Gilera Fuoco 500 Manuals

Gilera Fuoco 500 Manuals

Manuals and User Guides for Gilera Fuoco 500. We have 1 Gilera Fuoco 500 manual available for free PDF download: Service Station Manual

Gilera Fuoco 500 Service Station Manual

Gilera Fuoco 500 Service Station Manual (397 pages)

motorcycle

Brand: Gilera | Category: Motorcycle | Size: 14.76 MB

Table of Contents

Index of Topics
5
Characteristics
7
Safety Rules
8
Maintenance Rules
8
Vehicle Identification
9
Dimensions and Mass
9
Electrical System
11
Wheels and Tyres
11
Table of Contents
12
Upper Shock Absorber Clamp
13
- Overhaul Data
  15
- Assembly Clearances
  15
- Cylinder - Piston Assy.
  15
- Coupling Categories
  16
- Height to Measure the Piston
  16
- Piston Rings
  16
- Cylinder - Piston
  16
- Rings/Housing Coupling Clearances
  17
- Crankcase - Crankshaft - Connecting Rod
  18
- Axial Clearance between Crankshaft and Connecting Rod
  18
- Diameter of Crankshaft Bearings
  19
- Max. Admissible Displacement
  19
- Slot Packing System
  20
- Recommended Products Table
  21
- Products
  21
- Base Gasket Thickness
  21
- Tooling
  23
- Specific Tools
  24
- Maintenance
  35
- Maintenance Chart
  36
- Every 2 Years
  36
- After 1,000 Km
  36
- After 10,000 Km; 50,000 Km; 70,000 Km
  37
- After 15,000 Km; 45,000 Km; 75,000 Km
  37
- After 20,000 Km; 40,000 Km; 60,000 Km and 80,000 Km
  37
- Checking the Spark Advance
  38
- 30,000 Km
  38
- Spark Plug
  40
- Hub Oil
  41
- Replacement
  41
- Air Filter
  42
- Engine Oil
  42
- Engine Oil Filter
  45
- Oil Pressure Warning Light
  45
- Oil Top up
  45
- Adding Engine Coolant
  46
- Cooling System
  46
- Checking the Ignition Timing
  46
- Braking System Level Check
  47
- Top-Up
  47
- Headlight Adjustment
  48
- To Access the Headlight Adjusting Screws
  48
- Troubleshooting
  51
- Engine
  52
- Excessive Oil Consumption/Exhaust Smoke
  52
- Insufficient Lubrication Pressure
  52
- Clutch Grabbing or Performing Inadequately
  52
- Excessive Steering Play
  53
- Heavy Steering
  53
- Brakes Overheating
  53
- Insufficient Braking
  53
- Noisy Suspension
  54
- Suspension Oil Leakage
  54
- Electrical System
  55
- Components Arrangement
  58
- Ignition
  64
- Battery Recharge and Starting
  65
- Level Indicators and Enable Signals Section
  66
- Devices and Accessories
  67
- Lights and Turn Indicators
  68
- Checks and Inspections
  69
- Immobiliser
  70
- With the Key Switch Set to off
  71
- With the Key Switch in the off Position
  71
- Virgin Circuit
  72
- Diagnostic Codes
  73
- Diagnostic Code - 1 Flash
  74
- Diagnostic Code - 2 Flashes
  75
- Diagnostic Code - 3 Flashes
  75
- Battery Recharge Circuit
  75
- Stator Check
  75
- Voltage Regulator/Rectifier
  76
- Recharge System Voltage Check
  76
- Fuses
  77
- Fuse Table
  78
- Dashboard
  79
- Sealed Battery
  80
- Connectors
  81
- Injection Electronic Control Unit
  81
- Pick-Up Connector
  81
- Voltage Regulator Connector
  82
- Saddle Opening Receiver Connector
  82
- Turn Indicator Control Device Connector
  82
- Instrument Panel Connector "A"
  83
- Hv Coil Connector
  83
- Fuel Pump Connector
  83
- Anti-Theft Device Pre-Installation Connector
  83
- Instrument Panel Connector "B"
  84
- Parking Control Ecu Connector
  84
- Remote Seat Opening
  85
- Zeroing
  85
- Programming
  86
- Engine from Vehicle
  87
- Exhaust Assy. Removal
  88
- Removal of the Engine from the Vehicle
  88
- Transmission Cover
  94
- Automatic Transmission
  94
- Air Duct
  95
- Air Duct Filter
  96
- Removing the Driven Pulley Shaft Bearing
  96
- Refitting the Driven Pulley Shaft Bearing
  97
- Baffle Roller
  97
- Plastic Roller
  97
- Removing the Driven Pulley
  98
- Inspecting the Clutch Drum
  98
- Removing the Clutch
  99
- Inspecting the Clutch
  99
- Removing the Driven Half-Pulley Bearing
  100
- Pin Retaining Collar
  100
- Inspecting the Driven Fixed Half-Pulley
  101
- Inspecting the Driven Sliding Half-Pulley
  102
- Refitting the Driven Half-Pulley Bearing
  102
- Refitting the Driven Pulley
  103
- Inspecting the Clutch Spring
  103
- Refitting the Clutch
  104
- Drive-Belt
  105
- Removing the Driving Pulley
  105
- Inspecting the Rollers Case
  106
- Refitting the Driving Pulley
  107
- Refitting the Transmission Cover
  109
- End Gear
  111
- Removing the Hub Cover
  111
- Removing the Wheel Axle
  112
- Removing the Hub Bearings
  112
- Removing the Wheel Axle Bearings
  113
- Inspecting the Hub Shaft
  114
- Inspecting the Hub Cover
  115
- Refitting the Hub Cover Bearings
  117
- Refitting the Hub Bearings
  118
- Refitting the Ub Cover
  118
- Flywheel Cover
  119
- Removing the Flywheel Cover Components
  120
- Removing the Stator
  121
- Inspecting the Cover Components
  121
- Refitting the Stator
  124
- Refitting the Flywheel Cover Components
  124
- Refitting the Flywheel Cover
  126
- Flywheel and Starting
  128
- Starter Motor
  130
- Battery
  130
- Start-Up Remote Control Switch
  130
- Starter Transmission
  130
- Removing the Flywheel Magneto
  131
- Removing the Starter Motor
  131
- Refitting the Intermediate Gear
  137
- Refitting the Flywheel Magneto
  138
- Refitting the Starter Motor
  140
- Cylinder Assy. and Timing System
  140
- Removing the Intake Manifold
  141
- Removing the Rocker-Arms Cover
  141
- Removing the Timing System Drive
  141
- Removing the Cam Shaft
  143
- Removing the Cylinder Head
  144
- Removing the Valves
  145
- Removing the Cylinder - Piston Assy.
  146
- Inspecting the Small End
  147
- Inspecting the Wrist Pin
  147
- Inspecting the Piston
  148
- Inspecting the Piston Rings
  149
- Removing the Piston
  150
- Choosing the Gasket
  151
- Refitting the Piston Rings
  153
- Refitting the Cylinder
  153
- Inspecting the Cylinder Head
  153
- Maximum Allowable Run-Out
  154
- Inspecting the Valve Sealings
  154
- Inspecting the Timing System Components
  154
- Inspecting the Valve Housings
  155
- Inspecting the Valves
  155
- Standard Diameter
  155
- Minimum Admissible Diameter
  156
- Inspecting the Valve Stem Guide Clearance
  156
- Inlet
  157
- Outlet
  157
- Standard Valve Length
  157
- Inspecting the Springs and Half-Cones
  158
- Refitting the Valves
  158
- Admissible Limits
  159
- Standard Height
  159
- Inspecting the Cam Shaft
  159
- Refitting the Head and Timing System Components
  161
- Prescribed Clearance
  167
- Refitting the Timing Chain
  167
- 020460Y Scooter Diagnosis and Tester
  168
- 020330Y Stroboscopic Light for Timing Control
  168
- Refitting the Rocker-Arms Cover
  169
- Refitting the Intake Manifold
  170
- Crankcase - Crankshaft
  170
- 020335Y Magnetic Support for Dial Gauge
  171
- 020262Y Crankcase Splitting Strip
  171
- Splitting the Crankcase Halves
  171
- Removing the Crankshaft
  172
- Removing the Countershaft
  173
- Replacing the Countershaft Bearings
  173
- Inspecting the Crankshaft Components
  176
- Inspecting the Crankshaft Alignment
  177
- Max Admissible Displacement
  177
- Inspecting the Crankcase Halves
  178
- Inspecting the Crankshaft Plain Bearings
  179
- Check the Bench Bush
  180
- Coupling Chart
  180
- Countershaft
  182
- Refitting the Crankshaft
  182
- Refitting the Crankcase Halves
  184
- Lubrication
  185
- Technical Specifications
  185
- Sump Capacity
  185
- Recommended Engine Oil
  185
- Pre-Filter
  186
- Oil Filter
  186
- Oil Minimum Pressure Indicator Light Switch
  186
- Head Lubrication Control Jet
  186
- General Characteristics
  187
- Conceptual Diagrams
  187
- Diagnosis Guide
  188
- Standard Values
  189
- Oil Pressure Check
  190
- Oil Pump
  191
- Injection
  197
- Precautions
  200
- Terminals Setup
  202
- Terminal Layout
  202
- EMS Circuit Diagram
  203
- System Schematic
  203
- Troubleshooting Procedure
  204
- Engine Does Not Start
  204
- Starting Difficulties
  205
- Engine Start-Up Problems
  205
- Engine Stops at Idle
  205
- Engine Does Not Rev down
  206
- Exhaust Backfires in Deceleration
  206
- Engine Revs Irregularly
  207
- Poor Performance at Full Throttle
  207
- Engine Knocking
  208
- Fuel Supply System
  208
- Presence of Knocking (Overhead Knocking)
  208
- Removing the Butterfly Valve
  209
- Pump Supply Circuit
  211
- Injection Loads
  212
- Electrical Data
  212
- Fuel Filter Check
  216
- Inspecting the Injector Circuit
  218
- Code 1
  228
- Code 2
  229
- Code 3
  229
- Tachometer
  230
- HT Coil
  231
- Spark Advance
  236
- Inspecting the Spark Plug Shielded Cap
  236
- Coolant Temperature Sensor
  238
- Temperature Sensor
  238
- Zeroing the Throttle
  239
- Resetting the Throttle Valve Position Signal (TPS Reset)
  239
- Lambda Probe
  242
- Suspensions
  247
- Removing the Front Wheel
  248
- Front Wheel Hub Overhaul
  248
- The Tilt Mechanism
  250
Handlebar Fixing Screw
250
- Steering Tubes
  251
- Hydraulic System Layout
  251
- Parallelogram Device
  257
Side Headstock Lower Ring Nut
257
Fixing Nuts for Constant-Velocity Universal Joints
257
Arm Coupling Screws
261
Screws Fixing Arms to Side Headstocks
261
Screws Fixing Arms to Central Headstock
261
Screws Fixing the Half-Arm Coupling Flange
261
Geared Motor and Suspension Locking System
262
Fixing Screws for Tilt Locking Disc Section
262
Clamp Fixing Pump Bolt to Anti-Tilting Device
264
- 020376Y Adaptor Handle
  271
- Pressure Switch
  275
- Electrical Devices Test
  275
- Geared Motor
  278
- Tilt Locking-Unlocking Switch
  279
- Tilt Locking Calliper Sensor
  281
- Potentiometer
  282
- Rider Presence Sensor
  283
- Tone Wheel Sensor
  284
- Wheel Alignment
  287
- Tool Fitting
  287
- Removing the Rear Wheel
  291
- Refitting the Rear Wheel
  293
- Swing-Arm
  293
- Overhaul
  295
- Shock Absorbers
  299
- Swinging Arm Fitting
  299
Centre Stand Bolt
300
- Braking System
  301
- Rear Brake Calliper
  302
- Front Brake Calliper
  304
- Rear Brake Disc
  305
- Disc Inspection
  307
- Front Brake Disc
  307
- Front Brake Pads
  309
- Rear Brake Pads
  310
- Rear - Combined
  311
- Brake Pipes
  312
- Parking Brake
  313
- Circuit Diagram
  316
- Electric Fan Check
  317
- System Sealing Check
  318
- Coolant Replacement
  319
- System Top-Up Rules
  319
- Pompa Acqua
  319
- Water Pump
  319
- Removing the Water Pump Cover
  320
- Oil in the Fluid
  321
- Cooling Fluid Consumption
  321
- Excessive System Pressure
  321
- Chassis
  323
- Instrument Panel
  324
- Front Handlebar Cover
  325
- Headlight Assy.
  325
- Frame Central Cover
  327
- Legshield
  328
- Knee-Guard
  329
- Taillight Assy.
  331
- Footrest
  332
- Side Fairings
  332
- License Plate Holder
  333
- Helmet Bay
  333
- Fuel Tank
  335
- Handles and Top Side Fairings
  337
- Radiator Cover
  337
- Lower Cover
  339
- Pre-Delivery
  343
- Aesthetic Inspection
  344
- Tightening Torques Inspection
  344
- Front Wheel Fixing Screws
  345
- Static Control after the Test Ride
  346
- Static Test
  346
- Road Test
  346
- Functional Inspection
  347
- Time
  349
- Crankcase
  351
- Crankshaft
  352
- Cylinder Assy.
  353
- Cylinder Head Assy.
  354
- Rocker Arms Support Assy.
  355
- Cylinder Head Cover
  356
- Driven Pulley
  358
- Final Gear Assy.
  360
- Driving Pulley
  361
- Flywheel Magneto
  363
- Butterfly Valve
  364
- Exhaust Pipe
  365
- Air Cleaner
  366
- Frame
  367
- Legshield Spoiler
  369
- Central Cover
  371
- Mudguard
  372
- Fuel Tank
  373
- Rear Shock-Absorber
  374
- Handlebar Covers
  375
- Handlebar Components
  376
- Seat
  378
- Locks
  380
Front Wheel
383
- Rear Wheel
  384
- Electric Start
  385
- Electric Devices
  386
- Electronic Controls
  387
- Cable Harness
  387
- Transmissions
  388
- Helmet Compartment
  389
Front Suspension
390
Stickers
393

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