Gilera Fuoco 500ie manuel - [PDF Document] (2022)

  • SERVICE STATION MANUALXXXX

    Fuoco 500 i.e.

  • SERVICE STATIONMANUAL

    Fuoco 500 i.e.

    The descriptions and illustrations given in this publication arenot binding. While the basic specificationsas described andillustrated in this booklet remain unchanged, PIAGGIO-GILERAreserves the right, at

    any time and without being required to update this publicationbeforehand, to make any changes tocomponents, parts or accessories,which it considers necessary to improve the product or whichare

    required for manufacturing or construction reasons.Not allversions 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 rightsreserved. Reproduction of this publication

    in whole or in part is prohibited."PIAGGIO & C. S.p.A. -After-Sales

    V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

  • SERVICE STATION MANUALFuoco 500 i.e.

    This service station manual has been drawn up by Piaggio &C. Spa to be used by the workshops ofPiaggio-Gilera dealers. It isassumed that the user of this manual for maintaining and repairingPiaggiovehicles has a basic knowledge of mechanical principles andvehicle repair technique procedures. Anysignificant changes tovehicle characteristics or to specific repair operations will becommunicated byupdates to this manual. Nevertheless, no mountingwork can be satisfactory if the necessary equipmentand tools areunavailable. It is therefore advisable to read the sections of thismanual concerning specialtools, along with the special toolcatalogue.

    N.B. Provides key information to make the procedure easier tounderstand and carry out.

    CAUTION Refers to specific procedures to carry out forpreventing damages to the vehicle.

    WARNING Refers to specific procedures to carry out to preventinjuries to the repairer.

    Personal safety Failure to completely observe these instructionswill result in serious risk of personalinjury.

    Safeguarding the environment Sections marked with this symbolindicate the correct use of the vehicleto prevent damaging theenvironment.

    Vehicle intactness The incomplete or non-observance of theseregulations leads to the risk of seriousdamage to the vehicle andsometimes even the invalidity of the guarantee.

  • INDEX OF TOPICS

    CHARACTERISTICS CHAR

    TOOLING 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

  • INDEX OF TOPICS

    CHARACTERISTICS CHAR

  • This section describes the general specifications of thevehicle.

    Rules

    This section describes general safety rules for any maintenanceoperations performed on the scooter.

    Safety rules

    - If work can only be done on the vehicle with the enginerunning, make sure that the premises are well

    ventilated, using special extractors if necessary; never let theengine run in an enclosed area. Exhaust

    fumes are toxic.

    - The battery electrolyte contains sulphuric acid. Protect youreyes, clothes and skin. Sulphuric acid is

    highly corrosive; in the event of contact with your eyes orskin, rinse thoroughly with abundant water

    and seek immediate medical attention.

    - The battery produces hydrogen, a gas that can be highlyexplosive. Do not smoke and avoid sparks

    or flames near the battery, especially when charging it.

    - Fuel is highly flammable and it can be explosive given someconditions. Do not smoke in the working

    area, and avoid open flames or sparks.

    - Clean the brake pads in a well ventilated area, directing thejet of compressed air in such a way that

    you do not breathe in the dust produced by the wear of thefriction material. Even though the latter

    contains no asbestos, inhaling dust is harmful.

    Maintenance rules

    - Use original PIAGGIO spare parts and lubricants recommended bythe Manufacturer. Non-original or

    non-conforming spares may damage the vehicle.

    - Use only the appropriate tools designed for this vehicle.

    - Always use new gaskets, sealing rings and split pins uponreassembly.

    - After removal, clean the components using non-flammable or lowflash-point solvent. Lubricate all the

    work surfaces except the tapered couplings before refitting.

    - After refitting, make sure that all the components have beeninstalled correctly and work properly.

    - For removal, overhaul and refit operations use only tools withmetric measures. Metric bolts, nuts and

    screws are not interchangeable with coupling members withEnglish measurement. Using unsuitable

    coupling members and tools may damage the scooter.

    - When carrying out maintenance operations on the scooter thatinvolve the electrical system, make

    sure the electrical connections have been made properly,particularly the ground and battery connec-

    tions.

    Characteristics Fuoco 500 i.e.

    CHAR - 2

  • Vehicle identification

    Frame prefix (A):

    ZAPM61100

    Engine prefix (B):

    M661M

    Dimensions and mass

    Fuoco 500 i.e. Characteristics

    CHAR - 3

  • WEIGHTS AND DIMENSIONSSpecification Desc./QuantityKerb weight253 5 kg

    Maximum weight allowed 445 kgMaximum height 1.210 mm

    Width 790 mmWheelbase 1.550 mm

    length 2.210 mmTrack 420 mm

    Engine

    ENGINESpecification Desc./Quantity

    Type Single-cylinder, 4-stroke with double spark plugCubiccapacity 493 cmBore x Stroke 94 x 71 mm

    Compression ratio 10.5: 1Engine idle speed 1,500 100 rpm

    Timing system Four valves, single overhead camshaft, chaindriv-en.

    Valve clearance Inlet: 0.15 mmOutlet: 0.15 mm

    MAX. power 29 kW at 7,500 rpmMAX torque 44 Nm at 5,200rpmLubrication Engine lubrication with lobe pump (inside crank-

    case) controlled by a chain with double filter: meshandpaper.

    Lubrication pressure 3.5 4 barMinimum lubrication pressure (100C) 0.8 bar

    Fuel supply Electronic injection with electric fuel pump.CoolingForced coolant circulation system.

    Fuel Unleaded petrol (95 RON)

    Transmission

    TRANSMISSIONSpecification Desc./QuantityTransmission Automaticexpandable pulley variator with torque

    server, V belt, dry self-ventilating automatic cen-trifugalclutch and transmission housing with

    forced air circulation.Final reduction Gear reduction unit inoil bath.

    Capacities

    CAPACITYSpecification Desc./Quantity

    Engine oil 1.7 l

    Characteristics Fuoco 500 i.e.

    CHAR - 4

  • Specification Desc./QuantityTransmission oil 250 cm

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

    Electrical system

    ELECTRICAL SYSTEMSpecification Desc./Quantity

    Start-up ElectricIgnition High efficiency electronic inductiveignition, inte-

    grated with the injection system, with variable ad-vance andseparate HV coil.

    Ignition advance Three-dimensional map managed by controlunitSpark plug NGK CR7EKB

    Alternative spark plug -Battery 12 V / 14 Ah, SEALED BATTERY

    Generator In alternating current

    Frame and suspensions

    FRAME AND SUSPENSIONSSpecification Desc./Quantity

    Chassis Tubular and sheet steelFront suspension The tiltmechanism is composed of an articulated

    parallelogram suspension with die-cast aluminiumcontrol arms andtwo side headstocks plus shock

    absorbers with hydraulic locking system.Front suspension travel85 mm

    Rear suspension Two double-acting shock absorbers, adjustabletofour positions at preloading.

    Rear suspension travel 110 mm

    Brakes

    BRAKESSpecification Desc./QuantityFront brake 240 mm double diskwith hydraulic control acti-

    vated by the handlebar right-hand lever.Rear brake disc brake,diameter 240 mm, with hydraulic servo

    operated from the handlebar with the left-hand lev-er.

    Wheels and tyres

    WHEELS AND TYRESSpecification Desc./QuantityWheel rim type Lightalloy rims.

    Front rim 12'' x 3.00

    Fuoco 500 i.e. Characteristics

    CHAR - 5

  • Specification Desc./QuantityRear rim 14'' x 4.50Front tyreTubeless 120/70-12" 51S or 51PRear tyre Tubeless 140/70 - 14" 68Sor 68P reinf

    Front tyre pressure (with passenger) 1.6 bar (1.8 bar)Rear tyrepressure (with passenger) 2.4 bar (2.6 bar)

    Tightening Torques

    STEERINGName Torque in Nm

    Steering lower ring nut (central headstock) 22 27 loosen by90Steering upper ring nut (central headstock) 27 33

    Handlebar fixing screw 50 55Fixing screws for handlebar controlassembly U-

    bolts7 10

    CHASSISName Torque in Nm

    Swinging arm set screw bushing 5 7Engine arm bolt - frame arm32.5 40

    Swinging arm set screw bushing nut 54 60Engine-swinging arm bolt98 118Frame-swinging arm bolt 54 60

    Centre stand bolt 31 39

    FRONT SUSPENSIONName Torque in Nm

    Shock absorber lower clamp 19 26Upper shock absorber clamp 1929

    Front wheel fixing screws 19 24Steering arm bolt nut 20 25

    Tilt calliper fixing screws 20 25Front wheel shaft 74 88

    Arm coupling screws 45 50Screws fixing arms to side headstocks45 50

    Screws fixing arms to central headstock 45 50Screws fixing thehalf-arm coupling flange 20 25Fixing screws for tilt locking discsection 20 25

    Side headstock upper ring nut 20 - 24Side headstock lower ringnut 12 15

    Screw fixing sliding stem to shock absorber 45 50Clamp forsliding stem locking device 6.5 10.5

    Fixing nuts for constant-velocity universal joints 1820Potentiometer to anti-tilting device clamp 8 10Electric motor toanti-tilting device clamp 11 13

    Clamp fixing pump bolt to anti-tilting device 11 13Pump toanti-tilting device clamp 11 13

    Pressure switch to distribution frame 18 20Sensor to tiltgripper clamp 2.5 2.9

    Pipe terminals to fifth wheel check spring 7 11Joint toanti-tilting device pump 20 25

    Characteristics Fuoco 500 i.e.

    CHAR - 6

  • Name Torque in NmLower fitting for shock absorber slidinglocking

    clamp pipes20 25

    Upper fitting for shock absorber sliding lockingclamp pipes

    20 25

    REAR SUSPENSIONName Torque in Nm

    Upper shock absorber clamp 33 41Shock absorber lower clamp 3341

    Shock absorber-crankcase attachment bracket 20 25Rear wheel axle104 126

    Muffler arm clamping screws 27 30

    FRONT BRAKEName Torque in Nm

    Calliper coupling screw 22 27Oil bleed screw 812

    Disc tightening screw () 5 - 6Brake fluid pump - hose fitting 1620Brake fluid hose-calliper fitting 20 25

    Screw tightening calliper to the support 20 25Calliper upperpipe fitting 20 25

    REAR BRAKEName Torque in Nm

    Oil bleed screw 1216Rear brake disc screws() 5 6.5

    Rear brake calliper-pipe fitting 20 25Rigid / flexible pipefitting 13 18

    Rear brake pump-pipe fitting 16 20Rear brake calliper fixingscrews 20 25

    pad fastening pin screws 20 25

    REAR BRAKEProduct Description Specifications

    () Loctite 243 Medium strength threadlock Apply LOCTITE 243mediumstrength threadlock

    MUFFLERName Torque in Nm

    Muffler heat guard fixing screw 4 5Screw for fixing muffler tothe support arm 20 25Lambda probe clamp on exhaust manifold 4050

    Exhaust manifold-muffler joint clamp 12 13Manifold - mufflerdiaphragm tightening clamp 16 18

    LUBRICATIONName Torque in Nm

    Oil pump cover screws 0.7 0.9Screws fixing oil pump to thecrankcase 5 - 6

    Fuoco 500 i.e. Characteristics

    CHAR - 7

  • THERMAL UNIT AND TIMING SYSTEMName Torque in Nm

    Spark plug 12 14Head fixing stud bolts: ***

    Head fixing nuts 10 - 12Exhaust / intake head fixing nuts: 10 -12

    Head lubrication control jet 5 - 7Coolant temperature sensor 1012

    counterweight mass fixing screw 7 - 8.5Tensioner sliding blockfixing screw: 10 - 14

    Rpm timing sensor fixing screw: 3 - 4injector fixing screw 34

    Rpm timing sensor fixing screw 3 4Valve lifter mass stop bellfixing screws: 30 - 35

    inlet manifold fixing screws 11 - 13Tappet cover fixing screws:7 - 9Throttle body fixing screws 11 13

    Camshaft retaining bracket fixing screws 4 - 6Head fixing screws10 - 12

    Lambda probe on exhaust manifold 10 - 12Muffler to bracketfixing screw 14 - 16

    *** Apply a preliminary torque of 7 Nm in a crossed sequence. -Tighten by 90 in a crossed sequence. - Tighten again by 90 inacrossed sequence.

    TRANSMISSION COVERName Torque in Nm

    Driven pulley nut 92 - 100Drive pulley nut 160 - 175

    Anti-vibration roller screw 16.7 - 19.6M8 retainers fortransmission cover 23 - 26

    M6 retainer 11 13Anti-vibration roller retainer 17 - 19

    Clutch ring nut 65 - 75Air deflector unit screws 7 9

    Water pump cover screws 3 4Outside transmission cover screws 79

    Flywheel cover screws 11 - 13

    FLYWHEEL COVERName Torque in Nm

    Flywheel fixing nut 115 - 125Stator retainers 8 - 10

    Blow-by recovery duct fixing screws 3 - 4Screw fixing freewheelto flywheel 13 - 15

    Stator cable harness guide bracket screws 3 - 4

    CRANKCASE AND CRANKSHAFTName Torque in Nm

    Countershaft fixing nut 25 - 29Engine oil filter 12 - 16

    Engine oil drainage plug 24 30Engine-crankcase coupling screws11 13

    Oil pump screws 5 - 6

    Characteristics Fuoco 500 i.e.

    CHAR - 8

  • Name Torque in NmGear mounting on crankshaft screws 10 -12

    Bulkhead screws for oil pump housing cover 8 - 10

    COOLINGName Torque in Nm

    Water pump rotor cover 3 4Thermostat cover screws 3 4

    Bleed screw: 3

    FINAL REDUCTIONName Torque in Nm

    Rear hub cover screws 24 27

    ENGINE ASSEMBLYName Torque in Nm

    starter motor retainers 11 - 13

    Overhaul data

    Assembly clearances

    Cylinder - piston assy.

    Fuoco 500 i.e. Characteristics

    CHAR - 9

  • HEIGHT TO MEASURE THE PISTONSpecification Desc./Quantity

    A 10 mmB 43 mm

    CYLINDER - PISTONSpecification Desc./Quantity

    Cylinder diameter C 94 +0.018-0.01mmPiston diameter P 93.968 -0.014 mm

    COUPLING CATEGORIESName Initials Cylinder Piston Play onfitting

    Cylinder- Piston A 93.99093.997 93.95493.961 0.0290.043Cylinder-Piston B 93.99793.004 93.96193.968 0.0290.043Cylinder- Piston C94.00494.011 93.96893.975 0.0290.043Cylinder- Piston D 94.01194.01893.97593.982 0.0290.043

    N.B.THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDSTHE OUTLET SIDE,THE PISTON RINGS MUST BE INSTALLED WITH THE WORDTOP OR THE STAMPED MARKFACING UPWARDS.

    Piston rings

    *Fit rings 2 and 3 with the word TOP facing upwards.

    ** Position the openings in the rings as shown here.

    ***Value A of sealing ring inside the cylinder.

    Check the size of the sealing ring opening:

    Compression ring: 0.15 0.35 mm. Max. value 0.5 mm

    Characteristics Fuoco 500 i.e.

    CHAR - 10

  • Oil scraper ring: 0.25 0.50 mm. Max. value 0.65 mm

    Oil scraper ring: 0.25 0.50 mm. Max. value 0.65 mm

    Rings/housing coupling clearances:

    Carefully clean the sealing ring housings.

    Place a thickness gauge between the ring and the

    housing as shown in the drawing and check the

    coupling clearances.

    Top ring Standard coupling clearance:

    0.010.06 mm

    Maximum clearances allowed after use: 0.10

    mm

    Intermediate ring Standard coupling clear-

    ance:0.020.07 mm

    Maximum clearances allowed after use: 0.10

    mm

    Oil scraper ring Standard coupling clearance:

    0.010.06 mm

    Maximum clearances allowed after use: 0.10

    mm

    Replace the piston if clearances exceed the max-

    imum limits specified in the table.

    Fuoco 500 i.e. Characteristics

    CHAR - 11

  • Crankcase - crankshaft - connecting rod

    AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING RODNameDescription Dimensions Initials Quantity

    Transmission-sideshoulder

    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 0.50Flywheel-side

    shoulder1.8 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

  • Diameter of crankshaft bearings.

    Measure the capacity on both axes x-y.

    CRANKSHAFTSpecification Desc./Quantity

    Cat. 1 Standard diameter: 40.010 40.016Cat. 2 Standard diameter:40.016 40.022

    Crankshaft alignment

    Specific tooling020335Y Magnetic support for dial gauge

    MAX. ADMISSIBLE DISPLACEMENTSpecification Desc./Quantity

    A = 0.15 mmB = 0.010 mmC = 0.010 mmD = 0.10 mm

    Fuoco 500 i.e. Characteristics

    CHAR - 13

  • CharacteristicCrankshaft-crankcase axial clearance (H)

    0.1 0.405 mm (when cold)

    Compression ratio

    10.5: 1

    Slot packing system

    Shimming system to control compression ratio

    DISTANCE A IS A PROTRUSION OR RE-CESS VALUE OF THE PISTON CROWNWITHRESPECT TO THE CYLINDER PLANE.DISTANCE A HELPS DETERMINETHETHICKNESS OF GASKET B THAT HAS TOBE FITTED TO THE CYLINDER HEADIN OR-DER TO RESTORE COMPRESSION RATIO.BASE GASKET B MUST BETHICKER THEMORE THE PLANE FORMED BY THE PISTONTOP PROTRUDES FROMTHE PLANEFORMED BY THE CYLINDER HEAD. ON THEOTHER HAND, THE MORETHE PISTON TOP ISRECESSED INTO THE CYLINDER TOP PLANE,THE SMALLERTHE GASKET THICKNESS.

    Characteristics Fuoco 500 i.e.

    CHAR - 14

  • CharacteristicCompression ratio

    10.5: 1

    BASE GASKET THICKNESSName Measure A Thickness

    A MEASURE TAKEN - 0.185 - - 0.10 0.4 0.05A MEASURE TAKEN - 0.10- + 0.10 0.6 0.05A MEASURE TAKEN + 0.10 - + 0.185 0.8 0.05

    N.B.

    VALUES INDICATED WITH - REFER TO PISTON CROWN RECESSES WITHRESPECT TO THECYLINDER PLANE.N.B.

    DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B

    Products

    RECOMMENDED PRODUCTS TABLEProduct Description Specifications

    AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceedstherequirements of API GL3 specifi-

    cationsAGIP CITY HI TEC 4T Oil to lubricate flexibletransmis-

    sions (throttle control)Oil for 4-stroke engines

    AGIP FILTER OIL Oil for air filter sponge Mineral oil withspecific additivesfor increased adhesiveness

    AGIP GP 330 Grease for brake levers, throttle White calciumcomplex soap-based spray grease with NLGI 2;

    ISO-L-XBCIB2AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL,ACEA A3,

    JASO MA Synthetic oilAGIP BRAKE 4 Brake fluid FMVSS DOT 4Synthetic fluid

    SPECIAL AGIP PERMANENTfluid

    coolant Monoethylene glycol-based anti-freeze fluid, CUNA NC956-16

    Fuoco 500 i.e. Characteristics

    CHAR - 15

  • Characteristics Fuoco 500 i.e.

    CHAR - 16

  • INDEX OF TOPICS

    TOOLING TOOL

  • SPECIFIC TOOLS CORRECTStores code Description

    001330Y Tool for fitting steering seats

    001467Y002 Driver for OD 73 mm bearing

    001467Y006 Extraction pliers for 20 mm bear-ings

    001467Y007 Driver for OD 54 mm bearing

    001467Y008 Extraction pliers for 17 mmbearings

    001467Y014 Extraction pliers for 15 mmbearings

    Tooling Fuoco 500 i.e.

    TOOL - 2

  • Stores code Description001467Y031 Bell

    001467Y034 Extraction pliers for 15 mmbearings

    001467Y035 Bearing housing outside diame-ter 47 mm

    002465Y Pliers for circlips

    006029Y Punch for fitting fifth wheel seaton steering tube

    020004Y Punch for removing fifth wheelsfrom the headstock

    020055Y Wrench for steering tube ring nut

    020150Y Air heater support

    Fuoco 500 i.e. Tooling

    TOOL - 3

  • Stores code Description020151Y Air heater

    020193Y Oil pressure gauge

    020201Y Spacer bushing driving tube020262Y Crankcase splittingstrip

    020306Y Punch for assembling valve sealrings

    020329Y Mity-Vac vacuum operatedpump

    020330Y Stroboscopic light for timing con-trol

    Tooling Fuoco 500 i.e.

    TOOL - 4

  • Stores code Description020331Y Digital multimeter

    020333Y Single battery charger

    020334Y Multiple battery charger

    020335Y Magnetic support for dial gauge

    020357Y 32 x 35 mm adaptor020358Y 37x40 mm adaptor020359Y 42 x47 mm adaptor

    Fuoco 500 i.e. Tooling

    TOOL - 5

  • Stores code Description020360Y 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 fittingpunch

    020431Y Valve oil seal extractor

    Tooling Fuoco 500 i.e.

    TOOL - 6

  • Stores code Description020434Y Oil pressure control fitting

    020439Y 17 mm guide

    020444Y Tool for fitting/ removing the driv-en pulley clutch

    (Video) Gilera Nexus 500 Manual

    020456Y 24 mm adaptor

    020458Y Puller for lower bearing on steer-ing tube

    Fuoco 500 i.e. Tooling

    TOOL - 7

  • Stores code Description020459Y Punch for fitting bearing onsteer-

    ing tube

    020460Y Scooter diagnosis and tester

    020467Y Flywheel extractor

    020468Y Piston fitting band

    020469Y Reprogramming kit for scooterdiagnosis tester

    Tooling Fuoco 500 i.e.

    TOOL - 8

  • Stores code Description020470Y Pin retainers installationtool

    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

  • Stores code Description020478Y Punch for driven pulley rollercas-

    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

  • Stores code Description020512Y Piston fitting fork

    020527Y Engine support base

    020604Y011 Fitting adapter020565Y Flywheel lock calliperspanner

    Marelli MIU diagnosis software Marelli MIU diagnosissoftware

    020640y software euro3

    Fuoco 500 i.e. Tooling

    TOOL - 11

  • Tooling Fuoco 500 i.e.

    TOOL - 12

  • INDEX OF TOPICS

    MAINTENANCE MAIN

  • Follow these steps to reset the service icons:

    1. With the key set to OFF, hold down the

    "SET" button and turn the key to ON : the

    "BELT" and "SERVICE" icons start flashing.

    2. Push the "CLOCK" button for less than 1

    second and the icons are displayed sequen-

    tially. The icon selected remains ON and the

    other is no longer displayed.

    3. Press the "CLOCK" button again for more

    than 3 seconds to reset the relative mainte-

    nance step and the icon is no longer dis-

    played.

    Maintenance chart

    EVERY 2 YEARS60'

    ActionCoolant - changeBrake fluid - change

    AFTER 1,000 KM60'

    ActionSafety locks - checkThrottle lever - adjustmentEngine oil- changeElectrical system and battery - checkCoolant level -checkBrake fluid level - checkEngine oil - replacementBrake pads -check condition and wearTyre pressure and wear - checkVehicle andbrake test - road testHub oil - changeSteering - check

    AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000KM10'

    ActionEngine oil - level check/top-upBrake pads - checkcondition and wearCentre stand - lubrication

    Maintenance Fuoco 500 i.e.

    MAIN - 2

  • AFTER 10,000 KM; 50,000 KM; 70,000 KMAction

    Safety locks - checkDriving belt - replacementThrottle lever -adjustmentAir filter - cleanEngine oil - changeElectrical systemand battery - checkCoolant level - checkBrake fluid level -checkEngine oil - replacementBrake pads - check condition andwearSliding block / variable speed rollers - changeTyre pressureand wear - checkVehicle and brake test - road testHub oil -checkSuspensions - checkSteering - checkCentre stand -lubricationSpark plugs - replacementTilt locking gripper controlcable - adjustmentParking control unit software upgrading (ifavailable)

    AFTER 15,000 KM; 45,000 KM; 75,000 KM45'

    ActionEngine oil - level check/top-upBrake pads - checkcondition and wearCentre stand - lubrication

    AFTER 20,000 KM; 40,000 KM; 60,000 KM AND 80,000 KMAction

    Spark plugs - replacementDriving belt - replacementThrottlelever - adjustmentAir filter - checkEngine oil - changeValveclearance - checkElectrical system and battery - checkCoolant level- checkEngine oil - replacementBrake pads - check condition andwearSliding block / variable speed rollers - changeTyre pressureand wear - checkVehicle and brake test - road testHub oil -changeSuspensions - checkSteering - checkCentre stand -lubricationBrake fluid level - checkTilt locking gripper controlcable - adjustmentParking control unit software upgrading (ifavailable)

    Fuoco 500 i.e. Maintenance

    MAIN - 3

  • 30,000 KMAction

    Safety locks - checkDriving Belt - replacementThrottle lever -adjustmentAir filter - cleaningEngine oil - changeElectrical systemand battery - checkCoolant level - checkBrake fluid level -checkEngine oil - replacementHub oil - checkBrake pads - checkcondition and wearSliding block / variable speed rollers -changeTyre pressure and wear - checkVehicle and brake test - roadtestSuspensions - checkSteering - checkCentre stand -lubricationSpark plugs - replacementTilt locking gripper controlcable - adjustmentParking control unit software upgrading (ifavailable)

    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

    does in fact correspond with the value actually ac-

    tivated on the engine, by means of the strobo-

    scopic light.

    Proceed as follows:

    - Remove the spark plugs.

    - Remove the transmission crankcase.

    - Rotate the driving pulley fan until the reference

    marks between the flywheel and flywheel cover

    meet as shown in the photograph.

    Maintenance Fuoco 500 i.e.

    MAIN - 4

  • - Bring the reference mark onto the transmission

    side between the fan and the transmission cover

    as shown in the photograph.

    - Refit the spark plugs.

    - Refit the plastic cap on the flywheel cover.

    - Adjust the spark gap to the contact position (no

    reference mark visible) and install it on engine be-

    tween the spark plug and spark plug cap

    - Connect the induction clamp to the spark gap

    cable respecting the proper polarity (the arrow 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 timing

    - revolution-timing sensor

    - Injection control unit

    Specific tooling020460Y Scooter diagnosis and tester

    020330Y Stroboscopic light for timing control

    020621Y H.V. cable extraction adapter

    Fuoco 500 i.e. Maintenance

    MAIN - 5

  • Spark plug

    Remove the port on the left-hand side panel of the

    vehicle by undoing the fixing screw and using a

    small screwdriver in the rear recess shown in the

    figure, then do the following:

    - Disconnect the HV wire caps A of the spark

    plugs;

    - Unscrew the spark plugs using the wrench sup-

    plied;

    - Upon refitting, place the spark plugs at the re-

    quired angle and tighten by hand until it is finger

    tight;

    - Use the wrench only for final tightening of the

    spark plug;

    - Place cap A fully over the spark plugs

    - Refit the port making sure the rear hook is inser-

    ted.WARNING

    THE SPARK PLUG MUST BE REMOVED WHENTHE ENGINE IS COLD. REPLACETHE SPARKPLUG AS INDICATED IN THE SCHEDULEDMAINTENANCE TABLE. THEUSE OF ELEC-TRONIC CENTRAL UNITS AND OF NON-COM-PLIANT ELECTRONICIGNITIONS OR SPARKPLUGS OTHER THAN THOSE PRESCRIBEDMAY SERIOUSLYDAMAGE THE ENGINE.N.B.

    THE USE OF SPARK PLUGS OTHER THANTHE INDICATED TYPE OR OFSHIELDLESSSPARK PLUG CAPS CAN CAUSE ELECTRI-CAL SYSTEMFAILURES.

    CharacteristicSpark plug

    CHAMPION RG 6 YC

    Alternative spark plug

    NGK CR7EKB

    Electric characteristicElectrode gap

    0.7 0.8 mm

    Maintenance Fuoco 500 i.e.

    MAIN - 6

  • Hub oil

    Check

    -Park the vehicle on its centre stand on flat ground;

    - Remove the oil dipstick A, dry it with a clean

    cloth and put it back into its hole tightening it

    completely;

    Remove the dipstick and check that the oil level is

    slightly over the second notch starting from the

    lower end; if the level is below the MAX mark, 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 productsAGIP ROTRA 80W-90 Rear hub oil

    SAE 80W/90 Oil that exceeds the requirements of

    API GL3 specifications

    CharacteristicRear hub oil

    Capacity approximately 250 cc

    Fuoco 500 i.e. Maintenance

    MAIN - 7

  • Air filter

    Proceed as follows:

    Unscrew the nine fixing screws A and remove

    the air filter cover.

    - Wash the sponge with water and mild soap.

    - Dry it with a clean cloth and short blasts of compressedair.

    - Soak it in a mixture of 50% petrol and 50% specified oil.

    - Gently squeeze the filtering element with your hands but donot wring it; allow it to drip dry and then

    refit.CAUTION

    IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRYOUT MAINTENANCECONTROLS OF THE AIR FILTER TO AVOID DAMAGING THEENGINE.

    Recommended productsAGIP FILTER OIL Oil for air filtersponge

    Mineral oil with specific additives for increasedadhesiveness

    Engine oil

    In 4T engines, the engine oil is used to lubricate thedistribution elements, the bench bearings and the

    thermal group. An insufficient quantity of oil can cause seriousdamage to the engine.

    In all 4T engines, the deterioration of the oil characteristics,or a certain consumption should be con-

    sidered normal, especially if during the run-in period.Consumption levels in particular can be influenced

    by the conditions of use (e.g.: oil consumption increases whendriving at "full throttle".

    Maintenance Fuoco 500 i.e.

    MAIN - 8

  • Replacement

    Replace oil and filter as indicated in the scheduled

    maintenance table. Empty the engine by draining

    the oil through drainage plug B.

    To facilitate oil drainage, loosen the cap/dipstick

    A.

    Once all the oil has drained through the drainage

    opening, unscrew and remove the oil cartridge fil-

    ter C .

    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 plug

    A. Then start up the scooter, leave it running for

    Fuoco 500 i.e. Maintenance

    MAIN - 9

  • a few minutes and switch it off: after five minutes

    check the level and if necessary top up without

    exceeding the MAX level. The cartridge filter must

    be replaced every time the oil is changed. Use new

    oil of the recommended type for topping up and

    changing purposes.N.B.

    THE ENGINE MUST BE HOT WHEN THE OIL ISCHANGED.

    Recommended productsAGIP CITY HI TEC 4T Engine oil

    SAE 5W-40 Synthetic oil that exceed the require-

    ments of API SL, ACEA A3, JASO MA specifica-

    tions

    Locking torques (N*m)Engine oil filter 12 - 16 Engine oildrainageplug 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, if required.

    If the check is carried out after the vehicle has

    been used, and therefore with a hot engine, the

    level line will be lower; in order to carry out a cor-

    rect check, wait at least 10 minutes after the en-

    gine has been stopped so as to get the correct

    level.

    Maintenance Fuoco 500 i.e.

    MAIN - 10

  • Oil top up

    The oil should be topped up after having checked

    the level and in any case by adding oil without

    ever exceeding the MAX. level.

    Restoring the level from the MIN to the MAX marks

    requires approx. 400 m of oil.

    Engine oil filter

    The cartridge filter must be replaced every time the oil ischanged. Use new oil of the recommended

    type for topping up and changing purposes.

    Make sure the pre-filter and discharge tap O-rings are in goodcondition. Lubricate them and refit the

    mesh filter and oil drainage plug, screwing them up to thespecified torque. Refit the new cartridge filter

    being careful to lubricate the O-ring before the fitting. Changethe engine oil.

    Recommended productsAGIP 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 that lights up when the key is

    turned to the "ON" position. However, this light

    should switch off once the engine has been star-

    ted.

    If the light turns on during braking, at idling

    speed or while turning a corner, it is necessary

    to check the oil level and the lubrication sys-

    tem.

    Fuoco 500 i.e. Maintenance

    MAIN - 11

  • Checking the ignition timing

    -Remove the plastic cap on the flywheel cover

    - Turn the flywheel until the reference mark T on

    the rotor matches the reference mark on the fly-

    wheel cover as shown in the figure (TDC). Make

    sure that the 4V reference point on the camshaft

    control pulley is aligned with the reference point on

    the head as shown in the second figure. If the ref-

    erence is opposite the indicator on the head, turn

    the crankshaft once more.

    For the use of this reference mark, remove the

    spark plug and turn the engine in the direction that

    is the reverse of the normal direction 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 or below the MIN

    level edge. The liquid level must always be be-

    tween the MIN and MAX level.

    -The coolant consists of an ethylene glycol and

    corrosion inhibitor based 50% de-ionised water-

    antifreeze solution mix.CAUTION

    DO NOT EXCEED THE MAX. LEVEL WHENFILLING SO AS TO AVOID THECOOLANT ES-CAPING FROM THE EXPANSION TANK WHENTHE vehicle IS INUSE.

    Maintenance Fuoco 500 i.e.

    MAIN - 12

  • Recommended productsAGIP PERMANENT SPEZIAL Coolant

    Monoethylene glycol based antifreeze solution,

    CUNA NC 956-16

    Braking system

    Level check

    The front and rear brake fluid reservoirs are both

    positioned on the handlebars. Proceed as follows:

    - Rest the vehicle on its centre stand with the han-

    dlebars perfectly horizontal;

    - Check the fluid level through the sight glass

    C. A certain lowering of the level is caused by

    wear on the pads.

    Top-up

    Proceed as follows: Loosen 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 FLUIDS AREHIGHLY COR-ROSIVE. MAKE SURE THAT IT DOES NOTCOME INTO CONTACT WITHTHE PAINT-WORK.CAUTION

    MAKE SURE THE BRAKE FLUID DOES NOTGET INTO YOUR EYES OR ON YOURSKIN ORCLOTHES. IF THIS HAPPENS ACCIDENTALLY,WASH WITH WATER.

    Fuoco 500 i.e. Maintenance

    MAIN - 13

  • Recommended productsAGIP BRAKE FLUID DOT4 Brake fluid

    FMVSS DOT4 Synthetic fluid

    Headlight adjustment

    Proceed as follows:

    - Position the unloaded vehicle, in running order

    and with the tyres inflated to the prescribed pres-

    sure, onto a flat surface 10 m away from a half-lit

    white screen; make sure the vehicle axis is per-

    pendicular to the screen.

    - Remove the headlight assembly central cover.

    - Turn on the headlight 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 WITHTHE EUROPEAN STANDARDSREGARDINGMAXIMUM AND MINIMUM HEIGHT OF LIGHTBEAMS. REFER TO THESTATUTORY REGU-LATIONS IN FORCE IN EVERY COUNTRYWHERE THE vehicleIS USED.

    To access the headlight adjusting screws:

    - Unscrew the four screws A (two on each side)

    and remove the front cowl.

    - Unscrew the four screws B and remove the

    side cover.

    Maintenance Fuoco 500 i.e.

    MAIN - 14

  • Each bulb has two light beam adjusting screws,

    one for horizontal adjustment C and one for the

    vertical adjustment D. Adjust one headlamp at

    (Video) Piaggio MP3 How To Open The Seat With A Dead Battery

    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 WHENTHE ENGINE IS ON. ADJUST THELIGHT BEAMIN A WELL VENTILATED PLACE.

    Fuoco 500 i.e. Maintenance

    MAIN - 15

  • Maintenance Fuoco 500 i.e.

    MAIN - 16

  • INDEX OF TOPICS

    TROUBLESHOOTING TROUBL

  • This section makes it possible to find the solutions to use introubleshooting.

    For each breakdown, a list of the possible causes and respectiveinterventions is given.

    Engine

    Excessive oil consumption/Exhaust smoke

    EXCESSIVE CONSUMPTIONPossible Cause Operation

    Wrong valve adjustment Adjust the valve clearanceproperlyOverheated valves Remove the head and the valves, grind orreplace

    the valvesMisshapen/worn valve seats Replace the headassembly

    Worn cylinder, Worn or broken piston rings Replace the pistoncylinder assembly or pistonrings

    Worn or broken piston rings or piston rings thathave not beenfitted properly

    Replace the piston cylinder unit or just the pistonrings

    Oil leaks from the couplings or from the gaskets Check andreplace the gaskets or restore the cou-pling seal

    Worn valve oil guard Replace the valve oil guardWorn valveguides Check and replace the head unit if required

    Insufficient lubrication pressure

    POOR LUBRICATION PRESSUREPossible 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 checkson the oil pumpcomponents

    Oil filter too dirty Replace the cartridge filterOil level toolow Restore the level adding the recommended oil

    type

    Transmission and brakes

    Clutch grabbing or performing inadequately

    IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible CauseOperation

    Faulty clutch Check that there is no grease on the masses.Checkthat the clutch mass contact surface withthe casing is mainly inthe centre with equivalentcharacteristics on the three masses.Check that

    the clutch casing is not scored or worn in an anom-alous way

    Troubleshooting Fuoco 500 i.e.

    TROUBL - 2

  • Insufficient braking

    INEFFICIENT BRAKING SYSTEMPossible Cause Operation

    Inefficient braking system Check the pad wear (1.5 min). Checkthat thebrake discs are not worn, scored or warped. Checkthecorrect level of fluid in the pumps and replacebrake fluid ifnecessary. Check there is no air in

    the circuits; if necessary, bleed the air. Check thatthe frontbrake calliper moves in axis with the disc.

    Fluid leakage in hydraulic braking system Failing elasticfittings, plunger or brake pumpseals, replace

    Brake disc slack or distorted Check the brake disc screws arelocked; measurethe axial shift of the disc with a dial gauge andwith

    wheel mounted on the scooter.

    Brakes overheating

    BRAKES OVERHEATINGPossible Cause Operation

    Defective sliding of pistons Check calliper and replace anydamaged part.Brake disc slack or distorted Check the brake discscrews are locked; use a dial

    gauge and a wheel mounted on the vehicle tomeasure the axialshift of the disc.

    Clogged compensation holes on the pump Clean carefully and blastwith compressed airRe-inflated or glued rubber gaskets Replacegaskets.

    Steering and suspensions

    Heavy steering

    STEERING HARDENINGPossible Cause Operation

    Steering hardening Check the tightening of the top and bottomringnuts. If irregularities continue in turning the steer-

    ing even after making the above adjustments,check the seats inwhich the ball bearings rotate:if they are recessed or if the ballsare squashed,

    replace them.

    Excessive steering play

    EXCESSIVE STEERING CLEARANCEPossible Cause Operation

    Torque not conforming Check the tightening of the top and bottomringnuts. If irregularities continue in turning the steer-

    ing even after making the above adjustments,check the seats inwhich the ball bearings rotate:

    Fuoco 500 i.e. Troubleshooting

    TROUBL - 3

  • Possible Cause Operationif they are recessed or if the balls aresquashed,

    replace them.

    Noisy suspension

    NOISY SUSPENSIONPossible Cause Operation

    Malfunctions in the suspension system If the front suspension isnoisy, check: the efficien-cy of the front shock absorbers; thecondition ofthe ball bearings and relevant lock-nuts, thelimitswitch rubber buffers and the movement bushings.In conclusion,check the tightening torque of the

    wheel hub, the brake calliper, the shock absorberdisk in theattachment to the hub and the steering

    tube.

    Suspension oil leakage

    OIL LEAKAGE FROM SUSPENSIONPossible Cause Operation

    Seal fault or breakage Replace the shock absorber Check theconditionof wear of the steering covers and the adjust-

    ments.

    Troubleshooting Fuoco 500 i.e.

    TROUBL - 4

  • INDEX OF TOPICS

    ELECTRICAL SYSTEM ELE SYS

  • KEY

    1. Parking electronic control unit

    2. Right speed sensor

    3. Left speed sensor

    4. Potentiometer

    5. Rider presence sensor

    6. Magneto flywheel

    7. Locking/unlocking switch

    8. LV socket

    9. Voltage regulator

    10. Main fuses

    11. Key switch contacts

    12. 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

  • 20. Stop button on rear brake

    21. Stop button on front brake

    22. Starter button

    23. Saddle opening receiver

    24. Wiring for antitheft device

    25. Helmet compartment light switch

    26. Turn indicator switch

    27. Turn signal command device

    28. Hazard button

    29. Light switch

    30. Headlight remote control

    31. Helmet compartment light bulb

    32. License plate light bulb

    33. Rear left turn indicator

    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 brake

    45. External temperature sensor

    46. Horn

    47. Horn button

    48. Horn remote control

    49. Pressure sensor

    50. Injection load remote control

    Fuoco 500 i.e. Electrical system

    ELE SYS - 3

  • 51. Injector

    52. Fuel pump

    53. Revolution sensor

    54. HV coil

    55. Injection ECU

    56. Immobilizer aerial

    57. Brake calliper sensor

    58. Diagnosis connector

    59. Coolant temperature sensor

    60. Lambda probe

    61. MIU control unit power device

    62. Electric fan remote control

    63. Electric fan

    64. Geared motor

    Key

    Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: YellowGr:Grey

    Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

    Components arrangement

    Electrical system Fuoco 500 i.e.

    ELE SYS - 4

  • 1. Relays for lights/ horn/ injection load/ electric

    fan: remove the front shield to reach these relays.

    2 - Auxiliary fuses: remove the footrest flap to

    reach these fuses.

    Fuoco 500 i.e. Electrical system

    ELE SYS - 5

  • 3 / 4 / 19 - Electronic control unit for injection

    (MIU) / Start-up relay / Start-up enabling switch

    relay: remove the lid of the helmet compartment to

    reach these relays.

    5 - 6. Fuel pump / Fuel level sensor: remove the

    central chassis cover to reach these components.

    Electrical system Fuoco 500 i.e.

    ELE SYS - 6

  • 10.Coil: remove the helmet compartment to reach

    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

  • 11 / 12 - Diagnostics socket/ main fuses: these

    components are found in the helmet compartment.

    13 - Lambda probe: The lambda probe is mounted

    on the exhaust manifold.

    14 - Engine oil pressure sensor: remove the ex-

    haust end to reach it.

    15 - Parking control unit: remove the front shield

    to reach it.

    Electrical system Fuoco 500 i.e.

    ELE SYS - 8

  • 16 - Rider presence sensor: open the saddle and

    remove the cover to reach the rider presence sen-

    sor.

    17 - Coolant temperature sensor: remove the lid of

    the helmet compartment and disconnect the con-

    nector to reach it.

    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

  • Ignition

    KEY

    10. Main fuses

    11. Key switch contacts

    12. Auxiliary fuses

    15. Battery

    50. Injection load remote control

    54. HV coil

    55. Injection ECU

    56. Immobilizer aerial

    61. MIU control unit power device

    Electrical system Fuoco 500 i.e.

    ELE SYS - 10

  • Battery recharge and starting

    KEY

    6. Magneto flywheel

    9. Voltage regulator

    10. Main fuses

    11. Key switch contacts

    12. Auxiliary fuses

    14. Fuse

    15. Battery

    16. Starter motor

    17. Start-up remote control switch

    19. Start-up enabling remote control

    20. 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

  • 61. MIU control unit power device

    Level indicators and enable signals section

    KEY

    1. Parking electronic control unit

    2.Right speed sensor

    3.Left speed sensor

    4. Potentiometer

    5. Rider presence sensor

    10. Main fuses

    11. Key switch contacts

    12. 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

  • 53. Rpm sensor

    55. Injection ECU

    56. Immobilizer aerial

    57. Brake calliper sensor

    59. Coolant temperature sensor

    60. Lambda probe

    61. MIU control unit power device

    Devices and accessories

    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

  • 24. Wiring for antitheft device

    25. Helmet compartment light switch

    31. Helmet compartment light bulb

    42. MODE button

    43. Instrument panel

    46. Horn

    47. Horn button

    48. Horn remote control

    49. Pressure sensor

    50. Injection load remote control

    52. 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

  • 1. Parking electronic control unit

    10. Main fuses

    11. Key switch contacts

    12. Auxiliary fuses

    13. Key switch contacts

    15. Battery

    26. Turn indicator switch

    27. Turn signal command device

    28. Hazard button

    29. Light switch

    30. Headlight remote control

    32. License plate light 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 systemcomponents.

    Fuoco 500 i.e. Electrical system

    ELE SYS - 15

  • Immobiliser

    The electronic ignition system is controlled by the

    control unit with the integrated Immobilizer sys-

    tem. The immobilizer is an antitheft system that

    allows the vehicle to be operated only when it is

    started with coded keys recognised by the control

    unit. The code is integrated in a transponder in the

    key block. This allows the driver clear operation

    without having to do anything other than just turn-

    ing the key. The Immobiliser system consists of the

    following components:

    - electronic control unit

    - immobilizer aerial

    - Master key with incorporated transponder (red

    key)

    - service key with incorporated transponder (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. Subsequently, a flash confirms the switching

    to ON.The duration of the flash depends on the

    programming of the electronic control unit. If the

    (Video) GILERA FUOCO 500 IE - WALKAROUND & QUICK TESTDRIVE

    LED is off regardless of the position of the ignition-

    key switch and/or the instrument panel is not initi-

    ated, check if:

    there is battery voltage

    fuses 1-7-10-11 are in working order

    there is power to the control unit as

    specified below:

    Electrical system Fuoco 500 i.e.

    ELE SYS - 16

  • Remove the connector support bracket shown in

    the photograph and disconnect the connector from

    the control unit. Check the following conditions:

    With the key switch set to OFF:

    if there is battery voltage between ter-

    minals 6-26 and terminal 6-chassis

    ground (fixed power supply). If there is

    no voltage check that fuse 1 and its ca-

    ble are in working order.

    With the key switch in the OFF 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 the electronic control

    unit.

    After removing the shield back plate, remove the

    electrical connection from the aerial as shown in

    the photograph

    Fuoco 500 i.e. Electrical system

    ELE SYS - 17

  • Remove the protective base from the connector.

    With the ignition key switch at ON check there is

    battery voltage between the Red-White and Black

    cables

    With MIU connector disconnected check the con-

    tinuity between the Orange-White cable and pin 7

    of the interface wiring .

    Specific tooling020481Y Control unit interface wiring

    020331Y Digital multimeter

    Virgin circuit

    When the ignition system is not encrypted, any key will startthe engine but limited to 2000 rpm. The

    keys can only be recognised if the control unit has beenprogrammed properly. The data storage pro-

    cedure for a previously not programmed control unit provides forthe recognition of the master as the

    Electrical system Fuoco 500 i.e.

    ELE SYS - 18

  • first key to be stored to memory: this becomes particularlyimportant because it is the only key that

    enables the control unit to be wiped clean and reprogrammed forthe memorisation of the service keys.

    The master and service keys must be used to code the system asfollows:

    - Insert the Master key, turn it to ON and keep this positionfor two seconds (lower and upper limits

    1 to 3 seconds).

    - Insert the service key and turn it to ON for 2 seconds.

    - If you have copies of the key, repeat the operation with eachkey.

    - Insert the MASTER key again and turn it to ON for 2seconds.

    The maximum time to change keys is 10 seconds.

    A maximum of 7 service keys can be programmed at one time.

    It is essential to adhere to the times and the procedure. If youdo not, start again from the beginning.

    Once the system has been programmed, the master key transponderis strictly matched with the control

    unit. With this link established, it is now possible to encodenew service keys, in the event of losses,

    replacements, etc. Each new programming deletes the previous oneso, in order to add or eliminate

    keys, you must repeat the procedure using all the keys youintend to keep using. If a service key should

    become un-coded, the efficiency of the high voltage circuitshielding must be thoroughly inspected: In

    any case it is advisable to use resistive spark plugs.

    CharacteristicMASTER 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 various light codes dis-

    played. Regardless of the code transmitted, if at

    the end of the diagnosis the led remains off per-

    manently, the ignition is enabled. If, however, the

    led remains on permanently, it means the ignition

    is inhibited:

    1. Previously unused control unit - key inser-

    ted: a single 2 second flash is displayed, after

    which the LED remains off permanently. The keys

    can be stored to memory, the vehicle can be star-

    Fuoco 500 i.e. Electrical system

    ELE SYS - 19

  • ted but with a limitation imposed on the number of

    revs.

    2. Previously unused control unit - transpond-

    er absent or cannot be used: The LED is per-

    manently ON; in this condition, no operations are

    possible, including starting of the vehicle.

    3. Programmed control unit - the service key in

    (normal condition of use): a single 0.7 second

    flash is displayed, after which the LED remains off

    permanently. The engine can be started.

    4. Programmed control unit - Master key in: a

    0.7 sec. flash is displayed followed by the LED re-

    maining 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 isdisplayed according to the fault detected,

    after which the LED remains on permanently. The engine cannot bestarted. The codes that can be

    transmitted are:

    Code 1 flash

    2 flash code

    3 flash code

    Diagnostic code - 1 flash

    The one-flash code indicates a system where the

    serial line is not present or is not detected. Check

    the Immobiliser aerial wiring and change it if nec-

    essary.

    Electrical system Fuoco 500 i.e.

    ELE SYS - 20

  • Diagnostic code - 2 flashes

    Two-flash code shows a system where the control

    unit does not show the transponder signal. This

    might depend on the inefficiency of the immobiliser

    aerial or the transponder.

    Turn the switch to ON using several keys: if the

    code is repeated even with the Master key, check

    the aerial wiring and change it if necessary. If this

    is not the case, replace the defective key and/or

    reprogram the control unit. Replace the control unit

    if the problem continues.

    Diagnostic code - 3 flashes

    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 this is not the case, perform a re-

    programming.

    Battery recharge circuitThe recharge system is provided with athree phase alternator with permanent flywheel.

    The alternator is directly connected to the voltageregulator.

    This, in its turn, is connected directly to the ground and thebattery positive terminal passing through

    the 30A protective fuse.

    The three- phase generator provides good recharge power and atlow revs a good compromise is

    achieved between generated power and idle stability.

    Stator checkStator winding check-upWARNINGTHE CHECK-UP CAN BEMADE WITH THE STATOR PROPERLY INSTALLED.1 Remove the right sidepanel.

    2) Disconnect the connector between stator and regulator withthe three yellow cables as shown in the

    photograph.

    3) Measure the resistance between each of the yellow terminalsand the other two.

    Fuoco 500 i.e. Electrical system

    ELE SYS - 21

  • Electric characteristicResistance:

    0.2 - 1 4) Check that there is insulation between the each

    yellow cable and the earth.

    5) If values that are wrong are noted, replace the

    stator.

    Recharge system voltage check

    Look for any leakage

    1) Access the battery by removing its cover under thesaddle.

    2) Check that the battery does not show signs of losing fluidbefore checking the output voltage.

    3) Turn the ignition key to position OFF, connect the terminalsof the tester between the negative pole

    (-) of the battery and the black cable and only then disconnectthe black cable from the negative pole

    (-) of the battery.

    4) With ignition key still at OFF, the reading detected by theammeter must be 0.5 mA.Check the charging currentWARNING

    BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS INGOOD WORK-ING ORDER.

    1) Place the vehicle on its centre stand

    2) With the battery correctly connected to the circuit, placethe tester terminals between the battery

    terminals..

    3) Turn on the engine, increase the revs and, at the same time,measure the voltage.

    Electric characteristicVoltage ranging between 14.0 and 15.0V at5000 rpm.

    Maximum current output check.

    - With the engine off and the panel at ON with the lights on,allow the battery voltage to stop at 12V.

    - Connect ammeter pliers to the 2 recharge positive poles inoutput from the regulator.

    - Start the engine and rev it up to a high engine speed whilereading the value on the pincer.

    With an efficient battery a value must be detected: > 20A

    VOLTAGE REGULATOR/RECTIFIERSpecification Desc./Quantity

    Type Non-adjustable three-phase transistor

    Electrical system Fuoco 500 i.e.

    ELE SYS - 22

  • Specification Desc./QuantityVoltage 14 15V at 5000 rpm withlights off

    Fuses

    The electrical system has twelve fuses divided into

    two fuse boxes to protect the different installation

    circuits. One of them is inside the battery compart-

    ment A 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 FAILURETHATCAUSED IT TO BLOW. NEVER TRY TO RE-PLACE THE FUSE WITH ANYOTHER MATERI-AL (E.G., A PIECE OF ELECTRIC WIRE).

    Fuoco 500 i.e. Electrical system

    ELE SYS - 23

  • FUSE TABLESpecification Desc./Quantity

    1 Fuse No. 1 Capacity: 7.5 AProtected circuits:Injection ECUbattery

    power2 Fuse No. 2 Capacity: 15 A

    Protected circuits:Battery-powered injec-tion loads, electricalfan

    3 Fuse No. 3 Capacity: 15 AProtected circuits:Battery-poweredsaddle

    opening switch, glove-box lighting, lightswitch, turn indicatorswitch, antitheft instal-

    lation, fuse No. 124 Fuse No. 4 Capacity: 20A

    Protected circuits:battery-powered ECU forparking control

    5 Fuse No. 5 Capacity: 20AProtected circuits:battery-poweredfuse

    No. 7, live fuses No. 8 - No. 9 - No.10 - No.11

    6 Fuse No. 6 Capacity: 15 AProtected circuits:L.V. socket.

    7 Fuse No. 7 Capacity: 7.5 AProtected circuits:Battery-poweredinstru-

    ment panel8 Fuse No. 8 Capacity: 10A

    Protected circuits:Live stop, start-up andstart-up enablingswitch and start-up circuit.

    9 Fuse No. 9 Capacity: 7.5 AProtected circuits:live passing andhorn

    10 Fuse No. 10 Capacity: 7.5AProtected circuits:Live injectionECU, im-mobilizer aerial, electric fan remote control,

    injection loads remote control11 Fuse No. 11 Capacity: 7.5A

    Protected circuits:Live ECU parking lever,antitheftinstallation, instrument panel, head-

    light remote control, horn12 Fuse No. 12 Capacity: 7.5A

    Protected circuits:Live turn indicator con-trol, saddle openingswitch, tail lights, panel

    lighting

    Electrical system Fuoco 500 i.e.

    ELE SYS - 24

  • Dashboard

    A = Led immobilizer / anti-theft device

    B= Speedometer with twin scale (km/h and mph)

    C = CLOCK switch

    D = Digital display

    E = Front suspension locking system warning light

    (if available)

    F = SET switch

    G = Rpm indicator

    H = 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 system

    ELE SYS - 25

  • C = High-beam warning light

    A = Total odometer gauge

    B = BELT maintenance icon

    C = SERVICE maintenance icon

    D = Engine coolant temperature indicator

    E = Trip odometer gauge (A-B) and ambient temperature (selectedwith the MODE button)

    F = TIME-DATE indicator

    G = Low fuel warning light

    H = Trip odometer gauge (B)

    I = Trip odometer gauge (A)

    L = Kilometre - mile indicator

    Sealed battery

    If the vehicle is provided with a sealed battery, the onlymaintenance required is the check of its charge

    and recharging, if necessary.

    These operations should be carried out before delivering thevehicle, and on a six-month basis while

    the vehicle is stored in open circuit.

    Besides upon pre-delivery it is therefore necessary to check thebattery charge and recharge it, if re-

    quired, before storing the vehicle and afterwards every sixmonths.

    INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUITSTORAGE

    1) Voltage check up

    Before installing the battery on the vehicle, check the opencircuit voltage with a normal tester.

    - If voltage exceeds 12.60 V, the battery can be installedwithout any renewal recharge.

    - If voltage is below 12.60 V, a renewal recharge is required asexplained in 2).

    2) Constant voltage battery charge mode

    - Constant voltage charge equal to 14.40 14.70V

    -Initial charge voltage equal to 0.3 0.5 for nominalCapacity

    - Charge time:

    10 to 12 h recommended

    Minimum 6 h

    Maximum 24 h

    3) Constant current battery charge mode

    - Charge current equal to 1/10 of the battery rated capacity

    - Charge time: Maximum 5 h

    Electrical system Fuoco 500 i.e.

    ELE SYS - 26

  • Connectors

    INJECTION ELECTRONIC CONTROL UNIT

    1. Injection telltale light (Brown-Black)

    2. Rpm indicator on instrument panel (Yellow)

    3. CAN "L" Line (White-Blue)

    4. Lambda probe (-) (White-Green)

    5. Live supply (Red-White)

    6. Battery powered (Orange-Black)

    7. Immobilizer aerial (Orange-White)

    8. Electric fan remote control (Blue-Yellow)

    9. Coolant temperature sensor (Sky blue-Green)

    10. CAN "H" Line (Pink-White)

    11. Lambda probe (+) (Sky blue-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 enabling switch (Orange-Blue)

    25. Not connected

    26. Ground (Black)

    PICK-UP CONNECTOR

    1. Injection electronic control unit (Red)

    2. Injection electronic control unit (Brown)

    Fuoco 500 i.e. Electrical system

    ELE SYS - 27

  • VOLTAGE REGULATOR CONNECTOR

    1. +Battery (Red-Black)

    2. Ground (Black)

    3. +Battery (Red-Black)

    4. Ground (Black)

    SADDLE OPENING RECEIVER CONNECTOR

    1. Aerial (Purple)

    2. Saddle opening actuator (Yellow-Grey)

    3. Reset (Blue-Black)

    4. Battery powered (Blue)

    5. Not connected

    6. Live supply (Yellow-Black)

    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 connected

    12. Not connected

    Electrical system Fuoco 500 i.e.

    ELE SYS - 28

  • HV COIL CONNECTOR

    1. Injection load remote control (Black-Green)

    2. Injection electronic control unit (Pink-Black)

    ANTI-THEFT DEVICE PRE-INSTALLATION

    CONNECTOR

    1. LHS Turn indicators (Pink)

    2. RHS Turn indicators (White-Blue)

    3. Ground (Black)

    4. Battery powered (Blue)

    5. Live supply (Yellow-Red)

    6. Helmet 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)

    (Video) RESET REMEN PIAGGIO

    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. Not connected

    9. Not connected

    10. Not connected

    Fuoco 500 i.e. Electrical system

    ELE SYS - 29

  • 11. Ground (Black)

    12. Live supply (Yellow-Red)

    INSTRUMENT PANEL CONNECTOR "B"

    1. Scooter speed signal (Sky blue)

    2. Fuel level signal (White-Green)

    3. Water temperature sensor (Sky blue-Black)

    4. Water temperature sensor ground lead (Brown-

    White)

    5. MODE remote button (Green)

    6. Oil pressure warning light (Pink-White)

    7. LHS Turn indicator warning light (Pink)

    8. RHS Turn indicator warning light (White-Blue)

    9. High-beam warning light (Purple)

    10. Boot open warning light (Blue-Black)

    11. Rpm sensor (Yellow)

    12. Ambient temperature sensor (Yellow-Blue)

    13. Ambient temperature sensor 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. Potentiometer supply (Orange-Blue)

    2A. CAN "L" Line (White-Blue)

    3A. Warning light supply (Yellow-Green)

    4A. Tilt locking activated warning light (Pink-Black)

    5A. Tilt locking system failure warning light (Grey-

    Black)

    6A. Headlight remote control (White-Black)

    7A. Potentiometer ground lead, rpm sensor, rider

    presence sensor (Yellow)

    Electrical system Fuoco 500 i.e.

    ELE SYS - 30

  • 8. Ground (Black)

    1B. Live supply (Yellow-Red)

    2B. CAN "H" Line (Pink-White)

    3B. Left wheel turning sensor (Green)

    4B. Right wheel turning sensor (Red)

    5B. Potentiometer signal (Green-Blue)

    6B. Locking/unlocking switch (Green-Grey)

    7B. Horn remote control for alarms (White)

    8B. Geared motor (White-Red)

    1C. Battery powered (Blue-Red)

    2C. Diagnosis (Purple-White)

    3C. Locking/unlocking switch (Yellow-Blue)

    4C. Calliper 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 operation all the remote controls stored in

    the control unit will be deleted.WARNING

    THE CONTROL UNIT CAN PROGRAMME UPTO 8 REMOTE CONTROLS.

    Fuoco 500 i.e. Electrical system

    ELE SYS - 31

  • Programming

    Follow these steps to program the remote controls:

    1. Insert the remote control key to be programmed in thesteering lock key block.

    2. Turn the key to the ON position, press the button on theremote control, release the button, turn

    the key back to the OFF position from the ON position, allwithin four seconds.

    3. Wait from 1 to 8 seconds.

    4. Repeat steps 2 and 3 for 4 times without removing thekey.

    The control unit confirms the programming has been successfullyexecuted by opening the saddle.WARNING

    TO STORE THE OTHER REMOTE CONTROLS TO MEMORY (8 MAXIMUM) YOUNEED TO RE-PEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUTTHESE OPERATIONSWITHIN THE INDICATED TIMES WILL RESULT IN THEAUTOMATIC CANCELLATION OF THEPROCESS FOR PROGRAMMING THEREMOTE-CONTROLLED KEYS.WARNING

    AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FARAWAYFROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROLAND THE RE-CEIVER CAN BE IMPAIRED. SHOULD THIS BE THE CASE, REPEATTHE PROGRAMMINGPROCEDURE. DO NOT KEEP THE REMOTE CONTROL IN PLACESWITH TEMPERATURES EX-CEEDING 60 C THE BATTERY WILL RUN DOWN TOOQUICKLY.WARNING

    TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROLRADIO RE-CEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLEWAS SHUT OFF.JUST TURN THE KEY TO ON TO REACTIVATE THERECEIVER.

    Electrical system Fuoco 500 i.e.

    ELE SYS - 32

  • INDEX OF TOPICS

    ENGINE FROM VEHICLE ENG VE

  • This section describes the operations to carry out when removingthe engine from the vehicle.

    Exhaust assy. Removal

    - Remove the side fairings.

    - Remove the central frame cover.

    - Remove the exhaust end.

    - Disconnect the lambda probe connector.

    - Unscrew the probe.

    - Working from both sides, release the two clamps

    securing the exhaust manifold to the head.

    - Detach the exhaust manifold making it pass

    through the swinging arm.CAUTION

    SHOULD IT BE NECESSARY TO REMOVE ON-LY THE MUFFLER TIP, ALWAYSREPLACETHE GRAPHITE GASKET BETWEEN STUBAND TIP.

    To fit, follow the removal steps but in reverse order; becareful 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 battery.

    - Remove the engine cover inside the helmet compartment.

    - Remove the side fairings.

    - Remove the footrests.

    Remove the full muffler unit.

    Engine from vehicle Fuoco 500 i.e.

    ENG VE - 2

  • CAUTION

    THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.

    - Remove the rear wheel.

    - Remove the bracket supporting the rear brake

    callipers and the callipers as well.

    - After removing the air filter from the crankcase,

    undo the screws fixing the bracket that secures the

    rear brake pipes.

    - 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 motor

    as indicated.

    Fuoco 500 i.e. Engine from vehicle

    ENG VE - 3

  • - Remove the spark plug caps.

    - Remove the coolant temperature sensor con-

    nector indicated in the photo.

    - Remove the throttle cables from the throttle body

    by undoing the nuts indicated in the photograph.

    - 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

  • Remove the lower screw of the left-hand shock

    absorber.

    - Remove the engine-swinging arm fixing pin by

    undoing the nut and operating on the head of the

    pin as shown in the photograph.

    - The engine is now free.

    When refitting the engine to the scooter, carry out theoperations in reverse order from that adopted

    when removing it and respect the tightening torque shown in theCharacteristics Chapter.

    -Check the engine oil level and if necessary top it up with therecommended type.

    - Fill and bleed the cooling circuit.

    - Check the functioning of the accelerator and the electricaldevices.CAUTION

    PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMANDTRANSMISSIONPROPERLY.

    Fuoco 500 i.e. Engine from vehicle

    ENG VE - 5

  • Engine from vehicle Fuoco 500 i.e.

    ENG VE - 6

  • INDEX OF TOPICS

    ENGINE ENG

  • This section describes the operations to be carried out on theengine and the tools to be used.

    Automatic transmission

    Transmission cover

    - Loosen the 4 fastening screws

    - Extract the outside plastic transmission cover.

    - Using a screwdriver, remove the driven pulley

    axle cover near the bottom of the cap.

    - 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 ACONVENTIONAL POLYGONAL BUSH - MAYDAMAGE THE HEXAGONOBTAINED ON THESHAFT OR BREAK THE BUSH ITSELF.

    Engine Fuoco 500 i.e.

    ENG - 2

  • - Remove the six M6 screws.

    - Remove the four M8 screws.

    - Remove the transmission cover.

    - Check that the bearing rotates freely, otherwise

    replace it.

    Air duct

    - Remove the transmission cover.

    - Unscrew the two screws shown in the figure to

    remove the air conveyor.

    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

  • Air duct filter

    - Remove the external air conveyor.

    - Unscrew the 2 fastening screws shown in the fig-

    ure to remove the conveyor filter.

    Removing the driven pulley shaft bearing

    - Remove the transmission cover.

    - Remove the seeger ring.

    - Place transmission cover on a wood surface 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 THEBEARINGSEAT AND THE WOODEN SURFACE, SINCEWITHOUT BELL THE ENTIRECOVER STRUC-TURE WOULD BEND. NOT ONLY IN THE AREAOF MAXIMUMSTURDINESS.

    Specific tooling001467Y002 Driver for OD 73 mm bearing

    020376Y Adaptor handle

    020375Y 28 x 30 mm adaptor

    020439Y 17 mm guide

    Engine Fuoco 500 i.e.

    ENG - 4

  • Refitting the driven pulley shaft bearing

    - Heat the transmission cover interior using the

    heat gun.N.B.

    BE CAREFUL NOT TO OVERHEAT THE COV-ER AS THIS WOULD DAMAGE THEOUTSIDEPAINTED SURFACE.

    Specific tooling020151Y Air heater

    - Place the bearing onto the special tool with a little

    grease to prevent it from coming out.

    - Install the new bearing using the special tool.N.B.

    PROPERLY SUPPORT THE OUTSIDE COVERTO PREVENT DAMAGING THEPAINTED SUR-FACE.

    Specific tooling020376Y 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 COMPLETEROLLER.

    Installation of belt anti-vibration roller

    - Install the anti-flapping roller with the lip facing theengine crankcase.

    - Tighten the central screw to the prescribed torque.N.B.TURNTHE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THEBELTIS OBTAINED.Locking torques (N*m)

    Fuoco 500 i.e. Engine

    ENG - 5

  • Anti-vibration roller screw 16.7 - 19.6

    Removing the driven pulley

    - Remove the clutch bell.

    - Remove the fixed driving half-pulley.

    - Remove the driven pulley assembly with the belt.

    Inspecting the clutch drum

    - Check that the clutch bell is not worn or damaged.

    - Measure the clutch bell inside diameter.N.B.

    CHECK THE ECCENTRICITY MEASURED, 0.2MM MAX.

    CharacteristicMax. value:

    160.5 mm

    Standard value:

    160.2 mm

    Engine Fuoco 500 i.e.

    ENG - 6

  • Removing the clutch

    - To remove the clutch with the driven pulley it is

    necessary to use the special tool;

    - Arrange the tool with the mean pins screwed in

    position "E" on the inside;

    - Fit the adapter ring to the clutch assembly as

    shown in the photograph.

    - Install the driven pulley unit onto the tool inserting

    the pins into the ventilation holes;

    - Move the rear stop screw in abutment against the

    fixed driven pulley as shown in the figure.

    CAUTION

    THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIALTOOL. DO NOTTIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD CAUSE ANIRREVERSIBLE TOOLDEFORMATION.USING THE SPECIAL 55-MM WRENCH, REMOVETHE FASTENING RING NUT.LOOSEN THE TOOL SCREW AND DISASSEMBLE THEDRIVEN PULLEY UNIT, CLUTCH, SPRINGWITH SHEATH.

    Specific tooling020444Y Tool for fitting/ removing the drivenpulley clutch

    Inspecting the clutch

    - Check the thickness of the clutch mass friction material.

    CharacteristicMinimum thickness permitted:

    1 mm

    - The masses must not show traces of lubricants. Otherwise,check the driven pulley unit seals.N.B.

    UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACTSURFACE AND MUSTNOT BE DIFFERENT FROM ONE ANOTHER. VARIOUSCONDITIONS CAN CAUSE THE CLUTCHTO TEAR.

    Fuoco 500 i.e. Engine

    ENG - 7

  • - Do not open the masses using tools to prevent a

    variation in the return spring load.

    Pin retaining collar

    - Extract the collar using 2 screwdrivers.

    - Remove the 4 guide pins.

    - Extract the moving driven half-pulley.

    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

  • - Using the special tool inserted through the roller

    bearing, pull out the ball bearing.N.B.

    PROPERLY SUPPORT THE PULLEY TO PRE-VENT DAMAGING THETHREADING.

    Specific tooling020376Y Adaptor handle

    020456Y 24 mm adaptor

    020363Y 20 mm guideN.B.

    IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVENPULLEY UNIT, IT ISNECESSARY TO SUPPORT THE UNIT BY THE BELL

    Specific tooling001467Y002 Driver for OD 73 mm bearing

    - Remove the roller bearing using the special tool,

    supporting the fixed half-pulley with the bell.

    Specific tooling020376Y 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 the outer diameter of the pulley bushing.

    CharacteristicMinimum admissible diameter

    49.96 mm

    Standard diameter:

    49.965 mm

    Fuoco 500 i.e. Engine

    ENG - 9

  • Inspecting the driven sliding half-pulley

    - Check that the belt contact surface is free from

    wear.

    - Remove the 2 inside sealing rings and the 2 out-

    side O-rings.

    - Measure the movable half-pulley bushing inside

    diameter.

    CharacteristicMaximum admissible diameter:

    50.08 mm

    Standard diameter:

    50.085 mm

    Refitting the driven half-pulley bearing

    - Install a new roller bearing using the special tool.N.B.

    PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARDFACING OUT-WARDS.

    - Properly support the half-pulley to prevent damaging thethreading.

    If you are working on the driven pulley unit fully assembled,use the special tool.

    Specific tooling020478Y Punch for driven pulley rollercasing

    001467Y002 Driver for OD 73 mm bearing

    - Install a new ball bearing using the special tool.

    Specific tooling020376Y Adaptor handle

    020477Y 37 mm adaptor

    020363Y 20 mm guide

    - Insert the seeger lock ring.

    Engine Fuoco 500 i.e.

    ENG - 10

  • Refitting the driven pulley

    - Insert the new oil guards

    - Insert the new O-ringsN.B.

    O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THEMACHINING END RA-DIUS, AT THE BASE OF THE HALF-PULLEY.

    - Install the half-pulley on the bushing being careful

    not to damage the top sealing ring during the in-

    troduction.

    - Make sure the pins and collar are not worn, re-

    assemble the pins and collar.

    - Using a bent beak greaser, lubricate the driven pulley unitwith about 10 gr. of grease, this operation

    should be carried out through one of the two holes into thebushing to obtain the exit of the grease from

    the opposite hole. This operation is necessary to avoid thepresence of grease beyond the O-rings.

    (Video) Explications techniques en vidéo concernant le MP3 500 LT

    Recommended productsAGIP GREASE SM 2 Grease for the tone wheelrevolving ring

    Soap-based lithium grease containing NLGI 2 Molybdenumdisulphide; ISO-L-XBCHB2, DIN KF2K-20

    Inspe

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