driving 02_15 Some simple tips are provided below that will enable you to use your ve...

Page 43: ...LIMITS RIDING UNDER THE INFLUENCE OF AL COHOL OR OTHER DRUGS AND CERTAIN MEDICINES IS EXTREMELY DAN GEROUS CAUTION IN ORDER TO PREVENT ANY ACCIDENTS RIDE VERY CAREFULLY AFTER ADDING ACCESSORIES AND WHILE CARRYING LUGGAGE ADDING ACCES SORIES AND LUGGAGE CAN REDUCE THE VEHICLE S STABILITY PERFORM ANCE AND SAFETY DURING USE WARNING NEVER RIDE THE VEHICLE WITH ADDED ACCESSORIES CASE AND OR WINDSHIELD ...

Page 44: ...ressed The warning light E starts flashing when the key switch is set to ON This means that the system is enabled for locking activation When the Q switch is turned to 1 a continuous sound alarm signals that the locking system is engaged and at the same time the warning light E turns on steadily When the Q switch is turned to 2 an intermittent sound alarm signals that the locking system is disenga...

Page 45: ... saddle which ena bles the system to prevent vehicle motion and suspension unlocking in case of locked suspension when the rider is not properly seated in riding position in such case the WARNING light C turns on steadily CAUTION THE RIDER DETECTION SENSOR IS LOCATED IN THE FRONT PART OF THE SADDLE AVOID PLACING BAGS OR HEAVY OBJECTS ACCIDENTALLY ON THE SADDLE NOT OBSERVING THIS RULE MAY MOVE THE ...

Page 46: ...DER IS NOT SEATED ON THE SADDLE WHILE THE VEHICLE IS IN MOTION AND THE LOCKING SYSTEM IS ENGAGED AVOID OPERATING THE THROTTLE CONTROL PURPOSELESSLY AS THIS MAY DAMAGE THE CATA LYTIC CONVERTER CAUTION DO NOT RIDE DOWNHILL WITH THE SUSPENSION LOCKING SYSTEM ENGAG ED AND THE IGNITION SWITCH SET TO OFF With the vehicle off and the suspension locking system engaged it is possible to get off the vehicle...

Page 47: ...E IS PARKED UPHILL AND TO THE LEFT WHEN PARKED DOWNHILL 02_18 If the WARNING light C turns on flashes it means that there is a failure in the front suspension locking system Therefore it is necessary to contact an Authorised Serv ice Centre If the front suspension is locked it can be unlocked by operating the Q switch twice quickly on the unlocking position 2 Once the suspension is un locked the v...

Page 48: ...02_19 02_20 02_21 48 2 Use ...

Page 49: ...d footrest Operating this pedal brakes both the front brake discs and the rear brake disc simultaneously The brake pedal functions simultaneously with the conventional braking system As a result any of the three braking controls may be used indifferently CAUTION AS THE SYSTEM IS LINKED TO THE CONVENTIONAL BRAKE PUMPS OPER ATING HANDLEBAR CONTROLS AND FOOT PEDAL MAY CAUSE A PERCEP TIBLE MOVEMENT OF...

Page 50: ...50 2 Use ...

Page 51: ...Fuoco 500ie LT Chap 03 Maintenance 51 ...

Page 52: ...y problems we recommend checking oil level more fre quently than indicated in the Scheduled Maintenance table or before setting off on long journeys The vehicle is however equipped with an oil pressure warn ing light on the instrument panel 03_01 Engine oil level check 03_01 03_02 Every time the vehicle is used visually inspect the level of the engine oil when the engine is cold after completely u...

Page 53: ...ht insufficient oil pressure The vehicle is equipped with a warning light that comes on when the key is turned to ON However this light should switch off once the engine has been started If the light comes on while braking at idle speed or while turning a corner it is nec essary to check the oil level and top it up if required If after having topped up the oil the warning light still comes on whil...

Page 54: ...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 INSUFFICIENT LUBRICATION OR WITH INADE QUATE LUBRICANTS ACCELERATES THE WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE TOPPING...

Page 55: ...ll 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 TEA...

Page 56: ...ET THE OIL COME 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 GEAR SAE 80W 90 Lubricant for gearboxes and transmissions API GL 4 Characteristic Transmission oil 250 cm 56 3 Maintenance ...

Page 57: ...workshop equipped to replace tyres 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 CA...

Page 58: ... 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 MAINTENANCE OPERATIONS ...

Page 59: ...CR7EKB Electrode gap 0 7 0 9 mm 03_10 Removing the air filter 03_10 Proceed as follows Unscrew the nine fixing screws A and remove the air filter cover B Air filter cleaning 1 Wash the sponge with water and mild soap 2 Dry it with a clean cloth and short blasts of compressed air 3 Impregnate the sponge with a mixture of 50 petrol and 50 specified oil 59 3 Maintenance ...

Page 60: ... solution with corrosion inhibitors Recommended coolant supplied with the vehicle already mixed and ready for 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 ch...

Page 61: ...cated in the scheduled maintenance table Take your vehicle to an Authorised Service Centre for this operation CAUTION THE RECOMMENDED COOLANT MUST BE USED 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 AUTH...

Page 62: ... the handlebar Proceed as follows 1 Place the vehicle on its centre stand and make sure the handlebar is centred 2 Check the liquid through the sight glass C To check the integral braking system fluid level remove the cover on the right hand side of the footrest undoing the screw D Check the brake fluid level in the reservoir E A certain lowering of the level is caused by wear on the brake pads Sh...

Page 63: ...lly remove the fluid reservoir from its mounting taking care not to detach the pipe Undo the screw D and remove the plastic cover Loosen the screw F to take out the tank and remove the cap to refill Under standard climatic conditions replace fluid as indicated in the scheduled main tenance table This operation must be carried out by trained personnel take your vehicle to an au thorised Service cen...

Page 64: ...KEPT IN CONTAINERS THAT HAVE ALREADY BEEN OPENED OR PARTIALLY USED Recommended products AGIP BRAKE 4 Brake fluid Synthetic fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 03_21 Battery 03_21 To access the battery proceed as follows 1 Place the scooter on its centre stand 2 Open the saddle following the previously described procedure 3 Remove the two fasteners A and the cover B WARNIN...

Page 65: ...terminals are connected correctly CAUTION DO NOT REVERSE THE POLARITY RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELECTRICAL SYSTEM WARNING USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH REGULA TIONS IN FORCE 65 3 Maintenance ...

Page 66: ...ry make sure that all terminals are properly connected 03_24 03_25 Fuses 03_24 03_25 03_26 03_27 03_28 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 left footrest B To have access loosen the screw C and remove the plastic cover The chart ...

Page 67: ...03_26 03_27 03_28 67 3 Maintenance ...

Page 68: ...rcuits Saddle opening receiver battery power supply glove box lighting light switch turn indicator command device pre installation for anti theft device 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 9 10 11 Fuse No 6 Capacity 15A Protected circuits L V socket 68 3 Main...

Page 69: ...sing and horn Fuse No 10 Capacity 7 5A Protected circuits Live injection ECU immobilizer aerial electric fan relay injection load relay Fuse No 11 Capacity 7 5A Protected circuits Live ECU parking lever pre installation for antitheft device instrument panel headlight relay horn Fuse No 12 Capacity 7 5A Protected circuits Live turn indicator control saddle opening switch daylight running lights pan...

Page 70: ...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 bulb Type ALL GLASS 70 3 Maintenance ...

Page 71: ... 2W Quantity 4 Front light group 03_29 03_30 03_31 03_32 03_33 03_34 To access the tail light bulb Insert a 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 71...

Page 72: ...front wheel housing hold the high beam light bulb holder C or the low beam bulb holder D and then turn it anticlockwise To replace it disconnect the connector and insert a new bulb WARNING HIGH AND LOW BEAM BULBS ARE HALOGEN TYPE DO NOT TOUCH THEM WITH YOUR FINGERS TO AVOID DAMAGING THEIR FUNCTION 72 3 Maintenance ...

Page 73: ...03_32 03_33 03_34 73 3 Maintenance ...

Page 74: ...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 HICLE IS USED 03_35 T...

Page 75: ...nd one for the vertical adjustment D Adjust each headlamp at a time In order to 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 75 3 Maintenance ...

Page 76: ...03_39 03_40 Front direction indicators 03_40 To access the bulb undo the screw A and remove the glass B To replace the bulb hold it and then turn it clockwise 76 3 Maintenance ...

Page 77: ...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_43 Rear turn indicators 03_43 To access the bulb undo the screw A and remove the glass B To replace the bulb hold it and then turn it clockwise 77 3 Maintenance ...

Page 78: ...nd then remove the bulb holder The instructions apply for both license plate lights 03_45 Helmet compartment lighting bulb 03_45 Open the rear compartment and insert a small plain slot screwdriver in the lateral notch to detach the snap on glass D then replace the bulb 78 3 Maintenance ...

Page 79: ...aking circuit or a failure in the braking system In this case mainly due to the importance of brakes to guarantee safe riding conditions the vehicle should be taken to an Authorised Service Centre or Dealer CAUTION BRAKING 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 HOW...

Page 80: ...3_47 The vehicle is equipped with Tubeless tyres without inner tube In the event of a puncture Tubeless tyres unlike tyres with inner tubes go flat very slowly resulting in a greater steering safety In the event of a puncture an emergency repair can be carried out using an inflate and repair spray can For a final repair take your vehicle to an Authorised Service Centre or Dealer The replacement of...

Page 81: ...engine off and piston at the bottom dead centre remove the spark plug add 1 to 2 cc of oil through the opening adding more oil may damage the engine Operate the starter button 1 2 times for roughly 1 second to turn the engine over slowly then insert the spark plug again 4 Empty all fuel spread antirust grease on the uncoated metal parts keep the wheels lifted above the ground by resting the chassi...

Page 82: ...wax must always be preceded by washing CAUTION DETERGENTS CAN POLLUTE WATER THE VEHICLE MUST BE WASHED AT A WASH STATION EQUIPPED WITH A SPECIAL WATER PURIFICATION SYSTEM CAUTION THE USE OF A HIGH PRESSURE WATER JET IS STRONGLY DISCOURAGED FOR ANY ENGINE CLEANING OPERATION HOWEVER IF NO OTHER MEANS ARE AVAILABLE IT IS THEN NECESSARY TO ONLY USE A FANLIKE SPRAY JET DO NOT HOLD THE NOZZLE NEARER THA...

Page 83: ...OT TO DAM AGE THE LUSTRE FINISH OR ALTER THEIR MECHANICAL PROPERTIES US ING SILICONE BASED WAX CAN DAMAGE THE PAINTED SURFACES DE PENDING ON THE VEHICLE COLOUR SATIN COLOURS FOR FURTHER INFORMATION ON THIS MATTER CONTACT AN AUTHORISED SERVICE CEN TRE STARTING FAILURE Emergency switch in OFF Set the switch back to ON Fuse blown Replace the blown fuse and have the vehicle checked by an Authorised Se...

Page 84: ...ark plug Screw in the spark plug tightly Cylinder head loose piston gas rings worn Contact an Authorised Service Centre Valve stuck Contact an Authorised Service Centre HIGH CONSUMPTION AND LOW PERFORMANCE Air filter blocked or dirty Contact an Authorised Service Centre INSUFFICIENT BRAKING Greasy disc Worn pads Faulty braking system Presence of air in the front and rear brake circuit Contact an A...

Page 85: ...d shock absorber preloading incorrectly set Contact an Authorised Service Centre AUTOMATIC TRANSMISSION PROBLEMS CVT rollers and or drive belt damaged Contact an Authorised Service Centre STAND DOES NOT RETURN TO POSITION Presence of dirt Clean and grease 85 3 Maintenance ...

Page 86: ...86 3 Maintenance ...

Page 87: ...Fuoco 500ie LT Chap 04 Technical data 87 ...

Page 88: ...04_01 88 4 Technical data ...

Page 89: ...m at 5 250 rpm Transmission CVT expandable pulley variator with torque server V belt self ventilating dry automatic centrifugal clutch and transmission housing with forced circulation air cooling Final reduction gear Gear reduction unit in oil bath Lubrication Engine lubrication with lobe pump inside crankcase chain driven with double filter mesh and paper Cooling Forced coolant circulation system...

Page 90: ...t silencer Absorption type exhaust muffler with catalytic converter and lambda probe Emissions compliance EURO 2 VEHICLE SPECIFICATIONS Chassis Tubular and sheet steel Front suspension The roll system is composed of an articulated parallelogram suspension with die cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system rear suspension Two double actin...

Page 91: ...hree discs simultaneously and is controlled hydraulically via the pedal on the footrest Wheel rim type Light alloy wheel rims Front wheel rim 12 x 3 00 Rear wheel rim 14 x 4 50 Front tyre Tubeless 120 70 12 51S or 51P Rear tyre Tubeless 140 70 14 68S or 68P Front tyre pressure 1 6 bar Rear tyre pressure 2 5 bar Kerb weight 253 8 kg Maximum weight allowed 445 kg Battery 12V 12Ah CAPACITY Engine oil...

Page 92: ... 1 8 l 04_02 Tool kit 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 fuses The tools are stored in the helmet compartment 92 4 Technical data ...

Page 93: ...Fuoco 500ie LT Chap 05 Spare parts and accessories 93 ...

Page 94: ...RENDERS THE WARRANTY VOID WARNING PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG NISED AND GUARANTEED FOR USE IT IS THEREFORE ESSENTIAL TO CON TACT AN AUTHORISED DEALER OR SERVICE CENTRE IN ORDER TO CHOOSE AND FIT ACCESSORIES CORRECTLY THE USE OF NON ORIGINAL ACCES SORIES MAY AFFECT THE STABILITY AND OPERATION OF YOUR VEHICLE AND REDUCE SAFETY LEVELS WITH POTENTIAL RISKS FOR THE RIDER ...

Page 95: ...N INSTALLING AND REMOVING THE MECHAN ICAL ANTITHEFT DEVICE ON THE VEHICLE U SHAPED PADLOCK DISC BLOCK ETC MAINLY NEAR THE BRAKE PIPES TRANSMISSIONS AND OR ELECTRIC CA BLES AN INCORRECT INSTALLATION OR REMOVAL OF THE ANTITHEFT DEVICE AS WELL AS LEAVING IT ON BEFORE STARTING THE VEHICLE CAN SERIOUSLY DAMAGE ITS COMPONENTS COMPROMISE THE CORRECT FUNCTIONING OF THE VEHICLE AND USERS SAFETY 95 5 Spare ...

Page 96: ...96 5 Spare parts and accessories ...

Page 97: ...Fuoco 500ie LT Chap 06 Scheduled maintenance 97 ...

Page 98: ... reached the predicted mileage Carrying out scheduled services on time is essential for the validity of your warranty For all further information regarding the Guarantee application modes and the execution of the Programmed Mainte nance refer to the Guarantee Booklet SCHEDULED MAINTENANCE TABLE Km x 1 000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Safety fasteners I I I I I Throttle control ...

Page 99: ... filter C I C I C I C I Sliding shoes CVT rollers R R R R R R R R Suspension I I I I I I I I Spark plugs R R R R R R R R Roll lock calliper control cable A A A A A A A A Valve clearance I I I I I CHECK AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE Replace every 2 years RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP GEAR SAE 80W 90 Lub...

Page 100: ...ready to use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 AGIP FILTER OIL Special product for the treatment of foam filters AUTOSOL METAL POLISH Silencer cleaning paste Specific product for cleaning and polishing stainless steel mufflers AGIP GREASE SM 2 Gray black smooth textured lithium grease containing molybdenum disulphide AGIP GREASE PV2 Ivory smooth textured slightly stringy anhydrous...

Page 101: ...16 4 Cubic centimetres cm 1 Foot pound lb ft 1 356 Newton meter Nm 1 Miles per hour mi h 1 602 Kilometres per hour km h 1 Pound per square inch PSI 0 069 bar 1 Fahrenheit F 32 9 5 Celsius C 101 6 Scheduled maintenance ...

Page 102: ...102 6 Scheduled maintenance ...

Page 103: ...Identification 28 Immobilizer 19 20 22 Instrument panel 9 K Keys 19 L Light switch 17 M Maintenance 13 51 97 Mirrors 79 P Puncture 80 R Refuelling 32 S Saddle 23 26 28 Scheduled maintenance 97 Shock absorbers 36 Spark plug 58 Stand 41 Start up 18 Suspension 19 44 Switch 16 17 19 T Tank 25 Technical Data 87 Transmission 42 Turn indicators 77 Tyre pressure 34 Tyres 57 V Vehicle 7 81 82 103 ...

Page 104: ... changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in this publication are available in all countries The availability of each model should be checked at the official PIAGGIO sales network Copyright 2013 Piaggio C S p A All rights reserved Reproduction of this ...