Page 1 SERVICE STATION MANUAL XXXX Fuoco 500 i.e.
Page 2 The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA 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.
Page 3 This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Fuoco 500 i.e. Characteristics This section describes the general specifications of the vehicle. Rules This section describes general safety rules for any maintenance operations performed on the scooter. Safety rules - If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary;...
Page 9 Fuoco 500 i.e. Characteristics Vehicle identification Frame prefix (A): ZAPM61100 Engine prefix (B): M661M Dimensions and mass CHAR - 3...
Page 10 Fuoco 500 i.e. Characteristics WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 253 ± 5 kg Maximum weight allowed 445 kg Maximum height 1.210 mm Width 790 mm Wheelbase 1.550 mm length 2.210 mm Track 420 mm Engine ENGINE Specification Desc./Quantity...
Page 11: Electrical System
Fuoco 500 i.e. Characteristics Specification Desc./Quantity Transmission oil 250 cm³ Cooling system fluid ~ 1.8 l Fuel tank (reserve) ~ 12 l (~2 l) Electrical system ELECTRICAL SYSTEM Specification Desc./Quantity Start-up Electric Ignition High efficiency electronic inductive ignition, inte- grated with the injection system, with variable ad- vance and separate HV coil.
Page 12: Table Of Contents
Fuoco 500 i.e. Characteristics Specification Desc./Quantity Rear rim 14'' x 4.50 Front tyre Tubeless 120/70-12" 51S or 51P Rear tyre Tubeless 140/70 - 14" 68S or 68P reinf Front tyre pressure (with passenger) 1.6 bar (1.8 bar) Rear tyre pressure (with passenger) 2.4 bar (2.6 bar)
Page 13: Upper Shock Absorber Clamp
Fuoco 500 i.e. Characteristics Name Torque in Nm Lower fitting for shock absorber sliding locking 20 ÷ 25 clamp pipes Upper fitting for shock absorber sliding locking 20 ÷ 25 clamp pipes REAR SUSPENSION Name Torque in Nm Upper shock absorber clamp 33 ÷...
Page 14 Fuoco 500 i.e. Characteristics THERMAL UNIT AND TIMING SYSTEM Name Torque in Nm Spark plug 12 ÷ 14 Head fixing stud bolts: Head fixing nuts 10 - 12 Exhaust / intake head fixing nuts: 10 - 12 Head lubrication control jet...
Page 15 Fuoco 500 i.e. Characteristics Name Torque in Nm Gear mounting on crankshaft screws 10 -12 Bulkhead screws for oil pump housing cover 8 - 10 COOLING Name Torque in Nm Water pump rotor cover 3 ÷ 4 Thermostat cover screws 3 ÷...
Page 16 Fuoco 500 i.e. Characteristics HEIGHT TO MEASURE THE PISTON Specification Desc./Quantity 10 mm 43 mm CYLINDER - PISTON Specification Desc./Quantity Cylinder diameter C 94 +0.018-0.01mm Piston diameter P 93.968 - ±0.014 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting Cylinder- Piston 93.990÷93.997...
Page 17 Fuoco 500 i.e. Characteristics Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Rings/housing coupling clearances: Carefully clean the sealing ring housings. Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances.
Page 18 Fuoco 500 i.e. Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 1 ± 0.025 D = 0.20 ÷ 0.50 shoulder Half-shaft, trans- 20.9 - 0.05 D = 0.20 ÷ 0.50...
Page 19 Fuoco 500 i.e. Characteristics Diameter of crankshaft bearings. Measure the capacity on both axes x-y. CRANKSHAFT Specification Desc./Quantity Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022 Crankshaft alignment Specific tooling 020335Y Magnetic support for dial gauge MAX.
Page 20 Fuoco 500 i.e. Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.1 ÷ 0.405 mm (when cold) Compression ratio 10.5: 1 Slot packing system Shimming system to control compression ratio DISTANCE «A» IS A PROTRUSION OR RE- CESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE.
Page 21 Fuoco 500 i.e. Characteristics Characteristic Compression ratio 10.5: 1 BASE GASKET THICKNESS Name Measure A Thickness «A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 - + 0.185...
Page 22 Fuoco 500 i.e. Characteristics CHAR - 16...
Page 23 INDEX OF TOPICS TOOL OOLING...
Page 24 Fuoco 500 i.e. Tooling SPECIFIC TOOLS CORRECT Stores code Description 001330Y Tool for fitting steering seats 001467Y002 Driver for OD 73 mm bearing 001467Y006 Extraction pliers for 20 mm bear- ings 001467Y007 Driver for OD 54 mm bearing 001467Y008 Extraction pliers for ø 17 mm...
Page 25 Fuoco 500 i.e. Tooling Stores code Description 001467Y031 Bell 001467Y034 Extraction pliers for ø 15 mm bearings 001467Y035 Bearing housing outside diame- ter 47 mm 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y...
Page 26 Fuoco 500 i.e. Tooling Stores code Description 020151Y Air heater 020193Y Oil pressure gauge 020201Y Spacer bushing driving tube 020262Y Crankcase splitting strip 020306Y Punch for assembling valve seal rings 020329Y Mity-Vac vacuum operated pump 020330Y Stroboscopic light for timing con-...
Page 27 Fuoco 500 i.e. Tooling Stores code Description 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020358Y 37x40 mm adaptor 020359Y 42 x 47 mm adaptor...
Page 28 Fuoco 500 i.e. Tooling Stores code Description 020360Y 52 x 55 mm adaptor 020364Y 25 mm guide 020376Y Adaptor handle 020382Y012 bush (valve removing tool) 020412Y 15 mm guide 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor...
Page 29 Fuoco 500 i.e. Tooling Stores code Description 020434Y Oil pressure control fitting 020439Y 17 mm guide 020444Y Tool for fitting/ removing the driv- en pulley clutch 020456Y Ø 24 mm adaptor 020458Y Puller for lower bearing on steer- ing tube...
Page 30 Fuoco 500 i.e. Tooling Stores code Description 020459Y Punch for fitting bearing on steer- ing tube 020460Y Scooter diagnosis and tester 020467Y Flywheel extractor 020468Y Piston fitting band 020469Y Reprogramming kit for scooter diagnosis tester TOOL - 8...
Page 31 Fuoco 500 i.e. Tooling Stores code Description 020470Y Pin retainers installation tool 020471Y Pin for countershaft timing 020472Y Flywheel lock wrench 020474Y Driving pulley lock wrench 020475Y Piston position checking tool 020476Y Stud bolt set TOOL - 9...
Page 32 Fuoco 500 i.e. Tooling Stores code Description 020478Y Punch for driven pulley roller cas- 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide TOOL - 10...
Page 33 Fuoco 500 i.e. Tooling Stores code Description 020512Y Piston fitting fork 020527Y Engine support base 020604Y011 Fitting adapter 020565Y Flywheel lock calliper spanner Marelli MIU diagnosis software Marelli MIU diagnosis software 020640y software euro3 TOOL - 11...
Page 34 Fuoco 500 i.e. Tooling TOOL - 12...
Page 35 INDEX OF TOPICS MAIN AINTENANCE...
Page 36: Maintenance Chart
Fuoco 500 i.e. Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.
Page 37 Fuoco 500 i.e. Maintenance AFTER 10,000 KM; 50,000 KM; 70,000 KM Action Safety locks - check Driving belt - replacement Throttle lever - adjustment Air filter - clean Engine oil - change Electrical system and battery - check Coolant level - check...
Page 38 Fuoco 500 i.e. Maintenance 30,000 KM Action Safety locks - check Driving Belt - replacement Throttle lever - adjustment Air filter - cleaning Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check...
Page 39 Fuoco 500 i.e. Maintenance - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph. - Refit the spark plugs. - Refit the plastic cap on the flywheel cover. - Adjust the spark gap to the contact position (no...
Page 40: Spark Plug
Fuoco 500 i.e. Maintenance Spark plug Remove the port on the left-hand side panel of the vehicle by undoing the fixing screw and using a small screwdriver in the rear recess shown in the figure, then do the following: - Disconnect the HV wire caps «A» of the spark plugs;...
Page 41 Fuoco 500 i.e. Maintenance Hub oil Check -Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely; Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end;...
Page 42: Air Filter
Fuoco 500 i.e. Maintenance Air filter Proceed as follows: Unscrew the nine fixing screws «A» and remove the air filter cover. - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of compressed air.
Page 43 Fuoco 500 i.e. Maintenance Replacement Replace oil and filter as indicated in the scheduled maintenance table. Empty the engine by draining the oil through drainage plug «B». To facilitate oil drainage, loosen the cap/dipstick «A». Once all the oil has drained through the drainage opening, unscrew and remove the oil cartridge fil- ter «C ».
Page 44 Fuoco 500 i.e. Maintenance a few minutes and switch it off: after five minutes check the level and if necessary top up without exceeding the MAX level. The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended type for topping up and changing purposes.
Page 45: Engine Oil Filter
Fuoco 500 i.e. Maintenance Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level from the MIN to the MAX marks requires approx.
Page 46: Checking The Ignition Timing
Fuoco 500 i.e. Maintenance Checking the ignition timing -Remove the plastic cap on the flywheel cover - Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make...
Page 47: Braking System
Fuoco 500 i.e. Maintenance Recommended products AGIP PERMANENT SPEZIAL Coolant Monoethylene glycol based antifreeze solution, CUNA NC 956-16 Braking system Level check The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows: - Rest the vehicle on its centre stand with the han- dlebars perfectly horizontal;...
Page 48: Headlight Adjustment
Fuoco 500 i.e. Maintenance Recommended products AGIP BRAKE FLUID DOT4 Brake fluid FMVSS DOT4 Synthetic fluid Headlight adjustment Proceed as follows: - Position the unloaded vehicle, in running order and with the tyres inflated to the prescribed pres- sure, onto a flat surface 10 m away from a half-lit white screen;...
Page 49 Fuoco 500 i.e. Maintenance Each bulb has two light beam adjusting screws, one for horizontal adjustment «C» and one for the vertical adjustment «D». Adjust one headlamp at a time. In order to do that, remove the connector from the other bulbs so that you can adjust one headlamp at a time.
Page 50 Fuoco 500 i.e. Maintenance MAIN - 16...
Page 51 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 52 Fuoco 500 i.e. Troubleshooting This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause...
Page 53 Fuoco 500 i.e. Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.
Page 54 Fuoco 500 i.e. Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...
Page 55 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 56 Fuoco 500 i.e. Electrical system 1. Parking electronic control unit 2. Right speed sensor 3. Left speed sensor 4. Potentiometer 5. Rider presence sensor 6. Magneto flywheel 7. Locking/unlocking switch 8. LV socket 9. Voltage regulator 10. Main fuses 11. Key switch contacts 12.
Page 57 Fuoco 500 i.e. Electrical system 20. Stop button on rear brake 21. Stop button on front brake 22. Starter button 23. Saddle opening receiver 24. Wiring for antitheft device 25. Helmet compartment light switch 26. Turn indicator switch 27. Turn signal command device 28.
Page 58 Fuoco 500 i.e. Electrical system 51. Injector 52. Fuel pump 53. Revolution sensor 54. HV coil 55. Injection ECU 56. Immobilizer aerial 57. Brake calliper sensor 58. Diagnosis connector 59. Coolant temperature sensor 60. Lambda probe 61. MIU control unit power device 62.
Page 59 Fuoco 500 i.e. Electrical system 1. Relays for lights/ horn/ injection load/ electric fan: remove the front shield to reach these relays. 2 - Auxiliary fuses: remove the footrest flap to reach these fuses. ELE SYS - 5...
Page 60 Fuoco 500 i.e. Electrical system 3 / 4 / 19 - Electronic control unit for injection (MIU) / Start-up relay / Start-up enabling switch relay: remove the lid of the helmet compartment to reach these relays. 5 - 6. Fuel pump / Fuel level sensor: remove the central chassis cover to reach these components.
Page 61 Fuoco 500 i.e. Electrical system 10.Coil: remove the helmet compartment to reach 7 - Voltage regulator: remove the right side panel to reach it. 8 - Immobilizer: remove the shield back plate. 9 / 18 - Saddle opening receiver/ Turn indicator control device: remove the left fairing to reach them;...
Page 62 Fuoco 500 i.e. Electrical system 11 / 12 - Diagnostics socket/ main fuses: these components are found in the helmet compartment. 13 - Lambda probe: The lambda probe is mounted on the exhaust manifold. 14 - Engine oil pressure sensor: remove the ex- haust end to reach it.
Page 63 Fuoco 500 i.e. Electrical system 16 - Rider presence sensor: open the saddle and remove the cover to reach the rider presence sen- sor. 17 - Coolant temperature sensor: remove the lid of the helmet compartment and disconnect the con- nector to reach it.
Page 64 Fuoco 500 i.e. Electrical system Ignition 10. Main fuses 11. Key switch contacts 12. Auxiliary fuses 15. Battery 50. Injection load remote control 54. HV coil 55. Injection ECU 56. Immobilizer aerial 61. MIU control unit power device ELE SYS - 10...
Page 65 Fuoco 500 i.e. Electrical system Battery recharge and starting 6. Magneto flywheel 9. Voltage regulator 10. Main fuses 11. Key switch contacts 12. Auxiliary fuses 14. Fuse 15. Battery 16. Starter motor 17. Start-up remote control switch 19. Start-up enabling remote control 20.
Page 66 Fuoco 500 i.e. Electrical system 61. MIU control unit power device Level indicators and enable signals section 1. Parking electronic control unit 2.Right speed sensor 3.Left speed sensor 4. Potentiometer 5. Rider presence sensor 10. Main fuses 11. Key switch contacts 12.
Page 67 Fuoco 500 i.e. Electrical system 53. Rpm sensor 55. Injection ECU 56. Immobilizer aerial 57. Brake calliper sensor 59. Coolant temperature sensor 60. Lambda probe 61. MIU control unit power device Devices and accessories 1. Parking electronic control unit 7. Locking/unlocking switch 8.
Page 68 Fuoco 500 i.e. Electrical system 24. Wiring for antitheft device 25. Helmet compartment light switch 31. Helmet compartment light bulb 42. MODE button 43. Instrument panel 46. Horn 47. Horn button 48. Horn remote control 49. Pressure sensor 50. Injection load remote control 52.
Page 69 Fuoco 500 i.e. Electrical system 1. Parking electronic control unit 10. Main fuses 11. Key switch contacts 12. Auxiliary fuses 13. Key switch contacts 15. Battery 26. Turn indicator switch 27. Turn signal command device 28. Hazard button 29. Light switch 30.
Page 70 Fuoco 500 i.e. Electrical system Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem. The immobilizer is an antitheft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.
Page 71 Fuoco 500 i.e. Electrical system Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: • if there is battery voltage between ter- minals 6-26 and terminal 6-chassis ground (fixed power supply).
Page 72 Fuoco 500 i.e. Electrical system Remove the protective base from the connector. With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring .
Page 73 Fuoco 500 i.e. Electrical system first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
Page 74 Fuoco 500 i.e. Electrical system ted but with a limitation imposed on the number of revs. 2. Previously unused control unit - transpond- er absent or cannot be used: The LED is per- manently ON; in this condition, no operations are possible, including starting of the vehicle.
Page 75 Fuoco 500 i.e. Electrical system Diagnostic code - 2 flashes Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
Page 76 Fuoco 500 i.e. Electrical system Electric characteristic Resistance: 0.2 - 1 Ω 4) Check that there is insulation between the each yellow cable and the earth. 5) If values that are wrong are noted, replace the stator. Recharge system voltage check Look for any leakage 1) Access the battery by removing its cover under the saddle.
Page 77 Fuoco 500 i.e. Electrical system Specification Desc./Quantity Voltage 14 ÷ 15V at 5000 rpm with lights off Fuses The electrical system has twelve fuses divided into two fuse boxes to protect the different installation circuits. One of them is inside the battery compart- ment «A»...
Page 78 Fuoco 500 i.e. Electrical system FUSE TABLE Specification Desc./Quantity Fuse No. 1 Capacity: 7.5 A Protected circuits:Injection ECU battery power Fuse No. 2 Capacity: 15 A Protected circuits:Battery-powered injec- tion loads, electrical fan Fuse No. 3 Capacity: 15 A Protected circuits:Battery-powered saddle...
Page 79 Fuoco 500 i.e. Electrical system Dashboard A = Led immobilizer / anti-theft device B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E = Front suspension locking system warning light (if available) F = SET switch...
Page 80 Fuoco 500 i.e. Electrical system C = High-beam warning light A = Total odometer gauge B = «BELT» maintenance icon C = «SERVICE» maintenance icon D = Engine coolant temperature indicator E = Trip odometer gauge (A-B) and ambient temperature (selected with the MODE button)
Page 81 Fuoco 500 i.e. Electrical system Connectors INJECTION ELECTRONIC CONTROL UNIT 1. Injection telltale light (Brown-Black) 2. Rpm indicator on instrument panel (Yellow) 3. CAN "L" Line (White-Blue) 4. Lambda probe (-) (White-Green) 5. Live supply (Red-White) 6. Battery powered (Orange-Black) 7.
Page 82 Fuoco 500 i.e. Electrical system VOLTAGE REGULATOR CONNECTOR 1. +Battery (Red-Black) 2. Ground (Black) 3. +Battery (Red-Black) 4. Ground (Black) SADDLE OPENING RECEIVER CONNECTOR 1. Aerial (Purple) 2. Saddle opening actuator (Yellow-Grey) 3. Reset (Blue-Black) 4. Battery powered (Blue) 5. Not connected 6.
Page 83 Fuoco 500 i.e. Electrical system HV COIL CONNECTOR 1. Injection load remote control (Black-Green) 2. Injection electronic control unit (Pink-Black) ANTI-THEFT DEVICE PRE-INSTALLATION CONNECTOR 1. LHS Turn indicators (Pink) 2. RHS Turn indicators (White-Blue) 3. Ground (Black) 4. Battery powered (Blue) 5.
Page 84 Fuoco 500 i.e. Electrical system 11. Ground (Black) 12. Live supply (Yellow-Red) INSTRUMENT PANEL CONNECTOR "B" 1. Scooter speed signal (Sky blue) 2. Fuel level signal (White-Green) 3. Water temperature sensor (Sky blue-Black) 4. Water temperature sensor ground lead (Brown- White) 5.
Page 85 Fuoco 500 i.e. Electrical system 8. Ground (Black) 1B. Live supply (Yellow-Red) 2B. CAN "H" Line (Pink-White) 3B. Left wheel turning sensor (Green) 4B. Right wheel turning sensor (Red) 5B. Potentiometer signal (Green-Blue) 6B. Locking/unlocking switch (Green-Grey) 7B. Horn remote control for alarms (White) 8B.
Page 86 Fuoco 500 i.e. Electrical system 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 the «ON» position, press the button on the remote control, release the button, turn the key back to the «OFF»...
Page 87 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 88 Fuoco 500 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the side fairings. - Remove the central frame cover. - Remove the exhaust end.
Page 89 Fuoco 500 i.e. Engine from vehicle CAUTION THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD. - Remove the rear wheel. - Remove the bracket supporting the rear brake callipers and the callipers as well. - After removing the air filter from the crankcase, undo the screws fixing the bracket that secures the rear brake pipes.
Page 90 Fuoco 500 i.e. Engine from vehicle - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cables from the throttle body by undoing the nuts indicated in the photograph.
Page 91 Fuoco 500 i.e. Engine from vehicle Remove the lower screw of the left-hand shock absorber. - Remove the engine-swinging arm fixing pin by undoing the nut and operating on the head of the pin as shown in the photograph. - The engine is now free.
Page 92 Fuoco 500 i.e. Engine from vehicle ENG VE - 6...
Page 93 INDEX OF TOPICS NGINE...
Page 94: Automatic Transmission
Fuoco 500 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap.
Page 95 Fuoco 500 i.e. Engine - Remove the six M6 screws. - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. Air duct - Remove the transmission cover. - Unscrew the two screws shown in the figure to remove the air conveyor.
Page 96 Fuoco 500 i.e. Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover.
Page 97 Fuoco 500 i.e. Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COV- ER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.
Page 98 Fuoco 500 i.e. Engine Anti-vibration roller screw 16.7 - 19.6 Removing the driven pulley - Remove the clutch bell. - Remove the fixed driving half-pulley. - Remove the driven pulley assembly with the belt. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.
Page 99: Removing The Clutch
Fuoco 500 i.e. Engine Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool; - Arrange the tool with the mean pins screwed in position "E" on the inside; - Fit the adapter ring to the clutch assembly as shown in the photograph.
Page 100 Fuoco 500 i.e. Engine - Do not open the masses using tools to prevent a variation in the return spring load. Pin retaining collar - Extract the collar using 2 screwdrivers. - Remove the 4 guide pins. - Extract the moving driven half-pulley.
Page 101 Fuoco 500 i.e. Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PRE- VENT DAMAGING THE THREADING. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide N.B.
Page 102 Fuoco 500 i.e. Engine Inspecting the driven sliding half-pulley - Check that the belt contact surface is free from wear. - Remove the 2 inside sealing rings and the 2 out- side O-rings. - Measure the movable half-pulley bushing inside diameter.
Page 103 Fuoco 500 i.e. Engine Refitting the driven pulley - Insert the new oil guards - Insert the new O-rings N.B. O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RA- DIUS, AT THE BASE OF THE HALF-PULLEY.
Page 104 Fuoco 500 i.e. Engine Refitting the clutch - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool.
Page 105 Fuoco 500 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width 27.5 mm Overall width 28.7 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut to horizontally align the central inside holes and install the special tool.
Page 106 Fuoco 500 i.e. Engine - Move the belt downwards. - Suitable support the roller contrast and extract the mobile driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out. Inspecting the rollers case - Check that the inside bushings shown in the figure are not worn and measure the inside diameter.
Page 107 Fuoco 500 i.e. Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves. Refitting the driving pulley Installing the roller container - Install the spacer with the internal chamfer facing towards the inside.
Page 108 Fuoco 500 i.e. Engine - Insert the half-pulley on the crankshaft. - Insert the spacer bushing. Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the moving driving pulley.
Page 109 Fuoco 500 i.e. Engine - Insert the nut in the original position (nut side in contact with the belleville washer). - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY INSERTED INTO THE PULLEY AND IN THE ENGINE CRANKCASE.
Page 110 Fuoco 500 i.e. Engine - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 - 26 - Lock the 7 M6 retainers.
Page 111 Fuoco 500 i.e. Engine - Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase. N.B. ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE. - Install the outside plastic transmission cover.
Page 112 Fuoco 500 i.e. Engine Removing the wheel axle - Remove the countershaft. - Remove the wheel axis complete with gear. Removing the hub bearings - Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts.
Page 113 Fuoco 500 i.e. Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover using the column kit. - Pull out the bearing using the special tool. Specific tooling...
Page 114 Fuoco 500 i.e. Engine - Pull out the driven pulley shaft bearing from the engine crankcase using the special tool. Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm adaptor 020364Y 25 mm guide Inspecting the hub shaft - Check that the 3 shafts exhibit no wear or defor- mation on the grooved surfaces, at the bearings and at the oil guards.
Page 115 Fuoco 500 i.e. Engine B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Connection diameter for shaft driven pulley: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm F = diameter 25 - 0.01 -0.02 mm...
Page 116 Fuoco 500 i.e. Engine - Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS APPLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle...
Page 117 Fuoco 500 i.e. Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the column kit. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.
Page 118 Fuoco 500 i.e. Engine - Support the hub cover using the column kit. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase. Specific tooling...
Page 119 Fuoco 500 i.e. Engine Locking torques (N*m) Rear hub cover screws 24 ÷ 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
Page 120 Fuoco 500 i.e. Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support. N.B.
Page 121 Fuoco 500 i.e. Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
Page 122 Fuoco 500 i.e. Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Check that the mounting surface of the crankcase is not worn or deformed.
Page 123 Fuoco 500 i.e. Engine - Check the condition of the stator and of the re- spective cable harness. - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPER- ATURE. A CHECK WITH THE STATOR AT OP- ERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
Page 124 Fuoco 500 i.e. Engine Refitting the stator - Install the stator assembly together with the wir- ing harness, tightening the 3 screws to the pre- scribed torque. N.B. INSERT THE RUBBER WIRING SEALING GAS- KET INTO THE SPECIAL SEAT ON THE CRANKCASE.
Page 125 Fuoco 500 i.e. Engine - Oil vapour decantation chamber - Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar. - Insert the blow-by recovery duct using a new O- ring. - Tighten the screws to the prescribed torque.
Page 126 Fuoco 500 i.e. Engine - Refit the water pump cover and tighten the 6 fix- ing screws to the prescribed torque. Locking torques (N*m) Pump cover fixing screws: 3 ÷ 4 Refitting the flywheel cover - Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque.
Page 127 Fuoco 500 i.e. Engine - Lubricate the intermediate gear seat with torque limiter on the flywheel cover. - Align the water pump movement sensor with a reference and install the flywheel cover as descri- bed in the Flywheel cover chapter.
Page 128 Fuoco 500 i.e. Engine - Tighten the 14 retaining bolts of the cover to the prescribed torque. N.B. THE BOLTS HAVE FOUR LENGTHS: - THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE. - THE LONGEST IS INSERTED UNDER THE EN- GINE OIL FILLER PLUG.
Page 129 Fuoco 500 i.e. Engine 2 - Make sure the negative terminals (battery neg- ative and starter negative) are correctly connected to each other and to the frame. YES go to 4 NO go to 5 3 - Recharge and if necessary replace the battery.
Page 130 Fuoco 500 i.e. Engine 7- Low trailing speed High electrical absorption Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies are found, replace the starter motor. 8- Low trailing speed Low electrical absorption Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing them.
Page 131 Fuoco 500 i.e. Engine The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting.
Page 132 Fuoco 500 i.e. Engine - Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool. - Tighten the bushing of the flywheel lock tool on the removing tool threading. - Insert the special tool as shown in the figure,...
Page 133 Fuoco 500 i.e. Engine - Remove the washer. - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLY- WHEEL IS STRONGLY LOCKED; THE CONE...
Page 134 Fuoco 500 i.e. Engine - To remove the start-up rim from the freewheel it is necessary to turn it clockwise and pull it out. - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws. SINCE THE FREEWHEEL MUST BE REMOVED,...
Page 135 Fuoco 500 i.e. Engine Inspecting the flywheel components - Check the integrity of the magnets. - Check that the magnet support cage is free from deformation or cracks. - Check that the flywheel splines exhibit no loos- ening. Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers"...
Page 136 Fuoco 500 i.e. Engine Intermediate gear - Check that the toothing is not worn. - Check the diameter of the two bearings. Characteristic Diameter of gear bearing: 12 - 0 0.011 mm Also check the shaft diameter on the flywheel cov- er and on the engine crankcase.
Page 137 Fuoco 500 i.e. Engine Medium Loctite 243 threadlock - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel Seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 138 Fuoco 500 i.e. Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the flywheel magneto - Insert the key on the crankshaft.
Page 139 Fuoco 500 i.e. Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS RULE CAUSES THE LOCKING OF THE GUIDE ON THE FLY- WHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
Page 140 Fuoco 500 i.e. Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START-UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIRECTION.
Page 141 Fuoco 500 i.e. Engine Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket.
Page 142 Fuoco 500 i.e. Engine - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer.
Page 143 Fuoco 500 i.e. Engine Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft. - Remove the timing belt rim. Removing the cam shaft - Unscrew the 3 fastening screws and remove camshaft retaining bracket.
Page 144: Removing The Cylinder Head
Fuoco 500 i.e. Engine - Remove pins and rocking levers by the transmis- sion side holes. Removing the cylinder head - Remove the spark plugs. - Remove the cooling system outlet sleeve with thermostat. - Remove the coolant temperature sensor.
Page 145: Removing The Valves
Fuoco 500 i.e. Engine - Remove the two M6 screws into the distribution channel and the M6 screw on the spark plug side with the thermostat support. N.B. IF NECESSARY, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEV- ERS AND MOUNTING BRACKET.
Page 146 Fuoco 500 i.e. Engine - Remove the oil guards using the special tool. Specific tooling 020431Y Valve oil seal extractor - Remove the spring supports. N.B. BLOW THE SEATS WITH COMPRESSED AIR TO FACILITATE THE SPRING SUPPORT RE- MOVAL. Removing the cylinder - piston assy.
Page 147 Fuoco 500 i.e. Engine - Remove the 2 piston pin locking rings by the spe- cific housings. - Extract the pin and remove the piston. N.B. USE PAPER OR A CLOTH TO CLOSE THE CYL- INDER HOUSING MOUTH ON THE CRANK- CASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE.
Page 148 Fuoco 500 i.e. Engine - Calculate the coupling clearance between pin and connecting rod end. Characteristic Standard clearance: 0.015 ÷ 0.029 mm Inspecting the piston - Measure the capacity diameter on the piston. Characteristic Standard diameter: 22 + 0.006 +0.001mm - Calculate the piston pin coupling clearance.
Page 149 Fuoco 500 i.e. Engine - Using a bore meter, measure the cylinder inner diameter at a given height according to the direc- tions shown in the figure. Characteristic 43 mm Standard diameter: 94 mm nominal value - Check that coating is free from flakes.
Page 150: Removing The Piston
Fuoco 500 i.e. Engine - If higher values than those prescribed are meas- ured, replace the linings. Check the size of the sealing ring opening: Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷...
Page 151 Fuoco 500 i.e. Engine - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a punch - Install the pin lock using the key shown in the figure.
Page 152 Fuoco 500 i.e. Engine - Using an abutment plane, reset the comparator with a preload of a few millimetres. - Finally fix the comparator. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the comparator position.
Page 153 Fuoco 500 i.e. Engine Refitting the piston rings - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening op- posed to the spring junction and with the writing "top" facing the piston top. The chamfered side of the oil scraper ring should always be facing the piston crown.
Page 154 Fuoco 500 i.e. Engine Characteristic Maximum allowable run-out: 0.1 mm - In case of irregularities, replace the head. - Check the sealing surfaces for the intake and ex- haust manifold. - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
Page 155 Fuoco 500 i.e. Engine - If the sealing surface of the valve is found to be interrupted at one or more points or is not flat, re- place the valve. - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves.
Page 156 Fuoco 500 i.e. Engine MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Inlet: 4.96 mm Outlet: 4.945 mm - Calculate the clearance between valve and valve guide. - Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation by a comparator.
Page 157 Fuoco 500 i.e. Engine INLET Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm OUTLET Specification Desc./Quantity Standard clearance: 0.025 ÷ 0.052 mm Admissible limit: 0.09 mm STANDARD VALVE LENGTH Specification Desc./Quantity Inlet: 95.0 ± 0.3 mm Outlet: 94.2 ±...
Page 158 Fuoco 500 i.e. Engine TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
Page 159 Fuoco 500 i.e. Engine - Fit the valves, the springs and the spring retaining washers. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats. Specific tooling 020382Y Valve cotters equipped with part 012...
Page 160 Fuoco 500 i.e. Engine Specification Desc./Quantity discharge 33.026 mm Standard axial clearance: 0 - 0.22 mm Maximum admissible axial clearance: 0.3 mm - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
Page 161 Fuoco 500 i.e. Engine - Measure the inside diameter of each rocking lev- Characteristic Standard diameter: 13 + 0.026 +0.015 mm - Check that the cam contact sliding block and the articulated register plate is free from wear. - In case of wear, replace the component.
Page 162 Fuoco 500 i.e. Engine - Check that the head lubrication channel is per- fectly clean. Clean with compressed air jets, if required. - Insert the head. - Lubricate the stud bolts and the 4 fastening col- umns. - Tighten the 4 fastening columns crosswise to the prescribed torque as shown in the figure.
Page 163 Fuoco 500 i.e. Engine - Install the coolant temperature sensor with the washer and tighten to the prescribed torque. CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR. Locking torques (N*m) coolant temperature sensor: 10 - 12 - Fit the spark plugs and tighten them to the prescribed torque.
Page 164 Fuoco 500 i.e. Engine - Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush. - Apply the recommended product to the fixing screws and tighten to the prescribed torque. Recommended products Loctite 243 Medium strength threadlock...
Page 165 Fuoco 500 i.e. Engine - Keeping the belt slightly pulled, turn the crank- shaft using the driving pulley to make the reference on the magnet support collimate with that on the flywheel cover. - Install the counterweight mass. - Centre using the bell fastening screw.
Page 166 Fuoco 500 i.e. Engine - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product.
Page 167 Fuoco 500 i.e. Engine - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque. Locking torques (N*m) Tightener fastening screws: 11 ÷ 13 - Insert the spring with the central screw and the washer.
Page 168 Fuoco 500 i.e. Engine 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control Proceed as follows: - Remove the outside transmission cover as de- scribed in the automatic transmission chapter. - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover.
Page 169 Fuoco 500 i.e. Engine - Replace the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the menu on the "parameter" function. - Select the stroboscopic light command in the tra- ditional four-stroke engine position (1 spark 2 revs).
Page 170 Fuoco 500 i.e. Engine - Install the transmission cover and the relevant net filter and the outside transmission cover as descri- bed in the "Automatic transmission" chapter. - Install the cooling system sleeves using new bands, as described in the "Flywheel cover" chap- ter.
Page 171 Fuoco 500 i.e. Engine Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Standard clearance: 0.10 - 0.50 mm Admissible increase limit after use: 0.60 mm - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
Page 172 Fuoco 500 i.e. Engine - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase. - Remove the coupling gasket. N.B. THE BUSHING SUPPORT CAN BE LEFT IN THE FLYWHEEL SIDE HALF-CRANKCASE. Removing the crankshaft - Before removing the crankshaft, check the timing with the countershaft.
Page 173 Fuoco 500 i.e. Engine Removing the countershaft - Place the special tool as shown in the figure. Specific tooling 020479Y Countershaft lock wrench - Remove the fastening nut with relevant washer. - Remove the special tool and extract the counter- shaft with the control gear.
Page 174 Fuoco 500 i.e. Engine - Upturn the half-crankcase. - Remove the bearing from the flywheel side half- crankcase using the special tool and a mallet. Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm adaptor 020439Y 17 mm guide - Remove the bearing from the transmission side half-crankcase using the special tool.
Page 175 Fuoco 500 i.e. Engine - Fit the seeger ring. - Before installing the new bearing on the trans- mission side crankcase, heat the seat using the special tool. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
Page 176 Fuoco 500 i.e. Engine Inspecting the crankshaft components - Check the axial clearance on the connecting rod. Characteristic Standard clearance: 0.20 ÷ 0.40 mm - Check the connecting rod diametrical clearance. Characteristic Standard clearance: 0.046 ÷ 0.076 mm -Check the surfaces that limit the axial free-play...
Page 177 Fuoco 500 i.e. Engine Specific tooling 020074Y Support base for checking crankshaft alignment - If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase.
Page 178 Fuoco 500 i.e. Engine N.B. MAIN BEARINGS CANNOT BE MODIFIED. The connecting rod cannot be replaced. To check the connecting rod small end diameter, see chapter "Thermal unit and timing system". - When cleaning the crankshaft, be careful to prevent any impurity from entering into the shaft lubrication hole.
Page 179 Fuoco 500 i.e. Engine - For the flywheel side half-crankcase, special at- tention should be given to the lubrication channels for the main bearings and to the compartment and the channels for the oil pump, as well as to the duct for the by-pass located on the flywheel cover.
Page 180 Fuoco 500 i.e. Engine - The oil supply channel section is also affected by the bushings driving depth compared with the crankshaft axial clearance of the limiting surface. N.B. TO KEEP SUCH POSITION OF THE BUSHINGS ON THE CRANKCASE, DRIVING IS FORCED ON CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH HALF-CRANKCASES.
Page 181 Fuoco 500 i.e. Engine X = Crankshaft category Y = Crankcase half-shell category A = Red B = Blue C = Yellow D = Green In case of breakdown, crankcases are together with bushings and are classified according to the centre to centre distance of the countershaft.
Page 182 Fuoco 500 i.e. Engine THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS DESCRIBED IN CHAPTER "FINAL REDUCTION". Countershaft - Using a micrometer, measure the 2 bearings of the countershaft as shown in the figure.
Page 183 Fuoco 500 i.e. Engine TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN IN- SIDE HEXAGON SOCKET WRENCH. Locking torques (N*m) Gear mounting on crankshaft screws 10 -12 - Lubricate the main bearing on the flywheel side half-crankcase.
Page 184 Fuoco 500 i.e. Engine Refitting the crankcase halves - Remove the oil guard from the transmission side half-crankcase using a screwdriver. - Install a new oil guard after lubricating it, using the special tool, arranging it at a 0.5 mm recess from the crankcase plane.
Page 185 Fuoco 500 i.e. Engine - Insert the 14 fastening screws by arranging the single shorter screw "A" and the single longer screw "B" as shown in the figure. - Tighten the screws thoroughly and tighten to the prescribed torque. - Check that the crankshaft rotates freely.
Page 186 Fuoco 500 i.e. Engine Specification Desc./Quantity Plunger diameter 13.9 - 0.039 -0.057 mm Spring free length 62.5 mm Calibration pressure 4 bar PRE-FILTER Specification Desc./Quantity Type mesh, plastic OIL FILTER Specification Desc./Quantity Type Paper with pressure relief and anti-cavitation by-...
Page 187 Fuoco 500 i.e. Engine Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump impeller Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics...
Page 188 Fuoco 500 i.e. Engine The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the pressure of the circuit.
Page 189 Fuoco 500 i.e. Engine YES go to 3 NO go to 11 3 - Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and install the special tool with the relevant gasket. Specific tooling...
Page 190: Oil Pressure Check
Fuoco 500 i.e. Engine 7 - Replace the oil minimum pressure switch. 8 - If pressure lower than 1.3 - 1.5 bar is measured. AHEAD go to 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
Page 191: Oil Pump
Fuoco 500 i.e. Engine 020193Y Oil pressure gauge 020434Y Oil pressure control fitting AHEAD go to 3 3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to 4 NO go to 5 4 - Replace the damaged components.
Page 192 Fuoco 500 i.e. Engine - Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper. - Remove the gasket. - Remove the two screws and the oil pump cover.
Page 193 Fuoco 500 i.e. Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear. - Reassemble the rotors in the pump body, keep-...
Page 194 Fuoco 500 i.e. Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Refitting - Make sure the gasket is in the correct position. N.B.
Page 195 Fuoco 500 i.e. Engine Failure to observe the tightening torque may alter the coupling clearance of the rotors with the pump body. Locking torques (N*m) Screws fixing oil pump to the crankcase 5 - 6 - Insert the countershaft with gearing into the fly- wheel-side half-crankcase.
Page 196 Fuoco 500 i.e. Engine ENG - 104...
Page 197 INDEX OF TOPICS INJEC NJECTION...
Page 198 Fuoco 500 i.e. Injection KEY: 1.Throttle body and injection electronic control unit (MIU) 2. Battery 3. Instrument panel 4. Injection load remote control 5. Coolant temperature sensor 6. HV coil 7. Fuel pump 8. Lambda probe 9. Revolution sensor 10. Fuel injector 11.
Page 199 Fuoco 500 i.e. Injection Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further corrections are made according to the following parameters: - Coolant temperature. - Intake air temperature - Lambda probe strength The system implements an idle feeding correction with cold engine through a Stepper motor on a by- pass circuit of the throttle valve.
Page 200 Fuoco 500 i.e. Injection The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present,...
Page 201 Fuoco 500 i.e. Injection 5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump. 6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the level.
Page 202 Fuoco 500 i.e. Injection b. Dirty by-pass circuit c. Faulty Stepper motor F: Other a. Incorrect distribution timing b. Wrong idle mixture c.Incorrect reset of the throttle valve position sensor 2 MIU system faults may be caused by loose connectors. Make sure that all connections have been correctly made.
Page 203 Fuoco 500 i.e. Injection Specification Desc./Quantity Water temperature sensor Can «H» Line + Lambda probe Engine stop switch R.P.M. sensor (+) Fuel injector R.P.M. sensor (-) Diagnostics socket output Immobilizer LED Ground lead Connected to the engine stop switch and the water temperature sensor.
Page 204: Troubleshooting Procedure
Fuoco 500 i.e. Injection Specification Desc./Quantity Fuse 20 A Fuse 7.5 A Key switch contacts Engine stop switch Fuse 7.5 A Fuse Fuse 10 A Starter button Injection load remote control Start-up remote control relay Electric fan starter Starter motor...
Page 205 Fuoco 500 i.e. Injection Starting difficulties ENGINE START-UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature. Start up engine speed Starter motor and remote control...
Page 206 Fuoco 500 i.e. Injection Possible Cause Operation Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay...
Page 207 Fuoco 500 i.e. Injection Possible Cause Operation Muffler welding Engine revs irregularly IRREGULAR PROGRESS OF THE ENGINE WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and gas sensor Supplementary air pipe Stepper Intake system seal...
Page 208 Fuoco 500 i.e. Injection Engine knocking PRESENCE OF KNOCKING (OVERHEAD KNOCKING) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature. Lambda sensor Ignition efficiency Spark plug...
Page 209 Fuoco 500 i.e. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fitting from the injector support INJEC - 13...
Page 210 Fuoco 500 i.e. Injection Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU connector INJEC - 14...
Page 211 Fuoco 500 i.e. Injection Remove the gas command fitting as indicated in the photograph Pump supply circuit INJEC - 15...
Page 212 Fuoco 500 i.e. Injection INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine starts up, in the presence of phase rpm signal the pump is continuously supplied.
Page 213 Fuoco 500 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 214 Fuoco 500 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 2 15 A) and the remote control base.
Page 215 Fuoco 500 i.e. Injection After switching to «ON», check that there is battery voltage, for about 2 seconds, between the Black- Green cable of the pump connector and the ground lead with the pump connector disconnec- ted. Otherwise, check the continuity of the Black- Green cable between the pump connector and the remote control base.
Page 216 Fuoco 500 i.e. Injection Check during regular functioning by placing the appropriate tool between the pump and the injec- tor. With battery voltage > 12 V check that the fuel pressure is 3 BAR and that the input current is ~2.8 With the battery voltage >...
Page 217 Fuoco 500 i.e. Injection Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 21...
Page 218 Fuoco 500 i.e. Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 22...
Page 219 Fuoco 500 i.e. Injection Specification Desc./Quantity Electric fan starter When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of phase rpm signal the pump is continuously supplied.
Page 220 Fuoco 500 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is...
Page 221 Fuoco 500 i.e. Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 2 15 A) and the remote control base.
Page 222 Fuoco 500 i.e. Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check the presence of voltage,...
Page 223 Fuoco 500 i.e. Injection Install the appropriate tool for the fuel pressure check and position the manifold over a container graduated by at least 100 cc. Connect the injector with the cable making up part of the supply for the injection tester.
Page 224 Fuoco 500 i.e. Injection Remove the protective base from the connector. With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring .
Page 225 Fuoco 500 i.e. Injection The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem. The immobilizer is an antitheft system that allows the vehicle to be operated only when it is started with coded keys recognised by the control unit.
Page 226 Fuoco 500 i.e. Injection Remove the connector support bracket shown in the photograph and disconnect the connector from the control unit. Check the following conditions: With the key switch set to OFF: • if there is battery voltage between ter- minals 6-26 and terminal 6-chassis ground (fixed power supply).
Page 227 Fuoco 500 i.e. Injection - Insert the service key and turn it to «ON» for 2 seconds. - If you have copies of the key, repeat the operation with each key. - Insert the MASTER key again and turn it to «ON» for 2 seconds.
Page 228 Fuoco 500 i.e. Injection manently ON; in this condition, no operations are possible, including starting of the vehicle. 3. Programmed control unit - the service key in (normal condition of use): a single 0.7 second flash is displayed, after which the LED remains off permanently.
Page 229 Fuoco 500 i.e. Injection Code 2 Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
Page 230 Fuoco 500 i.e. Injection Tachometer With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
Page 231 Fuoco 500 i.e. Injection With the interface cable harness disconnected from the control unit and the rpm sensor connector disconnected, check that the red and brown cables (pin 13 - 15) are isolated from each other and in- sulated from the ground lead.
Page 232 Fuoco 500 i.e. Injection INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor Electric fan starter The ignition system combined with the injection is the high-efficiency induction type.
Page 233 Fuoco 500 i.e. Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 234 Fuoco 500 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is...
Page 235 Fuoco 500 i.e. Injection Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to «ON» Check the resistance of the primary coil between pin 22 of the interface wiring and the green black...
Page 236 Fuoco 500 i.e. Injection Inspecting the spark plug shielded cap Measure the shielded cap resistance. Electric characteristic Resistance: 5 KΩ If different values are measured (<1; >20KΩ), replace the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN AFFECT THE INJECTION SYSTEM.
Page 237 Fuoco 500 i.e. Injection - Remove the TDC reference inspection cap be- tween flywheel and crankcase cover. See the "fly- wheel cover" chapter - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC.
Page 238: Coolant Temperature Sensor
Fuoco 500 i.e. Injection - Injection control unit Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Water temperature sensor Engine stop switch Electronic control unit With the control unit side connector disconnected and the coolant temperature sensor connector connected, check that the resistance values be- tween pin 9 and ground correspond to the engine temperature.
Page 239 Fuoco 500 i.e. Injection With the control unit side connector disconnected and the coolant temperature connector discon- nected, check the continuity between pin 9 of the interface wiring harness and the light blue/green cable of the connector. Specific tooling 020481Y Control unit interface wiring...
Page 240 Fuoco 500 i.e. Injection Connect the diagnostic tester. Turn to "ON". Select the functions of the diagnostic tester on "TPS RESET". Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve is supporting the stop screw. Guaranteeing that this position will be kept, give the confirmation for the TPS reset procedure.
Page 241 Fuoco 500 i.e. Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING POSITION MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENT FROM THAT OF PRE-CALIBRATION.
Page 242 Fuoco 500 i.e. Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse Fuse Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 46...
Page 243 Fuoco 500 i.e. Injection Specification Desc./Quantity Electric fan starter The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e.
Page 244 Fuoco 500 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and Black- Violet cable of the remote control base. If there is...
Page 245 Fuoco 500 i.e. Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-)
Page 246 Fuoco 500 i.e. Injection INJEC - 50...
Page 247 INDEX OF TOPICS SUSP USPENSIONS...
Page 248: Removing The Front Wheel
Fuoco 500 i.e. Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Remove the 5 fixing screws indicated in the pho- tograph. Locking torques (N*m) Wheel fixing screw 20 ÷ 25...
Page 249 Fuoco 500 i.e. Suspensions - Remove the oil seal on the roller bearing side using a screwdriver. - Remove the roller bearing using the specific tool Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20 mm guide...
Page 250: Handlebar Fixing Screw
Fuoco 500 i.e. Suspensions Soap-based lithium grease with NLGI 3; ISO-L- XBCHA3, DIN K3K-20 Handlebar Removal - Remove the three handlebar covers working as explained in the Bodywork Chapter. - Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake levers.
Page 251 Fuoco 500 i.e. Suspensions Hydraulic system layout When tilting is locked, the geared motor activates the hydraulic pump indicated in the photograph and pressurises the circuit. The pressurised oil reaches the distribution frame «T» and the pressure sensor «A». Then, the pipes branch out to reach the upper joints on the side steering tubes.
Page 252 Fuoco 500 i.e. Suspensions Disconnect the tone wheel connector indicated in the photograph. Remove the hydraulic pipe fitting from the sliding locking device, making sure again that the liquid drained is collected. Remove the upper fittings, on the parallelogram, of the brake hydraulic pipes and the suspension lock indicated in the photograph.
Page 253 Fuoco 500 i.e. Suspensions Remove the suspension tilt locking device pipes from the headstock. Remove first the flexible part of the calliper from the steering tube as shown in the photograph, and then remove the rigid part. Remove the tone wheel wiring by disconnecting the connector on the fuel tank after removing the chassis central cover.
Page 254 Fuoco 500 i.e. Suspensions Remove the constant-velocity universal joint from the steering bar by undoing the nut indicated in the photograph. Use a specific tool to remove the upper tightening ring nut of the steering tube. Specific tooling 020055Y Wrench for steering tube ring nut Remove the hydraulic pipe support bracket.
Page 255 Fuoco 500 i.e. Suspensions Remove the steering tube lower ring nut and the protection cap indicated in the photograph. Now, it is possible to remove the steering tube. Check that the roller tapered bearing does not show signs of abnormal wear. If it is, replace it.
Page 256 Fuoco 500 i.e. Suspensions THE OPERATIONS DESCRIBED BELOW CAN ALSO BE CARRIED OUT EVEN WHEN THE SUSPENSION IS FITTED Remove the lower retainer of the sliding stem shown in the photograph. Remove the sliding stem locking device retainers indicated in the photograph.
Page 257: Side Headstock Lower Ring Nut
Fuoco 500 i.e. Suspensions For refitting, follow the operations for removal but in reverse order, observing the prescribed torques and greasing the bearings and their seats. STEERING TUBES Name Torque in Nm Side headstock upper ring nut 20 - 24 Side headstock lower ring nut 12 ÷...
Page 258 Fuoco 500 i.e. Suspensions Remove the 4 screws fixing the tilt brake disc sec- tor indicated in the photograph. Remove the retainers indicated in photograph of the half-arms joint flange. To facilitate the operations indicated below, re- move the suspension locking electronic control unit indicated in the photograph.
Page 259 Fuoco 500 i.e. Suspensions Remove the arm coupling retainers from the par- allelogram by loosening the retainers indicated. For easy refitting operations, remember to take note of the positions of the components. Separate the half-arms by hitting slightly with a wooden mallet where possible alternatively to the left and right side of the parallelogram.
Page 260 Fuoco 500 i.e. Suspensions Carry out a visual check of the upper and lower bearings on the headstocks and their seats. Re- place them in case of signs of abnormal wear. SUSP - 14...
Page 261: Screws Fixing The Half-Arm Coupling Flange
Fuoco 500 i.e. Suspensions Check the ball bearings on the parallelogram arms. Replace them in case of signs of abnormal wear. Check the inside tracks of the parallelogram bear- ings on the chassis. For refitting, follow the operations for removal but...
Page 262: Fixing Screws For Tilt Locking Disc Section
Fuoco 500 i.e. Suspensions Name Torque in Nm Fixing screws for tilt locking disc section 20 ÷ 25 Geared motor and Suspension locking system Select the SYSTEM RESET option from the main menu Turn the key switch to ON Select the LOWER STOP SEARCH option from...
Page 263 Fuoco 500 i.e. Suspensions The hand-held computer indicates the outcome of the stop search operation: POSSIBLE LIMIT STOP VALUES. TO EXIT, PRESS A KEY AND TURN OFF AND ON. SE- LECT PARAMETERS TO ADJUST AT 12°. Check the geared motor if the hand-held computer does not indicate this.
Page 264: Clamp Fixing Pump Bolt To Anti-Tilting Device
Fuoco 500 i.e. Suspensions Remove the protection cap, align the pump control and lock the screw to the prescribed torque Locking torques (N*m) Clamp fixing pump bolt to anti-tilting device 11 ÷ 13 Select the SYSTEM RESET option from the MAIN...
Page 265 Fuoco 500 i.e. Suspensions Select the POTENTIOMETER RESET option from the SYSTEM RESET menu and press OK. WAIT..PROCEDURE IN PROGRESS The hand-held computer displays the words: CHECK THAT THE CONTROL IS SET AT 12° FROM THE LOWER STOP. PRESS OK TO CON-...
Page 266 Fuoco 500 i.e. Suspensions When refitting, tighten the two bracket screws and the flexible transmission lever nut to the prescribed torque. Locking torques (N*m) Bracket tightening screws 8 ÷ 12 Unscrew the Allen screw and remove the switch. When refitting, place the switch with the button ori- ented to the stop indicated on the calliper lever;...
Page 267 Fuoco 500 i.e. Suspensions Unscrew the two pad pin screws, remove the pads with the spring. When refitting, tighten the two screws to the pre- scribed torque and use Threadlock. When refitting, adjust the cable properly so that the switch is pushed when the system is unlocked.
Page 268 Fuoco 500 i.e. Suspensions Fit the pinion and align the reference on the pinion teeth with the reference indicated on the second slot of the toothed sector. Grease the pinion and the toothed sector with spe- cific grease. Refit the toothed sector spacer.
Page 269 Fuoco 500 i.e. Suspensions Place the moulded washer of the flexible trans- mission control lever shaft and the tongue. Refit the flexible transmission control lever as shown in the figure. Refit the potentiometer (not forcing in the D-type connector ensures a sole position) with the con- nector directed to the opposite side of the hydraulic pump.
Page 270 Fuoco 500 i.e. Suspensions Extract the electric motor bearing with the specific tool. Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide Hold the crankcase in a perfectly horizontal posi- tion, heat it with a heat gun at a temperature of about 120 °C, use the specific tool to fit the bearing...
Page 271 Fuoco 500 i.e. Suspensions 020376Y Adaptor handle Remove the spring/toothed sector unit from its fit- ting, slightly hit with a mallet if necessary to release the unit. Extract the bearing of the spring/toothed sector unit with the specific tool. Specific tooling...
Page 272 Fuoco 500 i.e. Suspensions Hold the crankcase in a perfectly horizontal posi- tion, heat it with a specific heat gun at a tempera- ture of about 120 °C, use the specific tool to fit the bearing of the electric motor. Hit slightly with a mallet if necessary.
Page 273 Fuoco 500 i.e. Suspensions Disconnect the hydraulic pipes between the pump and the sliding stem locking clamps. Empty the system and use a container to collect the brake fluid. CAUTION ELIMINATE ANY REMAINING BRAKE FLUID SPILLS. WARNING: BRAKE FLUID IS HIGHLY POISON- OUS.
Page 274 Fuoco 500 i.e. Suspensions Unscrew the two potentiometer screws. When refitting, plug the potentiometer in D-type connector, afterwards place it with its electric con- nection directed to the opposite side of the pump. Remove the nut indicated in the figure, if neces- sary lock the lever with a vice making sure not to spoil the surface.
Page 275 Fuoco 500 i.e. Suspensions Remove the three fixing screws of the electric mo- tor. It is important to mark the direction of the electric motor position in order to refit it correctly. Remove the four screws indicated in the figure,...
Page 276 Fuoco 500 i.e. Suspensions 3: FUSE No. 11, 7.5A Check 7.5 A fuse No. 11 for efficiency. With inter- face wiring disconnected from the control unit, check the continuity of the blue - black cable be- tween pressure sensor connector and the horn remote control base as indicated in the photo- graph.
Page 277 Fuoco 500 i.e. Suspensions 1. Geared motor 2. Brake calliper sensor 3. Tilt unlocking-locking control switch 4. Potentiometer 5. Rider presence sensor 6.Left speed sensor 7.Right speed sensor 8. Diagnostic tester serial line 9. Engine electronic control unit 10. Direct +Battery 11.
Page 278 Fuoco 500 i.e. Suspensions 1: GEARED MOTOR With the interface wiring disconnected from the control unit, check the continuity between pin 28 and the white-red cable, between pin 38 and the blue cable on the geared motor connector SUSP - 32...
Page 279 Fuoco 500 i.e. Suspensions With the interface wiring disconnected from the control unit, check the continuity of the geared mo- tor winding placing the multimeter probes on pins 28 and 38 as indicated in the figure. TILT LOCKING-UNLOCKING SWITCH 0: REST POSITION...
Page 280 Fuoco 500 i.e. Suspensions 3: TILT LOCKING-UNLOCKING SWITCH With interface wiring disconnected from the control unit, check the continuity of the electrical lines be- tween the interface wiring and the tilt locking-un- locking switch: Pin 26 and green - grey cable...
Page 281 Fuoco 500 i.e. Suspensions 1: TILT LOCKING CALLIPER SENSOR The tilt locking calliper sensor is a normally opened switch. Check its correct operation with a multi- meter. With interface wiring disconnected from the control unit, check the continuity between pin 34 and the brown cable of the tilt locking gripper sensor con- nector on the system side.
Page 282 Fuoco 500 i.e. Suspensions Also check that the flexible transmission control lever activates the limit stop switch properly. POTENTIOMETER 1: POTENTIOMETER SUSP - 36...
Page 283 Fuoco 500 i.e. Suspensions With interface wiring connected to the control unit, secure the vehicle on its centre stand and switch to "ON". Select the reading scale on 20 V. Insert the multimeter probes on pins 17 and 25. Check that the voltage in the activated locking condition is 4V and 1V in the locking to rest condition.
Page 284 Fuoco 500 i.e. Suspensions 1: RIDER PRESENCE SENSOR With interface wiring disconnected from the control unit and connected to the system, check the fol- lowing conditions: pin 17 - 36: resistance 15 ÷ 18 kOhm when the rider is not seated on the saddle.
Page 285 Fuoco 500 i.e. Suspensions 1: Right tone wheel 2: Left tone wheel With interface wiring disconnected from the park- ing electrical control unit and connected to the system, check that the sensor resistance between pins 23 - 17 and 24 - 17 is between 774 and 946 Ohm at a temperature of approximately 20°...
Page 286 Fuoco 500 i.e. Suspensions With interface wiring disconnected from the control unit, check the continuity between pin 23 and the red cable of the LEFT wheel turning sensor con- nector; the continuity between pin 17 and the brown cables of the LEFT and RIGHT wheel turn- ing sensors;...
Page 287: Wheel Alignment
Fuoco 500 i.e. Suspensions With a thickness gauge, check that the air gap be- tween the screw head and the sensor is between 0.35 and 1 mm Wheel alignment Tool fitting Metodo di utilizzo dell'attrezzatura • Verificare che la pressione pneumatici sia corretta.
Page 288 Fuoco 500 i.e. Suspensions • Verificare la regolarità di rotazione dei cerchi ruota e l'eventuale presenza di giochi anomali dei cuscinetti e delle so- spensioni. • Verificare che il comando dello sterzo non presenti giochi anomali su giunti e cuscinetti. In caso contrario procedere con le necessarie riparazioni e succes- sive regolazioni.
Page 289 Fuoco 500 i.e. Suspensions • Fit the bracket locking the parallelo- gram in the holes of the previously re- moved screws; use the screws sup- plied with the tool and be careful to correctly centre the spacer in the bear- ing.
Page 290 Fuoco 500 i.e. Suspensions • Fit the steering guiding bracket in a straight riding position, fix one end to the attachment of the half-arm coupling flange and the other end to the screw fixing the steering control arm. • Place the frame so that the sliders...
Page 291: Removing The Rear Wheel
Fuoco 500 i.e. Suspensions • Make sure the frame is adequately centred by checking with a gauge that the lugs along the vertical axis show the standard protrusion. • Check that the pointers of both tyres are correctly aligned, as shown in the photograph.
Page 292 Fuoco 500 i.e. Suspensions - Undo the two screws fixing the clamp to the en- gine. - Undo the two screws fixing the clamp to the cen- tre stand. - Remove the cotter pin and collect the cap. - Unscrew the wheel fixing nut and collect the spacer.
Page 293 Fuoco 500 i.e. Suspensions - Collect the conical spacer. - Undo the five wheel fixing screws and remove the wheel. Refitting the rear wheel To fit, proceed in the reverse sequence from that used for the removal, being careful to fit the dis- tances on the wheel axle as shown in the photo- graph.
Page 294 Fuoco 500 i.e. Suspensions - Remove the silent-blocks. - Remove the retainer fixing the swinging arm to the frame: undo the screw. - Remove the pin. SUSP - 48...
Page 295 Fuoco 500 i.e. Suspensions - Unscrew the nut of the set screw bushing. - From the inside loosen the set screw bushing until the swinging arm is free. - Remove the swinging arm. - Check the entire swinging arm assembly.
Page 296 Fuoco 500 i.e. Suspensions - Check there is no sticking in the rotation. - Check the axial clearance of the swinging arm on the frame side Characteristic Standard clearance 0.40 ÷ 0.60 mm Allowable limit after use: 1.5 mm - Separate the swinging arm on the engine side from the vehicle side arm.
Page 297 Fuoco 500 i.e. Suspensions - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020244Y 15 mm diameter punch Characteristic Length of the swinging arm tube on the engine side: L 140.5 ±...
Page 298 Fuoco 500 i.e. Suspensions - Unscrew the retainer to the frame in order to re- move the silent block supporting clamp. Refitting For correct installation of the swinging arm on the scooter, proceed as follows: 1. Position the silent block supporting clamp with part 3 inserted, and slightly tighten part 1 2.
Page 299: Shock Absorbers
Fuoco 500 i.e. Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 98 ÷ 118 Part 3 5 ÷ 7 Part 4 88.5 ÷ 108 Part 5 54 ÷ 60 Swinging arm, engine side / Swinging arm, frame 32.5 ÷ 40...
Page 300: Centre Stand Bolt
Fuoco 500 i.e. Suspensions - undo the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and remove the shock absorbers themselves. Refitting Carry out the previous operations in reverse order. Locking torques (N*m) Shock absorber lower clamp 33 ÷...
Page 301 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 302 Fuoco 500 i.e. Braking system This section è is devoted to the description of the brake system components. Rear brake calliper Removal - Remove the rear wheel. - Undo the screws connecting the air filter to the crankcase so that the wrenches can be inserted.
Page 303 Fuoco 500 i.e. Braking system Refitting 1) insert the pistons (6) and the sealing rings (7) in the body; 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...
Page 304 Fuoco 500 i.e. Braking system Brake fluid hose-calliper fitting 20 ÷ 25 Pad fas- tening pin 20 ÷ 25 Refitting - To fit the rear brake calliper, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque.
Page 305 Fuoco 500 i.e. Braking system - Check that the pistons and their seats show no scratches. - Wash and blow all the components carefully - Fit the O-rings and new dust guards - Refit the pistons in their seats being careful to...
Page 306 Fuoco 500 i.e. Braking system Removal - Remove the rear wheel. - Loosen the nuts fixing the safety washers. - Undo the two screws fixing the plate supporting the calliper to the frame. - Remove the calliper supporting clamp. - Remove the brake disc Refitting - To fit the rear brake disc, follow the removal steps but in reverse order;...
Page 307 Fuoco 500 i.e. Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic New rear disc thickness...
Page 308 Fuoco 500 i.e. Braking system - Unscrew the fixing nut. - Remove the wheel hub. - Unscrew the six bolts securing the disc to the wheel hub. - Remove the disc. Refitting - To fit the front brake disc, follow the removal steps but in reverse order; be careful to tighten the screws to the prescribed torque using threadlock.
Page 309: Front Brake Pads
Fuoco 500 i.e. Braking system Characteristic Thickness of a new front disc 4.0 mm Disc thickness at wear limit (front) 3.5 mm - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits.
Page 310: Rear Brake Pads
Fuoco 500 i.e. Braking system - Remove the pads. Characteristic Minimum value 1.5 mm Refitting - Follow the removal steps but in reverse order; check that the Benzing snap ring of the pads is in good conditions. Rear brake pads...
Page 311 Fuoco 500 i.e. Braking system Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Through the bleed screw on the brake calliper, bleed the system using a hose of adequate diam- eter.
Page 312 Fuoco 500 i.e. Braking system Front - The operations described refer to only one cal- liper but are valid and must be observed for both. - Remove the rubber hood from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered.
Page 313: Parking Brake
Fuoco 500 i.e. Braking system Remove front Shield. Remove front wheel and mudguard. Disconnect the brake pipes from the calliper and drain the brake fluid. Then, remove the plastic and metallic straps. Unscrew the brake pump pipes as indicated in the figure.
Page 314 Fuoco 500 i.e. Braking system Remove the two fixing screws of the mechanic calliper and remove the calliper. To check calliper components, refer to the chapter on the tilt locking calliper. When refitting, secure to the specified torque. Locking torques (N*m) Screw tightening calliper to the support 20 ÷...
Page 315 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 316: Circuit Diagram
Fuoco 500 i.e. Cooling system Circuit diagram The cooling system is of the forced circulation type, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal unit.
Page 317 Fuoco 500 i.e. Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
Page 318 Fuoco 500 i.e. Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and end temperature.
Page 319: Coolant Replacement
Fuoco 500 i.e. Cooling system Coolant replacement System top-up rules - Prepare the mixture of 50% water and coolant. - Fill the system to reach a level ranging between the MIX and MAX levels indicated in the expansion tank filler.
Page 320 Fuoco 500 i.e. Cooling system • Remove the muffler to access the flywheel cover as described in the "Removing the Engine from the Scooter" Chapter. • Empty the cooling system, removing the hoses located on the water pump cover and the loading cap located on the expansion tank.
Page 321 Fuoco 500 i.e. Cooling system diagnosis Excessive system pressure 1 - Check the expansion tank cap efficiency. N.B. THE CAP IS PROVIDED WITH AN OVERPRESSURE VALVE CALIBRATED AT 0.9 BAR. There is also a valve that must allow air inlet during the cooling step.
Page 322 Fuoco 500 i.e. Cooling system COOL SYS - 8...
Page 323 INDEX OF TOPICS CHAS HASSIS...
Page 324: Instrument Panel
Fuoco 500 i.e. Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Raise the saddle. - Undo the screw shown in the figure, remove the cover and disconnect the rider presence sensor connector.
Page 325 Fuoco 500 i.e. Chassis Front handlebar cover - Unscrew the six screws and remove the upper cap and the rear handlebar cover. - Unscrew the two screws fixing the handlebar to remove the front part of the handlebar cover. Headlight assy.
Page 326 Fuoco 500 i.e. Chassis - Undo the two screws fixing it to the frame. - Undo the two screws fixing it to the upper part of the shield back plate. - Disconnect the assembly connectors at both sides and remove the support.
Page 327 Fuoco 500 i.e. Chassis Frame central cover - Unscrew the fuel tank cap. - Remove the saddle. - Remove the side fairings Working from both sides: - Undo the screw indicated and remove the cap lid. - Undo the two screws.
Page 328 Fuoco 500 i.e. Chassis Legshield - Remove the spoiler. - Unscrew the four screws indicated and remove the lower part from the headlight assembly sup- port. Working from both sides, remove the lateral sec- tions of the front shield: - Undo the two screws fixing it to the shield back plate, in the wheel housing, and to the upper part of the shield back plate.
Page 329 Fuoco 500 i.e. Chassis Knee-guard - Remove the front shield. - Remove the handlebar covers. - Remove the spoiler. - Remove the two central screws and the coolant cap cover screw. - Remove the expansion tank fixing screw and the frame from the instrument panel and manually re- lease the unions with the shield back plate.
Page 330 Fuoco 500 i.e. Chassis - Remove the key switch plastic ring and the two plastic covers near the footrest. - Remove the five screws on the shield back plate rear part. - Remove the two shield back plate front screws, see figure.
Page 331 Fuoco 500 i.e. Chassis - Remove the two shield back plate lower screws. - Remove the external temperature sensor con- nection. See also spoiler Legshield Taillight assy. - Remove the side fairings. - Remove the handgrips. - Undo the screw indicated in the figure.
Page 332 Fuoco 500 i.e. Chassis Footrest Remove the central cover. Remove the four screws and extract the half-foot- rest. Follow the same procedure for both half-footrests. Release the fuse-box See also Frame central cover Side fairings - These operations are described once but apply to both side fairings.
Page 333 Fuoco 500 i.e. Chassis License plate holder - Undo the two upper screws fixing it to the rear plastic element and the three screws fixing it to the frame. Helmet bay - Remove the side fairings. - Remove the side handgrips.
Page 334 Fuoco 500 i.e. Chassis - Undo the screws fixing the voltage regulator to the helmet compartment internal side. - Undo the two screws of the saddle lock, discon- nect the lock cables and release the sheath from the helmet compartment.
Page 335: Fuel Tank
Fuoco 500 i.e. Chassis - Remove the helmet compartment. spoiler - Remove the GILERA clip-on badge paying at- tention not to spoil the paint. - Undo the screw underneath. - Undo the four screws indicated. Fuel tank Remove the chassis central cover.
Page 336 Fuoco 500 i.e. Chassis Remove the two lower bracket retainers indicated in the figure. Disconnect the electric wiring and the fuel pipes. See also Footrest Rear Remove the four fixing screws of the cover and release it from the two leverages.
Page 337 Fuoco 500 i.e. Chassis Handles and top side fairings - Remove the side fairings. - Undo the seven screws fixing the turn indicator arrows. - Disconnect the license plate light connector. - Undo the three screws indicated at both sides and remove the handgrip clamp.
Page 338 Fuoco 500 i.e. Chassis - Undo the two screws indicated. - Undo the two screws of the supporting clamp. - Remove the supporting clamp. - Remove the two protective screws that fix the ra- diator lower protection to the shield back plate.
Page 339 Fuoco 500 i.e. Chassis Battery - Raise the saddle. - Undo the two screws of the battery cover. Lower cover Montaggio - Dalle viti di corredo prendere: tre viti con rondelle, tre piastrine elastiche e tre distanziali. - Inserire i distanziali nei tre fori indicati.
Page 340 Fuoco 500 i.e. Chassis - Inserire dove indicato le tre piastrine elastiche. - Montare il paracolpi inferiore, avvitando le tre viti complete di rondelle. Smontaggio - Svitare le tre viti complete di rondelle di fissaggio al telaio, e recuperare il distanziale.
Page 341 Fuoco 500 i.e. Chassis CHAS - 19...
Page 342 Fuoco 500 i.e. Chassis CHAS - 20...
Page 343 INDEX OF TOPICS PRE DE DELIVERY...
Page 344 Fuoco 500 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Position the plastic cover supplied with the cou- pling on the steering tube as shown in the figure. If a customer wishes to have mudflaps installed, proceed as follows: •...
Page 345: Front Wheel Fixing Screws
Fuoco 500 i.e. Pre-delivery • Front shock absorber upper fixing • Front shock absorber lower fixing • Sliding stems fixing • Break callipers fixing • Front wheels fixing screws • Front wheels axle nut • Rear wheel axle nut •...
Page 346: Road Test
Fuoco 500 i.e. Pre-delivery IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE. IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
Page 347 Fuoco 500 i.e. Pre-delivery CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. Functional inspection Verifica Funzionale: • Impianto frenante idraulico: corsa della leva • Frizione: verifica corretto funzionamento •...
Page 348 Fuoco 500 i.e. Pre-delivery PRE DE - 6...
Page 349 INDEX OF TOPICS TIME...
Page 350 Fuoco 500 i.e. Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replace- ment TIME - 2...
Page 351 Fuoco 500 i.e. Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Re- placement 001133 Engine crankcase- Replace- ment 001153 Half crankcase gasket - Re- placement TIME - 3...
Page 352 Fuoco 500 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 4...
Page 353 Fuoco 500 i.e. Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder piston - Replace- ment 001154 Pin ring piston unit - Service 001129 Chain tensioner - Service and Replacement TIME - 5...
Page 354 Fuoco 500 i.e. Time Cylinder head assy. GRUPPO TESTA Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 001083 Thermistor - Replacement 007012 Coolant bleed valve - Re- placement...
Page 355 Fuoco 500 i.e. Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Re- placement 001169 Decompressor - Replace- ment TIME - 7...
Page 356 Fuoco 500 i.e. Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replace- ment TIME - 8...
Page 357 Fuoco 500 i.e. Time Flywheel cover COPERCHIO VOLANO Code Action Duration 001087 Flywheel cover - replace 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001150 Flywheel cover gasket - Re- placement 001160 Minimum oil pressure sensor...
Page 358 Fuoco 500 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Re- placement TIME - 10...
Page 359 Fuoco 500 i.e. Time Oil pump POMPA OLIO Code Action Duration 001042 Oil pump - overhaul 001051 Belt/ Timing chain - Replace- ment 001112 Oil pump - change 001125 Chain guide pads - change TIME - 11...
Page 360 Fuoco 500 i.e. Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Serv- 001156 Gear reduction unit cover - Replacement 003065 Gear box oil - Replacement 004125 Rear gear shaft - Replace- ment...
Page 361 Fuoco 500 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001006 driving pulley - Service 001141 Belt anti-flapping roller - Re- placement 001066 driving pulley - Replacement 001177...
Page 362 Fuoco 500 i.e. Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Replacement 001096 External transmission cover - Replacement 001131 Transmission air intake - Re- placement 001135 Transmission cover bearing - Replacement 001170 Air manifold - replacement...
Page 363 Fuoco 500 i.e. Time Flywheel magneto VOLANO MAGNETE Code Action Duration 001173 Rotor - replace 001067 Stator - Replacement 001058 Flywheel - Replacement 001104 Start-up freewheel - Replace- ment TIME - 15...
Page 364 Fuoco 500 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - change 001047 Injector - Replacement 001023 Control unit - Replacement TIME - 16...
Page 365 Fuoco 500 i.e. Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment 001095 Muffler guard - Replacement 004169 Muffler guard - Replacement 005138 Lambda probe - Replace- ment TIME - 17...
Page 366: Air Cleaner
Fuoco 500 i.e. Time Air cleaner DEPURATORE ARIA Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Cleaner / Throttle body union - Replacement 001027 Body / air cleaner union - Re-...
Page 367 Fuoco 500 i.e. Time Frame CHASSIS Code Action Duration 004146 Front frame - Replacement 004001 Frame - replace 004147 footboard support bracket one side - Replacement 004143 Footrest support - replace 004116 Rear frame - Replacement 004148 footboard support bracket...
Page 368 Fuoco 500 i.e. Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 004179 Stand buffer - Replacement TIME - 20...
Page 369 Fuoco 500 i.e. Time Legshield spoiler RONT SHIELD Code Action Duration 004021 Shield upper section - Re- placement 004022 Shield lower section - Re- placement 004020 Headlight rim - Replacement 004085 Fairing (1) - Replacement 004064 Front shield - Replacement...
Page 370 Fuoco 500 i.e. Time Side fairings COPERTURE LATERALI Code Action Duration 004036 Lower chassis cover - Re- placement 004129 Rear fairing - Replacement 004037 Side aprons-Replacement 004121 Fianchetto sella (1) - Sostitu- zione Rear cover SCUDO POSTERIORE Code Action Duration...
Page 371 Fuoco 500 i.e. Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replacement 004135 Fuel tank port - Replacement 004011 Central chassis cover - re- place 004012 Rear fairings - Removal and refitting 004015 Footrest - Removal and Re-...
Page 372 Fuoco 500 i.e. Time Mudguard MUDGUARDS Code Action Duration 007015 Radiator air intake - Replace- ment 004009 Rear mudguard - Replace- ment 004181 Lower cover - Replacement 004184 Front mudguard support - re- placement 004002 Front mudguard - Replace- ment...
Page 373 Fuoco 500 i.e. Time Fuel tank UEL TANK Code Action Duration 004137 Injector pump pipe - Replace- ment 005010 Tank float - Replacement 004109 Fuel tank breather - change 004168 Fuel tank cap - Replacement 004005 Fuel tank - Replacement...
Page 374 Fuoco 500 i.e. Time Rear shock-absorber EAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting 003035 Shock absorber support and brake calliper - Replacement 003077 muffler/rear shock absorber support arm - Service TIME - 26...
Page 375 Fuoco 500 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE- MENT 004026 Handlebar cover - Replace- ment TIME - 27...
Page 376 Fuoco 500 i.e. Time Handlebar components OMPONENTI MANUBRIO Code Action Duration 002059 Right-hand knob - change 002060 Complete gas command - Replacement 002063 Complete gas transmission - Replacement 003001 Handlebar - Replacement 002071 LHS knob - Replacement 003059 Counterweight - Replace-...
Page 377 Fuoco 500 i.e. Time Swing-arm SWINGING ARM Code Action Duration 004058 Silent block - Replacement 003081 Swinging arm support flange - replace 001072 Swinging arm - Engine-chas- sis connection - Replacement 003080 Swinging arm on frame - Re- placement TIME - 29...
Page 378 Fuoco 500 i.e. Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement TIME - 30...
Page 379 Fuoco 500 i.e. Time Instrument panel RUPPO STRUMENTI Code Action Duration 005014 Odometer - Replacement 004099 Odometer housing - Replace- ment 004035 Instrument panel - Replace- ment TIME - 31...
Page 380 Fuoco 500 i.e. Time Locks LOCKS Code Action Duration 005146 Elettroattuatore apertura sella - Sostituzione 004054 Saddle lock catch - Replace- ment 005072 Immobilizer aerial - Replace- ment 004010 Anti-theft lock - Replacement Turn signal lights Front lights TIME - 32...
Page 381 Fuoco 500 i.e. Time ANALERIA LAMPEGGIATORI ANT Code Action Duration 005067 Front direction indicator bulb - Replacement 005012 Front direction indicators - Replacement 005002 Front light - Replacement 005008 Light bulbs - Replacement 005139 Tail light bulb - Replacement 005140...
Page 382 Fuoco 500 i.e. Time EAR TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005005 Taillight - Replacement 005022 Rear turn indicators - replace 005031 Licence plate light bulb - Re- placement 005032 Transparent licence plate cover - replace 005131 Licence plate light support -...
Page 383: Front Wheel
Fuoco 500 i.e. Time Front wheel RONT WHEELS Code Action Duration 003047 Front tyre - replace 003033 Front wheel hub- Replace- ment 003037 Front wheel rim- Replace- ment 005089 Tone wheel - Replacement 002041 Front brake disc - Replace- ment...
Page 384: Rear Wheel
Fuoco 500 i.e. Time Rear wheel EAR WHEEL Code Action Duration 002070 Rear brake disc - Replace- ment 001016 Rear wheel - Replacement 001071 Front wheel rim - Removal and refitting 004126 Rear wheel tyre - Replace- ment TIME - 36...
Page 385 Fuoco 500 i.e. Time Electric start AVVIAMENTO Code Action Duration 001017 Start-up pinion - Replace- ment 001020 Starter motor - Replacement 001151 Start-up driven gearing - Re- placement TIME - 37...
Page 386 Fuoco 500 i.e. Time Electric devices DISPOSITIVI ELETTRICI Code Action Duration 005035 Headlight remote control - Replacement 005011 Start-up remote control switch - Replacement 005007 Battery - Replacement 005003 Horn - Replacement 005096 Remote control for injection components - Replacement...
Page 387 Fuoco 500 i.e. Time ABLE HARNESS Code Action Duration 005001 electric system - change 005114 Electrical system - Service Electronic controls TIME - 39...
Page 388 Fuoco 500 i.e. Time COMANDI AL MANUBRIO Code Action Duration 005017 Stop switch - Replacement 005077 Emergency stop switch - Re- placement 005041 Starter button - replace 005040 Horn button - Replacement 005006 Light switch or turn indicators - Replacement...
Page 389 Fuoco 500 i.e. Time Code Action Duration 002026 Trasmissione freno di stazio- namento - sostituzione 002092 Transmission splitter/ hook transmission - Replacement Helmet bay HELMET COMPARTMENT Code Action Duration 005046 Battery cover - change 005026 Helmet compartment bulb - Replacement...
Page 390: Front Suspension
Fuoco 500 i.e. Time Front suspension FRONT SUSPENSION Code Action Duration 003010 Front suspension - Service 003111 Side steering tube - replace- ment 003038 Front wheel axle - Remov. and Refitt. 003040 Front wheel bearings - Re- placement 003107 Sliding stems - replacement...
Page 391 Fuoco 500 i.e. Time Cooling system MPIANTO DI RAFFREDDAMENTO Code Action Duration 007013 Radiator expansion tank con- nection pipe - Replacement 001052 Coolant and air bleed - Re- placement 007001 Expansion tank - Replace- ment 007024 Expansion tank cap - Re-...
Page 392 Fuoco 500 i.e. Time Braking system MPIANTO FRENANTE Code Action Duration 002025 Brake piping - Replacement 003096 Tilt locking calliper- replace- ment 003100 Tilt locking calliper pads - re- placement 003109 Parking brake mechanical calliper - replacement 002002 Shoes - Rear brake pads -...
Page 393 Fuoco 500 i.e. Time Code Action Duration 002007 Front brake pads - Replace- ment 002039 Front brake calliper - Re- placement 003104 Suspension system locking calliper- replacement 003119 Hoses for the pump-splitter suspension locking system - replacement 003105 Suspension locking system brake fluid - repl.
Page 394 Fuoco 500 i.e. Time The tilt mechanism ILT MECHANISM Code Action Duration 003073 Steering clearance - Adjust- ment 003112 Central steering tube - re- placement 003002 Steering fifth wheel - Re- placement 003115 Parallelogram arms - re- placement 003114 Parallelogram bearings - re-...
Page 395 Fuoco 500 i.e. Time Geared motor OTORIDUTTORE Code Action Duration 003101 Tilt locking calliper control lever - replacement 005009 Voltage regulator - replace 003095 Tilt locking calliper support bracket - replacement 001069 HV coil - replace 001094 Spark plug cap - Replace-...
Page 396 Fuoco 500 i.e. Time TIME - 48...

Gilera Fuoco 500 Service Station Manual

Quick Links

Troubleshooting

Related Manuals for Gilera Fuoco 500

Summary of Contents for Gilera Fuoco 500

Table of Contents