Gilera Fuoco 500ie LT Manual
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Gilera Fuoco 500ie LT Manual

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GILERA WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding
the vehicle for the first time. It contains information, 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 owner.
Fuoco 500ie LT
Ed. 01_06/2013

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  • Page 1 GILERA WOULD LIKE TO THANK YOU for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details and devices to assure you that you have made the right choice.
  • Page 2 The instructions given in this manual are intended to provide a clear, simple guide to using your vehicle; this booklet also details routine maintenance procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre. The booklet also contains instructions for simple repairs.
  • Page 3 Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging the environment. 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.

  • Page 5: Table Of Contents

    INDEX VEHICLE..................Checks..................32 Dashboard................Refuelling.................. 32 Analogue instrument panel............Tyre pressure................34 Clock..................12 Shock absorbers adjustment............ 36 Digital lcd display..............13 Running in................. 37 Maintenance icons..............13 Starting up the engine............... 37 *MODE* button..............14 Precautions................39 Keyswitch.................. 15 Difficult start up.................
  • Page 6 Fuses..................66 Front light group................ 71 Head light adjustment............74 Front direction indicators............76 Rear optical unit................ 77 Rear turn indicators..............77 Number plate light..............78 Helmet compartment lighting bulb..........78 Rear-view mirrors..............79 Front and rear disc brake............79 Puncture..................

  • Page 7: Vehicle

    Fuoco 500ie LT Chap. 01 Vehicle...
  • Page 8 01_01...

  • Page 9: Dashboard

    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...
  • Page 10 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 failure warning light M = Low fuel warning light N = Engine stop warning light...
  • Page 11 01_02...

  • Page 12: Clock

    Clock (01_03) Pushing the «CLOCK» button for less than 1 second displays the following sequence: • TIME • DATE To set the clock, push and hold the «CLOCK» button for other 3 seconds. The numbers showing the hours will begin flashing. Set the hour using the «SET»...

  • Page 13: Digital Lcd Display

    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 (selected with the MODE button) 01_04 F = TIME-DATE indicator G = Low fuel warning light H = Trip odometer gauge (B)

  • Page 14: Mode* Button

    *MODE* button (01_05, 01_06) Pushing the ''MODE'' «S» button for less than a second displays the following se- quence of functions: 1. Trip odometer «A» 2. Trip odometer «B» 3. Ambient temperature «°» Push the ''MODE'' «S» button for longer than 3 seconds to zero set the trip odometer. 01_05 UNIT OF MEASUREMENT SETTING Press and hold the "MODE"...

  • Page 15: Keyswitch

    Keyswitch (01_07) Ignition key «A» is located on the front leg shield back plate near the bag hook. SWITCH POSITIONS 1. LOCK = Ignition disabled, extractable key, mechanical antitheft device ena- bled. The parking brake cannot be released when engaged and can be engaged when released.

  • Page 16: Switch Direction Indicators

    CAUTION NEVER TURN THE KEY TO «LOCK» OR «OFF» WHILE RIDING. Switch direction indicators (01_09) Lever «F» towards «1» = left turn indicators switched on; Lever «F» towards «2» = right turn indicators switched on; The lever «F» automatically returns to «0 » and the turn indicators remain on; push the lever «F»...

  • Page 17: Light Switch

    Light switch (01_11) When the light switch «H» is set to «0», the low-beam light is on. When set to «1», the high-beam light is activated. If the light switch «H» is pressed when set to «2», the high-beam light is activated. The switch goes back to «0» automatically. When the ignition key is set to «ON»...

  • Page 18: Start-Up Button

    Start-up button (01_13) To start the engine, press the starter button «R» after pulling one of the two brake levers. If the rider is not on the vehicle, the suspension lock will start the engine at idling speed. 01_13 Engine stop button (01_14) The engine can be started when the emergency cut-off switch «N»...

  • Page 19: Front Suspension Unlock-Lock Switch

    Front suspension unlock-lock switch (01_15) The «Q» switch engages and disengages the front suspension locking system. As the topic is so complex, find the instructions for using this control in the Use chapter. 01_15 The immobilizer system In order to enhance theft protection, the vehicle is equipped with a «PIAGGIO IMMO- BILIZER »...

  • Page 20: Immobilizer Device Enabled Indicator Led

    Together with the two keys, you will be given a CODE CARD bearing the same code imprinted onto the two keys. WARNING LOOSING THE RED KEY PREVENTS ANY REPAIRS OF THE 'PIAGGIO IMMO- BILIZER' SYSTEM AND THE ENGINE CONTROL UNIT. WARNING 01_17 KEEP THE 'CODE CARD' AND THE RED HANDGRIP KEY IN A SAFE PLACE (NOT...

  • Page 21: Operation

    Operation Each time the starter key «B» is removed while in the «OFF», or «LOCK» position, the protection system activates the engine lock. Turning the key to "ON" disables the engine lock, provided that the safety system recognises the code transmitted by the key.

  • Page 22: Programming The Immobilizer System

    Programming the immobilizer system Below is described the procedure to follow for programming the PIAGGIO IMMOBIL- ISER system and/or for storing other key codes. The programming procedure should be carried out with the engine stop switch set to «RUN». START PROCEDURE Insert the «MASTER»...

  • Page 23: Saddle Opening Remote Control

    WARNING SHOULD YOU START THE ENGINE WITH THE MASTER KEY (WITH TRANS- PONDER OFF) OR IN THE EVENT OF WRONG OPERATION DURING PROGRAM- MING, REPEAT THE PROCEDURE FROM THE BEGINNING. Saddle opening remote control (01_20) The scooter is fitted with a remote control to open the saddle. This remote control is supplied together with the keys and it has been programmed to control the opening device control unit at the manufacturing stage.
  • Page 24 2. Turn the key to «ON», press the button on the remote control, release the button, then turn the key back to «OFF» within four seconds of turning «ON». 3. Wait 1 to 8 seconds. 4. Repeat steps 2 and 3 four more times without removing the key. The control unit confirms the programming has been successful by opening the sad- dle.

  • Page 25: Accessing The Fuel Tank

    JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER. 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. 01_21 01_22...

  • Page 26: Power Supply Socket

    Power supply socket (01_23) There is a plug socket «D» inside the helmet compartment. The plug socket may be used for external consumers (mobile phone, inspection light, etc.). CAUTION 01_23 PROLONGED USE OF THE PLUG SOCKET MAY RESULT IN PARTIAL DIS- CHARGE OF THE BATTERY Electric characteristic Plug socket...

  • Page 27: Opening The Saddle To Access The Helmet Compartment By Remote Control

    01_25 Opening the saddle to access the helmet compartment by remote control (01_26) When the key is in «LOCK» or «OFF» position you can open the saddle using the remote control. The saddle cannot be opened only when the key is set to "ON". WARNING OBJECTS INAPPROPRIATELY ARRANGED INSIDE THE HELMET COMPART- 01_26...

  • Page 28: Opening The Saddle

    UNINTENTIONAL OPENING OF THE SADDLE. REFER TO THE «OPENING THE SADDLE WITH REMOTE CONTROL» SECTION TO REPLACE BATTERIES. Opening the saddle (01_27) With the key set to «ON» or «OFF», press it and turn it anticlockwise. 01_27 Identification (01_28, 01_29) Identification registration numbers are made up of a prefix and a number, stamped on the chassis and on the engine.

  • Page 29: Bag Clip

    Chassis number To read the chassis number, remove the lid «A» in the helmet compartment. 01_28 Engine number The engine number «B» is stamped near the rear left shock absorber lower support. 01_29 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.

  • Page 31: Use

    Fuoco 500ie LT Chap. 02...

  • Page 32: Checks

    Checks (02_01) Before using the vehicle, check: 1. That there is enough fuel in the fuel tank. 2. That the fluid level for front and rear brakes is correct. 3. That tyres are properly inflated. 4. The correct functioning of daylight running lights, headlamp, turn indicators, stop light and license plate light.
  • Page 33 DO NOT ALLOW PETROL TO COME INTO CONTACT WITH HOT ENGINE OR ANY PLASTIC PARTS. CAUTION PETROL DAMAGES THE PLASTIC PARTS OF THE BODYWORK. WARNING 02_03 DO NOT RIDE WITH THE FUEL TANK ALMOST EMPTY, LACK OF FUEL CAN DAMAGE THE CATALYTIC CONVERTER. CAUTION USING NON-RECOMMENDED PETROL REDUCES THE EFFICIENCY OF THE EXHAUST AND FUEL SUPPLY SYSTEMS.

  • Page 34: Tyre Pressure

    WARNING IT IS HIGHLY INADVISABLE TO REFUEL USING METHODS OTHER THAN NOR- MAL FUEL PUMPS. IF PETROL IS NOT COMPLETELY CLEAN, IT CAN DAMAGE THE FUEL SUPPLY SYSTEM FILTERS. CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE.
  • Page 35 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. TYRE INFLATION PRESSURE Front tyre pressure 1.6 bar Rear tyre pressure...

  • Page 36: Shock Absorbers Adjustment

    Shock absorbers adjustment (02_05, 02_06) The preloading of the springs can be adjusted to 4 positions acting on the ring nut located in the lower part of the shock absorbers with the specific spanner supplied. Position 1: minimum preload: rider only Position 2 medium preloading: rider only Position 3 medium preloading: rider and passenger Position 4: maximum preloading: rider, passenger, and luggage.

  • Page 37: Running In

    Running in (02_07) DURING THE FIRST 1000 KM. DO NOT RIDE THE VEHICLE OVER 80% OF ITS MAX. SPEED. AVOID OPENING THE THROTTLE GRIP COMPLETELY OR KEEP- ING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD. AFTER THE FIRST 1000 KM. INCREASE SPEED PROGRESSIVELY, IF POSSIBLE, UNTIL THE MAXIMUM PERFORMANCE IS OBTAINED.
  • Page 38 3. Insert the key into the ignition switch «A» and turn it onto the 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 pressing the starter button «R».

  • Page 39: Precautions

    CAUTION DO NOT PUSH THE STARTER BUTTON OR TURN THE IGNITION SWITCH TO «ON» WHEN THE TANK IS EMPTY BECAUSE IT COULD DAMAGE THE START- UP SYSTEM. WARNING NEVER TRY TO START-UP THE ENGINE WITH THE THROTTLE GRIP TWISTED. THIS MAY LEAD TO LOSING CONTROL OF THE VEHICLE AND TO ROLLOVER, WITH CONSEQUENT SERIOUS OR, IN SOME CASES, LETHAL INJURIES.

  • Page 40: Difficult Start Up

    WARNING AFTER A LONG DISTANCE COVERED AT THE MAXIMUM SPEED, DO NOT STOP THE ENGINE IMMEDIATELY, BUT LET IT RUN AT IDLE FOR A FEW SECONDS. Difficult start up In the rare case of engine flooding, to facilitate start-up, it is possible to try to put the vehicle into action with the gas hand grip partially or completely open.

  • Page 41: Anti-Theft Ring

    CAUTION DO NOT SHUT OFF THE ENGINE WHILE THE VEHICLE IS MOVING. UNBURNED FUEL COULD ENTER THE CATALYTIC CONVERTER AND BURN, CAUSING THE CONVERTER TO OVERHEAT AND POSSIBLY DESTROYING IT. 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.

  • Page 42: Automatic Transmission

    Automatic transmission (02_14) To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans- mission with regulator and centrifugal clutch. The system is designed to provide the best performance (acceleration and consumption) while riding on both flat roads and uphill.
  • Page 43 4. Avoid setting off by mounting the vehicle while it is resting on the support. In any case, the rear wheel should not be turning when it comes into contact with the ground, in order to avoid abrupt departures. 5. When riding the vehicle on roads with sand, mud, snow mixed with salt, etc., we recommend that you clean the brake disc frequently with a non-aggressive detergent in order to avoid the formation of abrasive build-ups in the holes, which could result in early wear of brake pads.

  • Page 44: Front Suspension Locking System

    CAUTION DO NOT ADJUST THE MIRRORS WHILE RIDING. THIS COULD CAUSE YOU TO LOOSE CONTROL OF THE VEHICLE. CAUTION ANY ELABORATION THAT MODIFIES THE VEHICLE'S PERFORMANCES, SUCH AS TAMPERING WITH ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBID- DEN BY LAW, AND RENDERS THE VEHICLE NO LONGER CONFORMING TO THE APPROVED TYPE AND DANGEROUS FOR RIDING.
  • Page 45 • Engine rpm below 2500 rpm • Vehicle speed below 10 km/h • Locking system WARNING light «C» off (the system has not detected fail- ures) If one of these conditions is not checked, the warning light «E » remains off and locking cannot be engaged (in normal riding conditions, the warning light «E»...
  • Page 46 WARNING AVOID USING THE LOCKING SYSTEM WHEN RIDING THE VEHICLE ALONG IR- REGULAR ROADS OR ROADS WITH OBSTACLES (E.G. ROAD HUMPS, SIDE- WALK, ETC.). IN CASE OF ENGINE FAILURE (DISCHARGED BATTERY) AVOID PULLING THE VEHICLE WITH THE LOCKING SYSTEM ENGAGED. WITH THE LOCKING SYSTEM ENGAGED AND THE ENGINE OFF, AVOID MOV- ING THE VEHICLE AT SPEEDS ABOVE 5 Km/h.
  • Page 47 When the hand brake «B» is engaged, warning light «R» on the instrument panel turns When the hand brake is set to «B» and the key switch is turned to position «1», the safety system that prevents the hand brake from getting released is activated. To release the hand brake, turn the key switch to «2»...
  • Page 48 02_19 02_20 02_21...

  • Page 49: Parking Brake

    Parking brake (02_22) To engage the parking brake «B», move the lever from position «1» to position «2». 02_22 Integral pedal braking system (02_23) The vehicle is equipped with an integral braking system controlled by the brake pedal «A»located on the right hand footrest. Operating this pedal brakes both the front brake discs and the rear brake disc simultaneously.

  • Page 51: Maintenance

    Fuoco 500ie LT Chap. 03 Maintenance...

  • Page 52: Engine Oil Level

    Engine oil level Four stroke engine oil is used in the engines in order to lubricate the timing bodies, the bench bearings and the thermal group. An insufficient quantity of oil can seri- ously damage the engine. In all four-stroke engines, a loss of efficiency in oil performance and certain consumption should be considered normal.

  • Page 53: Engine Oil Top-Up

    03_02 Engine oil top-up Always check the oil level before carrying out top ups and add oil without exceeding the MAX level. Getting an oil level between the MIN and MAX levels requires ~ 400 cm³ of oil. An oil check-up and top-up should be carried out at any Authorised Service Centre, as indicated in the scheduled maintenance table.

  • Page 54: Engine Oil Change

    Engine oil change (03_03, 03_04) The oil and the filter must be changed as indicated in the scheduled maintenance table at an Authorised Service Centre. The engine should be emptied by draining the oil via the drainage tap «B» of the mesh filter on the transmission side. In order to facilitate oil drainage, loosen the cap/dipstick «A».

  • Page 55: Hub Oil Level

    Synthetic based lubricant for high-performance four-stroke engines. JASO MA, MA2 - API SL - ACEA A3 Hub oil level (03_05, 03_06) Check the oil in the rear hub. (oil content ~ 250 cc). To check the rear hub oil level, proceed as follows: 1) Rest the vehicle onto its centre stand, on level ground.
  • Page 56 CAUTION AN EXCESSIVE QUANTITY OF OIL CAN LEAD TO SPILL OVER, WHICH MAY CAUSE THE ENGINE AND THE WHEEL TO GET DIRTY. CAUTION WHEN REPLACING THE HUB OIL DO NOT LET THE OIL COME INTO CONTACT WITH THE REAR BRAKE DISC. CAUTION FOR OIL REPLACEMENT, CONTACT ANY AUTHORISED SERVICE CENTRE AS THEY ARE EQUIPPED TO DISPOSE OF USED OILS IN AN ENVIRONMENTALLY...

  • Page 57: Tyres

    Tyres (03_07) 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;...

  • Page 58: Spark Plug Dismantlement

    TYRE INFLATION PRESSURE Front tyre pressure 1.6 bar Rear tyre pressure 2.5 bar 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 by undoing the fixing screw «A»...

  • Page 59: Removing The Air Filter

    N.B. USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR UNSHIELDED SPARK PLUG CAPS CAN LEAD TO FAULTS IN THE VEHICLE 'S ELECTRICAL SYSTEM. Characteristic Spark plug NGK CR7EKB Electrode gap 0.7 ÷ 0.9 mm Removing the air filter (03_10) Proceed as follows: Unscrew the nine fixing screws «A»...

  • Page 60: Cooling Fluid Level

    4. Gently squeeze the filtering element, let it drip dry and then refit it. CAUTION IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE CHECKS OF THE AIR FILTER MORE OFTEN TO AVOID DAM- AGING THE ENGINE.
  • Page 61 c) Look inside the expansion tank; the fluid level must always be between the min and the max level d) If the coolant level is near the minimum mark, top up when the engine is cold. If it is necessary to top up the coolant frequently, or if the expansion tank is completely dry, you should look for the cause in the cooling system.

  • Page 62: Checking The Brake Oil Level

    TO ENSURE CORRECT ENGINE OPERATION, KEEP THE RADIATOR GRILLE CLEAN. Recommended products AGIP PERMANENT SPEZIAL Ethylene glycol-based antifreeze fluid with organic inhibition additives. Red, ready to use. ASTM D 3306 - ASTM D 4656 - ASTM D 4985 - CUNA NC 956-16 Checking the brake oil level (03_15, 03_16, 03_17) The front and rear brake fluid reservoirs are both positioned on the handlebar.

  • Page 63: Braking System Fluid Top Up

    03_17 Braking system fluid top up (03_18, 03_19, 03_20) Proceed as follows: Undo the screws «B» and remove the fuel tank cap «A». Top-up using only the fluid specified, without exceeding the maximum level. This procedure applies to the rear brake pump top-up operation; follow the same pro- cedure for the front brake pump.

  • Page 64: Battery

    CAUTION AVOID CONTACT OF BRAKE FLUID WITH EYES, SKIN, AND CLOTHING. IN CASE OF CONTACT, RINSE WITH WATER. THE BRAKING CIRCUIT FLUID IS HYGROSCOPIC, THAT IS, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING.

  • Page 65: Use Of A New Battery

    Characteristic Battery 12V-12Ah Use of a new battery (03_22) Make sure that the terminals are connected correctly. CAUTION DO NOT REVERSE THE POLARITY: RISK OF SHORT CIRCUIT AND DAMAGE TO THE ELECTRICAL SYSTEM. 03_22 WARNING USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH REGULA- TIONS IN FORCE.

  • Page 66: Long Periods Of Inactivity

    Long periods of inactivity (03_23) If the vehicle has not been used for long periods, it is necessary to periodically re- charge the battery, bearing in mind that the battery tends to go completely flat within around three months. The battery must be recharged with a current load equal to 1/10 of the battery rated capacity (~ 1A), for a period not longer than 8 hours.
  • Page 67 03_26 03_27 03_28...
  • Page 68 FUSE CHART Fuse No. 1 Capacity: 7.5 A Protected circuits:Injection ECU battery power Fuse No. 2 Capacity: 15A Protected circuits:Battery- powered injection loads, electric Fuse No. 3 Capacity: 15A Protected circuits:Saddle opening receiver battery power supply, glove box lighting, light switch, turn indicator command device, pre-installation for anti- theft device, fuse No.
  • Page 69 Fuse No. 7 Capacity: 7.5 A Protected circuits:Battery- powered instrument panel Fuse No. 8 Capacity: 10A Protected circuits:Live stop, start-up and starter circuit enabling lights Fuse No. 9 Capacity: 7.5 A Protected circuits:live passing and horn Fuse No. 10 Capacity: 7.5A Protected circuits:Live injection ECU, immobilizer aerial, electric fan relay, injection load relay...
  • Page 70 IGHT BULBS TABLE Low beam bulb Type: HALOGEN (H8) Power: 12V - 35W Quantity: 1 RHS + 1 LHS High beam 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...

  • Page 71: Front Light Group

    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».
  • Page 72 To access the high-beam light bulbs and the low-beam light bulbs: - Actuating on the inside of the 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 03_29 HIGH- AND LOW-BEAM BULBS ARE HALOGEN TYPE: DO NOT TOUCH THEM...
  • Page 73 03_32 03_33 03_34...

  • Page 74: Head Light Adjustment

    Head light adjustment (03_35, 03_36, 03_37, 03_38, 03_39) Proceed as follows: - Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit white screen; make sure the vehicle axis is perpendicular to the screen.
  • Page 75 Each bulb has two light beam adjusting screws, one for horizontal adjustment «C» and 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.

  • Page 76: Front Direction Indicators

    03_39 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. 03_40...

  • Page 77: Rear Optical Unit

    Rear optical unit (03_41, 03_42) To access the rear light unit bulbs, undo the screw «A» and remove the glass «B». Now tighten the screw «A» in its seat. To replace the stop light bulb «C», hold it and turn it anticlockwise. To replace the rear tail light bulb «D», hold it and pull it outwards.

  • Page 78: Number Plate Light

    Number plate light (03_44) In order to reach the bulb, unscrew the two screws «C» and then remove the bulb holder. The instructions apply for both license plate lights. 03_44 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.

  • Page 79: Rear-View Mirrors

    Rear-view mirrors (03_46) The mirrors can be set to the desired position by adjusting the mirror frame. 03_46 Front and rear disc brake The brake disc and pad wear is automatically compensated, therefore it has no effect on the functioning of the front and rear brakes. For this reason it is not necessary to adjust the brakes.

  • Page 80: Puncture

    TER REPLACING THE BRAKE PADS, DO NOT USE THE SCOOTER UNTIL YOU HAVE OPERATED THE BRAKE LEVER SEVERAL TIMES IN ORDER TO ALLOW THE PLUNGERS TO SETTLE AND THE LEVER STROKE TO BE SET TO THE CORRECT POSITION. CAUTION THE PRESENCE OF SAND, MUD, SNOW MIXED WITH SALT, ETC. ON THE ROAD, CAN DRASTICALLY REDUCE THE LIFE OF THE BRAKE PADS.

  • Page 81: Inactivity Of The Vehicle

    WARNING THE WHEELS FITTED WITH TYRES SHOULD ALWAYS BE BALANCED. RIDING THE VEHICLE WITH VERY LOW TYRE PRESSURE OR WITH INCORRECTLY BALANCED TYRES CAN LEAD TO DANGEROUS STEERING VIBRATIONS. Inactivity of the vehicle (03_48) We recommend carrying out the following operations: 1.

  • Page 82: Cleaning The Vehicle

    Cleaning the vehicle Use a low pressure jet of water to soften the caked dirt and mud deposited on the painted surfaces. Once softened, sponge off mud and dirt using a car body sponge soaked in a car body shampoo and water solution (2-4% of car shampoo in water). Then rinse with abundant water, and dry with a shammy cloth.
  • Page 83 CAUTION NEVER WASH THE SCOOTER IN DIRECT SUNLIGHT, ESPECIALLY IN SUMMER WHEN THE BODYWORK IS STILL HOT AS THE SHAMPOO COULD DAMAGE THE PAINTWORK IF IT DRIES BEFORE BEING RINSED OFF. NEVER USE CLOTHS SOAKED IN ALCOHOL, PETROL, DIESEL OIL OR KEROSENE FOR CLEANING THE PAINTED OR PLASTIC SURFACES, IN ORDER NOT TO DAM- AGE THE LUSTRE FINISH OR ALTER THEIR MECHANICAL PROPERTIES.
  • Page 84 Faulty ignition / injection control Contact an Authorised Service unit. Centre. Faulty coil. Due to the presence of Contact an Authorised Service high voltage, this check should Centre. only be carried out by an expert. LACK OF COMPRESSION Loose spark plug. Screw in the spark plug tightly Cylinder head loose, piston gas Contact an Authorised Service...
  • Page 85 INEFFICIENT SUSPENSION Shock absorber fault, oil leak, end Contact an Authorised Service buffers damaged; shock absorber Centre. preloading incorrectly set AUTOMATIC TRANSMISSION PROBLEMS CVT rollers and/or drive belt Contact an Authorised Service damaged Centre. STAND DOES NOT RETURN TO POSITION Presence of dirt Clean and grease...

  • Page 87: Technical Data

    Fuoco 500ie LT Chap. 04 Technical data...
  • Page 88 04_01...
  • Page 89 ENGINE SPECIFICATIONS Type Single-cylinder, 4-stroke Engine capacity 493 cm³ Bore x Stroke 94 x 71 mm Compression ratio 10.5 ± 0.5: 1 Engine idle speed 1,500 ± 100 rpm Timing system Four valves, single overhead camshaft, chain-driven. Valve clearance Intake: 0.15 mm Exhaust: 0.15 mm Max.
  • Page 90 injection system, with variable advance, separate HV coil and double spark plug. Ignition advance Three-dimensional map managed by control unit Spark plug NGK CR7EKB Electrode gap 0.7 ÷ 0.9 mm Fuel system Electronic injection with electric fuel pump. Fuel Unleaded petrol (95 RON) Exhaust silencer Absorption-type exhaust muffler with catalytic converter and...
  • Page 91 Front brake Ø 240-mm double disc brake with hydraulic control operated by the handlebar right-hand lever. Rear drum Ø 240-mm disc brake with hydraulic control operated by the handlebar left-hand lever. Integral braking system The system operates all three discs simultaneously and is controlled hydraulically via the pedal on the footrest.

  • Page 92: Tool Kit

    Cooling system fluid ~ 2 l Fuel tank (reserve) ~12 l (~1.8 l) 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.

  • Page 93: Spare Parts And Accessories

    Fuoco 500ie LT Chap. 05 Spare parts and accessories...

  • Page 94: Warnings

    Warnings (05_01, 05_02) WARNING TO PREVENT ACCIDENTS AND TO GUARANTEE PROPER STABILITY, PER- FORMANCE AND SAFETY, RIDE THE VEHICLE VERY CAREFULLY WHEN IT IS FITTED WITH ACCESSORIES OR WITH UNUSUAL LOADS. WARNING 05_01 IT IS ALSO RECOMMENDED THAT ORIGINAL PIAGGIO SPARE PARTS BE USED, AS THESE ARE THE ONLY ONES OFFERING YOU THE SAME QUALITY GUARANTEE AS THOSE INITIALLY FITTED ON THE SCOOTER.
  • Page 95 THERE ARE NOT PAIGE ACCESSORIES FITTED, OR AN ABNORMAL LOAD, OR IF THE VEHICLE IS NOT IN A GENERALLY GOOD CONDITION, OR WHENEVER WEATHER CONDITIONS DEMAND IT, SPEED SHOULD BE FURTHER RE- DUCED. WARNING BE EXTREMELY CAREFUL WHEN INSTALLING AND REMOVING THE MECHAN- ICAL ANTITHEFT DEVICE ON THE VEHICLE (U-SHAPED PADLOCK, DISC BLOCK, ETC.).

  • Page 97: Scheduled Maintenance

    Fuoco 500ie LT Chap. 06 Scheduled maintenance...

  • Page 98: Scheduled Servicing Table

    Scheduled servicing table (06_01) Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it.
  • Page 99 Km x 1,000 Hub oil Steering Parking control unit software upgrading (if available) Centre stand Drive belt Air filter Sliding shoes / CVT rollers Suspension Spark plugs Roll lock calliper control cable Valve clearance 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...
  • Page 100 Product Description Specifications AGIP GP 330 Water repellent stringy calcium spray grease. R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 - I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Page 9022 EM 25-89 eni i-Ride PG 5W-40 Synthetic based lubricant for high-performance JASO MA, MA2 - API SL - ACEA A3 four-stroke engines.
  • Page 101 1 Cubic inch (in³) 16.4 Cubic centimetres (cm³) 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)
  • Page 103 TABLE OF CONTENTS Air filter: 59 Fuel: 25 Maintenance: 13, 51, 97 Tank: 25 Fuses: 66 Mirrors: 79 Technical Data: 87 Transmission: 42 Turn indicators: 77 Tyre pressure: 34 Battery: 64, 65 Tyres: 57 Brake: 49, 62, 79 Horn: 16 Puncture: 80 Hub oil: 55 Vehicle: 7, 81, 82...
  • Page 104 The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.

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