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Gilera Fuoco 500, Service Station Manual

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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.

N.B.

IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF-SHAFTS OF DIF-
FERENT CATEGORY, REPLACE THE TWO HALF-CRANKCASES AS WELL, COUPLING THE TWO
COMPONENTS (SHAFT AND CRANKCASE) WITH THE SAME CATEGORY.

- To check the gearing of the crankshaft, see sec-

tion "Thermal unit and timing system".

See also

Cylinder assy. and timing system

Inspecting the crankcase halves

- Before proceeding to check the crankcase

halves, thoroughly clean the all surfaces and oil

ducts.

- For the transmission-side half-crankcase, special

attention should be given to the bushings, to the

cooling jet on the transmission side (see figure)

and to the lubrication duct.

N.B.

THE JET IS FED THROUGH THE MAIN BUSH-
INGS. PROPER OPERATION OF THIS COMPO-
NENT IMPROVES THE PISTON TOP COOLING.
CLOGGING HAS EFFECTS THAT ARE DIFFI-
CULT TO DETECT (PISTON TEMPERATURE
INCREASE). FAILURE OR LEAK CAN CONSID-
ERABLY DECREASE THE MAIN BUSHING
AND CONNECTING ROD LUBRICATION PRES-
SURE.

Engine

Fuoco 500 i.e.

ENG - 86

Summary of Contents for Fuoco 500

Page 1: ...SERVICE STATION MANUAL XXXX Fuoco 500 i e ...

Page 2: ...any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all Countries The availability of single versions should be checked at the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reproducti...

Page 3: ...ble to read the sections of this manual concerning special tools along with the special tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to complete...

Page 4: ......

Page 5: ...OOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ...pressed air in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always ...

Page 9: ...Vehicle identification Frame prefix A ZAPM61100 Engine prefix B M661M Dimensions and mass Fuoco 500 i e Characteristics CHAR 3 ...

Page 10: ...torque 44 Nm at 5 200 rpm Lubrication Engine lubrication with lobe pump inside crank case controlled by a chain with double filter mesh and paper Lubrication pressure 3 5 4 bar Minimum lubrication pressure 100 C 0 8 bar Fuel supply Electronic injection with electric fuel pump Cooling Forced coolant circulation system Fuel Unleaded petrol 95 RON Transmission TRANSMISSION Specification Desc Quantity...

Page 11: ...bular and sheet steel Front suspension The tilt mechanism is composed of an articulated parallelogram suspension with die cast aluminium control arms and two side headstocks plus shock absorbers with hydraulic locking system Front suspension travel 85 mm Rear suspension Two double acting shock absorbers adjustable to four positions at preloading Rear suspension travel 110 mm Brakes BRAKES Specific...

Page 12: ...ck absorber clamp 19 29 Front wheel fixing screws 19 24 Steering arm bolt nut 20 25 Tilt calliper fixing screws 20 25 Front wheel shaft 74 88 Arm coupling screws 45 50 Screws fixing arms to side headstocks 45 50 Screws fixing arms to central headstock 45 50 Screws fixing the half arm coupling flange 20 25 Fixing screws for tilt locking disc section 20 25 Side headstock upper ring nut 20 24 Side he...

Page 13: ...per pipe fitting 20 25 REAR BRAKE Name Torque in Nm Oil bleed screw 12 16 Rear brake disc screws 5 6 5 Rear brake calliper pipe fitting 20 25 Rigid flexible pipe fitting 13 18 Rear brake pump pipe fitting 16 20 Rear brake calliper fixing screws 20 25 pad fastening pin screws 20 25 REAR BRAKE Product Description Specifications Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium strength...

Page 14: ...que of 7 Nm in a crossed sequence Tighten by 90 in a crossed sequence Tighten again by 90 in a crossed sequence TRANSMISSION COVER Name Torque in Nm Driven pulley nut 92 100 Drive pulley nut 160 175 Anti vibration roller screw 16 7 19 6 M8 retainers for transmission cover 23 26 M6 retainer 11 13 Anti vibration roller retainer 17 19 Clutch ring nut 65 75 Air deflector unit screws 7 9 Water pump cov...

Page 15: ...OLING Name Torque in Nm Water pump rotor cover 3 4 Thermostat cover screws 3 4 Bleed screw 3 FINAL REDUCTION Name Torque in Nm Rear hub cover screws 24 27 ENGINE ASSEMBLY Name Torque in Nm starter motor retainers 11 13 Overhaul data Assembly clearances Cylinder piston assy Fuoco 500 i e Characteristics CHAR 9 ...

Page 16: ...3 Cylinder Piston C 94 004 94 011 93 968 93 975 0 029 0 043 Cylinder Piston D 94 011 94 018 93 975 93 982 0 029 0 043 N B THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE OUTLET SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS Piston rings Fit rings 2 and 3 with the word TOP facing upwards Position the openings in the rings as shown here Va...

Page 17: ...nd check the coupling clearances Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm Oil scraper ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Replace the piston if clearances exceed the max imum limits spec...

Page 18: ...tity Transmission side shoulder 1 0 025 A D 0 20 0 50 Half shaft trans mission side 20 9 0 05 B D 0 20 0 50 Connecting rod 22 0 10 0 15 C D 0 20 0 50 Flywheel side shoulder 1 8 0 025 F D 0 20 0 50 Flywheel side half shaft 19 6 0 05 E D 0 20 0 50 Complete crank shaft 65 5 0 1 0 05 G D 0 20 0 50 Characteristics Fuoco 500 i e CHAR 12 ...

Page 19: ...c 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 ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm Fuoco 500 i e Characteristics CHAR 13 ...

Page 20: ...PECT TO THE CYLINDER PLANE DISTANCE A HELPS DETERMINE THE THICKNESS OF GASKET B THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN OR DER TO RESTORE COMPRESSION RATIO BASE GASKET B MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD ON THE OTHER HAND THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE THE SMALLER THE GASKET THICKN...

Page 21: ...80W 90 Oil that exceeds the requirements of API GL3 specifi cations AGIP CITY HI TEC 4T Oil to lubricate flexible transmis sions throttle control Oil for 4 stroke engines AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness AGIP GP 330 Grease for brake levers throttle White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP CIT...

Page 22: ...Characteristics Fuoco 500 i e CHAR 16 ...

Page 23: ...INDEX OF TOPICS TOOLING TOOL ...

Page 24: ...g 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 bearings 001467Y014 Extraction pliers for ø 15 mm bearings Tooling Fuoco 500 i e TOOL 2 ...

Page 25: ...1467Y035 Bearing housing outside diame ter 47 mm 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube 020004Y Punch for removing fifth wheels from the headstock 020055Y Wrench for steering tube ring nut 020150Y Air heater support Fuoco 500 i e Tooling TOOL 3 ...

Page 26: ...Y 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 trol Tooling Fuoco 500 i e TOOL 4 ...

Page 27: ...Y 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 Fuoco 500 i e Tooling TOOL 5 ...

Page 28: ...Y 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 Tooling Fuoco 500 i e TOOL 6 ...

Page 29: ...on 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 Fuoco 500 i e Tooling TOOL 7 ...

Page 30: ...20459Y 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 Tooling Fuoco 500 i e TOOL 8 ...

Page 31: ...20470Y 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 Fuoco 500 i e Tooling TOOL 9 ...

Page 32: ... 020478Y Punch for driven pulley roller cas ing 020479Y Countershaft lock wrench 020480Y Petrol pressure check set 020481Y Control unit interface wiring 020482Y Engine support 020483Y 30 mm guide Tooling Fuoco 500 i e TOOL 10 ...

Page 33: ...2Y 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 Fuoco 500 i e Tooling TOOL 11 ...

Page 34: ...Tooling Fuoco 500 i e TOOL 12 ...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 36: ... the icon is no longer dis played Maintenance chart EVERY 2 YEARS 60 Action Coolant change Brake fluid change AFTER 1 000 KM 60 Action Safety locks check Throttle lever adjustment Engine oil change Electrical system and battery check Coolant level check Brake fluid level check Engine oil replacement Brake pads check condition and wear Tyre pressure and wear check Vehicle and brake test road test H...

Page 37: ...ilable AFTER 15 000 KM 45 000 KM 75 000 KM 45 Action Engine oil level check top up Brake pads check condition and wear Centre stand lubrication AFTER 20 000 KM 40 000 KM 60 000 KM AND 80 000 KM Action Spark plugs replacement Driving belt replacement Throttle lever adjustment Air filter check Engine oil change Valve clearance check Electrical system and battery check Coolant level check Engine oil ...

Page 38: ...pgrading if available Checking the spark advance The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to declare the reference values based on the engine rpm The ignition timing value is detectable any time using the diagnostic tester It is possible to check wheth er the ignition advance determined by the system d...

Page 39: ...w on the clamp must be pointing at the spark plug 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 Check that the real values of rpm and ignition advance match those measured using the diag nostic tester If the values do not correspond check distribution timi...

Page 40: ...ap A fully over the spark plugs Refit the port making sure the rear hook is inser ted WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD REPLACE THE SPARK PLUG AS INDICATED IN THE SCHEDULED MAINTENANCE TABLE THE USE OF ELEC TRONIC CENTRAL UNITS AND OF NON COM PLIANT ELECTRONIC IGNITIONS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE N B THE USE OF SPARK PLUG...

Page 41: ...ark it needs to be filled up with the right amount of hub oil Screw up the oil dipstick again and make sure it is locked properly into place Replacement Remove the oil cap A Unscrew the oil drainage cap B and drain out all the oil Screw in the drainage cap again and fill the hub with the prescribed oil Recommended products AGIP ROTRA 80W 90 Rear hub oil SAE 80W 90 Oil that exceeds the requirements...

Page 42: ...O AVOID DAMAGING THE ENGINE Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness Engine oil In 4T engines the engine oil is used to lubricate the distribution elements the bench bearings and the thermal group An insufficient quantity of oil can cause serious damage to the engine In all 4T engines the deterioration of the oil ...

Page 43: ...ridge fil ter C Make sure the pre filter and discharge tap O rings are in good condition Lubricate them and refit the mesh filter and oil drainage plug screwing them up to the specified torque Refit the new cartridge filter being careful to lubri cate the O ring before fitting it Change the engine oil Since a certain quantity of oil still remains in the circuit engine oil must be added through the...

Page 44: ...filter 12 16 Engine oil drainage plug 24 30 Check This operation must be carried out with the engine cold and following the procedure below Place the vehicle on its centre stand and on flat ground Unscrew the cap dipstick A dry it with a clean cloth and reinsert it screwing it all the way down Remove the cap dipstick again and check that the level is between the min and max reference marks top up ...

Page 45: ... plug screwing them up to the specified torque Refit the new cartridge filter being careful to lubricate the O ring before the fitting Change the engine oil Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the requirements of API SL ACEA A3 JASO MA specifications Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel t...

Page 46: ...ion using a cal liper spanner applied to the camshaft command pulley casing Cooling system Adding engine coolant Check coolant level when the engine is cold as in dicated in the scheduled maintenance table fol lowing the steps below Place the scooter on its centre stand and on flat ground Undo the screw shown in the figure and remove the expansion tank cap on RHS Top up if the fluid level is near ...

Page 47: ...sen the two fixing screws and remove the reservoir cover top up with the recommended fluid only without exceeding the MAX mark This procedure applies to the rear brake pump top up operation follow the same procedure for the front brake pump Under standard climatic conditions replace cool ant as indicated in the scheduled maintenance table WARNING ONLY USE DOT 4 CLASS BRAKE FLUIDS COOLING SYSTEM FL...

Page 48: ...t and check that the border line of the projected light beam should be lower than 9 10 of the distance from the ground to the centre of the vehicle s headlight and higher than 7 10 Otherwise adjust the headlight N B THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS REFER TO THE STATUTORY REGU LATIONS IN FORCE IN EVERY COUNTRY WHERE THE veh...

Page 49: ...ertical 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 N B THE HEADLAMPS CAN ONLY BE LIT WHEN THE ENGINE IS ON ADJUST THE LIGHT BEAM IN A WELL VENTILATED PLACE Fuoco 500 i e Maintenance MAIN 15 ...

Page 50: ...Maintenance Fuoco 500 i e MAIN 16 ...

Page 51: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 52: ...estore the cou pling seal Worn valve oil guard Replace the valve oil guard Worn valve guides Check and replace the head unit if required Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By Pass remains open Check the By Pass and replace if required Care fully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump ...

Page 53: ...rt Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Clogged compensation holes on the pump Clean carefully and blast with compressed air Re inflated or glued rubber gaskets Replace gaskets Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardeni...

Page 54: ...the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings In conclusion check the tightening torque of the wheel hub the brake calliper the shock absorber disk in the attachment to the hub and the steering tube Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage Replace the shock absorber Check the condition of...

Page 55: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 56: ...neto flywheel 7 Locking unlocking switch 8 LV socket 9 Voltage regulator 10 Main fuses 11 Key switch contacts 12 Auxiliary fuses 13 Key switch contacts 14 Fuse 15 Battery 16 Starter motor 17 Start up remote control switch 18 Saddle opening actuator 19 Start up enabling remote control Electrical system Fuoco 500 i e ELE SYS 2 ...

Page 57: ...r 34 Rear light A Tail light bulbs B Stop light bulbs 35 Rear right turn indicator 36 Front left turn indicator 37 Headlight A Left low beam light bulb B Left high beam light bulb C Tail light bulb D Right low beam light bulb E Right high beam light bulb 38 Front right turn indicator 39 Oil pressure sensor 40 Engine stop switch 41 Fuel level transmitter 42 MODE button 43 Instrument panel 44 Hand b...

Page 58: ...is connector 59 Coolant temperature sensor 60 Lambda probe 61 MIU control unit power device 62 Electric fan remote control 63 Electric fan 64 Geared motor Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Components arrangement Electrical system Fuoco 500 i e ELE SYS 4 ...

Page 59: ... 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 Fuoco 500 i e Electrical system ELE SYS 5 ...

Page 60: ... 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 Electrical system Fuoco 500 i e ELE SYS 6 ...

Page 61: ...h it 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 Fuoco 500 i e Electrical system ELE SYS 7 ...

Page 62: ...d 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 15 Parking control unit remove the front shield to reach it Electrical system Fuoco 500 i e ELE SYS 8 ...

Page 63: ...Coolant temperature sensor remove the lid of the helmet compartment and disconnect the con nector to reach it 20 Horn remove the shield back plate lower side to reach it 21 22 Plug socket helmet compartment light open the saddle to reach it Conceptual diagrams Fuoco 500 i e Electrical system ELE SYS 9 ...

Page 64: ...in 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 Electrical system Fuoco 500 i e ELE SYS 10 ...

Page 65: ... Auxiliary fuses 14 Fuse 15 Battery 16 Starter motor 17 Start up remote control switch 19 Start up enabling remote control 20 Stop button on rear brake 21 Stop button on front brake 22 Starter button 34 Rear light B Stop light bulbs 40 Engine stop switch 55 Injection ECU Fuoco 500 i e Electrical system ELE SYS 11 ...

Page 66: ...sor 3 Left speed sensor 4 Potentiometer 5 Rider presence sensor 10 Main fuses 11 Key switch contacts 12 Auxiliary fuses 15 Battery 39 Oil pressure sensor 41 Fuel level transmitter 42 MODE button 43 Instrument panel 45 External temperature sensor 50 Injection load remote control 51 Injector Electrical system Fuoco 500 i e ELE SYS 12 ...

Page 67: ...be 61 MIU control unit power device Devices and accessories KEY 1 Parking electronic control unit 7 Locking unlocking switch 8 LV socket 10 Main fuses 11 Key switch contacts 12 Auxiliary fuses 13 Key switch contacts 15 Battery 18 Saddle opening actuator 23 Saddle opening receiver Fuoco 500 i e Electrical system ELE SYS 13 ...

Page 68: ...t panel 46 Horn 47 Horn button 48 Horn remote control 49 Pressure sensor 50 Injection load remote control 52 Fuel pump 55 Injection ECU 58 Diagnosis connector 61 MIU control unit power device 62 Electric fan remote control 63 Electric fan 64 Geared motor Lights and turn indicators KEY Electrical system Fuoco 500 i e ELE SYS 14 ...

Page 69: ...ght bulb 33 Rear left turn indicator 34 Rear light A Tail light bulbs 35 Rear right turn indicator 36 Front left turn indicator 37 Headlight A Left low beam light bulb B Left high beam light bulb C Tail light bulb D Right low beam light bulb E Right high beam light bulb 38 Front right turn indicator 43 Instrument panel Checks and inspections This section is devoted to the checks on the electrical ...

Page 70: ...ansponder black key HV coil Diagnosis LED The diagnosis LED also works as a blinking light to deter theft This function is activated every time the key switch is set to OFF or the engine emer gency cut off switch is set to OFF It remains activated for 48 hours in order not to affect the battery charge When the ignition switch is turned to ON the deterring blinker function is deactiva ted Subsequen...

Page 71: ...FF position there is battery voltage between termi nals 5 26 and terminal 5 frame earth fixed power supply If there is no volt age check the key switch contacts that fuse no 10 and its cable are work ing order There is continuity between terminals 12 18 with the emergency cut off switch in the RUN position If there is no continuity check the contacts of the switch If no faults are found replace th...

Page 72: ...nterface wiring Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Virgin circuit When the ignition system is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage pro cedure for a previously not programmed control unit provides for the recognition of the m...

Page 73: ...possible to encode new service keys in the event of losses replacements etc Each new programming deletes the previous one so in order to add or eliminate keys you must repeat the procedure using all the keys you intend to keep using If a service key should become un coded the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is advisable to use resistive ...

Page 74: ...ng off for 2 sec and then by short 0 46 sec flashes the same number of times as there are keys stored in the memory including the Master key When the diagnosis has been completed the LED remains permanently OFF The engine can be started 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on permanently The engine cannot be ...

Page 75: ...replace the control unit If this is not the case perform a re programming Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel The alternator is directly connected to the voltage regulator This in its turn is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse The three phase generator ...

Page 76: ...rrent WARNING BEFORE CARRYING OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2 With the battery correctly connected to the circuit place the tester terminals between the battery terminals 3 Turn on the engine increase the revs and at the same time measure the voltage Electric characteristic Voltage ranging between 14 0 and 15 0V at 5000 r...

Page 77: ...art ment A and the other is at the internal side of the right footrest B To have access loosen the screw C and remove the plastic cover The chart shows the position and characteristics of the fuses in the vehicle CAUTION BEFORE REPLACING THE BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO RE PLACE THE FUSE WITH ANY OTHER MATERI AL E G A PIECE OF ELECTRIC WIRE Fuoco 500 i ...

Page 78: ...Fuse No 6 Capacity 15 A Protected circuits L V socket 7 Fuse No 7 Capacity 7 5 A Protected circuits Battery powered instru ment panel 8 Fuse No 8 Capacity 10A Protected circuits Live stop start up and start up enabling switch and start up circuit 9 Fuse No 9 Capacity 7 5 A Protected circuits live passing and horn 10 Fuse No 10 Capacity 7 5A Protected circuits Live injection ECU im mobilizer aerial...

Page 79: ...Fuel gauge I Warning light for helmet compartment courtesy light on L Engine control telltale light and injection sys tem failure warning light M Low fuel warning light N Engine stop warning light D Turn indicator warning light P Low oil pressure warning light Q Front suspension locking system failure warn ing light if available R Warning light for parking brake engaged Fuoco 500 i e Electrical sy...

Page 80: ...it is therefore necessary to check the battery charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN CIRCUIT STORAGE 1 Voltage check up Before installing the battery on the vehicle check the open circuit voltage with a normal tester If voltage exceeds 12 60 V the battery can be installed without any renewal r...

Page 81: ... Black 12 Engine stop switch Green Black 13 Engine revolution sensor positive Red 14 Fuel injector Red Yellow 15 Engine revolution sensor negative Brown 16 Diagnosis Purple White 17 Immobilizer LED Red Green 18 Engine stop switch coolant temperature sen sor Grey Green 19 Not connected 20 Injection load remote control Black Purple 21 Not connected 22 HV coil Pink Black 23 Not connected 24 Start up ...

Page 82: ...ck 7 Ground 8 Not connected 9 Not connected 10 Not connected 11 Channels 1 3 selector Green Blue 12 Alarm code Orange Black TURN INDICATOR CONTROL DEVICE CON NECTOR 1 Hazard switch Brown 2 LHS Switch White Pink 3 RHS Switch Blue Black 4 LHS Turn indicators Pink 5 RHS Turn indicators White Blue 6 Battery powered Blue 7 Not connected 8 Live supply Yellow Black 9 Ground Black 10 Not connected 11 Not ...

Page 83: ...compartment lighting Blue Black 7 Channels 1 3 selector Green Blue 8 Alarm code Orange Black FUEL PUMP CONNECTOR 1 Injection load remote control Black Green 2 Not connected 3 Not connected 4 Ground Black 5 Not connected INSTRUMENT PANEL CONNECTOR A 1 Not connected 2 Not connected 3 Not connected 4 Not connected 5 Instrument panel lighting Yellow Black 6 Battery powered Red Blue 7 Not connected 8 N...

Page 84: ... ground lead White Yellow 14 Engine disabled warning light Orange Blue 15 Immobilizer warning light Red Green 16 Engine check warning light Brown Black 17 Parking brake warning light Yellow Grey 18 Tilt locking activated warning light Pink Black 19 Tilt locking system failure warning light Grey Black 20 Live supply from the parking control ECU Yel low Green PARKING CONTROL ECU CONNECTOR 1A Potenti...

Page 85: ...er sensor Brown 5C Locking unlocking switch Purple Black 6C Rider presence sensor Purple 7C Scooter speed signal Sky blue 8C Geared motor Blue Remote seat opening Zeroing Remove the left side fairing to access the saddle opening receiver control unit indicated in the pho tograph Remove the metal terminal and connect it to a good earth point or to terminal 7 black for at least 10 seconds In this op...

Page 86: ...EAT THE WHOLE PROCEDURE AGAIN FAILURE TO CARRY OUT THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE CONTROLLED KEYS WARNING AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY FROM THE SCOOTER THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RE CEIVER CAN BE IMPAIRED SHOULD THIS BE THE CASE REPEAT TH...

Page 87: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 88: ... pass through the swinging arm CAUTION SHOULD IT BE NECESSARY TO REMOVE ON LY THE MUFFLER TIP ALWAYS REPLACE THE GRAPHITE GASKET BETWEEN STUB AND TIP To fit follow the removal steps but in reverse order be careful to tighten to the correct locking torques once the muffler silencer has been refitted Removal of the engine from the vehicle Use a jack to support the vehicle properly Disconnect the bat...

Page 89: ...at secures the rear brake pipes Remove the pipe feeding coolant into the pump as shown in the photograph and then empty the system Remove the engine coolant outlet pipe as indi cated Disconnect the fuel delivery pipe from the injector by removing the screw locking the retainer clamp Disconnect the injector wiring and the throttle body control unit wiring Remove the coolant outlet pipe from the mot...

Page 90: ...cated in the photograph Remove the negative terminal cable from the starter motor Remove the positive terminal cable from the starter motor as shown in the photograph Remove the engine ground lead Disconnect the connectors from the flywheel wir ing as shown in the photo Remove the cable from the retaining clip on the flywheel cover Engine from vehicle Fuoco 500 i e ENG VE 4 ...

Page 91: ... the operations in reverse order from that adopted when removing it and respect the tightening torque shown in the Characteristics Chapter Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check the functioning of the accelerator and the electrical devices CAUTION PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISS...

Page 92: ...Engine from vehicle Fuoco 500 i e ENG VE 6 ...

Page 93: ...INDEX OF TOPICS ENGINE ENG ...

Page 94: ... remove the driven pulley axle cover near the bottom of the cap Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush Remove the nut and the two washers N B DUE TO THE HIGH TIGHTENING TORQUE US ING DIFFERENT WRENCHES SUCH AS A CONVENTIONAL POLYGONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUS...

Page 95: ...rwise replace it Air duct Remove the transmission cover Unscrew the two screws shown in the figure to remove the air conveyor Locking torques N m Air conveyor screws 11 12 Remove the external transmission cover Unscrew the 4 fastening screws shown in the fig ure to remove the external air conveyor Fuoco 500 i e Engine ENG 3 ...

Page 96: ...face and use the special tool so that it is adequately sup ported Pull out the bearing using the special tool N B BELL MUST BE PLACED INTO THE TRANS MISSION COVER CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE SINCE WITHOUT BELL THE ENTIRE COVER STRUC TURE WOULD BEND NOT ONLY IN THE AREA OF MAXIMUM STURDINESS Specific tooling 001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y ...

Page 97: ...ific tooling 020376Y Adaptor handle 020358Y 37x40 mm adaptor 020439Y 17 mm guide Baffle roller Plastic roller Check that the roller does not show signs of wear and that it turns freely Loosen the retaining bolt using a 13 mm spanner Remove the complete roller with bearing N B IF THE ROLLER DOES NOT ROTATE FREELY REPLACE THE COMPLETE ROLLER Installation of belt anti vibration roller Install the ant...

Page 98: ...ng half pulley Remove the driven pulley assembly with the belt Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter N B CHECK THE ECCENTRICITY MEASURED 0 2 MM MAX Characteristic Max value 160 5 mm Standard value 160 2 mm Engine Fuoco 500 i e ENG 6 ...

Page 99: ...TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD CAUSE AN IRREVERSIBLE TOOL DEFORMATION USING THE SPECIAL 55 MM WRENCH REMOVE THE FASTENING RING NUT LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT CLUTCH SPRING WITH SHEATH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass friction material Characterist...

Page 100: ...ar Extract the collar using 2 screwdrivers Remove the 4 guide pins Extract the moving driven half pulley Removing the driven half pulley bearing Check that the bushing is free from wear and damage otherwise replace the fixed driven half pulley Remove the lock ring using pliers Engine Fuoco 500 i e ENG 8 ...

Page 101: ... UNIT BY THE BELL Specific tooling 001467Y002 Driver for OD 73 mm bearing Remove the roller bearing using the special tool supporting the fixed half pulley with the bell Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020364Y 25 mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half pulley Check that the belt contact surface is free from wear Measure th...

Page 102: ...r bearing using the special tool N B PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUT WARDS Properly support the half pulley to prevent damaging the threading If you are working on the driven pulley unit fully assembled use the special tool Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing Install a new ball bearing using...

Page 103: ...e driven pulley unit with about 10 gr of grease this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole This operation is necessary to avoid the presence of grease beyond the O rings Recommended products AGIP GREASE SM 2 Grease for the tone wheel revolving ring Soap based lithium grease containing NLGI 2 Molybdenum ...

Page 104: ...clutch on the driven pulley bushing N B BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END Tighten the ring nut by hand and complete the tightening using the special wrench to the prescri bed torque Specific tooling 020444Y Tool for fitting removing the driven pulley clutch Locking torques N m Clutch ring nut 65 75 To facilitate reassembly on the engine turn the moving driven pulley a...

Page 105: ...ol Specific tooling 020474Y Driving pulley lock wrench First fit the 2 retainer clamps of the special tool onto the pulley so that the splines are completely engaged Then insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself Tighten the two tool fixing screws also manually Loosen the central nut Remove the spring washer and the flat washer Remove t...

Page 106: ... not worn and measure the inside diameter CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHINGS Characteristic Maximum admissible diameter 30 12 mm Standard diameter 30 021 mm Measure the pulley sliding bushing outside di ameter shown in the figure Characteristic Minimum admissible diameter Ø 29 95 mm Standard diameter Ø 29 959 mm Check that the rollers are not damaged or worn Characteristic Minimum admi...

Page 107: ...ng the driving pulley Installing the roller container Install the spacer with the internal chamfer facing towards the inside Position the rollers on the half pulley as shown in the figure The closed side must rest on the inside thrust face of the roller container Assembly the half pulley with the roller contrast plate and sliding blocks Fuoco 500 i e Engine ENG 15 ...

Page 108: ...e 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 Remove the flat washer and the spring washer as shown in the figure Engine Fuoco 500 i e ENG 16 ...

Page 109: ...c tooling 020474Y Driving pulley lock wrench Install the lock ring from the rear so that the splines are completely engaged Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly Tighten the driving pulley fastening nut to the prescribed torque Remove the special tool Locking torques N m Drive pulley nut 160 175 Refitting the transmission cover Ensure the corre...

Page 110: ...y shaft N B INSERT THE SMALLER WASHER FIRST THEN THE LARGER ONE Insert the flanged nut Prepare the torque wrench for LHS locking using a machine hexagon wrench Tighten the driven pulley shaft fastening nut using an offset wrench N B DUE TO THE HIGH TIGHTENING TORQUE US ING DIFFERENT WRENCHES SUCH AS A CONVENTIONAL POLYGONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF...

Page 111: ...ARE COMPLETELY FREE Install the outside plastic transmission cover Tighten the 4 fastening screws to the prescribed torque Locking torques N m Outside transmission cover screws 7 9 End gear Removing the hub cover Drain the rear hub oil through the oil drainage cap located under the engine Remove the 7 fastening screws Remove the hub cover and the relevant gasket Fuoco 500 i e Engine ENG 19 ...

Page 112: ...5 mm bear ings 001467Y034 Extraction pliers for ø 15 mm bear ings 001467Y031 Bell Use the special extractor to disassemble the bearing on the engine chassis of the countershaft Specific tooling 001467Y006 Extraction pliers for 20 mm bear ings 001467Y035 Bearing housing outside diameter 47 mm Support the hub cover using the column kit Pull out the bearing using the special tool Specific tooling 020...

Page 113: ...Y 30 mm guide Remove the oil guard using a screwdriver Removing the driven pulley shaft bearing If you have to remove the driven pulley shaft the relevant bearing and the oil guard remove the transmission cover and the clutch unit as descri bed in the Automatic transmission chapter Extract the driven pulley shaft from its bearing Remove the oil guard using a screwdriver into the hub gear box Remov...

Page 114: ...tor 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 In case of faults replace the damaged parts Characteristic Connection diameter for countershaft A diameter 20 0 01 0 02 mm Connection diameter for wheel shaft Engine Fuoco 500 i e ENG 22 ...

Page 115: ...aring bearings In case of faults replace the hub cover Refitting the driven pulley shaft bearing Heat the crankcase using the heat gun Specific tooling 020151Y Air heater Insert the driven pulley shaft bearing until it abuts against the bottom of the seat 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 ha...

Page 116: ...ft bearing seat on the crank case Insert the gear shaft bearing in the upper crank case seat 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 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide Place the safety lock seeger ring of the driven pulley shaft bearing N B PLACE IT IN THE POSITION SHOWN IN THE ...

Page 117: ...ial tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS APPLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor 020363Y 20 mm guide Heat the gear shaft bearing seat from the cover outside Insert the gear shaft bearing on the cover using the special punch until abutment Specific tooling 020376Y Adaptor handle 020360Y 52 x 55 mm adaptor 020483Y 30 mm...

Page 118: ... the proper position of the centring dowels Install a new gasket Fit the gearbox cover making sure the breather pipe is in the correct position Position the 7 set screws tighten them to the prescribed torque being careful of the position of the bands holding the vent tube and the position of the 3 shortest screws as indicated in the figure Refill with the prescribed oil to the Max level Recommende...

Page 119: ...e feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO RE MOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS Removing the hub cover Drain the engine oil by removing the drainage cap Prepare a suitable container to collect the oil Remove the pre filter Fuoco 500 i e Engine ENG 27 ...

Page 120: ...support N B THE SCREWS ARE OF 4 DIFFERENT LENGTHS NOTE THE RELEVANT POSITIONS CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR CAUTION BE CAREFUL TO PREVENT SLIPPAGE OF THE BY PASS VALVE AND OF THE RELEVANT SPRING Removing the flywheel cover components Loosen the six mounting screws and remove the water pump cover Engine Fuoco 500 i e ENG 28 ...

Page 121: ...g the stator Remove the two retaining screws and the cable guide bracket Unscrew the 3 fastening screws and remove sta tor and its wiring Inspecting the cover components Loosen the two retaining screws and remove the reed valve support with bulkhead Fuoco 500 i e Engine ENG 29 ...

Page 122: ... crankcase is not worn or deformed Check that the by pass valve seat the torque limiter and the water pump shaft are free from wear Characteristic By pass housing hole diameter 13 9 mm Connection diameter for start up gear shaft 12 mm Connection diameter for pump shaft 8 mm Check that the oil filter union and matching sur face exhibit no deformations or wear Engine Fuoco 500 i e ENG 30 ...

Page 123: ...N VALUES HIGHER THAN THOSE STATED Electric characteristic Resistance 0 2 1 Ω Check the earth insulation of each phase If a fault is discovered carry out a close check of the cable harness that contains two types of cable Rigid cables close to the stator and flexible cables close to the connector Check that the winding is positioned so as not to interfere with the heads of the retaining screws Fuoc...

Page 124: ... N m Stator retainers 8 10 Install the wiring guide bracket tightening the 2 screws to the prescribed torque Locking torques N m Stator cable harness guide bracket screws 3 4 Refitting the flywheel cover components Before reassembling check that all components are perfectly clean For the cover carefully check all lubrication chan nels in particular The 3 by pass channels Oil pressure sensor feedin...

Page 125: ...ws 3 4 Insert the spring and the by pass piston on the flywheel cover N B LUBRICATE THE BY PASS VALVE Reinstall the blow by reed valve using a new sealing gasket Reinstall the support with head and tighten the screws to the prescribed torque Locking torques N m Supporting screws with bulkhead 0 3 0 4 Correctly fit a new O ring do not allow it to come into contact with grease or oil FAILURE TO OBSE...

Page 126: ...r and con nect the return hose to the pump cover using 3 new clamps N B TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS PAYING ATTENTION NOT TO CON STRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUFFICIENTLY Install the pre filter again and insert the engine oil drain plug tightening to the prescribed torque Refill the engine with the prescribed type of oil Recommended products AGIP CITY ...

Page 127: ...er to align the counter shaft movement sensor with a reference point on the crankcase see figure Repeat the alignment for the water pump crank shaft using the same reference point on the en gine N B THIS PREPARATION IS USEFUL PARTICU LARLY IN THE EVENT OF REPAIRS WITH THE WATER PUMP COVER INSTALLED Install the flywheel cover on the engine paying attention to avoid interference between the stator a...

Page 128: ...3 Flywheel and starting 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 N B THE BANDS MUST BE REPLACED TO RE MOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS The starter is sold as a complete part Before deciding to replace it carry out the follow...

Page 129: ...t cannot move long enough to measure the rpm and starter absorption N B THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER THE RPM READING IS NOT THE REAL ONE BUT IS VALID FOR DIAGNOSTIC PURPOSES Specific tooling 020460Y Scooter diagnosis and tester Electric characteristic Absorption at trailing speed 80 120 A Revolution speed approx 300 400 rpm YES go to 6 NO go to 7 NO go to 8 NO go to 9 5 R...

Page 130: ...te control switch 13 Test the battery again and if necessary replace the starter motor N B IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE CHECK THE FREEWHEEL OF THE TORQUE LIMITER SEE THE FLYWHEEL AND STARTER SYSTEM CHAPTER STARTER MOTOR Specification Desc Quantity Type Mitsuba sm13d Power 0 9 kW BATTERY Specification Desc Quantity Capacity 14 Ah Starting current 12...

Page 131: ...ore before insisting on the starter system check the consensus of the immobilizer As for checking the consensus circuit see the Electrical system chapter while for checking the engine shaft control transmission follow what is described in the Flywheel and starter system chapter Removing the starter motor N B THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED Loosen the two fasten...

Page 132: ... tool threading Insert the special tool as shown in the figure making sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush with the flywheel Specific tooling 020472Y Flywheel lock wrench Loosen the magneto flywheel fastening nut Remove the special tool and the fastening nut Engine Fuoco 500 i e ENG 40 ...

Page 133: ...GLY LOCKED THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS Insert the special removing tool Using a 27 mm wrench and a 19 mm bushing release the flywheel Specific tooling 020467Y Flywheel extractor Remove the extractor Remove the nut and extract the flywheel with the start up rim Remove the crankshaft key Fuoco 500 i e Engine ENG 41 ...

Page 134: ...THE FREEWHEEL MUST BE REMOVED IT IS ADVISABLE TO LOOSEN THE 6 FASTEN ING SCREWS IN ADVANCE WITH THE FLY WHEEL STILL INSTALLED ON THE CRANK SHAFT The freewheel is coupled to the flywheel with high precision if removal is difficult use 2 screws as gripping points and as removing tools if required Extract the intermediate gear provided with tor que limiter Engine Fuoco 500 i e ENG 42 ...

Page 135: ...haracteristic Hub outside diameter Diameter 45 665 0 008 0 005 mm Check the inside diameter of the bushing of the starter gearing Check that the toothing is not worn Characteristic Inside diameter of the bushing Diameter 27 0 020 0 041 mm N B IF THE FAULTS DISCOVERED AFFECT THE HUB REPLACE THE STARTER RING GEAR AND FREEWHEEL IF ONLY THE BUSHING IS WORN IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE S...

Page 136: ...ed profiles this assembly allows transmitting torque lower than 10 kgm In case of incorrect start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft which would impair the engine structure The limiter assembly cannot be overhauled In case of irregularities on the toothed discs replace the assembly Refitting the free wheel Make sure the free wheel ...

Page 137: ...h wheel Seeger ring visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the intermediate gear Lubricate the gear housing on the engine crank case Insert the intermediate gear with torque limiter Fuoco 500 i e Engine ENG 45 ...

Page 138: ...el turning it clockwise and inserting at the same time Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear with the start up rim Insert washer and nut on the crankshaft Engine Fuoco 500 i e ENG 46 ...

Page 139: ...0472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool Insert the special tool checking that the pins are perfectly introduced into the seat Specific tooling 020472Y Flywheel lock wrench Tighten the flywheel lock nut to the prescribed torque Locking torques N m Flywheel fixing nut 115 125 Fuoco 500 i e Engine ENG 47 ...

Page 140: ...N m Chain guide sliding block retain plate fasten ing screws 3 4 Refitting the starter motor Check that the O ring is in good working order and lubricate it Insert the starter motor Tighten the 2 fastening screws to the prescribed torque Locking torques N m Starter screws 11 13 Cylinder assy and timing system Remove the external and internal transmission cover Remove the flywheel cover the flywhee...

Page 141: ...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 Removing the timing system drive Turn the engine to close the intake valves Fuoco 500 i e Engine ENG 49 ...

Page 142: ...e valve lifting mass with relevant travel end washer N B BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COMPARTMENT Align the reference marks on the timing chain rim with those on the head Loosen the central screw on the tensioner first Unscrew the 2 fastening screws and remove the tensioner with relevant gasket Engine Fuoco 500 i e ENG 50 ...

Page 143: ...amshaft Remove the timing belt rim Removing the cam shaft Unscrew the 3 fastening screws and remove camshaft retaining bracket N B REMOVING THE FASTENING SCREWS MAY BE DIFFICULT BE CAREFUL NOT TO DAM AGE THE INSIDE HEXAGON IF NECESSARY SEPARATE THE THREADS IN ADVANCE Remove the cam shaft Fuoco 500 i e Engine ENG 51 ...

Page 144: ...the cooling system outlet sleeve with thermostat Remove the coolant temperature sensor N B THE SENSOR CONTROLS BOTH INJECTION AND THE ANALOGUE INSTRUMENT ON THE PANEL TO CHECK THIS COMPONENT SEE THE INJECTION CHAPTER Remove the 2 fastening nuts on the head on the exhaust and on the intake side Engine Fuoco 500 i e ENG 52 ...

Page 145: ... chain guide sliding block N B DO NOT REMOVE THE DOWELS IF THEY ARE FORCED INTO THEIR SEAT CAUTION WHEN YOU HAVE TO REMOVE THE HEAD PREPARE A SUITABLE CONTAINER SINCE THE THERMAL UNIT CONTAINS COOLANT Removing the valves Using the appropriate tool fitted with an adapter remove the cotters washers springs and valves Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y0...

Page 146: ...timing chain Loosen the fastening screw and remove the spacer and the tightening sliding block N B IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATION IS MAINTAINED Extract the cylinder with the relevant gasket and the centring dowel N B THE SECOND CENTRING IS ENSURED BY A PIN SET INTO THE CYLINDER CAUTION TO PREVENT DAMAGES TO THE PISTON SUPPORT IT WHILE ...

Page 147: ...G THE POSI TION IN CASE OF REUSE N B BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end Using a bore gauge measure the connecting rod small end diameter N B IF THE CONNECTING ROD SMALL END DIAM ETER EXCEEDS THE STANDARD DIAMETER EXHIBITS WEAR OR OVERHEATING PRO CEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT Characteristic Standard di...

Page 148: ...OUSINGS HAVE 2 LUBRICATION CHANNELS FOR THIS REASON MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS Characteristic Standard clearance 0 001 0 010 mm Measure the outside diameter of the piston per pendicular to the gudgeon pin axis Take the measurement in the position shown in the figure N B REFER TO THE SPECIFICATIONS SECTION FOR THE SIZES OF THE PISTON AND THE CYLINDER PISTON COUPLING CLEAR...

Page 149: ...eter The coupling is carried out in pairs A A B B C C D D N B REFER TO THE SPECIFICATIONS SECTION FOR THE SIZES OF THE CYLINDER AND THE CYLINDER PISTON COUPLING CLEARANCES Inspecting the piston rings Alternately insert the three sealing rings into the cylinder in the area where it retains its original di ameter Using the piston insert the rings perpen dicularly to the cylinder axis Make sure that ...

Page 150: ...n in the drawing and check the coupling clearances Top ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm Oil scraper ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Replace the piston if clearances exceed the ma...

Page 151: ...ecific tooling 020470Y Pin retainers installation tool N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Install a comparator on the special tool using the short union as shown in the figure Specific tooling 020475Y Piston position checking...

Page 152: ...er base gasket to be used for reassembly by the table below Cor rectly identify the cylinder base gasket thickness to keep the correct compression ratio Remove the special tool and the cylinder N B IF DEVIATIONS OR RECESSES OR PROJECTIONS CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED REPEAT THE MEASUREMENT AT THE OPPOSED SIDE TO DO SO REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION Character...

Page 153: ... RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Misalign the lining openings at 120 as shown in the figure Lubricate the components with engine oil The engine uses the first compression lining with an L section Refitting the cylinder Insert the cylinder base gasket with the thickness determined above Using the fork and the band clamp install the...

Page 154: ...m shaft timing gear and crankshaft pinion exhibit no wear In case of wear of the sliding blocks replace them In case of wear of the chain or rim replace the en tire unit N B IF THE CHAIN HAS DAMAGED THE PINION REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT Chain tensioner Remove the centre screw with the washer and the tensioner spring Check that the one way mechanism is n...

Page 155: ...housings Clean the valve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Standard value 1 1 3 mm Admissible limit 1 6 mm If the impression width on the valve seat is larger than the prescribed limits true the seats with a 45 mill and then grind In case of excessive wear or damages replace the head Inspecting the valves Measu...

Page 156: ...the deformation by a comparator Characteristic Limit values admitted 0 1 mm Check the concentricity of the valve head by ar ranging a comparator at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Inspecting the valve stem guide clearance After measuring the valve guide diameter and the valve stem diameter check the clearance betwe...

Page 157: ...gns of wear on the surface of contact with the articulated register terminal If the checks above give no failures you can use the same valves To obtain better sealing perform ance grind the valve seats Grind the valves gently with a fine grained lapping compound During the grinding keep the cylinder head with the valve ax es in a horizontal position This will prevent the lapping compound residues ...

Page 158: ...Check that the upper and lower supporting spring washers the cotters and the oil seal show no sign of abnormal wear Replace a component when worn Measure the free length of the spring Characteristic Standard length 44 4 mm Admissible limit after use 42 4 mm Refitting the valves Place the valve spring support washers on the head Alternately insert the 4 oil guards using the spe cial tool Lubricate ...

Page 159: ... WITH GREATER PITCH Inspecting the cam shaft Check that the camshaft ends exhibit no scratches or irregular wear Using a micrometer measure the camshaft capacity STANDARD DIAMETER Specification Desc Quantity Bearing A Ø 42 0 060 0 085 mm Bearing B diameter 20 0 020 0 041 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Bearing A Ø 41 910 mm Bearing B diameter 19 940 mm Using a gauge meas...

Page 160: ...with new ones Check that the retaining plate seat shown in the figure exhibits no wear Check that the automatic valve lifting device cam the travel end roller and the rubber abutment on the containment bell are free from wear Check that the valve lifting spring has not yielded Replace any defective or worn components Check that the rocking lever pins exhibit no scratches or wear Characteristic Sta...

Page 161: ...mponent Refitting the head and timing system components Insert the chain guide sliding block Insert the two centring dowels between head and cylinder Install the head gasket N B THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS The head gasket is made of steel and has a standard thicknes...

Page 162: ... figure Locking torques N m Head fixing stud bolts Apply a preliminary torque of 7 Nm in a crossed sequence Tighten by 90 in a crossed sequence Tighten again by 90 in a crossed sequence Tighten the fastening nuts on the exhaust and on the intake side to the prescribed torque Locking torques N m Exhaust intake head fixing nuts 10 12 Tighten the 3 side screws to the prescribed tor que Locking torque...

Page 163: ... Install the tensioner shoe with its spacer tight ening the bolt to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Tensioner sliding block fixing screw 10 14 Insert pins and rocking levers on the flywheel side Lubricate the two rocking levers through the holes at the top Clean the cam...

Page 164: ...ide hexagon Locking torques N m Camshaft retaining bracket fastening screws 4 6 Install the intermediate gear with torque limiter the flywheel and its cover as described in Chapter Flywheel and start up system and in Chapter Flywheel cover N B FOR MORE CONVENIENCE INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES Using the TORX wrench remove the timing check cap Insert the belt on the ...

Page 165: ...ng screws to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Counterweight screw 7 8 5 Nm Remove the central screw Install the valve lifting mass being careful to the proper positioning of the travel end ring Lubricate the mass and de compressor control pin Install the return spring an...

Page 166: ...B THE BELL TIMING IS ENSURED BY THE COUNTERWEIGHT MASS FASTENING SCREW HEAD Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Check that the decompression mass is free and that it is pulled by the spring Locking torques N m Valve lifter mass stop bell fixing screws 30 35 Place the tightener cursor in the rest position keeping the retain tab pressed Engine Fu...

Page 167: ...esc Quantity Inlet 0 15 mm engine cold drainage 0 15 mm engine cold In case different values are found adjust by loos ening the lock nut and use a screwdriver for the set screw as shown in the figure Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to declare the reference values bas...

Page 168: ...ibed in the automatic transmission chapter 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 Repeat for the reference between driving pulley and transmission housing Engine Fuoco 500 i e ENG 76 ...

Page 169: ...ific tooling 020460Y Scooter diagnosis and tester If the values do not match check distribution timing revolution timing sensor Injection control unit Refitting the rocker arms cover Check that the gasket is in good working order Tighten the two screws indicated in the figure with 1 and 2 to limit the reciprocal sliding of the cover surface with the head surface Tighten the remaining 4 screws in a...

Page 170: ...let manifold screws 11 13 Crankcase crankshaft Remove the outside and inside transmission cover and the complete driving pulley as described in Automatic transmission Remove the flywheel cover with the cooling system sleeves as described in the Flywheel cover chapter Remove the flywheel with the starting system following the instruction given in Flywheel and Starting system Remove the thermal unit...

Page 171: ... wear on the surfaces of the crankshaft casing support To carry out an accurate measurement measure the clearance in both directions between crankcase and crankshaft Splitting the crankcase halves Remove the engine support retain screw on the flywheel side half crankcase Remove the 14 crankcase coupling screws N B THE FASTENING SCREWS ARE OF 3 DIFFER ENT LENGTHS NOTE THEIR CORRECT POSI TION Fuoco ...

Page 172: ...ankshaft Remove the crankshaft with the shim adjustment washer on the flywheel side CAUTION WHILE OPENING THE CRANKCASE AND RE MOVING THE CRANKSHAFT CHECK THAT THE SHAFT THREADED ENDS DO NOT INTER FERE WITH THE MAIN BEARINGS FAILURE TO OBSERVE THIS PRECAUTION CAN DAM AGE THE MAIN BEARING Removing the oil pump and countershaft con trol gear To remove the control gear loosen the 4 fasten ing screws ...

Page 173: ...ve the fastening nut with relevant washer Remove the special tool and extract the counter shaft with the control gear Replacing the countershaft bearings Check that the bearings are free from irregular noise or clearance If it is replace it Flywheel side half crankcase Remove the inside seeger ring Fuoco 500 i e Engine ENG 81 ...

Page 174: ...467Y007 Driver for OD 54 mm bearing Before installing a new bearing heat the flywheel side half crankcase using the special tool Place the half crankcase on a wooden base Specific tooling 020151Y Air heater Insert a new bearing on the special tool after greasing the guide seat Install the new bearing on the half crankcase us ing the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE ...

Page 175: ...ater Insert a new bearing on the special tool after greasing the guide seat Install the new bearing on the engine crankcase using the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm adaptor 020439Y 17 mm guide Fuoco 500 i e Engine ENG 83 ...

Page 176: ...shown in the diagram N B BE CAREFUL NOT TO LET THE MEASURE MENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS Characteristic Standard dimensions 63 6 63 45 mm CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VAL UES AND THE SURFACES ARE FREE FROM SCRATCHES Shimming Check the overall height of the crankshaft shoulders gear assembly Characteristic Standard thickness...

Page 177: ...wo categories Cat 1 and Cat 2 STANDARD DIAMETER Specification Desc Quantity Cat 1 40 010 40 016 Cat 2 40 016 40 022 Inspecting the crankshaft alignment Install the crankshaft on the support and measure the displacement at the 4 points shown in the figure Specific tooling 020074Y Support base for checking crankshaft alignment MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm B 0 01 ...

Page 178: ...kshaft see sec tion Thermal unit and timing system See also Cylinder assy and timing system Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly clean the all surfaces and oil ducts For the transmission side half crankcase special attention should be given to the bushings to the cooling jet on the transmission side see figure and to the lubrication duct N B TH...

Page 179: ...ylinder surfaces Any defects in the crankcase gasket or matching surfaces see Flywheel cover coupling can cause pressurised oil leaks thereby affecting the connecting rod and main bearing lubrication pressure Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear For the dimensional check refer to the instructions relating to the axial clearance and dimensi...

Page 180: ...eck that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits Characteristic Crankshaft bushing maximum clearance admitted 0 08 mm The standard bushing diameter after driving is variable on the basis of a coupling selection The crankcase bushing seats are classified into 3 categories while the crankshaft ones into 2 cate gories Bushings are subdi...

Page 181: ...ntershaft with centre to centre distance A Complete FC3 type crankcase equipped with bushings for housing a category 1 crankshaft and a countershaft with centre to centre distance B Complete FC4 type crankcase equipped with bushings for housing a category 2 crankshaft and a countershaft with centre to centre distance B N B THE CRANKSHAFT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER A spare cr...

Page 182: ... TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NEC ESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL Before installing the gear on the crankshaft care fully clean the two matching surfaces removing any residues of LOCTITE from the holes using a brush Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE grip Apply the recommended product to t...

Page 183: ...Specific tooling 020471Y Pin for countershaft timing Insert the crankshaft on the pin and into the bush ing Before inserting thoroughly make the oil pump gear align with the control gear Insert thoroughly and remove the special tool N B WHEN INSERTING THE SHAFT ON THE HALF CRANKCASE BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM ING CONTROL TOOT...

Page 184: ...HE LUBRICATION OIL CIRCULA TION Specific tooling 020360Y 52 x 55 mm adaptor 020376Y Adaptor handle Insert the gasket on the flywheel side half crank case Lubricate the main bearing on the transmission side half crankcase Couple the 2 half crankcases being careful not to damage the bushing on the transmis sion side half crankcase with the threaded tang of the crankshaft Insert the engine support re...

Page 185: ...the cooling system sleeves as described in the Flywheel cover chapter Install the complete driving pulley the transmission cover and the relevant mesh filter and the outside transmission cover as described in the section Automatic transmission See also Cylinder assy and timing system Flywheel cover Lubrication TECHNICAL SPECIFICATIONS SUMP CAPACITY Specification Desc Quantity Overhaul 1 7 l Oil an...

Page 186: ...ssure relief and anti cavitation by pass OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Specification Desc Quantity Calibration 0 3 0 6 bar HEAD LUBRICATION CONTROL JET Specification Desc Quantity Diameter 1 0 05 mm Tightening torque 5 7 N m PISTON COOLING NOZZLE Specification Desc Quantity Diameter 0 8 0 05 mm BASE VENTILATION CHECK Specification Desc Quantity Device decantation chamber and metal re...

Page 187: ...istics Lubrication circuit is split into two sections High pressure Low pressure The high pressure section includes all components located on the engine crankcase while the low pressure section only refers to the thermal unit The trochoidal pump is installed into the sump and is controlled through a couple of gears To guarantee the integrity of the pump a pre filter is installed The pre filter is ...

Page 188: ...shaft is partly compensated by the oil supplied to the small end bearings The camshaft supplies the lubricant to the rocking levers via the bores provided these are installed in a position to ensure that the lubrication is maintained even after the scooter has stopped This is ach ieved when the camshaft reaches its most usual and likely position when the engine is switched off The oil used to lubr...

Page 189: ...ottom and pull back a few millimetres Specific tooling 020331Y Digital multimeter AHEAD go to 5 5 Measure pressure with cold and idling engine STANDARD VALUES Specification Desc Quantity 20 C Temperature 1400 rpm approx 4 5 bar N B RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE DIAGNOSTIC TESTER Specific tooling 020460Y Scooter diagnosis and tester YES go to 6 NO go to 12 6 Let th...

Page 190: ...d in quadrature YES go to 16 NO go to 17 15 Replace the faulty components Flywheel cover chapter 16 Overhaul the engine Crankcase and crankshaft chapter 17 Open the engine crankcase and remove the oil pump as described in the Crankcase and crank shaft chapter Check the oil pump as described in the following pages Check that the cooling nozzle and the timing feeding jet are properly installed Visua...

Page 191: ...EASE OF THE SYSTEM PRESSURE 1 If oil consumption is higher than 250 g 1000 km on run in engine proceed as follows AHEAD go to 2 2 Check the presence of oil at the recovery duct on the filter box YES go to 3 NO go to 4 3 Check the unidirectional reed valve and the decantation chamber drainage hole YES go to 5 NO go to 4 4 Check the thermal unit seals piston rings valve guides and oil guards see The...

Page 192: ...ng the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket Remove the two screws and the oil pump cover Remove the inside rotor retaining snap ring turn ing it to move the opening at the shaft face Engine Fuoco 500 i e ENG 100 ...

Page 193: ...e shaft with the gear and install the lock ring then turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body Using a thickness gauge check the distance be tween the rotors in the position shown in the figure Characteristic Admissible limit clearance 0 012 mm Check the distance between outside rotor and pump body see figure Characteristic Admissi...

Page 194: ...on the oil pump cover If non conforming values or signs of wear are found replace the pump Fit the pump cover in the position that permits the crankcase fixing screws to be aligned Tighten the two fastening screws to the prescri bed torque Locking torques N m Oil pump cover screws 0 7 0 9 Insert the oil pump with gear Insert the 2 retaining screws through the slots on the gear and tighten to the p...

Page 195: ...se Install the special tool in the position shown in the figure Specific tooling 020479Y Countershaft lock wrench Keep the countershaft in position and insert the washer with the nut Tighten the nut to the prescribed torque using the recommended product Remove the special tool Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Countershaft...

Page 196: ...Engine Fuoco 500 i e ENG 104 ...

Page 197: ...INDEX OF TOPICS INJECTION INJEC ...

Page 198: ...Revolution sensor 10 Fuel injector 11 Diagnosis connector MIU injection system This vehicle is fitted with an integrated injection and ignition system Injection is indirect in the manifold through an electro injector The injection and ignition are timed on the four stroke cycle by means of a tone wheel keyed on to the crankshaft 24 2 teeth and pick up sensor Injection Fuoco 500 i e INJEC 2 ...

Page 199: ...ulator The pump the filter and the regulator are placed inside the fuel tank on a single support The injector is connected by a pipe with fast release fittings The pressure regulator is located at the beginning of the circuit The fuel pump is controlled by the MIU control unit this ensures the scooter safety The ignition circuit consists of HV coil HV cable Shielded cap MIU control unit Spark plug...

Page 200: ...l unit is connected to a diagnostic LED on the instrument panel that also carries out the deterrent flashing functions The MIU control unit power supply is furthermore controlled by the emergency switch that is to provide further safety for the scooter Precautions 1 Before fixing any part of the injection system check to see if there are any registered faults Do not disconnect the battery before c...

Page 201: ...the MIU system connectors if required Before reconnecting check that the connectors are dry 12 When carrying out electric inspections do not force the tester probes into the connectors Do not take measurements not specifically foreseen by the manual 13 At the end of every check performed with the diagnostic tester protect the system connector with its cap Failure to do this may damage the MIU cont...

Page 202: ...ck the entire system before replacing the MIUIf the fault is fixed by replacing the MIU control unit install the original control unit again and check if the fault occurs again 4 When troubleshooting use a multimeter with an internal resistance over 10 Ohm V Instruments that are not suitable might damage the MIU control unit Instruments must be used with definitions over 0 1V and 0 5 W the precisi...

Page 203: ...Immobilizer LED 18 Ground lead Connected to the engine stop switch and the water temperature sensor 19 20 Injection load remote control 21 22 HV coil 23 24 Start up enabling 25 26 Ground lead EMS circuit diagram SYSTEM SCHEMATIC Specification Desc Quantity 1 Battery 12V 12 Ah 2 Engine rpm sensor 3 Water temperature sensor 4 Immobilizer aerial 5 Stop button Fuoco 500 i e Injection INJEC 7 ...

Page 204: ...dure Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient repair according to the indi cations of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Fuel supply Presence of fuel in the tank Activation of the fuel pump Fuel pressur...

Page 205: ...empera ture steps and actual opening Cleaning of the auxiliary air pipe and air filter effi ciency gas valve Engine stops at idle ENGINE DOES NOT HOLD IDLING IDLING IS UNSTABLE IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Ignition efficiency Spark plug Ignition timi...

Page 206: ...ld Filter box Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING 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 Correctness of the parameters Throttle valve position se...

Page 207: ...p relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER IRREGULAR ENGINE PROGRESS ON PICKUP 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 Spark plug pow...

Page 208: ...fold Filter box TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness Selection of the thickness of the cylinder base liner Fuel supply system The fuel supply circuit includes the electric pump the filter the pressure regulator the electro injector and the fuel delivery pipes The electrical pum...

Page 209: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Remove the fast release fitting from the injector support Fuoco 500 i e Injection INJEC 13 ...

Page 210: ...move 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 Injection Fuoco 500 i e INJEC 14 ...

Page 211: ...Remove the gas command fitting as indicated in the photograph Pump supply circuit Fuoco 500 i e Injection INJEC 15 ...

Page 212: ...n 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 ELECTRICAL DATA Pump winding resistance 1 8 Ohm Input current during regular functioning 2 8 A Check that the injection load 15A fuse No 2 works properly Check that the live control unit power supply 7 5A fuse No 10 works prope...

Page 213: ...trol energising coil after switching to ON make sure there is battery voltage for 2 seconds between the Red White cable and the Black Purple cable of the remote control base If there is not check the continuity of the Red White cable between fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUS...

Page 214: ...rol 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 N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Fuoco 500 i e INJEC 18 ...

Page 215: ...l pump by measuring the continuity between the pump connector black cable system side and the earth If when switching to ON the pump continues to turn after 2 seconds of activation check with the control unit disconnected and the injection load re mote control disconnected that the Black Purple cable pin 20 on the interface wiring is insulated from the ground Specific tooling 020331Y Digital multi...

Page 216: ...e available with a flow rate of approximately 1 L Rotate the pump using the active diagnosis of the palm top computer Using a pair of long flat needle nose pliers choke the fuel pipe making the pressure stabilise at approx 2 9 3 BAR Be careful not to further choke pipes if pressure remains evenly at 3 BAR while flow rate decreases Check that within 15 seconds the pump has a flow rate of approx 300...

Page 217: ...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 Fuoco 500 i e Injection INJEC 21 ...

Page 218: ...ECTION LOADS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 15A 3 Fuse 20A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Fuoco 500 i e INJEC 22 ...

Page 219: ...hm Input current during regular functioning 2 8 A Check that the injection load 15A fuse No 2 works properly Check that the live control unit power supply 7 5A fuse No 10 works properly 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 ...

Page 220: ... Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Fuoco 500 i e INJEC 24 ...

Page 221: ...rol 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 N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Fuoco 500 i e Injection INJEC 25 ...

Page 222: ...en the Black Green cable of the in jector connector and the earth With injector disconnected and the injector load remote control disconnected check the continuity of the Black Green cable between the injector con nector and remote control base Inspecting the injector hydraulics To check the injector remove the inlet manifold by removing the three fixing screws at the head and the three screws con...

Page 223: ...n 15 approx 70 cm of fuel is delivered with adjustment pres sure of approx 3 BAR Specific tooling 020480Y Petrol pressure check set Proceed with the injector seal test Dry the injector outlet with a blast of compressed air Activate the fuel pump Wait for one minute making sure there are no leaks coming from the injector Slight oozing is normal Value limit 1 drop per minute Immobiliser circuit Afte...

Page 224: ...e 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 Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Injection Fuoco 500 i e INJEC 28 ...

Page 225: ...oil Diagnosis LED The diagnosis LED also works as a blinking light to deter theft This function is activated every time the ignition switch is turned to the OFF position or the emergency stop switch is turned to the OFF position It remains activated for 48 hours in order not to affect the battery charge When the ignition switch is turned to the ON position the deterring blinker function is deactiv...

Page 226: ...n the RUN position If there is no continuity check the contacts of the switch If no faults are found replace the electronic control unit Virgin circuit When the ignition system is not encrypted any key will start the engine but limited to 2000 rpm The keys can only be recognised if the control unit has been programmed properly The data storage pro cedure for a previously not programmed control uni...

Page 227: ...ecome un coded the efficiency of the high voltage circuit shielding must be thoroughly inspected In any case it is advisable to use resistive spark plugs Characteristic MASTER key RED KEY SERVICE key BLACK KEY Diagnostic codes The immobiliser system is tested each time the ig nition key switch is turned from OFF to ON During this diagnosis phase a number of control unit sta tuses can be seen and v...

Page 228: ... been completed the LED remains permanently OFF The engine can be started 5 Programmed control unit fault detected a light code is displayed according to the fault detected after which the LED remains on permanently The engine cannot be started The codes that can be transmitted are Code 1 flash 2 flash code 3 flash code The LED indication is divided into 3 steps 1st step A flash ON switching recog...

Page 229: ...the aerial wiring and change it if necessary If this is not the case replace the defective key and or reprogram the control unit Replace the control unit if the problem continues Code 3 The three flash code indicates a system where the control unit does not recognise the key Turn the switch to ON using several keys if the error code is repeated even with the Master key replace the control unit If ...

Page 230: ...tor Start up the engine and wait for it to stop With the wiring connected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2 8 V With the interface cable harness disconnected from the control unit check continuity between pin 13 and the red cable of the rpm sensor connector and between pin 15 and the brown cable of the rpm sensor...

Page 231: ... 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 Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter HT coil Fuoco 500 i e Injection INJEC 35 ...

Page 232: ... the engine revs engine load temperature and environmental pressure With the engine at idle the ignition advance is optimised to stabilise the speed at 1500 100 rpms Magnetisation time The coil magnetisation time is controlled by the control unit The power of the ignition is increased during the engine start up phase The injection system recognises the four stroke cycle so the ignition is only com...

Page 233: ...mote 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 Fuoco 500 i e Injection INJEC 37 ...

Page 234: ...urple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC 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 remot...

Page 235: ...en switching to ON Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con trol disconnected Primary resistance 1 Ohm Fuoco 500 i e Injection INJEC 39 ...

Page 236: ...known by the control unit For this reason it is not possible to declare the reference values based on the engine rpm The ignition timing value is detectable any time using the diagnostic tester It is possible to check whether the ignition advance determined by the system does in fact correspond with the value actually activated on the engine by means of the stroboscopic light Specific tooling 0204...

Page 237: ...ne crankcase 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 Check that the real values of rpm and ignition advance match those measured using the diag nostic tester If the values do not match check distributio...

Page 238: ...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 20 2500 100 Ω 80 308 6 Ω With the control unit side connector disconnected and the coolant temperature connector discon nected check the insulation between the light blue green cable and ground Injection Fuoco 500 i e INJEC 42...

Page 239: ...ot be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper and the variation of the ignition advance The throttle body after the pre calibration has an opened valve with angle that can vary depending on the tolerances of the machining of the pipe and the valve itself The valve position sensor can also assume various fitting positio...

Page 240: ...agnostic 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 Injection Fuoco 500 i e INJEC 44 ...

Page 241: ...e 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 Fuoco 500 i e Injection INJEC 45 ...

Page 242: ...DS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 15A 3 Fuse 20A 4 Key switch contacts 5 Fuse 7 5 A 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda sensor Injection Fuoco 500 i e INJEC 46 ...

Page 243: ...east 350 C at 600 C and it has a reaction time of just 50 milliseconds The signal generated passes from a high value to a low value with a mixture with lambda 1 Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter Check that the injection load 15A fuse No 2 works properly Check that the live control unit power supply 7 5A fuse No 10 works properly Check the efficiency ...

Page 244: ... Violet cable of the remote control base If there is not check the continuity of the Red White cable between the fuse box and the remote control base and of the Black Purple cable between the pin 20 of the control unit and the remote control base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection Fuoco 500 i e INJEC 48 ...

Page 245: ... the multimeter between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throttle valve completely open the volt age is approx 1V During the closing phase the voltage is approx 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits inside it Fuoco 500 i e Injec...

Page 246: ...Injection Fuoco 500 i e INJEC 50 ...

Page 247: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 248: ... in the pho tograph Locking torques N m Wheel fixing screw 20 25 Front wheel hub overhaul Remove the ball bearing seeger ring indicated in the photograph Extract the ball bearing using the specific tool Specific tooling 001467Y014 Extraction pliers for ø 15 mm bear ings 001467Y017 Bell for bearings outside Ø 39 mm Suspensions Fuoco 500 i e SUSP 2 ...

Page 249: ...ops with the shielded side facing out Refit the ball bearing locking seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020359Y 42 x 47 mm adaptor 020412Y 15 mm guide Use the specific tool to fit and push the roller cas ing until it stops Refit the oil seal on the roller bearing side Lubricate the area between the roller bearing and the ball bearing Specific tooling 020038Y Pun...

Page 250: ...n of the throttle grip and remove the throttle Loosen the clamp fixing the handlebar to the steering tube and remove the handlebar by pulling it upwards N B IF THE HANDLEBAR IS BEING REMOVED TO REMOVE THE STEERING IT IS ONLY NECESSARY TO TILT THE HANDLEBAR FORWARD ONTO THE FRONT PART OF THE VEHICLE WITHOUT REMOVING THE PARTS FITTED SO AS TO AVOID DAMAGING THE SHAFTS Refitting Carry out the above o...

Page 251: ...en the pipes branch out to reach the upper joints on the side steering tubes Through the rigid flexible pipes inside the side steering tubes the oil reaches the stem sliding locking device placed parallel to the shock absorb er Steering tubes Remove the brake calliper pipe retainers and the hydraulic pipe fitting from the brake calliper making sure there is a container to collect the brake fluid F...

Page 252: ...ng 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 Remove the hydraulic pipe fitting fixing nuts indi cated in the figure from the support bracket Suspensions Fuoco 500 i e SUSP 6 ...

Page 253: ... 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 After that remove the retainers indicated in the figure Fuoco 500 i e Suspensions SUSP 7 ...

Page 254: ...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 Suspensions Fuoco 500 i e SUSP 8 ...

Page 255: ...ing 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 Fuoco 500 i e Suspensions SUSP 9 ...

Page 256: ...NSION 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 Check that the sliding stem locking device does not show signs of abnormal wear Suspensions Fuoco 500 i e SUSP 10 ...

Page 257: ...2 15 Screw fixing sliding stem to shock absorber 45 50 Clamp for sliding stem locking device 6 5 10 5 Fixing nuts for constant velocity universal joints 18 20 Parallelogram device Remove the steering tubes To facilitate removal operations of the brake disc sector loosen the 3 fixing screws in the hydraulic electro actuator indicated in the photograph Remove the hydraulic pipe retainers from the pa...

Page 258: ...cated 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 Suspensions Fuoco 500 i e SUSP 12 ...

Page 259: ...icated 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 Remove the headstocks Fuoco 500 i e Suspensions SUSP 13 ...

Page 260: ...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 Suspensions Fuoco 500 i e SUSP 14 ...

Page 261: ...ow the operations for removal but in reverse order lubricating the locking pins on the parallelogram half arms and observing the pre scribed torques PARALLELOGRAM DEVICE Name Torque in Nm Arm coupling screws 45 50 Screws fixing arms to side headstocks 45 50 Screws fixing arms to central headstock 45 50 Screws fixing the half arm coupling flange 20 25 Fuoco 500 i e Suspensions SUSP 15 ...

Page 262: ...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 the SYSTEM RESET menu WAIT PROCEDURE IN PROGRESS Suspensions Fuoco 500 i e SUSP 16 ...

Page 263: ...plays the option REL ATIVE POTENTIOMETER ANGLE This function is active coming from the LOWER STOP SEARCH procedure NOTE a slight oscillation of the angle value be tween 0 00 and 0 50 is considered normal Remove the protection cap of the geared motor set screw Use a plain slot screwdriver to turn the set screw anticlockwise until replicating the 12 condition on the hand held computer RELATIVE POTEN...

Page 264: ...ap 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 menu Suspensions Fuoco 500 i e SUSP 18 ...

Page 265: ...FF AND ON If this is not successful the tilt locking mechanism remains locked for safety Adjust the flexible transmission so that a small clearance is left to guarantee switch activation on the tilt locking calliper Remove the two bracket screws after releasing the spring and freeing the flexible transmission adjust ment CAUTION A FIRST PRODUCTION BATCH WILL BE EQUIPPED WITH DOUBLE COAXIAL SPRING ...

Page 266: ...ews 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 observing the reference indicated on the switch supporting bracket After refitting check in detail that the switch is reg ularly activated by the stop on the lever Suspensions Fuoco 500 i e SUSP 20 ...

Page 267: ...itch is pushed when the system is unlocked Refit the spring toothed sector unit hold the crank case in a perfectly horizontal and stable position place the spring toothed sector unit keeping it per fectly perpendicular to the bearing already fitted on the crankcase if necessary slightly hit the unit shaft end with a mallet and protect the thread by screwing in a nut Fuoco 500 i e Suspensions SUSP ...

Page 268: ... halves with slight hits of a mallet to get them into contact Place the flexible transmission supporting bracket refit the four screws screw them to the prescribed torque Locking torques N m Geared motor crankcase halves coupling screws 11 13 Refit the electric motor check the position is cor rect by means of the reference indicated during removal The motor should be so positioned that it does not...

Page 269: ...ody and tighten the screws to the prescribed torque Fit but not tighten the pump stem coupling screw and refit the plastic protection cap The synchronisation procedure should be com plete when the installation is finished Locking torques N m Geared motor hydraulic pump tightening screws 11 13 Remove the retaining seeger ring of the bearing of the flexible transmission lever control shaft bear ing ...

Page 270: ...ever control shaft Hit slightly with a mallet if necessary Refit the bearing check seeger ring Specific tooling 020151Y Air heater 020376Y Adaptor handle 020362Y 12 mm guide 020357Y 32 x 35 mm adaptor 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 of the electric motor Hit slightly with a malle...

Page 271: ...002 Driver for OD 73 mm bearing Extract the bearing of the electric motor with the specific tool 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 of the spring toothed sector unit Hit slightly with a mallet if necessary Specific tooling 020360Y 52 x 55 mm adaptor 020151Y Air heater 020376Y Adapto...

Page 272: ...m guide 020151Y Air heater 020376Y Adaptor handle 020477Y 37 mm adaptor Before removing the geared motor Disable the suspension lock Remove the front shield With the set nut indicated in the photograph re move the tensioning cable of the suspension lock ing mechanical calliper Remove the electrical connection of the geared motor position potentiometer Remove the electrical connection of the geared...

Page 273: ...D OCULAR TIS SUE IF YOU ACCIDENTALLY SPILL BRAKE FLUID ON YOURSELF TAKE OFF YOUR CLOTHES WASH WITH HOT WATER AND SOAP AND SEEK MEDICAL ADVICE IMMEDI ATELY IF BRAKE LIQUID GETS ACCIDEN TALLY IN CONTACT WITH YOUR EYES RINSE WITH ABUNDANT FRESH WATER AND SEEK MEDICAL ADVICE IMMEDIATELY KEEP BRAKE FLUID OUT OF THE REACH OF CHIL DREN Remove the 3 fixing screws indicated and remove the whole geared moto...

Page 274: ... 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 In case of difficulties when removing the lever use the specific tool Remove the tongue and then the moulded wash er Specific tooling 020234y extractor Suspensions Fuoco 500 i e SUSP 28 ...

Page 275: ...move the four screws indicated in the figure remove the flexible transmission supporting brack et separate the two crankcase halves if neces sary use a rubber mallet to hit the flexible transmission lever in order to separate the two crankcases Electrical devices test PRESSURE SWITCH 1 PRESSURE SWITCH 2 HORN REMOTE CONTROL Fuoco 500 i e Suspensions SUSP 29 ...

Page 276: ...he continuity between pin 27 and the remote control base white cable Check the continuity of the yellow red cable be tween the pressure switch connector and the fuse box 7 5A fuse No 11 and between the remote control base and the fuse box 7 5A fuse No 11 With a multimeter also check the pressure switch operation as well as the continuity at rest as this is normally closed switch PRINCIPLE DIAGRAM ...

Page 277: ...ed sensor 7 Right speed sensor 8 Diagnostic tester serial line 9 Engine electronic control unit 10 Direct Battery 11 Live Battery 12 To light switch 13 20A Fuse No 4 14 Light remote control 15 Pressure switch 16 Horn remote control 17 Instrument panel 18 Tilt locking system control unit GEARED MOTOR Fuoco 500 i e Suspensions SUSP 31 ...

Page 278: ...ith 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 Suspensions Fuoco 500 i e SUSP 32 ...

Page 279: ...rol 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 1 LOCKING POSITION 2 UNLOCKING POSITION Fuoco 500 i e Suspensions SUSP 33 ...

Page 280: ...t black cable Pin 33 and yellow blue cable Also check that the above indicated electrical lines are insulated from the earth Check the continuity between the black cable on the connector and an earth point on the chassis With a multimeter check the operation of the tilt locking unlocking switch referring to the diagram indicated in the figure KEY 1 GROUND 2 LOCKING 3 REST 4 UNLOCKING TILT LOCKING ...

Page 281: ...ion 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 Check the continuity of the connector black cable and an earth point on the chassis Fuoco 500 i e Suspensions SUSP 35 ...

Page 282: ...Also check that the flexible transmission control lever activates the limit stop switch properly POTENTIOMETER 1 POTENTIOMETER Suspensions Fuoco 500 i e SUSP 36 ...

Page 283: ...ated locking condition is 4V and 1V in the locking to rest condition With the interface wiring disconnected from the control unit check the continuity between pin 17 and the yellow cable of the potentiometer connec tor between pin 25 and the green blue cable between pin 11 and the orange blue cable Also check that these lines are insulated from each oth er and earth RIDER PRESENCE SENSOR Fuoco 500...

Page 284: ...he rider is not seated on the saddle pin 17 36 resistance of about 3 kOhm when the rider is seated on the saddle Check the continuity between the interface wiring pin 17 and the yellow cable of the rider presence connector Check the continuity between the interface wiring pin 36 and violet cable of the rider presence con nector TONE WHEEL SENSOR Suspensions Fuoco 500 i e SUSP 38 ...

Page 285: ...e 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 Fuoco 500 i e Suspensions SUSP 39 ...

Page 286: ...T wheel turning sensor In case of failures check the continuity between pin 23 and the connector green cable on the fuel tank after removing the chassis central cover be tween pin 17 and the yellow cables on both con nectors between pin 24 and the red cable on the connector With interface wiring disconnected from the control unit and the connectors disconnected from wheel turning sensors check tha...

Page 287: ... utilizzo dell attrezzatura Verificare che la pressione pneumatici sia corretta Posizionare il veicolo su un pavimento piano privo di asperità e irregolarità Posizionare il veicolo sul cavalletto centrale Assicurarsi che il sistema di staziona mento sia sbloccato Sollevare le ruote anteriori come mos trato in foto Fuoco 500 i e Suspensions SUSP 41 ...

Page 288: ...cedere con le necessarie riparazioni e succes sive regolazioni Characteristic Front tyre pressure with passenger 1 6 bar 1 8 bar Rear tyre pressure with passenger 2 4 bar 2 6 bar Get the vehicle off the stand back on the ground Remove the right lower coupling plate of the half arm by undoing the screws indicated in the photograph Remove the right upper screw and the left bottom screw of the parall...

Page 289: ... 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 Remove the nut fixing the steering con trol arm and keep the original washer in position Fuoco 500 i e Suspensions SUSP 43 ...

Page 290: ... and the other end to the screw fixing the steering control arm Place the frame so that the sliders come into contact with the rim maxi mum diameter but without interfering with the tyre If required reposition the frame by operating the 3 adjustable support feet Fit the frame locking bracket Suspensions Fuoco 500 i e SUSP 44 ...

Page 291: ...correctly aligned as shown in the photograph Maximum misalignment allowed 4 notches Rear Removing the rear wheel Before removing the rear wheel support the vehi cle properly and operate the parking brake so as to facilitate removing the wheel fixing screws Remove the exhaust silencer Undo the screw fixing the right shock absorber to the clamp Fuoco 500 i e Suspensions SUSP 45 ...

Page 292: ... 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 Unscrew the clamp Suspensions Fuoco 500 i e SUSP 46 ...

Page 293: ...e as shown in the photo graph Locking torques N m Muffler arm clamping screws 27 30 Rear wheel axle nut 104 126 Shock absorber crankcase attachment bracket 20 25 Lower shock absorber clamping screw 33 41 Nm Rear brake calliper fixing screws 25 30 Nm Swing arm Removal Rest the scooter on its centre stand Remove the retainer fixing the swinging arm to the engine unscrew the nut and remove the bolt F...

Page 294: ... Remove the silent blocks Remove the retainer fixing the swinging arm to the frame undo the screw Remove the pin Suspensions Fuoco 500 i e SUSP 48 ...

Page 295: ...the rear suspension Overhaul Properly support the swinging arm in the vice Check there is no jamming in the movement of the joint connecting the swinging arm on the engine side to the swinging arm on the frame side To check the clearance on the frame side arm mount the retainer using the pin fixing the swinging arm to the frame and two adaptor rings of the appropriate tool 020229Y Alternatively us...

Page 296: ... arm on the engine side from the vehicle side arm Remove the plastic bushings and the internal spacer shown in the photo Remove the pin connecting the engine swinging arm frame swinging arm The operations below are described once but ap ply to both sides of the swinging arm Remove the internal spacer Using a suitable pin remove the roller casings as shown in the photographs Suspensions Fuoco 500 i...

Page 297: ...e swinging arm tube on the frame side L 222 5 0 2 mm Lubricate roller casings and the plastic bushings with grease Insert the spacers Assembly both arms with the appropriate bolt Adjust the bolt as shown in the photograph Place the swinging arm frame side with the pro truding part facing the transmission side Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and swing...

Page 298: ...pporting clamp with part 3 inserted and slightly tighten part 1 2 Position the swinging arm inserting part 2 3 Tighten part 3 to the prescribed torque 4 Screw on and tighten part 4 to the prescribed torque 5 Screw on and tighten part 5 to the prescribed torque 6 Tighten part 1 to the prescribed torque Insert the swinging arm engine bolt and tighten to the prescribed torque Suspensions Fuoco 500 i ...

Page 299: ...orbers Removal Proceed as follows place the scooter on its centre stand lift the engine a little with a jack so as to free the two shock absorbers remove the exhaust silencer undo the shock absorber spring assembly clamp ing screw from the support fixed to the engine on the one side and from that fixed to the muffler on the other Fuoco 500 i e Suspensions SUSP 53 ...

Page 300: ... Shock absorber lower clamp 33 41 Upper shock absorber clamp 33 41 Centre stand Use a jack to support the vehicle properly Remove the two stand return springs Working from both sides undo the two bolts con necting it to the supporting plate To refit follow the removal steps but in reverse order be careful to tighten to the prescribed torque Locking torques N m Centre stand bolt 31 39 Suspensions F...

Page 301: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 302: ...e two male hexagonal screws 1 and take out the two pads 10 2 remove the two male hexagonal screws 2 and remove the reaction plate 3 3 take out the fixed plate 4 from the guide 4 remove the internal elements from the floating body 5 with the help of short blows of com pressed air through the brake fluid pipe in order to facilitate the expulsion of pistons 6 5 Check that the plates and the body are ...

Page 303: ...the action and reaction prin ciple to obtain the thrust for both pads The body and the reaction plate body work inte grally and can move axially with respect of the fixed plate that is integral to the strut The pistons forced by pressure to push the pad to the disk cause the reaction plate to push in turn the other pad towards the disc The brake pad lock spring 1 Pad fixing screws 2 Reaction plate...

Page 304: ...both Remove the wheel Undo the two fixing screws to the plate and re move the calliper Overhaul Remove the rear brake calliper Suitably hold the brake calliper in a clamp Remove the two calliper coupling screws as shown in the photo Remove the two pistons from the calliper body with the aid of short blasts of compressed air through the brake fluid holes Remove the dust ring and the O ring of each ...

Page 305: ...it the O rings and new dust guards Refit the pistons in their seats being careful to lubricate with brake fluid Re couple the half callipers and lock the two screws at the specified torque Locking torques N m Calliper coupling screw 22 27 Refitting Rear brake disc Fuoco 500 i e Braking system BRAK SYS 5 ...

Page 306: ...pporting clamp Remove the brake disc Refitting To fit the rear brake disc follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque using threadlock Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Rear disc screws 5 6 5 Nm Braking system Fuoco 500 i e BRAK SYS 6 ...

Page 307: ... the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front brake disc Removal The operations described refer to only one disc but apply to both Remove the wheel Remove the brake calliper...

Page 308: ...areful to tighten the screws to the prescribed torque using threadlock Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Front disc screws 5 6 Nm 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 Braking system Fuoco 500 i e BR...

Page 309: ...n the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front brake pads Removal Remove the brake calliper Remove the Benzing snap ring of the pad pin Slide off the pin paying attention to collect the retaining spring of the pads Fuoco 500 i e Braking system BRAK S...

Page 310: ...g the brake pads Remove the pads paying attention to the pad re taining spring Check the thickness of the pads If the thickness is less than the minimum value replace the pads with new pads Characteristic Minimum value 1 5 mm Refitting To fit the rear brake pads follow the removal steps but in reverse order be careful to tighten the screws to the prescribed torque Locking torques N m Screws tighte...

Page 311: ...ing up the brake system tank to prevent air being drawn into the system until no more air escapes at the bleed fitting The operation is finished when only brake fluid comes out of the bleed screw Close the bleed screw and tighten to the prescribed torque Close the brake system tank N B IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION EXAMINE ALL THE FIT TINGS IF SAID FITTINGS DO NOT SHOW SI...

Page 312: ...ERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO COMPLY WITH THIS NORM WILL ENDANGER THE PROPER WORKING AND EFFICIENCY OF THE BRAKE SYSTEM If necessary bleeding can...

Page 313: ...e calliper and drain the brake fluid Then remove the plastic and metallic straps Unscrew the brake pump pipes as indicated in the figure Parking brake Remove the rear wheel Loosen the transmission set screw and release the cable from the calliper Fuoco 500 i e Braking system BRAK SYS 13 ...

Page 314: ...shield back plate remove the engaging cable for the safety mechanism remov ing it from its fitting Remove the 4 screws shown in the figure When refitting pay attention to insert the metallic cable peg in the fitting marked A as indicated in the enlarged photograph Remove the electric connection from the engaged parking brake warning light switch Remove the parking brake cable from the lever by ope...

Page 315: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 316: ...diator cold box is connected to the lower side of the expansion tank in the fluid When the engine is cold the thermostat output to the radiator is closed even though there is still a little flow for de aeration obtained by a hole into the closing plate In this case the circulation into the thermal unit is active to ensure an even heating Once the working temperature has been reached the main circu...

Page 317: ...rts opening 90 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation start 105 C Electric ventilation end 100 C WATER PUMP Specification Desc Quantity Type Centrifugal Control Coaxial at the countershaft RADIATOR Specification Desc Quantity Type Aluminium with horizontal circulation EXPANSION TANK Specification Desc Quantity Calibration Automatic bleeding in pa...

Page 318: ...head and the relevant injection circuit see Injec tion chapter N B THE ELECTRIC FAN TEMPERATURE AT 105 C CAN ONLY BE MANAGED BY A SYSTEM SUP PLIED WITH A 50 MIXTURE AND PRESSURISED AT 0 9 BAR System sealing check Check the proper circuit sealing when it is in pressure and at the temperature For a more accurate check wait until the system has cooled down since small leaks may not be visible due to ...

Page 319: ...to reach the electric ventilation temperature Stop the engine Restore the level with cold engine CAUTION ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COM PLETED VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES Pompa acqua Water pump If noise or loss of liquid at the drain hole of the w...

Page 320: ...ents have been replaced fill and purge the system again N B FOR CHANGING THE COOLANT AND BLEED ING THE SYSTEM SEE THE COOLANT CHANGE SECTION Characteristic Cooling system 1 8 l Removing the water pump cover Check that the water pump cover is not deformed or dented Check that the sealing O ring is in good working order Otherwise replace the component Correctly fit a new O ring do not allow it to co...

Page 321: ...and timing system chapter 3 Replace the cap Cooling fluid consumption 1 Check the system outside seals as described above YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal unit and timing system chapter If water leaks are detected in the engine oil inspect the pad on the head cooling circuit 3 Fix any damaged seals Oil in the fluid 1 Oil into the coolant YES go to 2 2 Check the head ...

Page 322: ...Cooling system Fuoco 500 i e COOL SYS 8 ...

Page 323: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 324: ...in the figure remove the cover and disconnect the rider presence sensor connector Remove the three fixing screws shown in the fig ure Instrument panel Remove the front handlebar cover Remove the front shield Remove the shield back plate upper side Unscrew the six fixing screws and remove the instrument panel Chassis Fuoco 500 i e CHAS 2 ...

Page 325: ...ar handlebar cover Unscrew the two screws fixing the handlebar to remove the front part of the handlebar cover Headlight assy Remove the front shield Unscrew the screw of the tail light support Disconnect the electrical terminals and remove the support Fuoco 500 i e Chassis CHAS 3 ...

Page 326: ... 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 Undo the ten screws fixing it to the support and remove the headlight assemblies Chassis Fuoco 500 i e CHAS 4 ...

Page 327: ...ings Working from both sides Undo the screw indicated and remove the cap lid Undo the two screws Undo the screw connecting it to the helmet com partment Lift it so that the refuelling compartment opening cable can be released Remove the central frame cover Fuoco 500 i e Chassis CHAS 5 ...

Page 328: ... 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 Unscrew the three screws indicated release the cover from it fittings and remove it Chassis Fuoco 500 i e CHAS 6 ...

Page 329: ...e 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 Unhook the instrument panel wiring Remove the six screws and the cable guide strap in the front part of the shield back plate Fuoco 500 i e Chassis CHAS 7 ...

Page 330: ... 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 Chassis Fuoco 500 i e CHAS 8 ...

Page 331: ...o spoiler Legshield Taillight assy Remove the side fairings Remove the handgrips Undo the screw indicated in the figure Undo the two screws connecting it to the helmet compartment Disconnect the connectors and remove the sup port Undo the three screws and remove the light unit Fuoco 500 i e Chassis CHAS 9 ...

Page 332: ...oth half footrests Release the fuse box See also Frame central cover Side fairings These operations are described once but apply to both side fairings Undo the three screws on the handgrip cover Undo the seven fixing screws Remove the side fairing by pulling it in order to release the hooks Chassis Fuoco 500 i e CHAS 10 ...

Page 333: ...ove the central frame cover Undo the two screws on the battery compart ment detach the fuse terminal block the battery wires and the connector to the diagnostics socket Disconnect the connectors of the power socket and the helmet compartment light Undo the screws fixing the helmet compartment light switch to the compartment and disconnect the electrical terminals Fuoco 500 i e Chassis CHAS 11 ...

Page 334: ...de Undo the two screws of the saddle lock discon nect the lock cables and release the sheath from the helmet compartment Undo the four screws below the gaskets in the upper part of the compartment Undo the three screws fixing it to the frame on both sides Chassis Fuoco 500 i e CHAS 12 ...

Page 335: ...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 Remove the footrest Remove the three tank retainers Fuoco 500 i e Chassis CHAS 13 ...

Page 336: ...racket 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 Chassis Fuoco 500 i e CHAS 14 ...

Page 337: ...ator arrows Disconnect the license plate light connector Undo the three screws indicated at both sides and remove the handgrip clamp Radiator cover Remove the front shield Remove the headlight assembly Disconnect the turn indicators wirings Undo the two screws indicated Fuoco 500 i e Chassis CHAS 15 ...

Page 338: ...ting clamp Remove the supporting clamp Remove the two protective screws that fix the ra diator lower protection to the shield back plate After that press up and pull the protection front part so as to release it from the radiator frame Chassis Fuoco 500 i e CHAS 16 ...

Page 339: ...o 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 Fuoco 500 i e Chassis CHAS 17 ...

Page 340: ...re 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 Chassis Fuoco 500 i e CHAS 18 ...

Page 341: ...Fuoco 500 i e Chassis CHAS 19 ...

Page 342: ...Chassis Fuoco 500 i e CHAS 20 ...

Page 343: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 344: ...s shown in the figure making the 4 securing holes coincide Fit the 4 washers on the mudguard out er side and always on the same side insert the 4 screws and tighten to the prescribed torque Locking torques N m mudflap insert fixing screws 2 3 Aesthetic inspection Appearance checks Paintwork Fitting of plastics Scratches Dirt Tightening torques inspection Lock check Safety locks clamping screws Saf...

Page 345: ... currently in force Front and rear stop light buttons and bulb Turn indicators and their warning lights Instrument lighting instruments fuel and temperature indicator Instrument panel lights Horn electric start up Engine stopping with emergency stop switch Electric opening of saddle with remote control Tilting system locking unlocking button CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST B...

Page 346: ...THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Level check Hydraulic brake system liquid level Tilt locking system fluid level Rear hub oil level Engine coolant level Engine oil level Road test Test ride Cold start Instrument operations Response to the gas command Stability on acceleration and braking Rear and front bra...

Page 347: ...draulico corsa della leva Frizione verifica corretto funzionamento Motore verifica corretto funzionamento generale e assenza di rumorosità anomale Altro verifica documenti verifica n di telaio e n di motore attrezzi a corredo montaggio targa controllo serrature controllo pressione pneumatici montaggio specchietti montaggio paracolpi inferi ore ed eventuali accessori Fuoco 500 i e Pre delivery PRE ...

Page 348: ...Pre delivery Fuoco 500 i e PRE DE 6 ...

Page 349: ...INDEX OF TOPICS TIME TIME ...

Page 350: ...oted to the time necessary to carry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replace ment Time Fuoco 500 i e TIME 2 ...

Page 351: ...Crankcase CRANKCASE Code Action Duration 1 001100 Oil seal clutch side Re placement 2 001133 Engine crankcase Replace ment 3 001153 Half crankcase gasket Re placement Fuoco 500 i e Time TIME 3 ...

Page 352: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001098 Countershaft Replacement Time Fuoco 500 i e TIME 4 ...

Page 353: ...Cylinder assy CYLINDER GROUP Code Action Duration 1 001002 Cylinder piston Replace ment 2 001154 Pin ring piston unit Service 3 001129 Chain tensioner Service and Replacement Fuoco 500 i e Time TIME 5 ...

Page 354: ...ion 1 001045 Valves Replacement 2 001049 Valves Adjustments 3 001056 Head gasket Replacement 4 001126 Head Replacement 5 001083 Thermistor Replacement 6 007012 Coolant bleed valve Re placement 7 001057 Thermostat Replacement Time Fuoco 500 i e TIME 6 ...

Page 355: ...cker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Rocking lever valve Re placement 3 001169 Decompressor Replace ment Fuoco 500 i e Time TIME 7 ...

Page 356: ...Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replace ment Time Fuoco 500 i e TIME 8 ...

Page 357: ... 001113 Water pump Replacement 3 001123 Oil filter Replacement 4 001124 By pass valve Replacement 5 001150 Flywheel cover gasket Re placement 6 001160 Minimum oil pressure sensor Replacement 7 001102 Net oil filter Replacement Cleaning 8 003064 Engine oil change Fuoco 500 i e Time TIME 9 ...

Page 358: ...n pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley Overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell housing Re placement Time Fuoco 500 i e TIME 10 ...

Page 359: ...Oil pump POMPA OLIO Code Action Duration 1 001042 Oil pump overhaul 2 001051 Belt Timing chain Replace ment 3 001112 Oil pump change 4 001125 Chain guide pads change Fuoco 500 i e Time TIME 11 ...

Page 360: ...de Action Duration 1 001010 Geared reduction unit Serv ice 2 001156 Gear reduction unit cover Replacement 3 003065 Gear box oil Replacement 4 004125 Rear gear shaft Replace ment 5 002031 Rear wheel hub bearings Replacement Time Fuoco 500 i e TIME 12 ...

Page 361: ...086 Driving half pulley Replace ment 2 001011 Driving belt Replacement 3 001006 driving pulley Service 4 001141 Belt anti flapping roller Re placement 5 001066 driving pulley Replacement 6 001177 Variator rollers shoes Re placement Fuoco 500 i e Time TIME 13 ...

Page 362: ...ion 1 001065 Internal transmission cover Replacement 2 001096 External transmission cover Replacement 3 001131 Transmission air intake Re placement 4 001135 Transmission cover bearing Replacement 5 001170 Air manifold replacement Time Fuoco 500 i e TIME 14 ...

Page 363: ...Flywheel magneto VOLANO MAGNETE Code Action Duration 1 001173 Rotor replace 2 001067 Stator Replacement 3 001058 Flywheel Replacement 4 001104 Start up freewheel Replace ment Fuoco 500 i e Time TIME 15 ...

Page 364: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold change 2 001047 Injector Replacement 3 001023 Control unit Replacement Time Fuoco 500 i e TIME 16 ...

Page 365: ... Code Action Duration 1 001009 Muffler Replacement 2 001092 Exhaust manifold Replace ment 3 001095 Muffler guard Replacement 4 004169 Muffler guard Replacement 5 005138 Lambda probe Replace ment Fuoco 500 i e Time TIME 17 ...

Page 366: ... ARIA Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Cleaner Throttle body union Replacement 4 001027 Body air cleaner union Re placement Time Fuoco 500 i e TIME 18 ...

Page 367: ...04001 Frame replace 3 004147 footboard support bracket one side Replacement 4 004143 Footrest support replace 5 004116 Rear frame Replacement 6 004148 footboard support bracket two sides Replacement 7 902003 Supporto fanale anteriore Sostituzione Fuoco 500 i e Time TIME 19 ...

Page 368: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004179 Stand buffer Replacement Time Fuoco 500 i e TIME 20 ...

Page 369: ...Code Action Duration 1 004021 Shield upper section Re placement 2 004022 Shield lower section Re placement 3 004020 Headlight rim Replacement 4 004085 Fairing 1 Replacement 5 004064 Front shield Replacement Fuoco 500 i e Time TIME 21 ...

Page 370: ...hassis cover Re placement 2 004129 Rear fairing Replacement 3 004037 Side aprons Replacement 4 004121 Fianchetto sella 1 Sostitu zione Rear cover SCUDO POSTERIORE Code Action Duration 1 004065 Front shield rear section re moval and installation Time Fuoco 500 i e TIME 22 ...

Page 371: ... Spark plug inspection flap Replacement 2 004135 Fuel tank port Replacement 3 004011 Central chassis cover re place 4 004012 Rear fairings Removal and refitting 5 004015 Footrest Removal and Re fitting 6 004075 Front mat Replacement Fuoco 500 i e Time TIME 23 ...

Page 372: ...n Duration 1 007015 Radiator air intake Replace ment 2 004009 Rear mudguard Replace ment 3 004181 Lower cover Replacement 4 004184 Front mudguard support re placement 5 004002 Front mudguard Replace ment Time Fuoco 500 i e TIME 24 ...

Page 373: ...ation 1 004137 Injector pump pipe Replace ment 2 005010 Tank float Replacement 3 004109 Fuel tank breather change 4 004168 Fuel tank cap Replacement 5 004005 Fuel tank Replacement 6 004073 Fuel pump Replacement Fuoco 500 i e Time TIME 25 ...

Page 374: ...K ABSORBERS Code Action Duration 1 003007 Rear shock absorber Re moval and Refitting 2 003035 Shock absorber support and brake calliper Replacement 3 003077 muffler rear shock absorber support arm Service Time Fuoco 500 i e TIME 26 ...

Page 375: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE MENT 2 004026 Handlebar cover Replace ment Fuoco 500 i e Time TIME 27 ...

Page 376: ...r Replacement 5 002071 LHS knob Replacement 6 003059 Counterweight Replace ment 7 002037 Brake lever Replacement 8 002067 Rear brake pump Replace ment 9 002080 Rear brake oil bleeding sys tem Replacement 10 004162 Mirror support and or brake pump fitting u bolt Replace ment 11 002024 Front brake pump replace 12 002047 Front brake fluid and air bleeding system Replace ment Time Fuoco 500 i e TIME 2...

Page 377: ...e Action Duration 1 004058 Silent block Replacement 2 003081 Swinging arm support flange replace 3 001072 Swinging arm Engine chas sis connection Replacement 4 003080 Swinging arm on frame Re placement Fuoco 500 i e Time TIME 29 ...

Page 378: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Time Fuoco 500 i e TIME 30 ...

Page 379: ...Instrument panel GRUPPO STRUMENTI Code Action Duration 1 005014 Odometer Replacement 2 004099 Odometer housing Replace ment 3 004035 Instrument panel Replace ment Fuoco 500 i e Time TIME 31 ...

Page 380: ...n 1 005146 Elettroattuatore apertura sella Sostituzione 2 004054 Saddle lock catch Replace ment 3 005072 Immobilizer aerial Replace ment 4 004010 Anti theft lock Replacement Turn signal lights Front lights Time Fuoco 500 i e TIME 32 ...

Page 381: ...nt direction indicator bulb Replacement 2 005012 Front direction indicators Replacement 3 005002 Front light Replacement 4 005008 Light bulbs Replacement 5 005139 Tail light bulb Replacement 6 005140 Front light Replacement Rear lights Fuoco 500 i e Time TIME 33 ...

Page 382: ...005022 Rear turn indicators replace 3 005031 Licence plate light bulb Re placement 4 005032 Transparent licence plate cover replace 5 005131 Licence plate light support Replacement 6 005066 Rear light bulbs Replace ment 7 005068 Rear turn indicator bulb Re placement Time Fuoco 500 i e TIME 34 ...

Page 383: ...ration 1 003047 Front tyre replace 2 003033 Front wheel hub Replace ment 3 003037 Front wheel rim Replace ment 4 005089 Tone wheel Replacement 5 002041 Front brake disc Replace ment 6 004123 Front wheel Replacement Fuoco 500 i e Time TIME 35 ...

Page 384: ...REAR WHEEL Code Action Duration 1 002070 Rear brake disc Replace ment 2 001016 Rear wheel Replacement 3 001071 Front wheel rim Removal and refitting 4 004126 Rear wheel tyre Replace ment Time Fuoco 500 i e TIME 36 ...

Page 385: ...Electric start AVVIAMENTO Code Action Duration 1 001017 Start up pinion Replace ment 2 001020 Starter motor Replacement 3 001151 Start up driven gearing Re placement Fuoco 500 i e Time TIME 37 ...

Page 386: ... switch Replacement 3 005007 Battery Replacement 4 005003 Horn Replacement 5 005096 Remote control for injection components Replacement 6 005117 Electrical fan remote control Replacement 7 xxxxxx Teleruttore consenso avvia mento sostituzione 8 005052 Fuse Replacement 9 832311 Turn indicator blinker Re placement Time Fuoco 500 i e TIME 38 ...

Page 387: ...CABLE HARNESS Code Action Duration 1 005001 electric system change 2 005114 Electrical system Service Electronic controls Fuoco 500 i e Time TIME 39 ...

Page 388: ... 6 005039 Headlight switch replace 7 005142 Unlocking switch Replace ment 8 005084 Emergency light switch Re placement 9 005143 MODE button Replacement 10 888126 Pulsante sottosella sostitu zione Transmissions TRASMISSIONI SERRATURE Code Action Duration 1 003094 Tilt locking calliper control ca ble replacement 2 002082 Fuel tank cap opening drive Replacement 3 002083 Saddle opening transmission Re...

Page 389: ...ter hook transmission Replacement Helmet bay HELMET COMPARTMENT Code Action Duration 1 005046 Battery cover change 2 005026 Helmet compartment bulb Replacement 3 005027 Helmet compartment bulb support Replacement 4 004016 Helmet compartment re place 5 004142 Plug socket Replacement Fuoco 500 i e Time TIME 41 ...

Page 390: ...3010 Front suspension Service 2 003111 Side steering tube replace ment 3 003038 Front wheel axle Remov and Refitt 4 003040 Front wheel bearings Re placement 5 003107 Sliding stems replacement 6 003113 Front shock absorber re placement Time Fuoco 500 i e TIME 42 ...

Page 391: ... air bleed Re placement 3 007001 Expansion tank Replace ment 4 007024 Expansion tank cap Re placement 5 007003 Coolant delivery and return pipe Replacement 6 007016 Fan with support Replace ment 7 007002 Water radiator replacement 8 007014 Radiator thermal switch Re placement 9 004167 Grill radiator cover Re placement Fuoco 500 i e Time TIME 43 ...

Page 392: ...02 Shoes Rear brake pads Replacement 6 002020 Rear brake pipes Removal and refitting 7 002081 Rear brake disc piping Re placement 8 003118 Tilt locking disc section re placement 9 003103 Splitter for suspension lock ing system hoses replace ment 10 003102 Hoses for the splitter calliper suspension locking system replacement 11 003088 Tilt locking hydraulic pump replacement 12 002021 Front brake pi...

Page 393: ... replacement 17 003105 Suspension locking system brake fluid repl 18 003106 Suspension locking system pressure sensor Replace ment 19 003121 Parking brake control lever replacement 20 003122 Parking brake control lever micro switch replacement 21 002048 Rear brake calliper Re placement Stickers TRANSFERS Code Action Duration 1 004066 Driving mirror Replacement 2 004159 Plates Stickers Replace ment...

Page 394: ...ent 2 003112 Central steering tube re placement 3 003002 Steering fifth wheel Re placement 4 003115 Parallelogram arms re placement 5 003114 Parallelogram bearings re placement 6 003116 Steering rod replacement 7 003117 Constant velocity universal joint replacement Time Fuoco 500 i e TIME 46 ...

Page 395: ...6 003120 Tilt locking control unit re placement 7 003093 Geared motor crankcase re placement 8 003090 Geared electric motor re placement 9 003092 Geared motor bearings re placement 10 003091 Geared motor pinion re placement 11 003089 Geared motor potentiometer replacement 12 003097 Tilt locking calliper micro switch replacement 13 XXXXXX Centralina alimentazione MIU Sostituzione 14 005099 Electric...

Page 396: ...Time Fuoco 500 i e TIME 48 ...

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