FUOCO
GILERA WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your scooter. Please read it carefully before riding
the scooter for the first time. It contains information, tips and precautions for using your scooter. It also describes features, details and devices to assure
you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle and it will serve you
well for a long time to come. This booklet forms an integral part of the scooter; should the scooter be sold, it must be transferred to the new owner.
Fuoco 500ie
Ed. 2
The instructions given in this manual are intended to provide a clear, simple guide to using your scooter; this booklet also details routine maintenance
procedures and regular checks that should be carried out on the vehicle at an authorised Dealer or Service Centre. The booklet also contains
instructions for simple repairs. Any operations not specifically described in this manual require the use of special tools and/or particular technical
knowledge: to carry out these operations refer to any authorised Dealer of Service Centres.
2
Personal safety
Failure to completely observe these instructions will result in serious risk of personal
Safeguarding the environment
Sections marked with this symbol indicate the correct use of the vehicle to prevent dam-
aging the environment.
The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
The signs that you see on this page are very important. They are used to highlight those
parts of the booklet that should be read with particular care. As you can see, each sign
consists of a different graphic symbol, making it quick and easy to locate the various
topics.
injury.
Vehicle intactness
3
4
INDEX
VEHICLE...................................................................................... 7
Dashboard................................................................................ 9
Analogue instrument panel....................................................... 11
Clock......................................................................................... 12
Digital lcd display...................................................................... 12
Maintenance icons................................................................ 13
*MODE* button...................................................................... 13
Key switch................................................................................. 14
Locking the steering wheel.................................................... 14
Releasing the steering wheel................................................ 15
Switch direction indicators........................................................ 15
Horn button............................................................................... 16
Light switch............................................................................... 16
Emergency flashing light button................................................ 16
Start-up button.......................................................................... 17
Engine stop button.................................................................... 17
Front suspension unlock-lock switch........................................ 17
The immobilizer system............................................................ 18
Keys...................................................................................... 18
Immobilizerdevice enabled indicator led............................... 19
Operation............................................................................... 19
Programming the immobilizer system................................... 20
Saddle opening remote control................................................. 21
Remote control programming................................................ 22
Accessing the fuel tank............................................................. 23
Power supply socket................................................................. 24
The saddle................................................................................ 24
Opening the saddle to access the helmet compartment by
remote control....................................................................... 24
Opening the saddle............................................................... 25
Identification.............................................................................. 26
Bag clip..................................................................................... 26
USE.............................................................................................. 27
Checks...................................................................................... 28
Refuelling.................................................................................. 28
Tyre pressure............................................................................ 30
Shock absorbers adjustment.................................................... 31
Running in................................................................................. 32
Starting up the engine............................................................... 33
Precautions........................................................................... 35
Difficult start up......................................................................... 35
Stopping the engine.................................................................. 36
anello antifurto.......................................................................... 36
Stand......................................................................................... 37
Automatic transmission............................................................. 37
Safe driving............................................................................... 37
Front suspension locking system.............................................. 40
MAINTENANCE........................................................................... 45
Engine oil level.......................................................................... 46
Engine oil level check............................................................ 46
Engine oil top-up................................................................... 46
Warning light (insufficient oil pressure)................................. 46
Engine oil change.................................................................. 47
Hub oil level.............................................................................. 48
Tyres......................................................................................... 50
Spark plug dismantlement........................................................ 51
Removing the air filter............................................................... 52
Air filter cleaning....................................................................... 52
Cooling fluid level...................................................................... 53
Checking the brake oil level...................................................... 55
Braking system fluid top up................................................... 55
Battery....................................................................................... 57
Use of a new battery............................................................. 57
Long periods of inactivity.......................................................... 58
Fuses........................................................................................ 58
Front light group........................................................................ 63
5
Headlight adjustment............................................................. 64
Front direction indicators........................................................... 67
Rear optical unit........................................................................ 68
Rear turn indicators................................................................... 68
Number plate light..................................................................... 69
Helmet compartment lighting bulb............................................ 69
Rear-view mirrors...................................................................... 69
Front and rear disc brake.......................................................... 70
Puncture.................................................................................... 71
Periods of inactivity................................................................... 71
Cleaning the vehicle.................................................................. 72
TECHNICAL DATA...................................................................... 77
Kit equipment............................................................................ 82
SPARE PARTS AND ACCESSORIES........................................ 83
Warnings................................................................................... 84
PROGRAMMED MAINTENANCE............................................... 87
Scheduled maintenance table................................................... 88
6
Fuoco 500ie
Chap. 01
Vehicle
7
01_01
8
Dashboard (01_01)
1 Vehicle
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
9
10
01_02
Analogue instrument panel (01_02)
1 Vehicle
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 failure warning light
M = Low fuel warning light
N = Engine stop warning light
O= Turn indicator warning light
P = Low oil pressure warning light
Q = Front suspension locking system failure warning light
R = Warning light for parking brake engaged
S = High-beam warning light
11
01_03
01_04
Clock (01_03)
Pushing the «CLOCK» button for less than 1 second displays the following sequence:
•
TIME
•
DATE
To set the clock push and hold the «CLOCK» button longer than 3 seconds.
The numbers showing the hours will begin flashing.
Set the hour using the «SET» button. Push the «CLOCK» button again and the mi-
nutes numbers start flashing.
Set the minutes using 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 process, not pressing any buttons for a period longer than 8 seconds
ends the process automatically and the display shows the modified time.
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)
F = TIME-DATE indicator
12
1 Vehicle
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
01_05
01_06
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 maintenance service. A flashing «BELT» icon signals the driving belt needs replacing. In any
case, vehicle maintenance must be carried out at the kilometre service intervals recommended in this booklet.
WARNING
REFER TO THE «SCHEDULED MAINTENANCE TABLE» FOR FURTHER MAIN-
TENANCE OPERATIONS
*MODE* button (01_05, 01_06)
Pushing the ''MODE'' «S» button for less than a second displays the following sequence 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.
UNIT OF MEASUREMENT SETTING
Press and hold the "MODE" «S» button for at least 3 seconds and at the same time
turn the ignition key to "on".
The icons "kmi" and "°E" will start flashing.
13
01_07
"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.
Key switch (01_07)
The key switch «A» is located on the front knee-guard panel near the bag hook.
SWITCH POSITIONS
1. LOCK = Ignition disabled, extractable key, mechanical antitheft device enabled. The parking brake cannot be released when engaged and can be
engaged when released.
« OFF » = Ignition disabled, extractable key, mechanical antitheft device dis-
2.
abled and enabled/disabled parking brake.
3. ON = Ready to start, non-extractable key, mechanical antitheft device disabled.
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 it will go; turn the key «B» to «LOCK » and
remove it.
14
1 Vehicle
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.
Switch direction indicators (01_09)
Lever «F» towards «1» = left turn indicators switched on;
Lever «F» towards «2» = right turn indicators switched on;
The lever «F» automatically returns to «0 » and the turn indicators remain on; push
the lever «F» to turn them off.
01_09
15
01_10
01_11
Horn button (01_10)
Push the button «E» to sound the horn.
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» and the vehicle is not running, only the tail light
is on.
When the ignition key is set to «ON» and the vehicle is running, the low-beam lights
will turn on two seconds after the ignition; when the high-beam lights turn on, the lowbeam lights turn off.
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 keeps functioning even
if the key is set to «OFF» or «LOCK». To disable this function, simply turn the key
switch to «ON».
01_12
16
1 Vehicle
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» 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
01_14
01_15
DO NOT OPERATE THE ENGINE STOP SWITCH "N" WHILE RIDING UNLESS
THERE IS AN EMERGENCY.
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.
17
The immobilizer system
In order to enhance theft protection, the scooter is equipped with a «PIAGGIO IMMOBILIZER » electronic engine locking device that is activated automatically when
the starter key is removed. Upon start-up, the «PIAGGIO IMMOBILIZER» system
checks the starter key, and only if this key is recognised will the immobilizer system
allow the scooter to be started.
Keys (01_16, 01_17, 01_18)
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 maintenance operations. For this reason it
is advised that it be used only in exceptional circumstances.
The key «B» (single copy supplied) is used for regular operations such as:
- Engine start-up.
- Remote control saddle opening.
Together with the two keys, you will be given a CODE CARD bearing the same code
imprinted onto the two keys.
WARNING
LOSING THE RED KEY PREVENTS ANY REPAIRS OF THE "PIAGGIO IMMOBILIZER" SYSTEM AND THE ENGINE CONTROL UNIT.
18
1 Vehicle
01_19
WARNING
KEEP THE "CODE CARD" AND THE RED HANDGRIP KEY IN A SAFE PLACE
(NOT ON YOUR VEHICLE).
Immobilizerdevice enabled indicator led (01_19)
Activation of the "PIAGGIO IMMOBILIZER" system is signalled by a flashing «A»
indicator. In order to reduce battery discharge, the indicator LED turns off automatically
after 48 hours of uninterrupted functioning. Should the system fail, different LED flashing patterns will provide the Authorised Service Centre with information on the type
of fault detected.
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. If the code is not recognised, turn the key first to "OFF" and then to "ON"; if lock
persists, try again using the «A» MASTER key. If the engine cannot be started, contact
an Authorised Service Centre, which is provided with the electronic equipment re-
quired to detect and repair 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 engine.
19
WARNING
EACH KEY HAS ITS OWN AND UNIQUE CODE, WHICH MUST BE STORED BY
THE SYSTEM CONTROL UNIT.
VIOLENT SHOCKS MAY AFFECT THE ELECTRONIC COMPONENTS OF THE
KEY.
IF THE VEHICLE IS SOLD, THE MASTER-HANDGRIP KEY (AS WELL AS THE
OTHER STARTER KEYS) AND THE "CODE CARD" MUST ALSO BE TRANSFERRED TO THE NEW OWNER.
Programming the immobilizer system
Below is described the procedure to follow for programming the PIAGGIO IMMOBILIZER 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» key into the switch (in "OFF" position), turning it to «ON» position. After 1 - 3 seconds, turn the key to "OFF" again and pull it out.
INTERMEDIATE STAGE
After extracting the «MASTER» key, insert, within ten seconds, the key that is going
to be programmed and turn it immediately to «ON» position. After 1-3 seconds, turn
the key to "OFF" again and pull it out. In this way, a maximum of 7 keys can be programmed 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-
20
traction of the previous key). Leave it in this position for 1 to 3 seconds and return it
1 Vehicle
to the «OFF» position.
01_20
CORRECT PROGRAMMING CHECK PHASE
Insert the «MASTER» key, disabling the transponder (i.e., by tilting the key cap by
90°), and turn the key to «ON» position. Perform the engine start-up operation. Ensure
that the engine does not start. Insert the programmed key and repeat the start-up
operation. Check that engine starts.
WARNING
SHOULD YOU STAR THE ENGINE WITH THE MASTER KEY (WITH TRANSPONDER OFF) OR IN THE EVENT OF WRONG OPERATION DURING PROGRAMMING, 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. If the remote control is lost, a new one
can be requested and programmed at any Authorised Service Centre. The remote
control is powered by inner batteries that get discharged after extended used; If the
green LED turns on when the button is pressed, the remote control is working properly.
You may need to replace the batteries if the remote 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. When the
remote control is open, remove the two batteries from the contact terminal. Install the
two new CR1616 3V batteries with the positive pole facing the contact terminal.
Reassemble the remote control by pressing the two clip-on halves gently with your
fingers.
To open the saddle without the remote control, follow the procedure described in the
«Emergency Saddle Opening» section.
21
Remote control programming
Follow these steps to program the remote controls:
1. Insert the remote control key to be programmed in the steering lock key block.
2. Turn the key to «ON», press the button on the remote control, release the button,
turn the key back to «OFF» from the «ON» position, all within 4 seconds.
3 Wait 1 to 8 seconds.
4. Repeat steps 2 and 3 for 4 times without removing the key.
The control unit confirms the programming has been successfully executed by opening the saddle.
WARNING
TO STORE THE OTHER REMOTE CONTROLS TO MEMORY, (MAXIMUM 8), YOU
NEED TO REPEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUT
THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE
AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE
REMOTE-CONTROLLED KEYS.
WARNING
AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN
FAR AWAY FROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RECEIVER CAN BE IMPAIRED. SHOULD THIS BE
THE CASE, REPEAT THE PROGRAMMING PROCEDURE. DO NOT KEEP THE
REMOTE CONTROL IN PLACES WITH TEMPERATURES EXCEEDING 60° C THE
BATTERY WILL RUN DOWN TOO QUICKLY.
22
1 Vehicle
WARNING
TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL
RADIO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE
WAS SHUT OFF.
JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER.
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
23
Power supply socket (01_23)
There is a plug socket "D" inside the helmet compartment.
The plug socket may be used for external consumers (mobile phone, inspection light,
etc.).
CAUTION
01_23
01_24
PROLONGED USE OF THE PLUG SOCKET MAY RESULT IN PARTIAL DISCHARGE OF THE BATTERY
Electric characteristic
Plug socket
12 V - 180 W MAX
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
DO NOT USE THE VEHICLE WITHOUT THE PROTECTION COVER.
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".
24
1 Vehicle
01_25
01_26
WARNING
OBJECTS INAPPROPRIATELY ARRANGED INSIDE THE HELMET COMPARTMENT MAY DEFORM THE SADDLE CAUSING THE COURTESY LIGHT TO REMAIN 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 METRES WITH FULLY CHARGED BATTERIES. WHEN YOU ARE NEAR THE
SCOOTER, HANDLE THE REMOTE CONTROL CAREFULLY SO AS TO AVOID
UNINTENTIONAL OPENING OF THE SADDLE. REFER TO THE «OPENING THE
SADDLE WITH REMOTE CONTROL» SECTION TO REPLACE BATTERIES.
Opening the saddle (01_27)
With the key set to «ON» or «OFF», press it and turn it anticlockwise.
01_27
25
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. 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
01_28
01_29
01_30
BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS
CAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE,
ETC.).
Chassis number
To read the chassis number, remove the lid «A» in the helmet compartment.
Engine number
The engine number «B» is stamped near the rear left shock absorber lower support.
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.
26
Fuoco 500ie
Chap. 02
Use
27
Checks
Before using the vehicle, check:
1. There is enough fuel in the fuel tank.
2. The correct fluid level for front and rear brakes.
3. That tyres are properly inflated.
4. The correct functioning of tail lights, headlamp, turn indicators, stop light and license
plate light.
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.
Refuelling (02_01, 02_02)
Fuel: Open the access door to the fuel tank cap and remove the cap«T».
Recommended fuel: Unleaded petrol, min octane rating of 95. The instrument «H»
indicates the fuel level and the warning light «M» indicates the reserve.
WARNING
02_01
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 OR
ANY PLASTIC PARTS.
28
2 Use
CAUTION
PETROL DAMAGES THE PLASTIC PARTS OF THE BODYWORK.
WARNING
02_02
DO NOT RIDE WITH THE FUEL TANK ALMOST EMPTY, LACK OF FUEL CAN
DAMAGE THE CATALYTIC CONVERTER.
CAUTION
USING NON-RECOMMENDED PETROL REDUCES THE EFFICIENCY OF THE
EXHAUST AND FUEL SUPPLY SYSTEMS.
CAUTION
DO NOT USE THE VEHICLE TO THE COMPLETE EXHAUSTION OF THE FUEL;
IN THE EVENT THAT THIS SHOULD OCCUR, DO NOT ATTEMPT TO START THE
ENGINE. TURN THE KEY SWITCH TO OFF AND TOP-UP THE TANK AS SOON
AS POSSIBLE. FAILURE TO FOLLOW THESE GUIDELINES COULD DAMAGE
THE FUEL PUMP AND/OR THE CATALYTIC CONVERTER.
WARNING
IT IS HIGHLY INADVISABLE TO REFUEL USING METHODS OTHER THAN NORMAL FUEL PUMPS. IF PETROL IS NOT COMPLETELY CLEAN, IT CAN DAMAGE
THE FUEL SUPPLY SYSTEM FILTERS.
29
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