Fuoco Workshop Manual

Fuoco Workshop Manual
SERVICE STATION MANUAL
XXXX
Fuoco 500 i.e.
SERVICE STATION
MANUAL
Fuoco 500 i.e.
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
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. 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 MANUAL
Fuoco 500 i.e.
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant changes to vehicle characteristics or to specific repair operations will be communicated by
updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment
and tools are unavailable. It is therefore advisable 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 completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
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
PRE-DELIVERY
TIME
CHAS
PRE DE
TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Fuoco 500 i.e.
This section describes the general specifications of the vehicle.
Rules
This section describes general safety rules for any maintenance operations performed on the scooter.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. 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 some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the brake pads in a well ventilated area, directing the jet of compressed 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 use new gaskets, sealing rings and split pins upon reassembly.
- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the
work surfaces except the tapered couplings before refitting.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the scooter that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connections.
CHAR - 2
Fuoco 500 i.e.
Characteristics
Vehicle identification
Frame prefix (A):
ZAPM61100
Engine prefix (B):
M661M
Dimensions and mass
CHAR - 3
Fuoco 500 i.e.
Characteristics
WEIGHTS AND DIMENSIONS
Specification
Kerb weight
Maximum weight allowed
Maximum height
Width
Wheelbase
length
Track
Desc./Quantity
253 ± 5 kg
445 kg
1.210 mm
790 mm
1.550 mm
2.210 mm
420 mm
Engine
ENGINE
Specification
Type
Cubic capacity
Bore x Stroke
Compression ratio
Engine idle speed
Timing system
Valve clearance
MAX. power
MAX torque
Lubrication
Lubrication pressure
Minimum lubrication pressure (100° C)
Fuel supply
Cooling
Fuel
Desc./Quantity
Single-cylinder, 4-stroke with double spark plug
493 cm³
94 x 71 mm
10.5: 1
1,500 ± 100 rpm
Four valves, single overhead camshaft, chain driven.
Inlet: 0.15 mm
Outlet: 0.15 mm
29 kW at 7,500 rpm
44 Nm at 5,200 rpm
Engine lubrication with lobe pump (inside crankcase) controlled by a chain with double filter: mesh
and paper.
3.5 ÷ 4 bar
0.8 bar
Electronic injection with electric fuel pump.
Forced coolant circulation system.
Unleaded petrol (95 RON)
Transmission
TRANSMISSION
Specification
Transmission
Final reduction
Desc./Quantity
Automatic expandable pulley variator with torque
server, V belt, dry self-ventilating automatic centrifugal clutch and transmission housing with
forced air circulation.
Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification
Engine oil
CHAR - 4
Desc./Quantity
1.7 l
Fuoco 500 i.e.
Characteristics
Specification
Transmission oil
Cooling system fluid
Fuel tank (reserve)
Desc./Quantity
250 cm³
~ 1.8 l
~ 12 l (~2 l)
Electrical system
ELECTRICAL SYSTEM
Specification
Start-up
Ignition
Ignition advance
Spark plug
Alternative spark plug
Battery
Generator
Desc./Quantity
Electric
High efficiency electronic inductive ignition, integrated with the injection system, with variable advance and separate HV coil.
Three-dimensional map managed by control unit
NGK CR7EKB
12 V / 14 Ah, SEALED BATTERY
In alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification
Chassis
Front suspension
Front suspension travel
Rear suspension
Rear suspension travel
Desc./Quantity
Tubular and sheet steel
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.
85 mm
Two double-acting shock absorbers, adjustable to
four positions at preloading.
110 mm
Brakes
BRAKES
Specification
Front brake
Rear brake
Desc./Quantity
Ø 240 mm double disk with hydraulic control activated by the handlebar right-hand lever.
disc brake, diameter 240 mm, with hydraulic servo
operated from the handlebar with the left-hand lever.
Wheels and tyres
WHEELS AND TYRES
Specification
Wheel rim type
Front rim
Desc./Quantity
Light alloy rims.
12'' x 3.00
CHAR - 5
Fuoco 500 i.e.
Characteristics
Specification
Rear rim
Front tyre
Rear tyre
Front tyre pressure (with passenger)
Rear tyre pressure (with passenger)
Desc./Quantity
14'' x 4.50
Tubeless 120/70-12" 51S or 51P
Tubeless 140/70 - 14" 68S or 68P reinf
1.6 bar (1.8 bar)
2.4 bar (2.6 bar)
Tightening Torques
STEERING
Name
Steering lower ring nut (central headstock)
Steering upper ring nut (central headstock)
Handlebar fixing screw
Fixing screws for handlebar control assembly Ubolts
Torque in Nm
22 ÷ 27 loosen by 90°
27 ÷ 33
50 ÷ 55
7 ÷ 10
CHASSIS
Name
Swinging arm set screw bushing
Engine arm bolt - frame arm
Swinging arm set screw bushing nut
Engine-swinging arm bolt
Frame-swinging arm bolt
Centre stand bolt
Torque in Nm
5÷7
32.5 ÷ 40
54 ÷ 60
98 ÷ 118
54 ÷ 60
31 ÷ 39
FRONT SUSPENSION
Name
Shock absorber lower clamp
Upper shock absorber clamp
Front wheel fixing screws
Steering arm bolt nut
Tilt calliper fixing screws
Front wheel shaft
Arm coupling screws
Screws fixing arms to side headstocks
Screws fixing arms to central headstock
Screws fixing the half-arm coupling flange
Fixing screws for tilt locking disc section
Side headstock upper ring nut
Side headstock lower ring nut
Screw fixing sliding stem to shock absorber
Clamp for sliding stem locking device
Fixing nuts for constant-velocity universal joints
Potentiometer to anti-tilting device clamp
Electric motor to anti-tilting device clamp
Clamp fixing pump bolt to anti-tilting device
Pump to anti-tilting device clamp
Pressure switch to distribution frame
Sensor to tilt gripper clamp
Pipe terminals to fifth wheel check spring
Joint to anti-tilting device pump
CHAR - 6
Torque in Nm
19 ÷ 26
19 ÷ 29
19 ÷ 24
20 ÷ 25
20 ÷ 25
74 ÷ 88
45 ÷ 50
45 ÷ 50
45 ÷ 50
20 ÷ 25
20 ÷ 25
20 - 24
12 ÷ 15
45 ÷ 50
6.5 ÷ 10.5
18 ÷ 20
8 ÷ 10
11 ÷ 13
11 ÷ 13
11 ÷ 13
18 ÷ 20
2.5 ÷ 2.9
7 ÷ 11
20 ÷ 25
Fuoco 500 i.e.
Characteristics
Name
Lower fitting for shock absorber sliding locking
clamp pipes
Upper fitting for shock absorber sliding locking
clamp pipes
Torque in Nm
20 ÷ 25
20 ÷ 25
REAR SUSPENSION
Name
Upper shock absorber clamp
Shock absorber lower clamp
Shock absorber-crankcase attachment bracket
Rear wheel axle
Muffler arm clamping screws
Torque in Nm
33 ÷ 41
33 ÷ 41
20 ÷ 25
104 ÷ 126
27 ÷ 30
FRONT BRAKE
Name
Calliper coupling screw
Oil bleed screw
Disc tightening screw (°)
Brake fluid pump - hose fitting
Brake fluid hose-calliper fitting
Screw tightening calliper to the support
Calliper upper pipe fitting
Torque in Nm
22 ÷ 27
8÷12
5-6
16 ÷ 20
20 ÷ 25
20 ÷ 25
20 ÷ 25
REAR BRAKE
Name
Oil bleed screw
Rear brake disc screws(°)
Rear brake calliper-pipe fitting
Rigid / flexible pipe fitting
Rear brake pump-pipe fitting
Rear brake calliper fixing screws
pad fastening pin screws
Torque in Nm
12÷16
5 ÷ 6.5
20 ÷ 25
13 ÷ 18
16 ÷ 20
20 ÷ 25
20 ÷ 25
REAR BRAKE
Product
(°) Loctite 243
Description
Medium strength threadlock
Specifications
Apply LOCTITE 243 medium
strength threadlock
MUFFLER
Name
Muffler heat guard fixing screw
Screw for fixing muffler to the support arm
Lambda probe clamp on exhaust manifold
Exhaust manifold-muffler joint clamp
Manifold - muffler diaphragm tightening clamp
Torque in Nm
4÷5
20 ÷ 25
40 ÷ 50
12 ÷ 13
16 ÷ 18
LUBRICATION
Name
Oil pump cover screws
Screws fixing oil pump to the crankcase
Torque in Nm
0.7 ÷ 0.9
5-6
CHAR - 7
Fuoco 500 i.e.
Characteristics
THERMAL UNIT AND TIMING SYSTEM
Name
Spark plug
Head fixing stud bolts:
Head fixing nuts
Exhaust / intake head fixing nuts:
Head lubrication control jet
Coolant temperature sensor
counterweight mass fixing screw
Tensioner sliding block fixing screw:
Rpm timing sensor fixing screw:
injector fixing screw
Rpm timing sensor fixing screw
Valve lifter mass stop bell fixing screws:
inlet manifold fixing screws
Tappet cover fixing screws:
Throttle body fixing screws
Camshaft retaining bracket fixing screws
Head fixing screws
Lambda probe on exhaust manifold
Muffler to bracket fixing screw
Torque in Nm
12 ÷ 14
***
10 - 12
10 - 12
5-7
10 ÷ 12
7 - 8.5
10 - 14
3-4
3÷4
3÷4
30 - 35
11 - 13
7-9
11 ÷ 13
4-6
10 - 12
10 - 12
14 - 16
*** 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.
TRANSMISSION COVER
Name
Driven pulley nut
Drive pulley nut
Anti-vibration roller screw
M8 retainers for transmission cover
M6 retainer
Anti-vibration roller retainer
Clutch ring nut
Air deflector unit screws
Water pump cover screws
Outside transmission cover screws
Flywheel cover screws
Torque in Nm
92 - 100
160 - 175
16.7 - 19.6
23 - 26
11 ÷ 13
17 - 19
65 - 75
7÷9
3÷4
7÷9
11 - 13
FLYWHEEL COVER
Name
Flywheel fixing nut
Stator retainers
Blow-by recovery duct fixing screws
Screw fixing freewheel to flywheel
Stator cable harness guide bracket screws
Torque in Nm
115 - 125
8 - 10
3-4
13 - 15
3-4
CRANKCASE AND CRANKSHAFT
Name
Countershaft fixing nut
Engine oil filter
Engine oil drainage plug
Engine-crankcase coupling screws
Oil pump screws
CHAR - 8
Torque in Nm
25 - 29
12 - 16
24 ÷ 30
11 ÷ 13
5-6
Fuoco 500 i.e.
Characteristics
Name
Gear mounting on crankshaft screws
Bulkhead screws for oil pump housing cover
Torque in Nm
10 -12
8 - 10
COOLING
Name
Water pump rotor cover
Thermostat cover screws
Bleed screw:
Torque in Nm
3÷4
3÷4
3
FINAL REDUCTION
Name
Rear hub cover screws
Torque in Nm
24 ÷ 27
ENGINE ASSEMBLY
Name
starter motor retainers
Torque in Nm
11 - 13
Overhaul data
Assembly clearances
Cylinder - piston assy.
CHAR - 9
Fuoco 500 i.e.
Characteristics
HEIGHT TO MEASURE THE PISTON
Specification
A
B
Desc./Quantity
10 mm
43 mm
CYLINDER - PISTON
Specification
Cylinder diameter C
Piston diameter P
Desc./Quantity
94 +0.018-0.01mm
93.968 - ±0.014 mm
COUPLING CATEGORIES
Name
Cylinder- Piston
Cylinder- Piston
Cylinder- Piston
Cylinder- Piston
Initials
A
B
C
D
Cylinder
93.990÷93.997
93.997÷93.004
94.004÷94.011
94.011÷94.018
Piston
93.954÷93.961
93.961÷93.968
93.968÷93.975
93.975÷93.982
Play on fitting
0.029÷0.043
0.029÷0.043
0.029÷0.043
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.
***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
CHAR - 10
Fuoco 500 i.e.
Characteristics
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Rings/housing coupling clearances:
Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clearance: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 maximum limits specified in the table.
CHAR - 11
Fuoco 500 i.e.
Characteristics
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Transmission-side
shoulder
Half-shaft, transmission side
Connecting rod
Flywheel-side
shoulder
Flywheel side halfshaft
Complete crankshaft
CHAR - 12
Description
Dimensions
1 ± 0.025
Initials
A
Quantity
D = 0.20 ÷ 0.50
20.9 - 0.05
B
D = 0.20 ÷ 0.50
22 0.10 - 0.15
1.8 ± 0.025
C
F
D = 0.20 ÷ 0.50
D = 0.20 ÷ 0.50
19.6 + 0.05
E
D = 0.20 ÷ 0.50
65.5 +0.1 -0.05
G
D = 0.20 ÷ 0.50
Fuoco 500 i.e.
Characteristics
Diameter of crankshaft bearings.
Measure the capacity on both axes x-y.
CRANKSHAFT
Specification
Cat. 1
Cat. 2
Desc./Quantity
Standard diameter: 40.010 ÷ 40.016
Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification
A=
B=
C=
D=
Desc./Quantity
0.15 mm
0.010 mm
0.010 mm
0.10 mm
CHAR - 13
Characteristics
Characteristic
Crankshaft-crankcase axial clearance (H)
0.1 ÷ 0.405 mm (when cold)
Compression ratio
10.5: 1
Slot packing system
Shimming system to control compression ratio
DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH
RESPECT TO THE CYLINDER PLANE.
DISTANCE «A» HELPS DETERMINE THE
THICKNESS OF GASKET «B» THAT HAS TO
BE FITTED TO THE CYLINDER HEAD IN ORDER 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 THICKNESS.
CHAR - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Characteristics
Characteristic
Compression ratio
10.5: 1
BASE GASKET THICKNESS
Name
«A» MEASURE TAKEN
«A» MEASURE TAKEN
«A» MEASURE TAKEN
Measure A
- 0.185 - - 0.10
- 0.10 - + 0.10
+ 0.10 - + 0.185
Thickness
0.4 ± 0.05
0.6 ± 0.05
0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
N.B.
DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»
Products
RECOMMENDED PRODUCTS TABLE
Product
AGIP ROTRA 80W-90
AGIP CITY HI TEC 4T
AGIP FILTER OIL
AGIP GP 330
AGIP CITY HI TEC 4T
AGIP BRAKE 4
SPECIAL AGIP PERMANENT
fluid
Description
Rear hub oil
Specifications
SAE 80W/90 Oil that exceeds the
requirements of API GL3 specifications
Oil to lubricate flexible transmisOil for 4-stroke engines
sions (throttle control)
Oil for air filter sponge
Mineral oil with specific additives
for increased adhesiveness
Grease for brake levers, throttle White calcium complex soapbased spray grease with NLGI 2;
ISO-L-XBCIB2
Engine oil
SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
Brake fluid
FMVSS DOT 4 Synthetic fluid
coolant
Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16
CHAR - 15
Characteristics
CHAR - 16
Fuoco 500 i.e.
INDEX OF TOPICS
TOOLING
TOOL
Fuoco 500 i.e.
Tooling
SPECIFIC TOOLS CORRECT
TOOL - 2
Stores code
001330Y
Description
Tool for fitting steering seats
001467Y002
Driver for OD 73 mm bearing
001467Y006
Extraction pliers for 20 mm bearings
001467Y007
Driver for OD 54 mm bearing
001467Y008
Extraction pliers for ø 17 mm
bearings
001467Y014
Extraction pliers for ø 15 mm
bearings
Fuoco 500 i.e.
Tooling
Stores code
001467Y031
Description
Bell
001467Y034
Extraction pliers for ø 15 mm
bearings
Bearing housing outside diameter 47 mm
001467Y035
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
TOOL - 3
Fuoco 500 i.e.
Tooling
TOOL - 4
Stores code
020151Y
Description
Air heater
020193Y
Oil pressure gauge
020201Y
020262Y
Spacer bushing driving tube
Crankcase splitting strip
020306Y
Punch for assembling valve seal
rings
020329Y
Mity-Vac vacuum operated
pump
020330Y
Stroboscopic light for timing control
Fuoco 500 i.e.
Tooling
Stores code
020331Y
Description
Digital multimeter
020333Y
Single battery charger
020334Y
Multiple battery charger
020335Y
Magnetic support for dial gauge
020357Y
020358Y
020359Y
32 x 35 mm adaptor
37x40 mm adaptor
42 x 47 mm adaptor
TOOL - 5
Fuoco 500 i.e.
Tooling
TOOL - 6
Stores code
020360Y
Description
52 x 55 mm adaptor
020364Y
25 mm guide
020376Y
Adaptor handle
020382Y012
020412Y
bush (valve removing tool)
15 mm guide
020424Y
Driven pulley roller casing fitting
punch
020431Y
Valve oil seal extractor
Fuoco 500 i.e.
Tooling
Stores code
020434Y
Description
Oil pressure control fitting
020439Y
17 mm guide
020444Y
Tool for fitting/ removing the driven pulley clutch
020456Y
Ø 24 mm adaptor
020458Y
Puller for lower bearing on steering tube
TOOL - 7
Fuoco 500 i.e.
Tooling
TOOL - 8
Stores code
020459Y
Description
Punch for fitting bearing on steering tube
020460Y
Scooter diagnosis and tester
020467Y
Flywheel extractor
020468Y
Piston fitting band
020469Y
Reprogramming kit for scooter
diagnosis tester
Fuoco 500 i.e.
Tooling
Stores code
020470Y
Description
Pin retainers installation tool
020471Y
Pin for countershaft timing
020472Y
Flywheel lock wrench
020474Y
Driving pulley lock wrench
020475Y
Piston position checking tool
020476Y
Stud bolt set
TOOL - 9
Fuoco 500 i.e.
Tooling
TOOL - 10
Stores code
020478Y
Description
Punch for driven pulley roller casing
020479Y
Countershaft lock wrench
020480Y
Petrol pressure check set
020481Y
Control unit interface wiring
020482Y
Engine support
020483Y
30 mm guide
Fuoco 500 i.e.
Tooling
Stores code
020512Y
Description
Piston fitting fork
020527Y
Engine support base
020604Y011
020565Y
Fitting adapter
Flywheel lock calliper spanner
Marelli MIU diagnosis software
Marelli MIU diagnosis software
020640y
software euro3
TOOL - 11
Tooling
TOOL - 12
Fuoco 500 i.e.
INDEX OF TOPICS
MAINTENANCE
MAIN
Fuoco 500 i.e.
Maintenance
Follow these steps to reset the service icons:
1. With the key set to OFF, hold down the
"SET" button and turn the key to ON : the
"BELT" and "SERVICE" icons start flashing.
2. Push the "CLOCK" button for less than 1
second and the icons are displayed sequentially. 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 maintenance step and the icon is no longer displayed.
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
Hub oil - change
Steering - check
AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000 KM
10'
Action
Engine oil - level check/top-up
Brake pads - check condition and wear
Centre stand - lubrication
MAIN - 2
Fuoco 500 i.e.
Maintenance
AFTER 10,000 KM; 50,000 KM; 70,000 KM
Action
Safety locks - check
Driving belt - replacement
Throttle lever - adjustment
Air filter - clean
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - check
Suspensions - check
Steering - check
Centre stand - lubrication
Spark plugs - replacement
Tilt locking gripper control cable - adjustment
Parking control unit software upgrading (if available)
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 - replacement
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Hub oil - change
Suspensions - check
Steering - check
Centre stand - lubrication
Brake fluid level - check
Tilt locking gripper control cable - adjustment
Parking control unit software upgrading (if available)
MAIN - 3
Fuoco 500 i.e.
Maintenance
30,000 KM
Action
Safety locks - check
Driving Belt - replacement
Throttle lever - adjustment
Air filter - cleaning
Engine oil - change
Electrical system and battery - check
Coolant level - check
Brake fluid level - check
Engine oil - replacement
Hub oil - check
Brake pads - check condition and wear
Sliding block / variable speed rollers - change
Tyre pressure and wear - check
Vehicle and brake test - road test
Suspensions - check
Steering - check
Centre stand - lubrication
Spark plugs - replacement
Tilt locking gripper control cable - adjustment
Parking control unit software upgrading (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 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.
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.
MAIN - 4
Fuoco 500 i.e.
Maintenance
- Bring the reference mark onto the transmission
side between the fan and the transmission cover
as shown in the photograph.
- Refit the spark plugs.
- Refit the plastic cap on the flywheel cover.
- Adjust the spark gap to the contact position (no
reference mark visible) and install it on engine between 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 traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
If the values do not correspond, check:
- distribution timing
- revolution-timing sensor
- Injection control unit
Specific tooling
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light for timing control
020621Y H.V. cable extraction adapter
MAIN - 5
Maintenance
Spark plug
Remove the port on the left-hand side panel of the
vehicle by undoing the fixing screw and using a
small screwdriver in the rear recess shown in the
figure, then do the following:
- Disconnect the HV wire caps «A» of the spark
plugs;
- Unscrew the spark plugs using the wrench supplied;
- Upon refitting, place the spark plugs at the required 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 inserted.
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 ELECTRONIC CENTRAL UNITS AND OF NON-COMPLIANT ELECTRONIC IGNITIONS OR SPARK
PLUGS OTHER THAN THOSE PRESCRIBED
MAY SERIOUSLY DAMAGE THE ENGINE.
N.B.
THE USE OF SPARK PLUGS OTHER THAN
THE INDICATED TYPE OR OF SHIELDLESS
SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEM FAILURES.
Characteristic
Spark plug
CHAMPION RG 6 YC
Alternative spark plug
NGK CR7EKB
Electric characteristic
Electrode gap
0.7 ÷ 0.8 mm
MAIN - 6
Fuoco 500 i.e.
Fuoco 500 i.e.
Maintenance
Hub oil
Check
-Park the vehicle on its centre stand on flat ground;
- Remove the oil dipstick «A», dry it with a clean
cloth and put it back into its hole tightening it
completely;
Remove the dipstick and check that the oil level is
slightly over the second notch starting from the
lower end; 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 products
AGIP ROTRA 80W-90 Rear hub oil
SAE 80W/90 Oil that exceeds the requirements of
API GL3 specifications
Characteristic
Rear hub oil
Capacity approximately 250 cc
MAIN - 7
Maintenance
Fuoco 500 i.e.
Air filter
Proceed as follows:
Unscrew the nine fixing screws «A» and remove
the air filter cover.
- Wash the sponge with water and mild soap.
- Dry it with a clean cloth and short blasts of compressed air.
- Soak it in a mixture of 50% petrol and 50% specified oil.
- Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then
refit.
CAUTION
IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE
CONTROLS OF THE AIR FILTER TO 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 characteristics, or a certain consumption should be considered 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 when driving at "full throttle".
MAIN - 8
Fuoco 500 i.e.
Maintenance
Replacement
Replace oil and filter as indicated in the scheduled
maintenance table. Empty the engine by draining
the oil through drainage plug «B».
To facilitate oil drainage, loosen the cap/dipstick
«A».
Once all the oil has drained through the drainage
opening, unscrew and remove the oil cartridge filter «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 lubricate 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
MAIN - 9
Maintenance
a few minutes and switch it off: after five minutes
check the level and if necessary top up without
exceeding the MAX level. The cartridge filter must
be replaced every time the oil is changed. Use new
oil of the recommended type for topping up and
changing purposes.
N.B.
THE ENGINE MUST BE HOT WHEN THE OIL IS
CHANGED.
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
Locking torques (N*m)
Engine oil 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, 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 correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
MAIN - 10
Fuoco 500 i.e.
Fuoco 500 i.e.
Maintenance
Oil top up
The oil should be topped up after having checked
the level and in any case by adding oil without
ever exceeding the MAX. level.
Restoring the level from the MIN to the MAX marks
requires approx. 400 m³ of oil.
Engine oil filter
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.
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 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 that lights up when the key is
turned to the "ON" position. However, this light
should switch off once the engine has been started.
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 system.
MAIN - 11
Maintenance
Checking the ignition timing
-Remove the plastic cap on the flywheel cover
- Turn the flywheel until the reference mark «T» on
the rotor matches the reference mark on the flywheel 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 reference 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 calliper spanner applied to the camshaft command
pulley casing.
Cooling system
Adding engine coolant.
Check coolant level when the engine is cold as indicated in the scheduled maintenance table, following 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 between the MIN and MAX level.
-The coolant consists of an ethylene glycol and
corrosion inhibitor based 50% de-ionised waterantifreeze solution mix.
CAUTION
DO NOT EXCEED THE MAX. LEVEL WHEN
FILLING SO AS TO AVOID THE COOLANT ESCAPING FROM THE EXPANSION TANK WHEN
THE vehicle IS IN USE.
MAIN - 12
Fuoco 500 i.e.
Fuoco 500 i.e.
Maintenance
Recommended products
AGIP PERMANENT SPEZIAL Coolant
Monoethylene glycol based antifreeze solution,
CUNA NC 956-16
Braking system
Level check
The front and rear brake fluid reservoirs are both
positioned on the handlebars. Proceed as follows:
- Rest the vehicle on its centre stand with the handlebars 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 topup operation; follow the same procedure for the
front brake pump.
Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance
table.
WARNING
ONLY USE DOT 4 CLASS BRAKE FLUIDS.
COOLING SYSTEM FLUIDS ARE HIGHLY CORROSIVE. MAKE SURE THAT IT DOES NOT
COME INTO CONTACT WITH THE PAINTWORK.
CAUTION
MAKE SURE THE BRAKE FLUID DOES NOT
GET INTO YOUR EYES OR ON YOUR SKIN OR
CLOTHES. IF THIS HAPPENS ACCIDENTALLY,
WASH WITH WATER.
MAIN - 13
Maintenance
Recommended products
AGIP BRAKE FLUID DOT4 Brake fluid
FMVSS DOT4 Synthetic fluid
Headlight adjustment
Proceed as follows:
- Position the unloaded vehicle, in running order
and with the tyres inflated to the prescribed pressure, onto a flat surface 10 m away from a half-lit
white screen; make sure the vehicle axis is perpendicular to the screen.
- Remove the headlight assembly central cover.
- Turn on the headlight and check that the borderline 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 REGULATIONS IN FORCE IN EVERY COUNTRY
WHERE THE vehicle IS 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.
MAIN - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Maintenance
Each bulb has two light beam adjusting screws,
one for horizontal adjustment «C» and one for the
vertical adjustment «D». Adjust one headlamp at
a time. In order to do that, remove the connector
from the other bulbs so that you can adjust one
headlamp at a time.
N.B.
THE HEADLAMPS CAN ONLY BE LIT WHEN
THE ENGINE IS ON. ADJUST THE LIGHT BEAM
IN A WELL VENTILATED PLACE.
MAIN - 15
Maintenance
MAIN - 16
Fuoco 500 i.e.
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Fuoco 500 i.e.
Troubleshooting
This section makes it possible to find the solutions to use in troubleshooting.
For each breakdown, a list of the possible causes and respective interventions is given.
Engine
Excessive oil consumption/Exhaust smoke
EXCESSIVE CONSUMPTION
Possible Cause
Wrong valve adjustment
Overheated valves
Operation
Adjust the valve clearance properly
Remove the head and the valves, grind or replace
the valves
Misshapen/worn valve seats
Replace the head assembly
Worn cylinder, Worn or broken piston rings
Replace the piston cylinder assembly or piston
rings
Worn or broken piston rings or piston rings that Replace the piston cylinder unit or just the piston
have not been fitted properly
rings
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling 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
By-Pass remains open
Oil pump with excessive clearance
Oil filter too dirty
Oil level too low
Operation
Check the By-Pass and replace if required. Carefully clean the By-Pass area.
Perform the dimensional checks on the oil pump
components
Replace the cartridge filter
Restore the level adding the recommended oil
type
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE
Possible Cause
Faulty clutch
TROUBL - 2
Operation
Check that there is no grease on the masses.
Check that the clutch mass contact surface with
the casing is mainly in the centre with equivalent
characteristics on the three masses. Check that
the clutch casing is not scored or worn in an anomalous way
Fuoco 500 i.e.
Troubleshooting
Insufficient braking
INEFFICIENT BRAKING SYSTEM
Possible Cause
Inefficient braking system
Fluid leakage in hydraulic braking system
Brake disc slack or distorted
Operation
Check the pad wear (1.5 min). Check that the
brake discs are not worn, scored or warped. Check
the correct level of fluid in the pumps and replace
brake fluid if necessary. Check there is no air in
the circuits; if necessary, bleed the air. Check that
the front brake calliper moves in axis with the disc.
Failing elastic fittings, plunger or brake pump
seals, replace
Check the brake disc screws are locked; measure
the axial shift of the disc with a dial gauge and with
wheel mounted on the scooter.
Brakes overheating
BRAKES OVERHEATING
Possible Cause
Defective sliding of pistons
Brake disc slack or distorted
Clogged compensation holes on the pump
Re-inflated or glued rubber gaskets
Operation
Check calliper and replace any damaged part.
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.
Clean carefully and blast with compressed air
Replace gaskets.
Steering and suspensions
Heavy steering
STEERING HARDENING
Possible Cause
Steering hardening
Operation
Check the tightening of the top and bottom ring
nuts. If irregularities continue in turning the steering even after making the above adjustments,
check the seats in which the ball bearings rotate:
if they are recessed or if the balls are squashed,
replace them.
Excessive steering play
EXCESSIVE STEERING CLEARANCE
Possible Cause
Torque not conforming
Operation
Check the tightening of the top and bottom ring
nuts. If irregularities continue in turning the steering even after making the above adjustments,
check the seats in which the ball bearings rotate:
TROUBL - 3
Fuoco 500 i.e.
Troubleshooting
Possible Cause
Operation
if they are recessed or if the balls are squashed,
replace them.
Noisy suspension
NOISY SUSPENSION
Possible Cause
Malfunctions in the suspension system
Operation
If the front suspension is noisy, check: the efficiency of the front shock absorbers; the condition of
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
Seal fault or breakage
TROUBL - 4
Operation
Replace the shock absorber Check the condition
of wear of the steering covers and the adjustments.
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
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
ELE SYS - 2
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
20. Stop button on rear brake
21. Stop button on front brake
22. Starter button
23. Saddle opening receiver
24. Wiring for antitheft device
25. Helmet compartment light switch
26. Turn indicator switch
27. Turn signal command device
28. 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
ELE SYS - 3
Electrical system
51. Injector
52. Fuel pump
53. Revolution sensor
54. HV coil
55. Injection ECU
56. Immobilizer aerial
57. Brake calliper sensor
58. Diagnosis connector
59. Coolant temperature sensor
60. Lambda probe
61. MIU control unit power device
62. 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
ELE SYS - 4
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
1. Relays for lights/ horn/ injection load/ electric
fan: remove the front shield to reach these relays.
2 - Auxiliary fuses: remove the footrest flap to
reach these fuses.
ELE SYS - 5
Electrical system
3 / 4 / 19 - Electronic control unit for injection
(MIU) / Start-up relay / Start-up enabling switch
relay: remove the lid of the helmet compartment to
reach these relays.
5 - 6. Fuel pump / Fuel level sensor: remove the
central chassis cover to reach these components.
ELE SYS - 6
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
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;
ELE SYS - 7
Electrical system
11 / 12 - Diagnostics socket/ main fuses: these
components are found in the helmet compartment.
13 - Lambda probe: The lambda probe is mounted
on the exhaust manifold.
14 - Engine oil pressure sensor: remove the exhaust end to reach it.
15 - Parking control unit: remove the front shield
to reach it.
ELE SYS - 8
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
16 - Rider presence sensor: open the saddle and
remove the cover to reach the rider presence sensor.
17 - Coolant temperature sensor: remove the lid of
the helmet compartment and disconnect the connector 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
ELE SYS - 9
Electrical system
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
ELE SYS - 10
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
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
ELE SYS - 11
Electrical system
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
ELE SYS - 12
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
53. Rpm sensor
55. Injection ECU
56. Immobilizer aerial
57. Brake calliper sensor
59. Coolant temperature sensor
60. Lambda probe
61. MIU control unit power device
Devices and accessories
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
ELE SYS - 13
Electrical system
24. Wiring for antitheft device
25. Helmet compartment light switch
31. Helmet compartment light bulb
42. MODE button
43. Instrument panel
46. Horn
47. Horn button
48. Horn remote control
49. Pressure sensor
50. Injection load remote control
52. 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
ELE SYS - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
1. Parking electronic control unit
10. Main fuses
11. Key switch contacts
12. Auxiliary fuses
13. Key switch contacts
15. Battery
26. Turn indicator switch
27. Turn signal command device
28. Hazard button
29. Light switch
30. 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 system components.
ELE SYS - 15
Electrical system
Immobiliser
The electronic ignition system is controlled by the
control unit with the integrated Immobilizer system. 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 turning 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 emergency 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 deactivated. Subsequently, a flash confirms the switching
to «ON».The duration of the flash depends on the
programming of the electronic control unit. If the
LED is off regardless of the position of the ignitionkey switch and/or the instrument panel is not initiated, 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:
ELE SYS - 16
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
Remove the connector support bracket shown in
the photograph and disconnect the connector from
the control unit. Check the following conditions:
With the key switch set to OFF:
•
if there is battery voltage between terminals 6-26 and terminal 6-chassis
ground (fixed power supply). If there is
no voltage check that fuse 1 and its cable are in working order.
With the key switch in the OFF position:
•
there is battery voltage between terminals 5-26 and terminal 5-frame earth
(fixed power supply). If there is no voltage, check the key switch contacts,
that fuse no. 10 and its cable are working 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
ELE SYS - 17
Electrical system
Fuoco 500 i.e.
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 continuity between the Orange-White cable and pin 7
of the interface 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 procedure for a previously not programmed control unit provides for the recognition of the master as the
ELE SYS - 18
Fuoco 500 i.e.
Electrical system
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for 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 each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
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 you do not, start again from the beginning.
Once the system has been programmed, the master key transponder is strictly matched with the control
unit. With this link established, it is now 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 spark plugs.
Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY
Diagnostic codes
The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During
this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at
the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the
led remains on permanently, it means the ignition
is inhibited:
1. Previously unused control unit - key inserted: 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-
ELE SYS - 19
Electrical system
Fuoco 500 i.e.
ted but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transponder absent or cannot be used: The LED is permanently 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 remaining 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 started. 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 necessary.
ELE SYS - 20
Fuoco 500 i.e.
Electrical system
Diagnostic code - 2 flashes
Two-flash code shows a system where the control
unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. 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 reprogramming.
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 provides good recharge power and at low revs a good compromise is
achieved between generated power and idle stability.
Stator check
Stator winding check-up
WARNING
THE CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.
1 Remove the right side panel.
2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the
photograph.
3) Measure the resistance between each of the yellow terminals and the other two.
ELE SYS - 21
Fuoco 500 i.e.
Electrical system
Electric characteristic
Resistance:
0.2 - 1 Ω
4) Check that there is insulation between the each
yellow cable and the earth.
5) If values that are wrong are noted, replace the
stator.
Recharge system voltage check
Look for any leakage
1) Access the battery by removing its cover under the saddle.
2) Check that the battery does not show signs of losing fluid before checking the output voltage.
3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole
(-) of the battery and the black cable and only then disconnect the black cable from the negative pole
(-) of the battery.
4) With ignition key still at OFF, the reading detected by the ammeter must be ≤ 0.5 mA.
Check the charging current
WARNING
BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING 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 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 in output from the regulator.
- Start the engine and rev it up to a high engine speed while reading the value on the pincer.
With an efficient battery a value must be detected: > 20A
VOLTAGE REGULATOR/RECTIFIER
Specification
Type
ELE SYS - 22
Desc./Quantity
Non-adjustable three-phase transistor
Fuoco 500 i.e.
Specification
Voltage
Electrical system
Desc./Quantity
14 ÷ 15V at 5000 rpm with lights off
Fuses
The electrical system has twelve fuses divided into
two fuse boxes to protect the different installation
circuits. One of them is inside the battery compartment «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 REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE).
ELE SYS - 23
Fuoco 500 i.e.
Electrical system
FUSE TABLE
1
Specification
Fuse No. 1
2
Fuse No. 2
3
Fuse No. 3
4
Fuse No. 4
5
Fuse No. 5
6
Fuse No. 6
7
Fuse No. 7
8
Fuse No. 8
9
Fuse No. 9
10
Fuse No. 10
11
Fuse No. 11
12
Fuse No. 12
ELE SYS - 24
Desc./Quantity
Capacity: 7.5 A
Protected circuits:Injection ECU battery
power
Capacity: 15 A
Protected circuits:Battery-powered injection loads, electrical fan
Capacity: 15 A
Protected circuits:Battery-powered saddle
opening switch, glove-box lighting, light
switch, turn indicator switch, antitheft installation, fuse No. 12
Capacity: 20A
Protected circuits:battery-powered ECU for
parking control
Capacity: 20A
Protected circuits:battery-powered fuse
No. 7, live fuses No. 8 - No. 9 - No.10 - No.
11
Capacity: 15 A
Protected circuits:L.V. socket.
Capacity: 7.5 A
Protected circuits:Battery-powered instrument panel
Capacity: 10A
Protected circuits:Live stop, start-up and
start-up enabling switch and start-up circuit.
Capacity: 7.5 A
Protected circuits:live passing and horn
Capacity: 7.5A
Protected circuits:Live injection ECU, immobilizer aerial, electric fan remote control,
injection loads remote control
Capacity: 7.5A
Protected circuits:Live ECU parking lever,
antitheft installation, instrument panel, headlight remote control, horn
Capacity: 7.5A
Protected circuits:Live turn indicator control, saddle opening switch, tail lights, panel
lighting
Fuoco 500 i.e.
Electrical system
Dashboard
A = Led immobilizer / anti-theft device
B= Speedometer with twin scale (km/h and mph)
C = CLOCK switch
D = Digital display
E = Front suspension locking system warning light
(if available)
F = SET switch
G = Rpm indicator
H = Fuel gauge
I = Warning light for helmet compartment courtesy
light on
L = Engine control telltale light and injection system failure warning light
M = Low fuel warning light
N = Engine stop warning light
D= Turn indicator warning light
P = Low oil pressure warning light
Q = Front suspension locking system failure warning light (if available)
R = Warning light for parking brake engaged
ELE SYS - 25
Electrical system
Fuoco 500 i.e.
C = High-beam warning light
A = Total odometer gauge
B = «BELT» maintenance icon
C = «SERVICE» maintenance icon
D = Engine coolant temperature indicator
E = Trip odometer gauge (A-B) and ambient temperature (selected with the MODE button)
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 only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, 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 recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained 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 nominal Capacity
- 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
ELE SYS - 26
Fuoco 500 i.e.
Electrical system
Connectors
INJECTION ELECTRONIC CONTROL UNIT
1. Injection telltale light (Brown-Black)
2. Rpm indicator on instrument panel (Yellow)
3. CAN "L" Line (White-Blue)
4. Lambda probe (-) (White-Green)
5. Live supply (Red-White)
6. Battery powered (Orange-Black)
7. 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 sensor (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)
ELE SYS - 27
Electrical system
VOLTAGE REGULATOR CONNECTOR
1. +Battery (Red-Black)
2. Ground (Black)
3. +Battery (Red-Black)
4. Ground (Black)
SADDLE OPENING RECEIVER CONNECTOR
1. Aerial (Purple)
2. Saddle opening actuator (Yellow-Grey)
3. Reset (Blue-Black)
4. Battery powered (Blue)
5. Not connected
6. 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 CONNECTOR
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
ELE SYS - 28
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
HV COIL CONNECTOR
1. Injection load remote control (Black-Green)
2. Injection electronic control unit (Pink-Black)
ANTI-THEFT DEVICE PRE-INSTALLATION
CONNECTOR
1. LHS Turn indicators (Pink)
2. RHS Turn indicators (White-Blue)
3. Ground (Black)
4. Battery powered (Blue)
5. 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)
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
ELE SYS - 29
Electrical system
11. Ground (Black)
12. Live supply (Yellow-Red)
INSTRUMENT PANEL CONNECTOR "B"
1. Scooter speed signal (Sky blue)
2. Fuel level signal (White-Green)
3. Water temperature sensor (Sky blue-Black)
4. Water temperature sensor ground lead (BrownWhite)
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 (GreyBlack)
20. Live supply from the parking control ECU (Yellow-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 (GreyBlack)
6A. Headlight remote control (White-Black)
7A. Potentiometer ground lead, rpm sensor, rider
presence sensor (Yellow)
ELE SYS - 30
Fuoco 500 i.e.
Fuoco 500 i.e.
Electrical system
8. Ground (Black)
1B. Live supply (Yellow-Red)
2B. CAN "H" Line (Pink-White)
3B. Left wheel turning sensor (Green)
4B. Right wheel turning sensor (Red)
5B. Potentiometer signal (Green-Blue)
6B. Locking/unlocking switch (Green-Grey)
7B. Horn remote control for alarms (White)
8B. 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 photograph
- 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 UP
TO 8 REMOTE CONTROLS.
ELE SYS - 31
Electrical system
Fuoco 500 i.e.
Programming
Follow these steps to program the remote controls:
1. Insert the remote control key to be programmed in the steering lock key block.
2. Turn the key to the «ON» position, press the button on the remote control, release the button, turn
the key back to the «OFF» position from the «ON» position, all within four seconds.
3. Wait from 1 to 8 seconds.
4. Repeat steps 2 and 3 for 4 times without removing the key.
The control unit confirms the programming has been successfully executed by opening the saddle.
WARNING
TO STORE THE OTHER REMOTE CONTROLS TO MEMORY (8 MAXIMUM) YOU NEED TO REPEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUT THESE OPERATIONS
WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE
PROCESS FOR PROGRAMMING THE REMOTE-CONTROLLED KEYS.
WARNING
AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAY
FROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RECEIVER CAN BE IMPAIRED. SHOULD THIS BE THE CASE, REPEAT THE PROGRAMMING
PROCEDURE. DO NOT KEEP THE REMOTE CONTROL IN PLACES WITH TEMPERATURES EXCEEDING 60° C THE BATTERY WILL RUN DOWN TOO QUICKLY.
WARNING
TO AVOID BATTERY DISCHARGE, THE SADDLE OPENING REMOTE CONTROL RADIO RECEIVER DEACTIVATES 7 DAYS AFTER THE LAST TIME THE VEHICLE WAS SHUT OFF.
JUST TURN THE KEY TO «ON» TO REACTIVATE THE RECEIVER.
ELE SYS - 32
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
Engine from vehicle
Fuoco 500 i.e.
This section describes the operations to carry out when removing the engine from the vehicle.
Exhaust assy. Removal
- Remove the side fairings.
- Remove the central frame cover.
- Remove the exhaust end.
- 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 ONLY 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 battery.
- Remove the engine cover inside the helmet compartment.
- Remove the side fairings.
- Remove the footrests.
Remove the full muffler unit.
ENG VE - 2
Fuoco 500 i.e.
Engine from vehicle
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.
- Remove the rear wheel.
- Remove the bracket supporting the rear brake
callipers and the callipers as well.
- After removing the air filter from the crankcase,
undo the screws fixing the bracket that secures the
rear brake pipes.
- 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 indicated.
- 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.
ENG VE - 3
Engine from vehicle
- Remove the spark plug caps.
- Remove the coolant temperature sensor connector 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 wiring as shown in the photo.
- Remove the cable from the retaining clip on the
flywheel cover.
ENG VE - 4
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine from vehicle
Remove the lower screw of the left-hand shock
absorber.
- Remove the engine-swinging arm fixing pin by
undoing the nut and operating on the head of the
pin as shown in the photograph.
- The engine is now free.
When refitting the engine to the scooter, carry out 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 TRANSMISSION
PROPERLY.
ENG VE - 5
Engine from vehicle
ENG VE - 6
Fuoco 500 i.e.
INDEX OF TOPICS
ENGINE
ENG
Engine
Fuoco 500 i.e.
This section describes the operations to be carried out on the engine and the tools to be used.
Automatic transmission
Transmission cover
- Loosen the 4 fastening screws
- Extract the outside plastic transmission cover.
- Using a screwdriver, remove the driven pulley
axle cover near the bottom of the cap.
- 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, USING DIFFERENT WRENCHES - SUCH AS A
CONVENTIONAL POLYGONAL BUSH - MAY
DAMAGE THE HEXAGON OBTAINED ON THE
SHAFT OR BREAK THE BUSH ITSELF.
ENG - 2
Fuoco 500 i.e.
Engine
- Remove the six M6 screws.
- Remove the four M8 screws.
- Remove the transmission cover.
- Check that the bearing rotates freely, otherwise
replace it.
Air duct
- Remove the transmission cover.
- Unscrew the two screws shown in the figure to
remove the air conveyor.
Locking torques (N*m)
Air conveyor screws 11 ÷ 12
- Remove the external transmission cover.
- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.
ENG - 3
Engine
Air duct filter
- Remove the external air conveyor.
- Unscrew the 2 fastening screws shown in the figure 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 supported.
- Pull out the bearing using the special tool.
N.B.
BELL MUST BE PLACED INTO THE TRANSMISSION COVER, CLOSE TO THE BEARING
SEAT AND THE WOODEN SURFACE, SINCE
WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA
OF MAXIMUM STURDINESS.
Specific tooling
001467Y002 Driver for OD 73 mm bearing
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020439Y 17 mm guide
ENG - 4
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Refitting the driven pulley shaft bearing
- Heat the transmission cover interior using the
heat gun.
N.B.
BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE
PAINTED SURFACE.
Specific tooling
020151Y Air heater
- Place the bearing onto the special tool with a little
grease to prevent it from coming out.
- Install the new bearing using the special tool.
N.B.
PROPERLY SUPPORT THE OUTSIDE COVER
TO PREVENT DAMAGING THE PAINTED SURFACE.
Specific 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 anti-flapping roller with the lip facing the engine crankcase.
- Tighten the central screw to the prescribed torque.
N.B.
TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT
IS OBTAINED.
Locking torques (N*m)
ENG - 5
Engine
Anti-vibration roller screw 16.7 - 19.6
Removing the driven pulley
- Remove the clutch bell.
- Remove the fixed driving half-pulley.
- Remove the driven pulley assembly with the belt.
Inspecting the clutch drum
- Check that the clutch bell is not worn or damaged.
- 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
ENG - 6
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Removing the clutch
- To remove the clutch with the driven pulley it is
necessary to use the special tool;
- Arrange the tool with the mean pins screwed in
position "E" on the inside;
- Fit the adapter ring to the clutch assembly as
shown in the photograph.
- 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 SPECIAL TOOL. DO NOT
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.
Characteristic
Minimum 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 CONTACT SURFACE AND MUST
NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH
TO TEAR.
ENG - 7
Engine
- Do not open the masses using tools to prevent a
variation in the return spring load.
Pin retaining collar
- Extract the collar using 2 screwdrivers.
- Remove the 4 guide pins.
- Extract the moving driven half-pulley.
Removing the driven half-pulley bearing
- Check that the bushing is free from wear and
damage; otherwise replace the fixed driven halfpulley.
- Remove the lock ring using pliers.
ENG - 8
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Using the special tool inserted through the roller
bearing, pull out the ball bearing.
N.B.
PROPERLY SUPPORT THE PULLEY TO PREVENT DAMAGING THE THREADING.
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
N.B.
IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS
NECESSARY TO SUPPORT THE 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 the outer diameter of the pulley bushing.
Characteristic
Minimum admissible diameter
49.96 mm
Standard diameter:
49.965 mm
ENG - 9
Engine
Fuoco 500 i.e.
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 outside O-rings.
- Measure the movable half-pulley bushing inside
diameter.
Characteristic
Maximum 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 GUARD FACING OUTWARDS.
- 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 the special tool.
Specific tooling
020376Y Adaptor handle
020477Y 37 mm adaptor
020363Y 20 mm guide
- Insert the seeger lock ring.
ENG - 10
Fuoco 500 i.e.
Engine
Refitting the driven pulley
- Insert the new oil guards
- Insert the new O-rings
N.B.
O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, 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 introduction.
- Make sure the pins and collar are not worn, reassemble the pins and collar.
- Using a bent beak greaser, lubricate the 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 disulphide; ISO-L-XBCHB2, DIN KF2K-20
Inspecting the clutch spring
- Measure the length of the spring, while it is relaxed.
Characteristic
Standard length:
125.5 mm
Admissible limit after use:
120 mm
ENG - 11
Engine
Fuoco 500 i.e.
Refitting the clutch
- Prepare the special tool as for removal;
- Preassemble the driven pulley unit with the drive
belt according to its direction of rotation;
- Insert the driven pulley unit, the spring with
sheath and clutch into the tool.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
- Compress the spring and insert the 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 prescribed 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 and insert the belt onto the smaller
diameter.
Refitting the driven pulley
- Install the driven pulley assembly with belt.
ENG - 12
Fuoco 500 i.e.
Engine
Drive-belt
- Check that the driving belt is not damaged.
- Check the width of the belt.
Characteristic
Minimum width
27.5 mm
Overall width
28.7 mm
Removing the driving pulley
- Using a 27 mm wrench, turn the central pulley nut
to horizontally align the central inside holes and
install the special tool.
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 the fixed driving half-pulley.
- Remove the bushing connection washer.
ENG - 13
Engine
Fuoco 500 i.e.
- Move the belt downwards.
- Suitable support the roller contrast and extract
the mobile driving half-pulley with the relevant
bushing and the rear washer, being careful not to
make the rollers come out.
Inspecting the rollers case
- Check that the inside bushings shown in the figure are not worn and measure the inside diameter.
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 diameter 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 admissible diameter
Ø 24.5 mm
Standard diameter:
Ø 24.9 mm
ENG - 14
Fuoco 500 i.e.
Engine
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
Refitting the driving pulley
Installing the roller container
- Install the spacer with the internal chamfer facing
towards the inside.
- 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.
ENG - 15
Engine
- Insert the half-pulley on the crankshaft.
- Insert the spacer bushing.
Installing the fixed driving half-pulley
- Insert the spacer.
- Install the fixed driving half-pulley and check that
it is in contact with the spacer and with the guide
bushing of the moving driving pulley.
- Remove the flat washer and the spring washer
as shown in the figure.
ENG - 16
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Insert the nut in the original position (nut side in
contact with the belleville washer).
- Turn the central pulley nut to horizontally align
the holes and install the special tool.
N.B.
CHECK THAT THE STOP WRENCH TOOL IS
EASILY INSERTED INTO THE PULLEY AND IN
THE ENGINE CRANKCASE.
Specific 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 correct installation on the crankcase
of the 2 centring dowels.
ENG - 17
Engine
- Insert the transmission cover with the bearing
and install the relevant retainers.
- Lock the four M8 retainers.
Locking torques (N*m)
M8 retainers for transmission cover 23 - 26
- Lock the 7 M6 retainers.
Locking torques (N*m)
M6 retainer 11 ÷ 13
- Insert the washers on the driven pulley 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, USING DIFFERENT WRENCHES - SUCH AS A
CONVENTIONAL POLYGONAL BUSH - MAY
DAMAGE THE HEXAGON OBTAINED ON THE
SHAFT OR BREAK THE BUSH ITSELF.
Locking torques (N*m)
Driven pulley nut 92 - 100
ENG - 18
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Install the driving pulley shaft cover, positioning
the tooth gap on the lower part with the reference
mark on the transmission crankcase.
N.B.
ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.
- Install the outside plastic transmission cover.
- 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.
ENG - 19
Engine
Removing the wheel axle
- Remove the countershaft.
- Remove the wheel axis complete with gear.
Removing the hub bearings
- Check all bearings (wear, clearance and noise).
In case of anomalies, proceed as follows.
To remove the gear shaft bearing on the engine
crankcase, use the following parts.
Specific tooling
001467Y014 Extraction pliers for ø 15 mm bearings
001467Y034 Extraction pliers for ø 15 mm bearings
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 bearings
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
020476Y Stud bolt set
001467Y006 Extraction pliers for 20 mm bearings
001467Y007 Driver for OD 54 mm bearing
ENG - 20
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Removing the wheel axle bearings
- Take out the clip on the outside of the gearbox
cover.
- Support the hub cover using the column kit.
- Pull out the bearing using the special tool.
Specific tooling
020476Y Stud bolt set
020376Y Adaptor handle
020477Y 37 mm adaptor
020483Y 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 described 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.
- Remove the seeger ring shown in the figure.
ENG - 21
Engine
- Pull out the driven pulley shaft bearing from the
engine crankcase using the special tool.
Specific tooling
020376Y Adaptor handle
020358Y 37x40 mm adaptor
020364Y 25 mm guide
Inspecting the hub shaft
- Check that the 3 shafts exhibit no wear or deformation 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:
ENG - 22
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
B = diameter 30 - 0.010 -0.023 mm
C = diameter 15 - 0.01 -0.02 mm
Connection diameter for shaft driven pulley:
D = diameter 17 - 0.01 -0.02 mm
E = diameter 20 - 0.01 -0.02 mm
F = diameter 25 - 0.01 -0.02 mm
Inspecting the hub cover
- Check that the mounting surface is not damaged or deformed.
- Check the bearing 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 handle
020360Y 52 x 55 mm adaptor
020364Y 25 mm guide
ENG - 23
Engine
- Heat the intermediate gear bearing seat.
- Insert the intermediate shaft bearing using the
special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE HUB
(THIS APPLIES TO BEARINGS WITH PLASTIC
CAGE).
Specific tooling
020376Y Adaptor handle
020359Y 42 x 47 mm adaptor
020363Y 20 mm guide
- Heat the gear shaft bearing seat on the crankcase.
- Insert the gear shaft bearing in the upper crankcase 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
FIGURE.
- Insert the pulley shaft oil guard on the transmission side.
ENG - 24
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Refitting the hub cover bearings
- Heat the bearing seats on the cover using the
heat gun.
- Support the hub cover using the column kit.
Specific tooling
020151Y Air heater
020476Y Stud bolt set
- Insert the intermediate shaft bearing on the cover
using the special tool.
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 guide
- Replace the snap ring
ENG - 25
Engine
Fuoco 500 i.e.
- Support the hub cover using the column kit.
- Insert the wheel shaft oil guard with the sealing
lip facing the inside of the cover.
- Place the oil guard flush with the crankcase.
Specific tooling
020376Y Adaptor handle
020360Y 52 x 55 mm adaptor
020476Y Stud bolt set
Refitting the hub bearings
- Place the 3 shafts as shown in the figure.
Refitting the ub cover
- Check 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.
Recommended products
AGIP ROTRA 80W-90 rear oil hub
SAE 80W/90 Oil that exceeds the API GL3 specifications
Characteristic
Quantity:
approx. 250 cc
ENG - 26
Fuoco 500 i.e.
Engine
Locking torques (N*m)
Rear hub cover screws 24 ÷ 27
Flywheel cover
- Remove the three bands shown in the figure for
an easier removal of the flywheel cover, remove
the feed hoses and disconnect the return hose
from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO REMOVE 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.
ENG - 27
Engine
Fuoco 500 i.e.
- Remove the oil filter using a filter tape or shaped
cup wrench.
- Loosen the 14 fastening screws.
- Remove the flywheel cover with the relevant gasket and the cooling system sleeve 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.
ENG - 28
Fuoco 500 i.e.
Engine
- Remove the by-pass and the relevant spring.
- Remove the oil pump seal.
Removing the stator
- Remove the two retaining screws and the cable
guide bracket.
- Unscrew the 3 fastening screws and remove stator and its wiring.
Inspecting the cover components
- Loosen the two retaining screws and remove the
reed valve support with bulkhead.
ENG - 29
Engine
- Remove the blow-by reed valve with the relevant
sealing gasket.
- Unscrew the fastening screw and remove the gas
outlet union with the relevant O-ring.
- Check that the mounting surface of the crankcase
is not worn or deformed.
- 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 surface exhibit no deformations or wear.
ENG - 30
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Check the condition of the stator and of the respective cable harness.
- Check the continuity between the 3 phases.
N.B.
VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERATURE MAY RESULT IN
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.
ENG - 31
Engine
Refitting the stator
- Install the stator assembly together with the wiring harness, tightening the 3 screws to the prescribed torque.
N.B.
INSERT THE RUBBER WIRING SEALING GASKET INTO THE SPECIAL SEAT ON THE
CRANKCASE.
Locking torques (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 channels, in particular:
- The 3 by-pass channels.
- Oil pressure sensor feeding duct.
ENG - 32
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Oil vapour decantation chamber
- Temporarily install the distribution timing check
hole cover and the engine oil filling cap/bar.
- Insert the blow-by recovery duct using a new Oring.
- Tighten the screws to the prescribed torque.
Locking torques (N*m)
Blow-by recovery duct fixing screws 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 OBSERVE THIS ADVICE CAN IRRETRIEVABLY DEFORM THE O-RING.
ENG - 33
Engine
- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.
Locking torques (N*m)
Pump cover fixing screws: 3 ÷ 4
Refitting the flywheel cover
- Install a new oil filter, lubricate the gasket, screw
on and finally tighten to the prescribed torque.
Locking torques (N*m)
Engine oil filter 12 - 16
- Install the supply hose to the cylinder and connect the return hose to the pump cover using 3 new
clamps.
N.B.
TIGHTEN THE CLAMPS USING APPROPRIATE
PLIERS, PAYING ATTENTION NOT TO CONSTRICT 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 HI TEC 4T Engine oil
SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil
Locking torques (N*m)
Engine oil drainage plug 24 ÷ 30
ENG - 34
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Lubricate the intermediate gear seat with torque
limiter on the flywheel cover.
- Align the water pump movement sensor with a
reference and install the flywheel cover as described in the Flywheel cover chapter.
- Install a new gasket on the engine crankcase.
- Check the presence of the three centring dowels.
- Turn the crankshaft in order to align the countershaft movement sensor with a reference point on
the crankcase (see figure).
- Repeat the alignment for the water pump crankshaft using the same reference point on the engine.
N.B.
THIS PREPARATION IS USEFUL PARTICULARLY 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 and
rotor.
WARNING
FAILURE TO OBSERVE THIS INSTRUCTION MAY RESULT IN DESTRUCTION OF THE CERAMIC
MAGNETS.
ENG - 35
Engine
- Tighten the 14 retaining bolts of the cover to the
prescribed torque.
N.B.
THE BOLTS HAVE FOUR LENGTHS:
- THE 3 SHORTEST ARE INSERTED AS
SHOWN IN THE FIGURE.
- THE LONGEST IS INSERTED UNDER THE ENGINE OIL FILLER PLUG.
N.B.
- THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD
SUPPORT (SHOWN IN THE FIGURE) ARE
SLIGHTLY LONGER.
Locking torques (N*m)
Flywheel cover screws 11 - 13
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 REMOVE 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 following tests:
1 - Battery
Check the voltage after not running (a few hours):
Voltage >12.5V
Check the density of the electrolyte of each cell:
Bé = 30 ÷ 32
Specific weight: 1.25 - 1.26
YES go to 2 NO go to 3
ENG - 36
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
2 - Make sure the negative terminals (battery negative and starter negative) are correctly connected
to each other and to the frame.
YES go to 4 NO go to 5
3 - Recharge and if necessary replace the battery.
4 - Connect the diagnostic tester (see chapter "Injection system").
Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor.
Remove the 10A fuse no. 12 (see "fuses" chapter).
Switch in position "ON" with interrupt switch in position "RUN" and side stand raised.
Select the "PARAMETERS" function.
Start the engine (so that it 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 - Restore the connections
6- The values are correct.
Finally carry out a check of the power consumption at idle speed.
Remove the starter motor (see the flywheel and starter system).
Reconnect the earth and positive and perform the test.
Electric characteristic
Current consumption at idle speed:
<40 A
YES go to 10 NO go to 11
ENG - 37
Fuoco 500 i.e.
Engine
7- Low trailing speed
High electrical absorption
Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies
are found, replace the starter motor.
8- Low trailing speed
Low electrical absorption
Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing
them.
Check the new values.
YES go to 12 NO go to 13
9 - High trailing speed
Low electrical absorption
The engine turns too freely, check the compression end pressure.
If the values are not correct proceed as follows.
10 - The starter motor works properly.
11 - Check the rotation of the armature.
12 - Replace the starter remote 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
Type
Power
Desc./Quantity
Mitsuba sm13d
0.9 kW
BATTERY
Specification
Capacity
Starting current
Desc./Quantity
14 Ah
125 A
START-UP REMOTE CONTROL SWITCH
Specification
Type
Maximum load
Desc./Quantity
SEALED
150 A continuous
STARTER TRANSMISSION
Specification
Ring gear and freewheel coaxial to the flywheel.
Desc./Quantity
Intermediate gear with built-in torque limiter.
The starter system has a transmission between the motor armature and engine shaft equipped with
freewheel coaxial to the flywheel and torque limiter on the intermediate shaft.
ENG - 38
Fuoco 500 i.e.
Engine
The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and
the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations.
The freewheel is used for a sufficiently silent starting.
The starter control (energised remote control) is slaved to enabling signals by the side stand and the
emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
The starter control circuit is not controlled by the immobilizer system, therefore 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 fastening screws.
- Extract the complete starter motor.
Removing the flywheel magneto
N.B.
IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE
SLIDING BLOCK RETAIN PLATE FIRST.
- Unscrew the 3 fastening screws and remove the
chain guide sliding block retain plate and the startup rim.
ENG - 39
Engine
- Align the holes obtained on the flywheel with the
crankcase housing to allow the introduction of the
special tool.
- Tighten the bushing of the flywheel lock tool on
the removing tool threading.
- Insert the special tool as shown in the figure,
making sure that the pins are perfectly inserted into the previously aligned holes and that it is perfectly 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.
ENG - 40
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Remove the washer.
- Insert the nut again so as to slightly uncover the
shaft and free the space that was occupied by the
washer.
CAUTION
THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY 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.
ENG - 41
Engine
- To remove the start-up rim from the freewheel it
is necessary to turn it clockwise and pull it out.
- Remove the freewheel from the flywheel by loosening the 6 fastening screws.
SINCE THE FREEWHEEL MUST BE REMOVED,
IT IS ADVISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.
- 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 torque limiter.
ENG - 42
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Inspecting the flywheel components
- Check the integrity of the magnets.
- Check that the magnet support cage is free from
deformation or cracks.
- Check that the flywheel splines exhibit no loosening.
Starter gear rim
- Check that there is no wear or abnormal impressions on the "rollers" of the freewheel and on the
surface of the starter ring gear hub.
- Check the hub outside diameter.
Characteristic
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 STARTUP RIM. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANKSHAFT.
ENG - 43
Engine
Fuoco 500 i.e.
Intermediate gear
- Check that the toothing is not worn.
- Check the diameter of the two bearings.
Characteristic
Diameter of gear bearing:
12 - 0 0.011 mm
Also check the shaft diameter on the flywheel cover and on the engine crankcase.
Characteristic
Shaft diameter on the flywheel cover
12 + 0.034 -0.016 mm
Shaft diameter on the engine crankcase:
12 + 0.034 -0.016 mm
N.B.
THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH
DRIVE PLATES.
Driven plates consist of 4 Belleville springs provided with grooved profiles; this assembly allows
transmitting torque lower than 10 kgm.
In case of incorrect start-up manoeuvres, the limiter 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 contact surfaces are in good condition.
- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Recommended products
Loctite 243 Medium strength threadlock
ENG - 44
Fuoco 500 i.e.
Engine
Medium Loctite 243 threadlock
- Fit the freewheel on the magneto flywheel making
sure that the ground side is in contact with the flywheel itself, i.e. with wheel Seeger ring visible.
- Lock the six clamping screws in criss-cross fashion 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 crankcase.
- Insert the intermediate gear with torque limiter
ENG - 45
Engine
- Lubricate the inside bushing and the starter ring
gear hub surface.
- Install the start-up rim on the flywheel turning it
clockwise and inserting at the same time.
Refitting the flywheel magneto
- Insert the key on the crankshaft.
- 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.
ENG - 46
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Tighten thoroughly the guide bushing of the flywheel lock tool and loosen by 1/4 turn.
N.B.
FAILURE TO OBSERVE THIS RULE CAUSES
THE LOCKING OF THE GUIDE ON THE FLYWHEEL.
Specific tooling
020472Y Flywheel lock wrench
- Align the 2 holes of the flywheel with the case
housing to allow the introduction of the special tool.
- 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
ENG - 47
Engine
- Install the chain guide retain plate tightening the
3 screws to the prescribed torque.
N.B.
BEFORE TIGHTENING THE SCREWS, MOVE
THE START-UP RIM IN CONTACT WITH THE
CRANKCASE AND CHECK THAT IT IS FREE
TO ROTATE IN ANTICLOCKWISE DIRECTION.
Locking torques (N*m)
Chain guide sliding block retain plate fastening 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 flywheel and the
torque limiter.
ENG - 48
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Removing the intake manifold
- Remove the 3 mounting screws.
- Remove the intake manifold unit.
Removing the rocker-arms cover
- Loosen the 6 special screws with stop and the
relevant rubber gaskets.
- Remove the tappet cover with relevant gasket.
Removing the timing system drive
- Turn the engine to close the intake valves.
ENG - 49
Engine
- Remove the central screw and the valve lifting
device mass stop bell using the special tool.
Specific tooling
020565Y Flywheel lock calliper spanner
- Remove the return spring and the valve lifting
mass with relevant travel end washer.
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.
ENG - 50
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Remove the inside hexagon screw and the counterweight as shown in the figure.
- Remove the timing belt rim from the camshaft.
- Remove the timing belt rim.
Removing the cam shaft
- Unscrew the 3 fastening screws and remove
camshaft retaining bracket.
N.B.
REMOVING THE FASTENING SCREWS MAY
BE DIFFICULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEXAGON. IF NECESSARY,
SEPARATE THE THREADS IN ADVANCE.
- Remove the cam shaft.
ENG - 51
Engine
- Remove pins and rocking levers by the transmission side holes.
Removing the cylinder head
- Remove the spark plugs.
- Remove 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.
ENG - 52
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Remove the two M6 screws into the distribution
channel and the M6 screw on the spark plug side
with the thermostat support.
N.B.
IF NECESSARY, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND MOUNTING BRACKET.
- Loosen the 4 head-cylinder fastening nuts in 2 or
3 times and in a crossed sequence.
- Remove the head, the 2 centring dowels, the
gasket and the lower 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
020382Y012 bush (valve removing tool)
CAUTION
ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLYWHEEL SIDE AND TRANSMISSION SIDE).
ENG - 53
Engine
- Remove the oil guards using the special tool.
Specific tooling
020431Y Valve oil seal extractor
- Remove the spring supports.
N.B.
BLOW THE SEATS WITH COMPRESSED AIR
TO FACILITATE THE SPRING SUPPORT REMOVAL.
Removing the cylinder - piston assy.
- Remove the 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 ORDER TO ENSURE THAT THE INITIAL DIRECTION 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 REMOVING THE CYLINDER.
ENG - 54
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Remove the 2 piston pin locking rings by the specific housings.
- Extract the pin and remove the piston.
N.B.
USE PAPER OR A CLOTH TO CLOSE THE CYLINDER HOUSING MOUTH ON THE CRANKCASE TO PREVENT SLIPPAGE OF ONE OF
THE PIN LOCKING RINGS INTO THE CASE.
- Remove the piston sealing rings and the oil scraper.
CAUTION
NOTE THE ASSEMBLY POSITIONS OF THE
LININGS TO PREVENT INVERTING THE POSITION 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 DIAMETER EXCEEDS THE STANDARD DIAMETER,
EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS
DESCRIBED IN CHAPTER CRANKCASE AND
CRANKSHAFT.
Characteristic
Standard diameter:
22 + 0.025 +0.015 mm
Inspecting the wrist pin
- Check the pin outside diameter using a micrometer.
Characteristic
Standard diameter:
22 0 - -0.004 mm
ENG - 55
Engine
Fuoco 500 i.e.
- Calculate the coupling clearance between pin
and connecting rod end.
Characteristic
Standard clearance:
0.015 ÷ 0.029 mm
Inspecting the piston
- Measure the capacity diameter on the piston.
Characteristic
Standard diameter:
22 + 0.006 +0.001mm
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS 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, perpendicular 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 CLEARANCES.
Characteristic
A:
10 mm
Piston diameter:
94 mm nominal value
ENG - 56
Fuoco 500 i.e.
Engine
- Using a bore meter, measure the cylinder inner
diameter at a given height according to the directions shown in the figure.
Characteristic
B:
43 mm
Standard diameter:
94 mm nominal value
- Check that coating is free from flakes.
- Check that the head matching surface exhibits no deformations or wear.
Characteristic
Maximum allowable run-out:
0.05 mm
- Pistons and cylinders are classified into categories based on their diameter. 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 diameter. Using the piston, insert the rings perpendicularly to the cylinder axis.
- Make sure that each single sealing ring evenly
adheres to the cylinder liner. If it does not, this
means the ring is worn. Replace it.
- Measure the opening (see figure) of the sealing
rings using a feeler gauge.
ENG - 57
Engine
- If higher values than those prescribed are measured, replace the linings.
Check the size of the sealing ring opening:
Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 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:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clearance: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 maximum limits specified in the table.
Removing the piston
- Install piston and wrist pin onto the connecting
rod, aligning the piston arrow the arrow facing towards the exhaust.
ENG - 58
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Insert the locking ring into the special tool, with
the opening in the position indicated on the tool.
S = left
D= right
- Place the wrist pin stop ring into position using a
punch
- Install the pin lock using the key shown in the
figure.
Specific 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 tool
ENG - 59
Engine
Fuoco 500 i.e.
- Using an abutment plane, reset the comparator
with a preload of a few millimetres.
- Finally fix the comparator.
- Check the perfect sliding of the feeler pin.
- Install the tool on the cylinder without changing
the comparator position.
- Lock the tool using the original head fixing nuts.
- Rotate the crankshaft until TDC (the inverted
point of the dial gauge rotation)
- Measure the deviation from the reset value.
- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Correctly 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.
Characteristic
Recess / Projection measured 1
- 0.185 - - 0.10
Gasket thickness 1
0.4 ± 0.05
Recess / Projection measured 2
- 0.10 - + 0.10
Gasket thickness 2
0.6 ± 0.05
Recess / Projection measured 3
+ 0.10 - + 0.185
Gasket thickness 3
0.8 ± 0.05
ENG - 60
Fuoco 500 i.e.
Engine
Refitting the piston rings
- Place the scraper ring spring on the piston.
- Install the scraper ring keeping the opening opposed to the spring junction and with the writing
"top" facing the piston top. The chamfered side of
the oil scraper ring should always be facing the
piston crown.
- Fit the second lining with the identification letter
or the writing "top" facing the piston crown. In any
case, the step must be facing opposite the piston
top.
- Install the first compression lining in the direction
imposed by the housing.
- It is advisable to use a fitter to facilitate the installation of the linings.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A
TAPERED CYLINDRICAL CONTACT CROSSSECTION. 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
cylinder as shown in the figure.
N.B.
BEFORE INSTALLING THE CYLINDER, CAREFULLY BLOW THE LUBRICATION DUCT AND
LUBRICATE THE CYLINDER LINER. CHECK
THE PRESENCE OF THE TWO REFERENCE
DOWELS.
Specific tooling
020468Y Piston fitting band
020512Y Piston fitting fork
Inspecting the cylinder head
- Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted.
ENG - 61
Engine
Fuoco 500 i.e.
Characteristic
Maximum allowable run-out:
0.1 mm
- In case of irregularities, replace the head.
- Check the sealing surfaces for the intake and exhaust manifold.
- Check that the camshaft and the rocker pin capacities exhibit no wear.
- Check that the head cover surface is not worn.
- Check that the coolant sealing pad exhibits no
oxidation.
Inspecting the timing system components
- Check that the guide shoe and the tensioner shoe
are not worn out.
- Check that the crankshaft pinion and the camshaft 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 entire 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 not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Visually inspect the valve sealing surface.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
ENG - 62
Fuoco 500 i.e.
Engine
- If the sealing surface of the valve is found to be
interrupted at one or more points or is not flat, replace the valve.
- Insert the valves into the cylinder head.
- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
Inspecting the valve 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
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
STANDARD DIAMETER
Specification
Inlet:
Outlet:
Desc./Quantity
4.987 - 4.972 mm
4.975 - 4.960 mm
ENG - 63
Fuoco 500 i.e.
Engine
MINIMUM ADMISSIBLE DIAMETER
Specification
Inlet:
Outlet:
Desc./Quantity
4.96 mm
4.945 mm
- Calculate the clearance between valve and valve guide.
- Check the deviation of the valve stem by resting
it on a "V" shaped abutment and measuring the
extent of the deformation by a comparator.
Characteristic
Limit values admitted:
0.1 mm
- Check the concentricity of the valve head by arranging 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 between
guide and stem.
ENG - 64
Fuoco 500 i.e.
Engine
INLET
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.013 - 0.04 mm
0.08 mm
OUTLET
Specification
Standard clearance:
Admissible limit:
Desc./Quantity
0.025 ÷ 0.052 mm
0.09 mm
STANDARD VALVE LENGTH
Specification
Inlet:
Outlet:
Desc./Quantity
95.0 ± 0.3 mm
94.2 ± 0.3 mm
- Check that there are no signs 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 performance, grind the valve seats. Grind the valves gently
with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the
lapping compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
ENG - 65
Engine
Fuoco 500 i.e.
TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN
NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE
VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
Inspecting the springs and half-cones
- 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 special tool.
- Lubricate the oil guards and the valve guides.
Specific tooling
020306Y Punch for assembling valve seal
rings
ENG - 66
Fuoco 500 i.e.
Engine
- Fit the valves, the springs and the spring retaining
washers. Using the appropriate tool with adapter,
compress the springs and insert the cotters in their
seats.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020382Y012 bush (valve removing tool)
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS 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
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
42 - 0.060 -0.085 mm
20 - 0.020 -0.041 mm
MINIMUM ADMISSIBLE DIAMETER
Specification
Bearing A Ø:
Bearing B diameter:
Desc./Quantity
41.910 mm
19.940 mm
-Using a gauge, measure the cam height.
STANDARD HEIGHT
Specification
intake
discharge
Desc./Quantity
33.774 mm
33.273
ADMISSIBLE LIMITS
Specification
intake
Desc./Quantity
33.526 mm
ENG - 67
Fuoco 500 i.e.
Engine
Specification
discharge
Standard axial clearance:
Maximum admissible axial clearance:
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- 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
Standard diameter:
13 - 0.010 -0.018 mm
ENG - 68
Desc./Quantity
33.026 mm
0 - 0.22 mm
0.3 mm
Fuoco 500 i.e.
Engine
- Measure the inside diameter of each rocking lever.
Characteristic
Standard diameter:
13 + 0.026 +0.015 mm
- Check that the cam contact sliding block and the articulated register plate is free from wear.
- In case of wear, replace the component.
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 thickness.
ENG - 69
Engine
Fuoco 500 i.e.
- Check that the head lubrication channel is perfectly clean. Clean with compressed air jets, if
required.
- Insert the head.
- Lubricate the stud bolts and the 4 fastening columns.
- Tighten the 4 fastening columns crosswise to the prescribed torque as shown in the 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 torque.
Locking torques (N*m)
Head fixing screws 10 - 12
ENG - 70
Fuoco 500 i.e.
Engine
- Install the coolant temperature sensor with the
washer and tighten to the prescribed torque.
CAUTION
FAILURE TO OBSERVE THE TIGHTENING
TORQUE CAN DAMAGE THE SENSOR.
Locking torques (N*m)
coolant temperature sensor: 10 - 12
- Fit the spark plugs and tighten them to the prescribed torque.
Locking torques (N*m)
Spark plug 12 ÷ 14 Nm
- Insert the timing control belt on the crankshaft
according to the initial direction of rotation.
- Install the tensioner shoe with its spacer, tightening 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 camshaft by blowing with little compressed air jets, especially the retaining plate
housing.
- Lubricate the 2 shafts.
- Insert the camshaft into the head with the cams
opposite the rocking levers.
ENG - 71
Engine
Fuoco 500 i.e.
- Remove any LOCTITE residues from the screws
fixing the camshaft retaining bracket using a
brush.
- Apply the recommended product to the fixing
screws and tighten to the prescribed torque.
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
- Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the
prescribed torque, being careful not to damage the inside 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 camshaft control timing rim.
- Insert the timing rim on the camshaft checking
that the references are aligned.
N.B.
DURING THE STROKE CHECK, KEEP THE
BELT TENSIONED BY PRESSING ON THE
TIGHTENER COMPARTMENT SIDE.
ENG - 72
Fuoco 500 i.e.
Engine
- Keeping the belt slightly pulled, turn the crankshaft using the driving pulley to make the reference
on the magnet support collimate with that on the
flywheel cover.
- Install the counterweight mass.
- Centre using the bell fastening screw.
- Lock the mass fixing 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 and load it by about 3/4
turn.
ENG - 73
Engine
Fuoco 500 i.e.
- Turn the engine to move the references to the top
as shown in the figure (intake end).
- Insert the valve lifting device mass stop bell.
- Tighten the retaining screw to the prescribed torque, using the recommended product.
N.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.
ENG - 74
Fuoco 500 i.e.
Engine
- Install a new tightener on the cylinder using a new
gasket.
- Tighten the two fastening screws to the prescribed torque.
Locking torques (N*m)
Tightener fastening screws: 11 ÷ 13
- Insert the spring with the central screw and the
washer.
- Tighten the central screw to the prescribed torque.
Locking torques (N*m)
Tightener screw: 5 - 6
- Place the engine with the valve clearance adjustment timing references aligned with the head.
- Check the clearance between valve and rocking lever using a thickness gauge.
PRESCRIBED CLEARANCE
Specification
Inlet
drainage
Desc./Quantity
0.15 mm (engine cold)
0.15 mm (engine cold)
- In case different values are found, adjust by loosening 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 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
ENG - 75
Engine
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light for timing control
Proceed as follows:
- Remove the outside transmission cover as described in the automatic transmission chapter.
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the flywheel 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.
ENG - 76
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Replace the inspection cap on the flywheel side.
- Connect the diagnostic tester.
- Start the engine.
- Select the menu on the "parameter" function.
- Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
Specific 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 crossed sequence (3, 4, 5, 6).
N.B.
CHECK THE PROPER POSITION OF THE GASKET.
Locking torques (N*m)
Tappet cover fixing screws: 7 - 9
ENG - 77
Engine
Fuoco 500 i.e.
- Install the transmission cover and the relevant net
filter and the outside transmission cover as described in the "Automatic transmission" chapter.
- Install the cooling system sleeves using new
bands, as described in the "Flywheel cover" chapter.
Refitting the intake manifold
- Install the intake manifold on the engine.
- Insert the 3 fastening screws, one of which with
a support band for the cooling system sleeve, and
tighten to the prescribed torque.
Locking torques (N*m)
Inlet 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 (cylinder, head, piston) as described in the Thermal unit and timing system
chapter.
- Before opening the crankcase, check the crankshaft axial clearance.
For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.
ENG - 78
Fuoco 500 i.e.
Engine
Specific tooling
020262Y Crankcase splitting strip
020335Y Magnetic support for dial gauge
Characteristic
Standard clearance:
0.10 - 0.50 mm
Admissible increase limit after use:
0.60 mm
- Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
- 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 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION.
ENG - 79
Engine
- Split the crankcases while keeping the crankshaft
inserted on the flywheel side half-crankcase.
- Remove the coupling gasket.
N.B.
THE BUSHING SUPPORT CAN BE LEFT IN THE
FLYWHEEL SIDE HALF-CRANKCASE.
Removing the crankshaft
- Before removing the crankshaft, check the timing
with the countershaft. To carry out this check, turn
the crankshaft to align the two holes obtained on
the crankshaft with the hole on the countershaft
control gear.
This is an optimal position also to remove the
crankshaft.
- Remove the crankshaft with the shim adjustment
washer on the flywheel side.
CAUTION
WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT, CHECK THAT
THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS. FAILURE
TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BEARING.
Removing the oil pump and countershaft control gear.
- To remove the control gear, loosen the 4 fastening screws.
Remove the gear only if actually required.
CAUTION
THE SCREWS HAVE A COUNTERSUNK HEAD
AND THEIR THREADING IS LOCKED BY LOCTITE. BE CAREFUL NOT TO DAMAGE THE
CONTROL HEXAGON. TO OBTAIN BETTER
RESULTS IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH.
ENG - 80
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
Removing the countershaft
- Place the special tool as shown in the figure.
Specific tooling
020479Y Countershaft lock wrench
- Remove the fastening nut with relevant washer.
- Remove the special tool and extract the countershaft 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.
ENG - 81
Engine
- Upturn the half-crankcase.
- Remove the bearing from the flywheel side halfcrankcase using the special tool and a mallet.
Specific tooling
020376Y Adaptor handle
020358Y 37x40 mm adaptor
020439Y 17 mm guide
- Remove the bearing from the transmission side
half-crankcase using the special tool.
Specific tooling
001467Y008 Extraction pliers for ø 17 mm bearings
001467Y007 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 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
ENG - 82
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Fit the seeger ring.
- Before installing the new bearing on the transmission side crankcase, heat the seat using the
special tool.
Specific tooling
020151Y Air heater
- Insert a new bearing on the special tool after
greasing the guide seat.
- 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
ENG - 83
Engine
Fuoco 500 i.e.
Inspecting the crankshaft components
- Check the axial clearance on the connecting rod.
Characteristic
Standard clearance:
0.20 ÷ 0.40 mm
- Check the connecting rod diametrical clearance.
Characteristic
Standard clearance:
0.046 ÷ 0.076 mm
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crankshaft between these surfaces, as shown in the
diagram.
N.B.
BE CAREFUL NOT TO LET THE MEASUREMENT 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 VALUES AND THE SURFACES ARE FREE FROM SCRATCHES.
Shimming
- Check the overall height of the crankshaft - shoulders - gear assembly.
Characteristic
Standard thickness:
71.804 - 72.000 mm
- Check that shim adjustment is free from scratches.
N.B.
IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION.
ENG - 84
Fuoco 500 i.e.
Engine
Specific tooling
020074Y Support base for checking crankshaft alignment
- If the crankshaft - crankcase axial clearance is higher than the standard value and the crankshaft
exhibits no irregularity, the problem is caused by wear or by a wrong machining on the engine crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfaces shown in the figure. Half-shafts are classified
into two categories, Cat. 1 and Cat. 2.
STANDARD DIAMETER
Specification
Cat. 1
Cat. 2
Desc./Quantity
40.010 ÷ 40.016
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
A
B
C
D
Desc./Quantity
= 0.15 mm
= 0.01 mm
= 0.01 mm
= 0.10 mm
- Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded
tangs are in good working order.
- In case of failures, replace the crankshaft.
ENG - 85
Engine
Fuoco 500 i.e.
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 DIFFERENT 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 section "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 BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES THE PISTON TOP COOLING.
CLOGGING HAS EFFECTS THAT ARE DIFFICULT TO DETECT (PISTON TEMPERATURE
INCREASE). FAILURE OR LEAK CAN CONSIDERABLY DECREASE THE MAIN BUSHING
AND CONNECTING ROD LUBRICATION PRESSURE.
ENG - 86
Fuoco 500 i.e.
Engine
- For the flywheel side half-crankcase, special attention should be given to the lubrication channels
for the main bearings and to the compartment and
the channels for the oil pump, as well as to the duct
for the by-pass located on the flywheel cover.
N.B.
AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAPTER, IT IS ESPECIALLY IMPORTANT THAT THE BY-PASS HOUSING ON THE
FLYWHEEL COVER IS FREE FROM WEAR
THAT MAY IMPAIR THE PROPER SEALING OF
THE LUBRICATION PRESSURE ADJUSTMENT
PISTON. THE HEAD LUBRICATION CHANNEL
IS PROVIDED WITH A SHUTTER JET; THIS
GIVES A "LOW PRESSURE" HEAD LUBRICATION. THIS CHOICE WAS MADE TO REDUCE
THE OIL TEMPERATURE IN THE SUMP.
The jet clogging impairs the head lubrication and the timing mechanisms.
A jet failure causes a decrease of the main bearing and connecting rod lubrication pressure.
- Check that the surfaces are free from dents or deformations, with special attention to the crankcase
coupling and the crankcase-cylinder 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 dimensions check on
the crankshaft
Inspecting the crankshaft plain bearings
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure
(4 bar) and a good oil flow rate; the bushings must
be correctly positioned so as not to obstruct the oil
supply channels.
- The main bushings are comprised of two halfbearings, one containing holes and channels for
lubrication and the other solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal to the cylinder axis, as shown in the figure.
ENG - 87
Fuoco 500 i.e.
Engine
- The oil supply channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP SUCH POSITION OF THE BUSHINGS ON THE CRANKCASE, DRIVING IS FORCED ON
CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH HALF-CRANKCASES.
- Check the inside diameter of the main bushings
in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
N.B.
DO NOT TAKE THE MEASUREMENT ON THE
TWO HALF-SHELL COUPLING SURFACE
SINCE THE ENDS ARE RELIEVED TO ALLOW
BENDING DURING THE DRIVING OPERATION.
Before assembling, check 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 categories.
- Bushings are subdivided into 4 categories according to their thickness (see the table).
CHECK THE BENCH BUSH
Name
Type A - Red
Type B - Blue
Type C - Yellow
Type D - Green
Description
Dimensions
1.971 ÷ 1.974
1.974 ÷ 1.977
1.977 ÷ 1.980
1.980 ÷ 1.983
Initials
Quantity
Coupling chart
The following kinds of bushings indicated in the table must be used according to the kind of coupling
between the crankshaft and the crankcase.
ENG - 88
Fuoco 500 i.e.
Engine
KEY
X = Crankshaft category
Y = Crankcase half-shell category
A = Red
B = Blue
C = Yellow
D = Green
In case of breakdown, crankcases are together with bushings and are classified according to the centre
to centre distance of the countershaft. Find below the possible couplings.
- Complete FC1 type crankcase equipped with bushings for housing a category 1 crankshaft and a
countershaft with centre to centre distance A.
- Complete FC2 type crankcase equipped with bushings for housing a category 2 crankshaft and a
countershaft 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 crankcase cannot be combined with a driving shaft with mixed categories. Spare shafts have
half-shafts of the same category.
N.B.
TO REPLACE THE HALF-SHAFTS, REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED
ABOVE. REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI-FLAPPING ROLLER FROM
ENG - 89
Engine
Fuoco 500 i.e.
THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN CHAPTER "AUTOMATIC
TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT GEARS AND BEARINGS AS
DESCRIBED IN CHAPTER "FINAL REDUCTION".
Countershaft
- Using a micrometer, measure the 2 bearings of
the countershaft as shown in the figure.
Characteristic
Standard diameter:
17 - 0.01 - 0.02 mm
- Check that the water pump drive is not worn.
Refitting the crankshaft
- Check that the oil pump and countershaft control gear are free from deformations or dents. Replace,
if required.
N.B.
IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS NECESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL.
- Before installing the gear on the crankshaft, carefully 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 the holes again.
Recommended products
Loctite 243 Medium strength threadlock
Medium Loctite 243 threadlock
- Repeat the same procedure for the 4 fastening screws.
- Insert the control gear on the crankshaft with the hole countersink visible.
- Tighten the 4 fastening screws to the prescribed torque.
N.B.
ENG - 90
Fuoco 500 i.e.
Engine
TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN INSIDE HEXAGON SOCKET WRENCH.
Locking torques (N*m)
Gear mounting on crankshaft screws 10 -12
- Lubricate the main bearing on the flywheel side
half-crankcase.
- Lubricate the shim adjustment washer.
- Insert the shim adjustment washer on the crankshaft in its original position.
- Insert the special timing tool in the hole on the
countershaft.
Specific tooling
020471Y Pin for countershaft timing
- Insert the crankshaft on the pin and into the bushing.
- 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 TIMING CONTROL TOOTHED PINION.
- Install the oil pump closing plate.
- Tighten the 2 flanged fastening screws to the
prescribed torque.
Locking torques (N*m)
Bulkhead screws for oil pump housing cover
8 - 10
ENG - 91
Engine
Refitting the crankcase halves
- Remove the oil guard from the transmission side
half-crankcase using a screwdriver.
- Install a new oil guard after lubricating it, using
the special tool, arranging it at a 0.5 mm recess
from the crankcase plane.
CAUTION
A WRONG POSITIONING OF THE OIL GUARD
AFFECTS THE LUBRICATION OIL CIRCULATION.
Specific tooling
020360Y 52 x 55 mm adaptor
020376Y Adaptor handle
- Insert the gasket on the flywheel side half-crankcase.
- Lubricate the main bearing on the transmission
side half-crankcase.
- Couple the 2 half-crankcases being careful
not to damage the bushing on the transmission side half-crankcase with the threaded
tang of the crankshaft.
- Insert the engine support retain screw on the flywheel side half-crankcase without tightening.
ENG - 92
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Insert the 14 fastening screws by arranging the
single shorter screw "A" and the single longer
screw "B" as shown in the figure.
- Tighten the screws thoroughly and tighten to the prescribed torque.
- Check that the crankshaft rotates freely.
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER
PLANE, TO ENSURE BETTER SEALING PERFORMANCE.
Locking torques (N*m)
Engine-crankcase coupling screws 11 ÷ 13
- Install the thermal unit (cylinder, head, piston) as described in section "Thermal unit and timing system".
- Install the flywheel with start-up control as described in the "Flywheel and start-up" chapter.
- Install the flywheel cover with 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
Overhaul
Oil and filter replacement
Desc./Quantity
1.7 l
1.5 l
RECOMMENDED ENGINE OIL
Product
AGIP CITY HI TEC 4T
Description
Engine oil
Specifications
SAE 5W-40, API SL, ACEA A3,
JASO MA Synthetic oil
OIL PUMP
Specification
Type
Rotor thickness
Assembly clearances
Outside rotor radial clearance
Rotor axial clearance
Desc./Quantity
Trochoidal
8 mm
Lobe ends 0.05-0.008 mm
0.05- 0.12 mm
0.025 - 0.065 mm
BY-PASS
Specification
Type
Desc./Quantity
piston
ENG - 93
Fuoco 500 i.e.
Engine
Specification
Plunger diameter
Spring free length
Calibration pressure
Desc./Quantity
13.9 - 0.039 -0.057 mm
62.5 mm
4 bar
PRE-FILTER
Specification
Type
Desc./Quantity
mesh, plastic
OIL FILTER
Specification
Type
Desc./Quantity
Paper with pressure relief and anti-cavitation bypass
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH
Specification
Calibration
Desc./Quantity
0.3 - 0.6 bar
HEAD LUBRICATION CONTROL JET
Specification
Diameter
Desc./Quantity
1 ± 0.05 mm *
* Tightening torque 5÷7 N·m
PISTON COOLING NOZZLE
Specification
Diameter
Desc./Quantity
0.8 ± 0.05 mm
BASE VENTILATION CHECK
Specification
Device
ENG - 94
Desc./Quantity
decantation chamber and metal reed valve
Fuoco 500 i.e.
Engine
Conceptual diagrams
PRINCIPLE DIAGRAM
Specification
A
B
C
D
E
F
G
H
L
M
N
O
Desc./Quantity
Camshaft
Cylinder-head plane
Cylinder-crankcase plane
Water pump impeller
Minimum oil pressure sensor
Oil filter cartridge
To the oil sump
By-pass valve
Oil pump
Mesh pre-filter
Crankshaft
Connecting rod
General characteristics
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 of the screw-in type and the plug serves at the same time as an engine oil drain plug.
ENG - 95
Engine
Fuoco 500 i.e.
The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the
cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the
pressure of the circuit.
The by-pass located before the cartridge filter improves the operating conditions for the filter proper,
particularly with cold oil.
The filter is equipped with an anti-cavitation valve and a pressure relief valve; the latter intervenes when
the filtering element causes a pressure drop exceeding 1± 0.2 bar.
These conditions naturally occur only with cold oil and at high engine revs or if the filter is clogged.
The filtered oil is used to lubricate the shaft of the water pump and once at the engine crankcase, to
lubricate the crankcase bearings, the connecting rod head and the piston cooling nozzle located on the
bearings on the transmission side.
The crankcase bearing on the transmission side is provided with an oil seal and the respective drain
line.
The supply line for the timing system comes from the flywheel-side bearing; the supply to the head is
controlled by the respective spray jets in the engine crankcase.
The components of the timing system function with low-pressure oil.
The camshaft bearings are marked directly on the aluminium of the head; the axial clearance of the
camshaft 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 achieved when the camshaft reaches its most usual and likely position when the engine is switched off.
The oil used to lubricate the head returns to the sump via the ducts in the chain casing and hence also
provides lubrication for the chain.
In order to avoid the gas collecting in the bottom of the tank carrying oil out of the housing, a non-return
valve and a decantation chamber are used. The one-way valve is of metal sheet design; the decantation
chamber is provided with a drainage bore. If they fail oil can get into the pipe supplying air to the engine.
Excessive oil vapours may result in a blockage in the ducts of the throttle body.
In order to signal low oil pressure in the circuit, a pressure switch is used, located immediately after the
oil filter outlet.
The lubrication circuit does not include the countershaft; its lubrication comes from the oil transported
by the gearing or by the centrifugal effect of the crankshaft.
The same applies to the piston or the pin, but in this case the cooling nozzle is particularly important.
Diagnosis guide
1 - Minimum oil pressure warning light on with hot engine.
AHEAD - go to 2
2 - Remove the minimum pressure switch electric connector.
Check that the warning light turns off.
ENG - 96
Fuoco 500 i.e.
Engine
YES go to 3 NO go to 11
3 - Check the actual oil pressure.
AHEAD - go to 4
4 - Remove the switch and install the special tool with the relevant gasket.
Specific tooling
020193Y Oil pressure gauge
020434Y Oil pressure control fitting
- Remove the bar with the oil filler plug and insert a cap with the temperature probe supplied with the
special tool. Insert the probe to feel contact with the case bottom 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
20°C Temperature
1400 rpm
Desc./Quantity
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 the engine warm up and repeat the check with hot engine.
STANDARD VALUES
Specification
80°C Temperature
1400 rpm
Desc./Quantity
approx. 1.5 bar
YES go to 7 NO go to 8
ENG - 97
Engine
Fuoco 500 i.e.
7 - Replace the oil minimum pressure switch.
8 - If pressure lower than 1.3 - 1.5 bar is measured.
AHEAD go to 9
9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
YES go to 10 NO go to 13
10 - The failure was fixed.
It is recommended to respect the suggested number of kilometres covered.
11 - Check and restore the electrical system.
12 - If pressure lower than 4 bar is measured.
AHEAD go to 9
13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket efficiency towards
the case internal side, as described in the "Flywheel cover" chapter.
YES go to 14 NO go to 15
14 - Check whether there is an irregular clearance on the crankshaft:
- axial clearance (see the "Crankcase and crankshaft" chapter)
- radial clearance, especially in the direction of the cylinder axis
- clearance according to the direction of rotation with the connecting rod 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 crankshaft" chapter.
- Check the oil pump as described in the following pages.
- Check that the cooling nozzle and the timing feeding jet are properly installed.
- Visually inspect the crankshaft couplings and their size ("Crankcase and crankshaft" chapter).
N.B.
ANY FAILURES OF THE COUPLINGS AND OF THE TIMING COMPONENTS CANNOT BE DETECTED BY THE INSPECTION OF THE LUBRICATION PRESSURE. THE FAILURES MAY BECOME EVIDENT BY AN INCREASE OF NOISE.
N.B.
IN CASE OF IRREGULAR PRESSURE ON THE BASE, CARRY OUT A VISUAL AND DIMENSIONAL
INSPECTION OF THE TIMING COMPONENTS (SEE THERMAL UNIT AND TIMING SYSTEM CHAPTER).
Oil pressure check
1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket, check the lubrication
pressure.
AHEAD go to 2
2 - Install the special tool.
Specific tooling
ENG - 98
Fuoco 500 i.e.
Engine
020193Y Oil pressure gauge
020434Y Oil pressure control fitting
AHEAD go to 3
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
YES go to 4 NO go to 5
4 - Replace the damaged components.
5 - Check the adjustment by-pass efficiency (see "Flywheel cover" chapter) and restore the proper
sliding.
N.B.
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY. A
HIGHER VISCOSITY CAUSES AN INCREASE 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 "Thermal unit and timing
system" chapter.
5 - Restore the valve or the drainage hole efficiency.
Oil pump
Removal
- Remove the closing plate of the oil pump housing
by loosening the 2 retaining screws with their
washers.
ENG - 99
Engine
- Remove the oil pump complete with the gearing
by loosening the 2 retaining screws through the
eyes machined in the gearing proper.
- Remove the gasket.
- Remove the two screws and the oil pump cover.
- Remove the inside rotor retaining snap ring turning it to move the opening at the shaft face.
ENG - 100
Fuoco 500 i.e.
Fuoco 500 i.e.
Engine
- Remove and wash the rotors thoroughly with petrol and compressed air.
- Extract the shaft with its gear and check that it is
in good working order and free from wear.
- Reassemble the rotors in the pump body, keeping the two reference marks visible
- Insert the 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 between 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
Admissible limit clearance:
0.25 mm
ENG - 101
Engine
Fuoco 500 i.e.
- Check the rotor axial clearance using a rectified
bar as reference plane, as shown in the figure.
Characteristic
Limit values admitted:
0.1 mm
Refitting
- Make sure the gasket is in the correct position.
N.B.
THE TOOTH OF THE GASKET MUST BE IN ITS
SEAT.
- Lubricate the internal rotors.
- Check there are no signs of scoring or wear 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 prescribed 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 prescribed torque.
N.B.
THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS.
ENG - 102
Fuoco 500 i.e.
Engine
Failure to observe the tightening torque may alter
the coupling clearance of the rotors with the pump
body.
Locking torques (N*m)
Screws fixing oil pump to the crankcase 5 - 6
- Insert the countershaft with gearing into the flywheel-side half-crankcase.
- 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 fixing nut 25 - 29
ENG - 103
Engine
ENG - 104
Fuoco 500 i.e.
INDEX OF TOPICS
INJECTION
INJEC
Injection
Fuoco 500 i.e.
KEY:
1.Throttle body and injection electronic control unit (MIU)
2. Battery
3. Instrument panel
4. Injection load remote control
5. Coolant temperature sensor
6. HV coil
7. Fuel pump
8. Lambda probe
9. Revolution sensor
10. Fuel injector
11. 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.
INJEC - 2
Fuoco 500 i.e.
Injection
Combustion and ignition are managed on the basis of engine revs and throttle valve opening. Further
corrections are made according to the following parameters:
- Coolant temperature.
- Intake air temperature
- Lambda probe strength
The system implements an idle feeding correction with cold engine through a Stepper motor on a bypass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening
time, thereby ensuring the idle steadiness and the proper combustion.
In all conditions of use, mixture preparation is managed by modifying the injector opening time.
The fuel supply pressure is kept constant based on the ambient pressure.
The fuel supply circuit consists of:
- Fuel pump
- Fuel filter
- Injector
- Pressure regulator
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
The MIU control unit manages ignition with the best advance ensuring four-stroke timing (ignition only
in the compression phase) at the same time.
The MIU injection-ignition system controls engine functions by means of a pre-set program.
Should any input signals fail, an acceptable working order of the engine is ensured to allow the user to
reach a service station.
Of course, this cannot happen when the rev counter signal is missing, or when the failure involves the
control circuits:
- Fuel pump
- HV coil
- Injector
INJEC - 3
Injection
Fuoco 500 i.e.
The control unit is provided with a self-diagnosis
system connected to an indicator light in the instrument panel.
Failures are detected and restored by the diagnostic tester.
In any case, when the fault is no longer present,
the data storage is wiped clean after 16 cycles of
use (cold start, running at normal engine temperature, stop).
The diagnostic tester is also required for adjusting
the idle mixture.
Specific tooling
020460Y Scooter diagnosis and tester
The MIU injection-ignition system carries out
checks on the rpm counter and the electric fan for
radiator cooling.
The MIU control unit has a decoder for the antitheft immobiliser.
The MIU control 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 checking for faults.
2. The feeding system is pressurised at 300 kPa (3 BAR). Before disconnecting the fast-release fitting
of the power supply pipe, check that there are no naked flames. Do not smoke. Act with caution to
prevent spraying in the eyes.
3. When fixing electric components, operate with battery connected only when actually required.
4. When functional checks are performed, check that the battery voltage is more than 12V.
INJEC - 4
Fuoco 500 i.e.
Injection
5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to
respect this norm will damage the fuel pump.
6. If the scooter is expected to remain unused for a long time, refill the tank up to a little over half the
level. This will ensure the pump will be covered by fuel.
7. When washing the vehicle, be careful with the electric components and wiring.
8. When an ignition fault is detected, start the checks from the battery and the injection system connections.
9. Before disconnecting the MIU control unit connector, perform the following steps in the order shown:
- Set the switch to «OFF»
- Disconnect the battery
Failure to respect this norm may damage the control unit.
10. Do not invert the polarity when fitting the battery.
11. To avoid damage, only disconnect and reconnect 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 control unit.
14. Before reconnecting the quick couplers of the power supply system, check that the terminals are
perfectly clean.
Troubleshooting hints
1 A fault in the MIU system could most likely be due to the connections and not the components.
Before troubleshooting the MIU system, carry out the following checks:
A: Electrical power supply
a. Battery voltage
b. Blown fuse
c. Remote controls
d. Connectors
B: Chassis earthing
C: Fuel supply
a. Broken fuel pump
b. Dirty fuel filter
D: Ignition system
a. Faulty spark plug
b. Broken coil
c. Broken shielded cap
E: Intake circuit
a. Dirty air filter
INJEC - 5
Fuoco 500 i.e.
Injection
b. Dirty by-pass circuit
c. Faulty Stepper motor
F: Other
a. Incorrect distribution timing
b. Wrong idle mixture
c.Incorrect reset of the throttle valve position sensor
2 MIU system faults may be caused by loose connectors. Make sure that all connections have been
correctly made.
Check the connections as follows:
A check that the terminals are not bent.
B check that the connectors have been properly connected.
C see whether the malfunction can be fixed by shaking the connector slightly.
3 Check 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 precision must be greater than 2%.
Terminals setup
TERMINAL LAYOUT
1
2
3
4
5
6
7
8
INJEC - 6
Specification
Injection warning light
Rpm indicator signal
Can «L» Line
- Lambda probe
+ battery under permanent power supply
+ Battery
Immobilizer aerial
Electric fan starter
Desc./Quantity
Fuoco 500 i.e.
Injection
9
10
11
12
13
14
15
16
17
18
Specification
Water temperature sensor
Can «H» Line
+ Lambda probe
Engine stop switch
R.P.M. sensor (+)
Fuel injector
R.P.M. sensor (-)
Diagnostics socket output
Immobilizer LED
Ground lead
19
20
21
22
23
24
25
26
Injection load remote control
HV coil
Start up enabling
Ground lead
Desc./Quantity
Connected to the engine stop switch and the
water temperature sensor.
EMS circuit diagram
SYSTEM SCHEMATIC
1
2
3
4
5
Specification
Battery
Engine rpm sensor
Water temperature sensor
Immobilizer aerial
Stop button
Desc./Quantity
12V - 12 Ah
INJEC - 7
Fuoco 500 i.e.
Injection
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Specification
Fuse
Fuse
Key switch contacts
Engine stop switch
Fuse
Fuse
Fuse
Starter button
Injection load remote control
Start-up remote control relay
Electric fan starter
Starter motor
Electric fan
Fuel pump
HV coil
Fuel injector
Lambda sensor
Rpm indicator
"WARNING" light
Immobilizer LED
Diagnostics socket connector
Starter remote control
Control unit power device
Desc./Quantity
20 A
7.5 A
7.5 A
15A
10 A
Troubleshooting procedure
Engine does not start
ENGINE DOES NOT START IF ONLY PULLED
Possible Cause
Immobiliser enabling signal
Operation
System not encoded
System not efficient, repair according to the indications 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 pressure (low)
Injector capacity (low)
Power to the spark plug
Shielded spark-plug cap HV coil (secondary insulation)
Parameter reliability
Coolant temperature.
Distribution timing - injection ignition
- Intake air temperature
End of compression pressure
End of compression pressure
INJEC - 8
Fuoco 500 i.e.
Injection
Starting difficulties
ENGINE START-UP PROBLEMS
Possible Cause
Presence of faults detected by the self diagnosis
Start up engine speed
End of compression pressure
Power to the spark plug
Fuel supply
Correctness of the parameters
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Starter motor and remote control
Battery
Earth connections
End of compression pressure
Spark plug
Shielded cap
HV coil
Phase rpm sensor
- Ignition advance
Fuel pressure (low)
Injector capacity (low)
Injector seal (poor)
Coolant temperature.
Stepper throttle valve position intake air temperature (steps and actual opening)
Cleaning of the auxiliary air pipe and air filter efficiency gas valve
Engine stops at idle
ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
Intake system cleaning
Intake system seal (infiltrations)
Fuel feed (low pressure)
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Spark plug
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Air filter
Diffuser and gas sensor
Supplementary air pipe Stepper
Intake manifold - head
throttle body - manifold
Intake manifold
Filter box
Fuel pump
Pressure regulator
INJEC - 9
Fuoco 500 i.e.
Injection
Possible Cause
Operation
Fuel filter
Injector capacity
Engine does not rev down
ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Correctness of the parameters
Intake system seal (infiltrations)
Fuel feed (low pressure)
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Ignition timing
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
throttle body - manifold
Intake manifold
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Exhaust backfires in deceleration
EXHAUST BACKFIRES WHEN DECELERATING
Possible Cause
Presence of faults detected by the self diagnosis
Correctness of the parameters
Intake system seal (infiltrations)
Fuel feed (low pressure)
Exhaust system seal (infiltrations)
INJEC - 10
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Lambda sensor
Throttle valve position sensor
Stepper
Coolant temperature sensor
Intake air temperature sensor
Intake manifold - head
throttle body - manifold
Intake manifold
Filter box
Fuel pump
Pressure regulator
Fuel filter
Injector capacity
Manifold - cylinder head
Manifold - muffler
Fuoco 500 i.e.
Possible Cause
Injection
Operation
Muffler welding
Engine revs irregularly
IRREGULAR PROGRESS OF THE ENGINE WITH VALVE SLIGHTLY OPEN
Possible Cause
Intake system cleaning
Intake system seal
Ignition system
Parameter reliability
TPS reset successful
Presence of faults detected by the self diagnosis
Operation
Air filter
Diffuser and gas sensor
Supplementary air pipe Stepper
Intake manifold
Filter box
Spark-plug wear control
Throttle valve position signal
coolant temperature signal
Intake air temperature indicator
- Ignition advance
TPS reset successful
Pump 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
Presence of faults detected by the self diagnosis
Spark plug power supply
Intake system
Parameter reliability
Fuel supply
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Lambda sensor
Spark plug
Shielded cap
HV Cable.
HV coil
Air filter
Filter box (seal)
Intake hose (seal)
Throttle valve position signal
coolant temperature signal
Intake air temperature indicator
- Ignition advance
Fuel level in the tank
Fuel pressure
Fuel filter
Injector capacity
INJEC - 11
Fuoco 500 i.e.
Injection
Engine knocking
PRESENCE OF KNOCKING (OVERHEAD KNOCKING)
Possible Cause
Presence of faults detected by the self diagnosis
Ignition efficiency
Parameter reliability
Intake system seal
TPS reset successful
Fuel supply
Selection of the cylinder base gasket thickness
Operation
Pump relay
HV coil
Injector
revolution timing sensor
Air temperature
Coolant temperature.
Lambda sensor
Spark plug
Throttle valve position signal
coolant temperature signal
Intake air temperature indicator
- Ignition advance
Intake manifold
Filter box
TPS reset successful
Fuel pressure
Fuel filter
Injector capacity
Fuel quality
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 pump is located in the tank from which the fuel is pumped and sent to the injector through
the filter.
The pressure is controlled by the pressure regulator situated in the pump assembly in the tank.
INJEC - 12
Fuoco 500 i.e.
Injection
Removing the butterfly valve
Remove the fuel piping clamping screw indicated
in the figure.
Remove the fast-release fitting from the injector
support
INJEC - 13
Injection
Remove the injector connector
Remove the three screws fixing the manifold to the
cylinder head and the clip fixing the throttle body
to the manifold.
Remove the MIU connector
INJEC - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Remove the gas command fitting as indicated in
the photograph
Pump supply circuit
INJEC - 15
Fuoco 500 i.e.
Injection
INJECTION LOADS
Specification
Battery
Fuse
Fuse
Key switch contacts
Fuse
Injection load remote control
Fuel pump
HV coil
Fuel injector
Lambda sensor
Electric fan starter
1
2
3
4
5
6
7
8
9
10
11
Desc./Quantity
12V - 12 Ah
15A
20A
7.5 A
When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine
starts up, in the presence of phase rpm signal the pump is continuously supplied.
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 properly.
INJEC - 16
Fuoco 500 i.e.
Injection
Check the efficiency of the injection load remote
control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.
Check the power supply line of the injection load
remote control 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 MUST BE CARRIED OUT
WITH THE COMPONENTS DISCONNECTED.
(REMOTE CONTROLS, CONTROL UNIT,
FUSES ETC.).
INJEC - 17
Injection
Check the presence of fixed voltage between the
grey/black cable of the remote control base and
earth. If there is none check the continuity of the
grey/black cable between the fuse box (No. 2 15
A) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT
WITH THE COMPONENTS DISCONNECTED.
(REMOTE CONTROLS, CONTROL UNIT,
FUSES ETC.).
INJEC - 18
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
After switching to «ON», check that there is battery
voltage, for about 2 seconds, between the BlackGreen cable of the pump connector and the
ground lead with the pump connector disconnected. Otherwise, check the continuity of the BlackGreen cable between the pump connector and the
remote control base.
Check the efficiency of the earth line of the fuel
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 remote control disconnected, that the Black-Purple
cable (pin 20 on the interface wiring) is insulated
from the ground.
Specific tooling
020331Y Digital multimeter
Circuit leak test
Install the specific tool for checking the fuel pressure, with the pipe fitted with the gauge.
INJEC - 19
Injection
Fuoco 500 i.e.
Check during regular functioning by placing the
appropriate tool between the pump and the injector.
With battery voltage > 12 V check that the fuel
pressure is 3 BAR and that the input current is ~2.8
A
With the battery voltage > 12 V, check the capacity of the pump flow rate by disconnecting from the
injector the pipe equipped with the pressure gauge of the appropriate tool. Make a graded burette
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
cm³.
Specific tooling
020480Y Petrol pressure check set
Fuel filter check
Disconnect the terminals from the electric pump
Remove the screw shown in the photograph
INJEC - 20
Fuoco 500 i.e.
Injection
Remove the clip fixing the piping to the filter shown
in the photograph
Separate the lower part of the pump support as
shown in the photograph.
Remove the filter from the pump support
INJEC - 21
Fuoco 500 i.e.
Injection
Inspecting the injector circuit
INJECTION LOADS
1
2
3
4
5
6
7
8
9
10
INJEC - 22
Specification
Battery
Fuse
Fuse
Key switch contacts
Fuse
Injection load remote control
Fuel pump
HV coil
Fuel injector
Lambda sensor
Desc./Quantity
12V - 12 Ah
15A
20A
7.5 A
Fuoco 500 i.e.
Injection
Specification
Electric fan starter
11
Desc./Quantity
When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine
starts up, in the presence of phase rpm signal the pump is continuously supplied.
ELECTRICAL DATA
•
Pump winding resistance ~ 0.8 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 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 between pins 30 and
87 of the remote control.
INJEC - 23
Injection
Check the power supply line of the injection load
remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and BlackViolet 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.).
INJEC - 24
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Check the presence of fixed voltage between the
grey/black cable of the remote control base and
earth. If there is none check the continuity of the
grey/black cable between the fuse box (No. 2 15
A) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT
WITH THE COMPONENTS DISCONNECTED.
(REMOTE CONTROLS, CONTROL UNIT,
FUSES ETC.).
INJEC - 25
Injection
With the control unit and the injector disconnected,
check the continuity of the Red-Yellow cable between pin 14 of the interface wiring and the injector
connector
Switch to "ON" and check the presence of voltage,
with injector disconnected and control unit connected, between the Black-Green cable of the injector 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 connector 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 connecting the control unit to the
manifold.
INJEC - 26
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Install the appropriate tool for the fuel pressure
check and position the manifold over a container
graduated by at least 100 cc. Connect the injector
with the cable making up part of the supply for the
injection tester. Connect the clamps of the cable
to an auxiliary battery. Activate the fuel pump with
the active diagnosis. Check that within 15 approx.
70 cm³ of fuel is delivered with adjustment pressure 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
After removing the shield back plate, remove the
electrical connection from the aerial as shown in
the photograph
INJEC - 27
Injection
Remove the protective base from the connector.
With the ignition key switch at ON check there is
battery voltage between the Red-White and Black
cables
With MIU connector disconnected check the continuity between the Orange-White cable and pin 7
of the interface wiring .
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
INJEC - 28
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
The electronic ignition system is controlled by the
control unit with the integrated Immobilizer system. 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 turning 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 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 deactivated. Subsequently, a flash confirms the switching to the "ON"
status. The duration of the flash depends on the
programming of the electronic control unit If the
LED is off regardless of the position of the ignitionkey switch and/or the instrument panel is not initiated, check if:
•
there is battery voltage
•
fuses 1,7,10 are in working order
•
there is power to the control unit as
specified below:
INJEC - 29
Fuoco 500 i.e.
Injection
Remove the connector support bracket shown in
the photograph and disconnect the connector from
the control unit. Check the following conditions:
With the key switch set to OFF:
•
if there is battery voltage between terminals 6-26 and terminal 6-chassis
ground (fixed power supply). If there is
no voltage check that fuse 1 and its cable are in working order.
With the key switch in the OFF position:
•
there is battery voltage between terminals 5-26 and terminal 5-frame earth
(fixed power supply). If there is no voltage, check the key switch contacts,
that fuse no. 10 and its cable are working 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.
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 procedure for a previously not programmed control unit provides for the recognition of the master as the
first key to be stored to memory: this becomes particularly important because it is the only key that
enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
The master and service keys must be used to code the system as follows:
- Insert the Master key, turn it to «ON» and keep this position for two seconds (lower and upper limits
1 to 3 seconds).
INJEC - 30
Fuoco 500 i.e.
Injection
- Insert the service key and turn it to «ON» for 2 seconds.
- If you have copies of the key, repeat the operation with each key.
- Insert the MASTER key again and turn it to «ON» for 2 seconds.
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 you do not, start again from the beginning.
Once the system has been programmed, the master key transponder is strictly matched with the control
unit. With this link established, it is now 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 spark plugs.
Characteristic
MASTER key:
RED KEY
SERVICE key.
BLACK KEY
Diagnostic codes
The immobiliser system is tested each time the ignition-key switch is turned from OFF to ON. During
this diagnosis phase a number of control unit statuses can be seen and various light codes displayed. Regardless of the code transmitted, if at
the end of the diagnosis the led remains off permanently, the ignition is enabled. If, however, the
led remains on permanently, it means the ignition
is inhibited:
1. Previously unused control unit - key inserted: 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 started but with a limitation imposed on the number of
revs.
2. Previously unused control unit - transponder absent or cannot be used: The LED is per-
INJEC - 31
Fuoco 500 i.e.
Injection
manently ON; in this condition, no operations are
possible, including starting of the vehicle.
3. Programmed control unit - the service key in
(normal condition of use): a single 0.7 second
flash is displayed, after which the LED remains off
permanently. The engine can be started.
4. Programmed control unit - Master key in: a
0.7 sec. flash is displayed followed by the LED remaining 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 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 recognition
2nd step: Series of flashes: diagnosis code indication
3rd step: Solid light on or off:
- ON = start-up disabled
- OFF = start-up enabled
Code 1
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 necessary.
INJEC - 32
Fuoco 500 i.e.
Injection
Code 2
Two-flash code shows a system where the control
unit does not show the transponder signal. This
might depend on the inefficiency of the immobiliser
aerial or the transponder.
Turn the switch to ON using several keys: if the
code is repeated even with the Master key, check
the aerial wiring and change it if necessary. 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 this is not the case, perform a reprogramming.
INJEC - 33
Injection
Fuoco 500 i.e.
Tachometer
With wiring disconnected from the control unit and
connected to the system, check that the sensor
resistance between pins 13 - 15 is between 100
and 150 Ohm at an engine temperature of approximately 20°
Disconnect the fuel pipe connector. 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 connector
INJEC - 34
Fuoco 500 i.e.
Injection
With the interface cable harness disconnected
from the control unit and the rpm sensor connector
disconnected, check that the red and brown cables
(pin 13 - 15) are isolated from each other and insulated from the ground lead.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
HT coil
INJEC - 35
Fuoco 500 i.e.
Injection
INJECTION LOADS
1
2
3
4
5
6
7
8
9
10
11
Specification
Battery
Fuse
Fuse
Key switch contacts
Fuse
Injection load remote control
Fuel pump
HV coil
Fuel injector
Lambda sensor
Electric fan starter
Desc./Quantity
12V - 12 Ah
15A
20A
7.5 A
The ignition system combined with the injection is the high-efficiency induction type.
The control unit controls two important parameters:
- Ignition advance
This is optimised from moment to moment in accordance with 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 commanded in the compression phase.
Specific tooling
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.
INJEC - 36
Fuoco 500 i.e.
Injection
Check the efficiency of the injection load remote
control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.
INJEC - 37
Injection
Check the power supply line of the injection load
remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and BlackViolet 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.).
Check the presence of fixed voltage between the
grey/black cable of the remote control base and
earth. If there is none check the continuity of the
grey/black cable between the fuse box (No. 2 15
A) and the remote control base.
N.B.
CONTINUITY TESTS MUST BE CARRIED OUT
WITH THE COMPONENTS DISCONNECTED.
(REMOTE CONTROLS, CONTROL UNIT,
FUSES ETC.).
INJEC - 38
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Check there is voltage between pins 22 and 26 of
the interface wiring for around two seconds when
switching to «ON»
Check the resistance of the primary coil between
pin 22 of the interface wiring and the green black
cable of the injection load remote control base with
the control unit disconnected and the remote control disconnected.
Primary resistance ~ 1 Ohm
INJEC - 39
Injection
Fuoco 500 i.e.
Inspecting the spark plug shielded cap
Measure the shielded cap resistance.
Electric characteristic
Resistance:
5 KΩ
If different values are measured (<1; >20KΩ), replace the shielded cap.
N.B.
A SHIELDLESS CAP OR SPARK PLUG CAN AFFECT THE INJECTION SYSTEM.
FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTENANCE» CHAPTERS.
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 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
020460Y Scooter diagnosis and tester
020330Y Stroboscopic light for timing control
Proceed as follows:
- Remove the transmission compartment cover as
described in the "automatic transmission" chapter.
INJEC - 40
Fuoco 500 i.e.
Injection
- Remove the TDC reference inspection cap between flywheel and crankcase cover. See the "flywheel 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 engine 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 traditional four-stroke engine position (1 spark 2
revs).
- Check that the real values of rpm and ignition
advance match those measured using the diagnostic tester.
If the values do not match, check:
- distribution timing
- revolution-timing sensor
INJEC - 41
Fuoco 500 i.e.
Injection
- Injection control unit
Coolant temperature sensor
TEMPERATURE SENSOR
1
2
3
Specification
Water temperature sensor
Engine stop switch
Electronic control unit
With the control unit side connector disconnected
and the coolant temperature sensor connector
connected, check that the resistance values between 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 disconnected, check the insulation between the light
blue/green cable and ground.
INJEC - 42
Desc./Quantity
Fuoco 500 i.e.
Injection
With the control unit side connector disconnected
and the coolant temperature connector disconnected, check the continuity between pin 9 of the
interface wiring harness and the light blue/green
cable of the connector.
Specific tooling
020481Y Control unit interface wiring
020331Y Digital multimeter
Zeroing the throttle
Resetting the throttle valve position signal (TPS reset)
The MIU control unit is supplied with throttle valve position sensor and is pre-calibrated.
Pre-calibration entails regulating the minimum opening of the throttle valve to obtain a certain flow of
air under pre-set reference conditions.
Pre-calibration ensures optimal air flow for the control of the idling.
This regulation must not 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 positions. For these reasons the mVs of the
sensor with the valve at minimum can vary from one throttle body to another.
To obtain the optimum fuel preparation, especially at small openings of the throttle valve, it is essential
to match the throttle body with the control unit following the procedure known as TPS resetting.
With this operation we inform the control unit, as the starting point, of the mV value corresponding to
the pre-calibrated position.
To reset, proceed as follows.
INJEC - 43
Injection
Connect the diagnostic tester.
Turn to "ON".
Select the functions of the diagnostic tester on
"TPS RESET".
Specific tooling
020460Y Scooter diagnosis and tester
Make sure that the throttle valve is supporting the
stop screw.
Guaranteeing that this position will be kept, give
the confirmation for the TPS reset procedure.
INJEC - 44
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Reset should be performed in the following cases:
- on first fitting.
- if the injection control unit is replaced.
N.B.
THE TPS RESETTING POSITION MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY
BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE
AIR FLOW DIFFERENT FROM THAT OF PRE-CALIBRATION.
INJEC - 45
Fuoco 500 i.e.
Injection
Lambda probe
INJECTION LOADS
1
2
3
4
5
6
7
8
9
10
INJEC - 46
Specification
Battery
Fuse
Fuse
Key switch contacts
Fuse
Injection load remote control
Fuel pump
HV coil
Fuel injector
Lambda sensor
Desc./Quantity
12V - 12 Ah
15A
20A
7.5 A
Fuoco 500 i.e.
11
Injection
Specification
Electric fan starter
Desc./Quantity
The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen
content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type,
i.e. there is oxygen or there is not. The sensor is positioned on the exhaust manifold before the catalytic
converter in an area where the gas temperature is always high. The temperature at which the sensor
works is at least 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 of the injection load remote
control: Check the resistance of the energising coil
between pins 86 and 85: 40 to 80 Ohm
Apply a voltage of 12V to pins 86 and 85; make
sure that there is continuity between pins 30 and
87 of the remote control.
INJEC - 47
Injection
Check the power supply line of the injection load
remote control energising coil: after switching to
"ON", make sure there is battery voltage, for two
seconds, between the Red-White cable and BlackViolet 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.).
INJEC - 48
Fuoco 500 i.e.
Fuoco 500 i.e.
Injection
Install the electronic control unit interface wiring.
Start the engine and warm up until the electric fan
switches on.
Use an analogue multimeter with a direct voltage
scale measuring down to 2 V.
Place the tips of the multimeter between pins 4 (-)
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 voltage 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..
INJEC - 49
Injection
INJEC - 50
Fuoco 500 i.e.
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
This section is devoted to operations that can be carried out on the suspension.
Front
Removing the front wheel
- Remove the 5 fixing screws indicated in the photograph.
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 bearings
001467Y017 Bell for bearings, outside Ø 39 mm
SUSP - 2
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
- Remove the oil seal on the roller bearing side
using a screwdriver.
- Remove the roller bearing using the specific tool
Specific tooling
020376Y Adaptor handle
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
- Heat the roller bearing seat with a heat gun
- Use the specific tool to introduce and push the
bearing until it stops, 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 casing 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 Punch
Recommended products
AGIP GREASE MU3 Grease for odometer
transmission gear case
SUSP - 3
Suspensions
Fuoco 500 i.e.
Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20
Handlebar
Removal
- Remove the three handlebar covers working as explained in the Bodywork Chapter.
- Remove the handlebar wiring retaining straps and disconnect the electric connectors from the brake
levers.
- Unscrew the fittings, then remove the front and rear brake pump piping.
- Remove the flexible transmission 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 operations by working in the reverse order from those of the removal.
Locking torques (N*m)
Handlebar fixing screw 50 ÷ 55
The tilt mechanism
SUSP - 4
Fuoco 500 i.e.
Suspensions
Hydraulic system layout
When tilting is locked, the geared motor activates
the hydraulic pump indicated in the photograph
and pressurises the circuit.
The pressurised oil reaches the distribution frame
«T» and the pressure sensor «A». Then, the pipes
branch out to reach the upper joints on the side
steering tubes.
Through the rigid-flexible pipes inside the side
steering tubes, the oil reaches the stem sliding
locking device placed parallel to the shock absorber.
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.
SUSP - 5
Suspensions
Disconnect the tone wheel connector indicated in
the photograph.
Remove the hydraulic pipe fitting from the sliding
locking device, making sure again that the liquid
drained is collected.
Remove the upper fittings, on the parallelogram,
of the brake hydraulic pipes and the suspension
lock indicated in the photograph.
Remove the hydraulic pipe fitting fixing nuts indicated in the figure from the support bracket.
SUSP - 6
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Remove the suspension tilt locking device pipes
from the headstock.
Remove first the flexible part of the calliper from
the steering tube as shown in the photograph, and
then remove the rigid part.
Remove the tone wheel wiring by disconnecting
the connector on the fuel tank after removing the
chassis central cover.
After that, remove the retainers indicated in the
figure.
SUSP - 7
Suspensions
Remove the constant-velocity universal joint from
the steering bar by undoing the nut indicated in the
photograph.
Use a specific tool to remove the upper tightening
ring nut of the steering tube.
Specific tooling
020055Y Wrench for steering tube ring nut
Remove the hydraulic pipe support bracket.
SUSP - 8
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Remove the steering tube lower ring nut and the
protection cap indicated in the photograph.
Now, it is possible to remove the steering tube.
Check that the roller tapered bearing does not
show signs of abnormal wear. If it is, replace it.
SUSP - 9
Suspensions
THE OPERATIONS DESCRIBED BELOW CAN
ALSO BE CARRIED OUT EVEN WHEN THE
SUSPENSION IS FITTED
Remove the lower retainer of the sliding stem
shown in the photograph.
Remove the sliding stem locking device retainers
indicated in the photograph.
Check that the sliding stem locking device does
not show signs of abnormal wear.
SUSP - 10
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
For refitting, follow the operations for removal but
in reverse order, observing the prescribed torques
and greasing the bearings and their seats.
STEERING TUBES
Name
Side headstock upper ring nut
Side headstock lower ring nut
Screw fixing sliding stem to shock absorber
Clamp for sliding stem locking device
Fixing nuts for constant-velocity universal joints
Torque in Nm
20 - 24
12 ÷ 15
45 ÷ 50
6.5 ÷ 10.5
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 parallelogram.
SUSP - 11
Suspensions
Remove the 4 screws fixing the tilt brake disc sector indicated in the photograph.
Remove the retainers indicated in photograph of
the half-arms joint flange.
To facilitate the operations indicated below, remove the suspension locking electronic control
unit indicated in the photograph.
SUSP - 12
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Remove the arm coupling retainers from the parallelogram by loosening the retainers indicated.
For easy refitting operations, remember to take
note of the positions of the components.
Separate the half-arms by hitting slightly with a
wooden mallet where possible alternatively to the
left and right side of the parallelogram.
Remove the headstocks.
SUSP - 13
Suspensions
Carry out a visual check of the upper and lower
bearings on the headstocks and their seats. Replace them in case of signs of abnormal wear.
SUSP - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Check the ball bearings on the parallelogram
arms. Replace them in case of signs of abnormal
wear.
Check the inside tracks of the parallelogram bearings on the chassis.
For refitting, follow the operations for removal but
in reverse order, lubricating the locking pins on the
parallelogram half-arms and observing the prescribed torques.
PARALLELOGRAM DEVICE
Name
Arm coupling screws
Screws fixing arms to side headstocks
Screws fixing arms to central headstock
Screws fixing the half-arm coupling flange
Torque in Nm
45 ÷ 50
45 ÷ 50
45 ÷ 50
20 ÷ 25
SUSP - 15
Fuoco 500 i.e.
Suspensions
Name
Fixing screws for tilt locking disc section
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
SUSP - 16
Torque in Nm
20 ÷ 25
Fuoco 500 i.e.
Suspensions
The hand-held computer indicates the outcome of
the stop search operation:
POSSIBLE LIMIT STOP VALUES. TO EXIT,
PRESS A KEY AND TURN OFF AND ON. SELECT PARAMETERS TO ADJUST AT 12°.
Check the geared motor if the hand-held computer
does not indicate this.
Select the PARAMETERS option from the main
menu
The hand-held computer displays the option: RELATIVE POTENTIOMETER ANGLE
This function is active coming from the LOWER
STOP SEARCH procedure.
NOTE: a slight oscillation of the angle value between 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 POTENTIOMETER ANGLE 12° (a
slight value oscillation is considered normal)
Refit the protection cap
SUSP - 17
Suspensions
Remove the protection cap, align the pump control
and lock the screw to the prescribed torque
Locking torques (N*m)
Clamp fixing pump bolt to anti-tilting device 11
÷ 13
Select the SYSTEM RESET option from the MAIN
menu
SUSP - 18
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Select the POTENTIOMETER RESET option from
the SYSTEM RESET menu and press OK.
WAIT....
PROCEDURE IN PROGRESS
The hand-held computer displays the words:
CHECK THAT THE CONTROL IS SET AT 12°
FROM THE LOWER STOP. PRESS OK TO CONTINUE
Press OK
The hand-held computer displays the words: POSSIBLE LIMIT STOP VALUES. PRESS A KEY AND
SHIFT OFF 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 adjustment.
CAUTION: A FIRST PRODUCTION BATCH WILL
BE EQUIPPED WITH DOUBLE COAXIAL
SPRING.
It is very important to remove the flexible transmission from its fitting only for replacement.
SUSP - 19
Suspensions
When refitting, tighten the two bracket screws and
the flexible transmission lever nut to the prescribed
torque.
Locking torques (N*m)
Bracket tightening screws 8 ÷ 12
Unscrew the Allen screw and remove the switch.
When refitting, place the switch with the button oriented 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 regularly activated by the stop on the lever.
SUSP - 20
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Unscrew the two pad pin screws, remove the pads
with the spring.
When refitting, tighten the two screws to the prescribed torque and use Threadlock.
When refitting, adjust the cable properly so that the
switch is pushed when the system is unlocked.
Refit the spring/toothed sector unit, hold the crankcase in a perfectly horizontal and stable position,
place the spring/toothed sector unit keeping it perfectly 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.
SUSP - 21
Suspensions
Fit the pinion and align the reference on the pinion
teeth with the reference indicated on the second
slot of the toothed sector.
Grease the pinion and the toothed sector with specific grease.
Refit the toothed sector spacer.
Recommended products
MONTBLANC MOLYBDENUM GREASE MONTBLANC MOLYBDENUM GREASE
Molybdenum disulphide grease
Lubricate the interference areas, match the crankcase 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 correct by means of the reference indicated during
removal.
The motor should be so positioned that it does not
protrude from the reduction unit mould, see figure.
Tighten the screws to the prescribed torque.
Locking torques (N*m)
Electric motor coupling screws 11 ÷ 13
SUSP - 22
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Place the moulded washer of the flexible transmission control lever shaft and the tongue.
Refit the flexible transmission control lever as
shown in the figure.
Refit the potentiometer (not forcing in the D-type
connector ensures a sole position) with the connector directed to the opposite side of the hydraulic
pump.
Refit the hydraulic pump on the geared motor body
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 complete 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 bearing.
Remove the bearing with the specific tool.
Specific tooling
020376Y Adaptor handle
020441Y 26 x 28 mm adaptor
020362Y 12 mm guide
SUSP - 23
Suspensions
Extract the electric motor bearing with the specific
tool.
Specific tooling
020376Y Adaptor handle
020375Y 28 x 30 mm adaptor
020363Y 20 mm guide
Hold the crankcase in a perfectly horizontal position, heat it with a heat gun at a temperature of
about 120 °C, use the specific tool to fit the bearing
of the flexible transmission lever 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 position, 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 mallet if
necessary.
Specific tooling
020363Y 20 mm guide
020358Y 37x40 mm adaptor
020151Y Air heater
SUSP - 24
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
020376Y Adaptor handle
Remove the spring/toothed sector unit from its fitting, slightly hit with a mallet if necessary to release
the unit.
Extract the bearing of the spring/toothed sector
unit with the specific tool.
Specific tooling
001467Y002 Driver for OD 73 mm bearing
Extract the bearing of the electric motor with the
specific tool.
Hold the crankcase in a perfectly horizontal position, 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 Adaptor handle
SUSP - 25
Suspensions
Hold the crankcase in a perfectly horizontal position, heat it with a specific 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
mallet if necessary.
Specific tooling
020363Y 20 mm 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, remove the tensioning cable of the suspension locking mechanical calliper.
Remove the electrical connection of the geared
motor position potentiometer.
Remove the electrical connection of the geared
motor electric motor.
SUSP - 26
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Disconnect the hydraulic pipes between the pump
and the sliding stem locking clamps. Empty the
system and use a container to collect the brake
fluid.
CAUTION
ELIMINATE ANY REMAINING BRAKE FLUID
SPILLS.
WARNING: BRAKE FLUID IS HIGHLY POISONOUS. DO NOT INGEST OR SWALLOW. IF ACCIDENTALLY SWALLOWED, DRINK LARGE
QUANTITIES OF MILK OR WATER AND SEEK
MEDICAL ADVICE IMMEDIATELY. BRAKE
FLUID DESTROYS SKIN AND OCULAR TISSUE. IF YOU ACCIDENTALLY SPILL BRAKE
FLUID ON YOURSELF, TAKE OFF YOUR
CLOTHES, WASH WITH HOT WATER AND
SOAP AND SEEK MEDICAL ADVICE IMMEDIATELY. IF BRAKE LIQUID GETS ACCIDENTALLY IN CONTACT WITH YOUR EYES, RINSE
WITH ABUNDANT FRESH WATER AND SEEK
MEDICAL ADVICE IMMEDIATELY. KEEP
BRAKE FLUID OUT OF THE REACH OF CHILDREN.
Remove the 3 fixing screws indicated and remove
the whole geared motor.
Use a screwdriver to remove the plastic access
cover to the pump joint/geared motor
Unscrew the pump joint screw.
Unscrew the two geared motor pump locking
screws.
SUSP - 27
Suspensions
Unscrew the two potentiometer screws.
When refitting, plug the potentiometer in D-type
connector, afterwards place it with its electric connection directed to the opposite side of the pump.
Remove the nut indicated in the figure, if necessary 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 washer.
Specific tooling
020234y extractor
SUSP - 28
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
Remove the three fixing screws of the electric motor.
It is important to mark the direction of the electric
motor position in order to refit it correctly.
Remove the four screws indicated in the figure,
remove the flexible transmission supporting bracket, separate the two crankcase halves, if necessary, 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
SUSP - 29
Suspensions
3: FUSE No. 11, 7.5A
Check 7.5 A fuse No. 11 for efficiency. With interface wiring disconnected from the control unit,
check the continuity of the blue - black cable between pressure sensor connector and the horn
remote control base as indicated in the photograph. Check the continuity between pin 27 and
the remote control base white cable.
Check the continuity of the yellow-red cable between 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 FOR TILT LOCKING ELECTRICAL SYSTEM
SUSP - 30
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
KEY
1. Geared motor
2. Brake calliper sensor
3. Tilt unlocking-locking control switch
4. Potentiometer
5. Rider presence sensor
6.Left speed sensor
7.Right speed sensor
8. Diagnostic tester serial line
9. Engine electronic control unit
10. Direct +Battery
11. 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
SUSP - 31
Suspensions
1: GEARED MOTOR
With the interface wiring disconnected from the
control unit, check the continuity between pin 28
and the white-red cable, between pin 38 and the
blue cable on the geared motor connector
SUSP - 32
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
With the interface wiring disconnected from the
control unit, check the continuity of the geared motor 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
SUSP - 33
Suspensions
3: TILT LOCKING-UNLOCKING SWITCH
With interface wiring disconnected from the control
unit, check the continuity of the electrical lines between the interface wiring and the tilt locking-unlocking switch:
Pin 26 and green - grey cable
Pin 35 and violet - 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 CALLIPER SENSOR
SUSP - 34
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
1: TILT LOCKING CALLIPER SENSOR
The tilt locking calliper sensor is a normally opened
switch. Check its correct operation with a multimeter.
With interface wiring disconnected from the control
unit, check the continuity between pin 34 and the
brown cable of the tilt locking gripper sensor connector on the system side.
Check the continuity of the connector black cable
and an earth point on the chassis
SUSP - 35
Suspensions
Also check that the flexible transmission control
lever activates the limit stop switch properly.
POTENTIOMETER
1: POTENTIOMETER
SUSP - 36
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
With interface wiring connected to the control unit,
secure the vehicle on its centre stand and switch
to "ON". Select the reading scale on 20 V. Insert
the multimeter probes on pins 17 and 25. Check
that the voltage in the activated locking condition
is 4V and 1V in the locking to rest condition.
With the interface wiring disconnected from the
control unit, check the continuity between pin 17
and the yellow cable of the potentiometer connector, 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 other and earth.
RIDER PRESENCE SENSOR
SUSP - 37
Suspensions
1: RIDER PRESENCE SENSOR
With interface wiring disconnected from the control
unit and connected to the system, check the following conditions:
pin 17 - 36: resistance 15 ÷ 18 kOhm when the
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 connector.
TONE WHEEL SENSOR
SUSP - 38
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
1: Right tone wheel
2: Left tone wheel
With interface wiring disconnected from the parking 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°
SUSP - 39
Suspensions
With interface wiring disconnected from the control
unit, check the continuity between pin 23 and the
red cable of the LEFT wheel turning sensor connector; the continuity between pin 17 and the
brown cables of the LEFT and RIGHT wheel turning sensors; and between pin 24 and the red cable
of the RIGHT 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; between pin 17 and the yellow cables on both connectors; 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 that pin 23 - 17 and 24 - 17
are insulated from each other and from earth.
SUSP - 40
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
With a thickness gauge, check that the air gap between the screw head and the sensor is between
0.35 and 1 mm
Wheel alignment
Tool fitting
Metodo di utilizzo dell'attrezzatura
•
Verificare che la pressione pneumatici
sia corretta.
•
Posizionare il veicolo su un pavimento
piano privo di asperità e irregolarità .
•
Posizionare il veicolo sul cavalletto
centrale.
•
Assicurarsi che il sistema di stazionamento sia sbloccato.
•
Sollevare le ruote anteriori come mostrato in foto
SUSP - 41
Suspensions
•
Verificare la regolarità di rotazione dei
cerchi ruota e l'eventuale presenza di
giochi anomali dei cuscinetti e delle sospensioni.
•
Verificare che il comando dello sterzo
non presenti giochi anomali su giunti e
cuscinetti. In caso contrario procedere
con le necessarie riparazioni e successive 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 parallelogram
unit .
SUSP - 42
Fuoco 500 i.e.
Fuoco 500 i.e.
•
Suspensions
Fit the bracket locking the parallelogram in the holes of the previously removed screws; use the screws supplied with the tool and be careful to
correctly centre the spacer in the bearing.
•
Remove the nut fixing the steering control arm and keep the original washer
in position.
SUSP - 43
Suspensions
•
Fit the steering guiding bracket in a
straight riding position, fix one end to
the attachment of the half-arm coupling
flange and the other end to the screw
fixing the steering control arm.
•
Place the frame so that the sliders
come into contact with the rim maximum diameter but without interfering
with the tyre. If required, reposition the
frame by operating the 3 adjustable
support feet.
•
SUSP - 44
Fit the frame locking bracket
Fuoco 500 i.e.
Fuoco 500 i.e.
•
Suspensions
Make sure the frame is adequately
centred by checking with a gauge that
the lugs along the vertical axis show
the standard protrusion.
•
Check that the pointers of both tyres
are correctly aligned, as shown in the
photograph. Maximum misalignment
allowed: 4 notches
Rear
Removing the rear wheel
Before removing the rear wheel, support the vehicle 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.
SUSP - 45
Suspensions
- Undo the two screws fixing the clamp to the engine.
- Undo the two screws fixing the clamp to the centre stand.
- Remove the cotter pin and collect the cap.
- Unscrew the wheel fixing nut and collect the
spacer.
- Unscrew the clamp.
SUSP - 46
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
- Collect the conical spacer.
- Undo the five wheel fixing screws and remove the
wheel.
Refitting the rear wheel
To fit, proceed in the reverse sequence from that
used for the removal, being careful to fit the distances on the wheel axle as shown in the photograph.
Locking torques (N*m)
Muffler arm clamping screws 27 ÷ 30 Rear
wheel axle nut 104 ÷ 126 Shock absorbercrankcase 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.
SUSP - 47
Suspensions
- Remove the silent-blocks.
- Remove the retainer fixing the swinging arm to
the frame: undo the screw.
- Remove the pin.
SUSP - 48
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
- Unscrew the nut of the set screw bushing.
- From the inside loosen the set screw bushing
until the swinging arm is free.
- Remove the swinging arm.
- Check the entire swinging arm assembly.
- Check all the components- Teflon bushings, silent-blocks, roller bushings, spacers.
- Replace the work components that cause excessive clearance on 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 use two washers
with inner diameter for 12-mm pins, min. outer diameter: 30 mm: min. thickness: 4 mm.
SUSP - 49
Suspensions
- Check there is no sticking in the rotation.
- Check the axial clearance of the swinging arm on
the frame side
Characteristic
Standard clearance
0.40 ÷ 0.60 mm
Allowable limit after use:
1.5 mm
- Separate the swinging arm on the engine side
from the vehicle side arm.
- 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 apply to both sides of the swinging arm.
- Remove the internal spacer.
- Using a suitable pin remove the roller casings as
shown in the photographs
SUSP - 50
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
- Using an appropriate tool plant new roller casings, being careful to position the bearings with the
O-rings facing outwards
Specific tooling
020244Y 15 mm diameter punch
Characteristic
Length of the swinging arm tube on the engine
side:
L 140.5 ± 0.7 mm
Frame side swinging arm plastic bushing
shim:
3.5 ± 0.05 mm
Length of the internal swinging arm spacer on
the frame side:
L182.5 ± 0.3 mm
Length of the 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 protruding part facing the transmission side
Recommended products
AGIP GREASE PV2 Grease for the steering
bearings, pin seats and swinging arm
Soap-based lithium and zinc oxide grease containing NLGI 2; ISO-L-XBCIB2 of the swinging arm
- Check that the silent block is not broken. Otherwise, replace it.
SUSP - 51
Suspensions
- Unscrew the retainer to the frame in order to remove the silent block supporting clamp.
Refitting
For correct installation of the swinging arm on the
scooter, proceed as follows:
1. Position the silent block supporting clamp with
part 3 inserted, and slightly tighten part 1
2. 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
SUSP - 52
Fuoco 500 i.e.
Fuoco 500 i.e.
Suspensions
SWINGING ARM FITTING
Name
Part 1
Part 3
Part 4
Part 5
Swinging arm, engine side / Swinging arm, frame
side, bolt
Torque in Nm
98 ÷ 118
5÷7
88.5 ÷ 108
54 ÷ 60
32.5 ÷ 40
Shock absorbers
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 clamping screw from the support fixed to the engine on
the one side and from that fixed to the muffler on
the other;
SUSP - 53
Suspensions
Fuoco 500 i.e.
- undo the two upper nuts (one on each side) fixing
the shock absorber spring assembly to the frame
and remove the shock absorbers themselves.
Refitting
Carry out the previous operations in reverse order.
Locking torques (N*m)
Shock absorber lower clamp 33 ÷ 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 connecting 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
SUSP - 54
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
This section è is devoted to the description of the brake system components.
Rear brake calliper
Removal
- Remove the rear wheel.
- Undo the screws connecting the air filter to the
crankcase so that the wrenches can be inserted.
- Undo the two fixing screws and remove the calliper.
N.B.
IF IT IS NECESSARY TO REPLACE OR SERVICE THE BRAKE CALLIPER, BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO
THE SUPPORT BRACKET, FIRST LOOSEN
THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING
EXAMINED.
Overhaul
Proceed as follows:
1) remove the 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 compressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the calliper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
BRAK SYS - 2
Fuoco 500 i.e.
Fuoco 500 i.e.
Braking system
Refitting
1) insert the pistons (6) and the sealing rings (7) in
the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corresponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction principle to obtain the thrust for both pads.
The body and the reaction plate body work integrally 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 fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE CALLIPER IS
SERVICED.
Locking torques (N*m)
BRAK SYS - 3
Braking system
Fuoco 500 i.e.
Brake fluid hose-calliper fitting 20 ÷ 25 Pad fastening pin 20 ÷ 25
Refitting
- To fit the rear brake calliper, follow the removal steps but in reverse order; be careful to tighten the
screws to the prescribed torque.
Locking torques (N*m)
Screw tightening calliper to the support 20 ÷ 25
Front brake calliper
Removal
- The operations described refer to only one calliper but apply to both.
- Remove the wheel.
- Undo the two fixing screws to the plate and remove 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 half
calliper.
- Remove the O-rings in the half calliper.
N.B.
WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER
SEATS
BRAK SYS - 4
Fuoco 500 i.e.
Braking system
- Check that the pistons and their seats show no
scratches.
- Wash and blow all the components carefully
- Fit the O-rings and new dust guards
- Refit the pistons in their seats being careful to
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
BRAK SYS - 5
Braking system
Fuoco 500 i.e.
Removal
- Remove the rear wheel.
- Loosen the nuts fixing the safety washers.
- Undo the two screws fixing the plate supporting
the calliper to the frame.
- Remove the calliper supporting clamp.
- Remove the brake disc
Refitting
- To fit the rear brake disc, follow the removal steps but in reverse order; 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
BRAK SYS - 6
Fuoco 500 i.e.
Braking system
Disc Inspection
Checking the disc is important; it must be perfectly
clean, with no sign of rust, oil or grease or other
dirt and must not show signs of deep scoring.
Characteristic
New rear disc thickness
5 mm
Disc thickness at wear limit (rear)
3.5 mm
- Remove the wheel and check using the appropriate 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.
- Remove the cotter pin and remove the cap.
BRAK SYS - 7
Braking system
Fuoco 500 i.e.
- Unscrew the fixing nut.
- Remove the wheel hub.
- Unscrew the six bolts securing the disc to the
wheel hub.
- Remove the disc.
Refitting
- To fit the front brake disc, follow the removal steps but in reverse order; be careful to tighten the screws
to the prescribed torque using threadlock.
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.
BRAK SYS - 8
Fuoco 500 i.e.
Braking system
Characteristic
Thickness of a new front disc
4.0 mm
Disc thickness at wear limit (front)
3.5 mm
- Remove the wheel and check using the appropriate 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 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.
BRAK SYS - 9
Braking system
Fuoco 500 i.e.
- Remove the pads.
Characteristic
Minimum value
1.5 mm
Refitting
- Follow the removal steps but in reverse order; check that the Benzing snap ring of the pads is in good
conditions.
Rear brake pads
Removal
Proceed as follows:
- Remove the rear brake calliper
- Remove the two pins holding the brake pads.
- Remove the pads, paying attention to the pad retaining 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 tightening the pad fixing pin 20 ÷ 25 Nm
Fill
BRAK SYS - 10
Fuoco 500 i.e.
Braking system
Rear - combined
Proceed as follows:
- Position the vehicle on a flat surface and on the
stand
- Loosen the two screws shown in the figure and
open the front brake fluid reservoir.
- Through the bleed screw on the brake calliper,
bleed the system using a hose of adequate diameter.
- Collect the used fluid in a container.
- Pump on the brake lever to completely drain the system of all used fluid.
- Tighten the bleed valve.
- Refill the brake system tank up to the maximum level with the prescribed fluid.
- Attach the tube of the special tool to the bleed fitting.
- Actuate the tool at the bleed fitting, at the same time constantly topping 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 FITTINGS. IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT
AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. WHEN CARRYING OUT
THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND
ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE
DISC.
Specific tooling
020329Y Mity-Vac vacuum operated pump
Locking torques (N*m)
Oil bleed screw 12 - 16
BRAK SYS - 11
Braking system
Fuoco 500 i.e.
Front
- The operations described refer to only one calliper but are valid and must be observed for both.
- Remove the rubber hood from the bleed screw.
- Insert a rubber pipe in the bleed screw to permit
the brake fluid to be recovered.
- With the right-hand brake lever, load the system and bring it up to the required pressure.
- Keeping the right-hand brake lever pulled, loosen the bleed screw to permit the air in the system to
escape. Then tighten the bleed screw.
- Repeat the operation until only brake fluid comes out of the rubber pipe.
- Remove the fluid recovery pipe and refit the rubber hood over the bleed screw.
- Top up the brake fluid to the right level in the tank.
N.B.
DURING THE BLEEDING OPERATIONS, 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 be done using a special vacuum pump
Specific tooling
020329Y Mity-Vac vacuum operated pump
Locking torques (N*m)
Oil bleed screw 8÷12
Brake pipes
Unscrew the braking splitter screw.
Disconnect the brake pipes removing the two metallic straps indicated in the figure.
Remove the brake oil tube fitting from the rigid pipe
inside the front suspension arm and loosen the
hydraulic joint fixing nut of the suspension locking
to release the brake pipes.
BRAK SYS - 12
Fuoco 500 i.e.
Braking system
Remove front Shield.
Remove front wheel and mudguard.
Disconnect the brake pipes from the calliper and
drain the brake fluid.
Then, remove the plastic and metallic straps.
Unscrew the brake pump pipes as indicated in the
figure.
Parking brake
Remove the rear wheel.
Loosen the transmission set screw and release the
cable from the calliper.
BRAK SYS - 13
Braking system
Remove the two fixing screws of the mechanic
calliper and remove the calliper. To check calliper
components, refer to the chapter on the tilt locking
calliper.
When refitting, secure to the specified torque.
Locking torques (N*m)
Screw tightening calliper to the support 20 ÷ 25
After removing the shield back plate, remove the
engaging cable for the safety mechanism removing 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
operating the set screw indicated in the photograph.
BRAK SYS - 14
Fuoco 500 i.e.
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
Cooling system
Fuoco 500 i.e.
Circuit diagram
The cooling system is of the forced circulation type, with continuous venting and air pressurisation.
Circulation takes places by a centrifugal pump driven by the countershaft.
The pump delivers the coolant to the thermal unit.
The two-way thermostat support is connected in output to the head. One way is connected to the pump
and the other to the radiator (of the horizontal circulation type).
The radiator output is directly connected to the pump.
The expansion tank is connected in parallel to the radiator.
The radiator hot box is connected to the upper side of the expansion tank (in air).
The radiator 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 circulation on radiator and expansion tank
starts.
With the small openings in the thermostat there is a flow overlapping (recirculation and main one).
When the temperature is higher, the thermostat allows excluding the recirculation to favour the main
circulation.
In this case, the flow is consistent in the expansion tank as well, and this ensures a continuous automatic
venting.
COOL SYS - 2
Fuoco 500 i.e.
Cooling system
For the system venting during the circuit filling step, there is a special union at the top of the head (see
filling rules).
To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection
system.
TECHNICAL SPECIFICATIONS
Specification
Cooling system capacity
Prescribed fluid
Desc./Quantity
1.8 l
Mixture of 50% water and 50% fluid for sealed circuits
Cap calibrated at 0.9 bar
Sealing pressure
THERMOSTAT
Specification
Type
Starts opening
Desc./Quantity
Wax, with deviator
90 ± 2°C
ELECTRIC VENTILATION
Specification
Type
Electric ventilation start
Electric ventilation end
Desc./Quantity
With piston
105°C
100°C
WATER PUMP
Specification
Type
Control
Desc./Quantity
Centrifugal
Coaxial at the countershaft
RADIATOR
Specification
Type
Desc./Quantity
Aluminium, with horizontal circulation
EXPANSION TANK
Specification
Calibration
Desc./Quantity
Automatic bleeding, in parallel with the radiator
Electric fan check
- Connect the injection diagnostic tester and select
the menu on the "ERRORS" function.
- Check any failures in the electric fan control circuit (see "Injection" chapter)
Specific tooling
020460Y Scooter diagnosis and tester
COOL SYS - 3
Cooling system
Fuoco 500 i.e.
- Select the menu on the "ACTIVE DIAGNOSIS"
function and start the electric fan operation simulation (see "Injection" chapter).
- If the electric fan is certainly efficient, check the
ventilation start and end temperature.
- Select the "PARAMETERS" function in the menu
to display the coolant temperature.
Electric fan starts: 105°C
Electric fan stops: 100°C
- If non-conforming values are detected, replace
the injection control unit (see «Injection» Chapter).
- If the analogue instrument temperature is close
to the red zone, but the degrees indicated by the
diagnostic tester are below the electric fan start
temperature, check the temperature sensor on the
head and the relevant injection circuit (see «Injection» chapter);
N.B.
THE ELECTRIC FAN TEMPERATURE AT 105° C CAN ONLY BE MANAGED BY A SYSTEM SUPPLIED 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 evaporation
- The water pump is provided with a drainage hole
in case of leaks from the cooling system mechanical seal, or from the shaft sealing oil guard.
- If coolant or oil leaks are detected, replace the pump (see «Flywheel Cover» Chapter).
N.B.
DO NOT USE OILS OR GREASES WHILE MOUNTING THE COOLING SYSTEM. FAILURE TO OBSERVE THIS REGULATION CAN CAUSE IRREVERSIBLE DEFORMATION TO THE SEALING
GASKETS.
COOL SYS - 4
Fuoco 500 i.e.
Cooling system
Coolant replacement
System top-up rules
- Prepare the mixture of 50% water and coolant.
- Fill the system to reach a level ranging between
the MIX and MAX levels indicated in the expansion
tank filler.
- Do not close the expansion tank with the cap.
- Use a transparent hose to connect the venting
union with the expansion tank filler.
- Loosen the vent and start the engine.
- Keep it open until the air has been fully vented.
- Close the bleed screw.
- Stop the engine.
- Restore the level into the expansion tank and tighten the cap.
- Start the engine and let it warm up 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 COMPLETED.
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 water pump is discovered, replace the flywheel cover
and the water pump as described in the "Flywheel Cover" Chapter.
Proceed to carry out a few preliminary operations as described below:
•
Place the vehicle on its centre stand and on flat ground.
•
Remove the bodywork components as described in the "Bodywork" Chapter.
COOL SYS - 5
Cooling system
•
Fuoco 500 i.e.
Remove the muffler to access the flywheel cover as described in the "Removing the Engine
from the Scooter" Chapter.
•
Empty the cooling system, removing the hoses located on the water pump cover and the
loading cap located on the expansion tank.
CAUTION
THIS OPERATION MUST BE CARRIED OUT WHEN THE ENGINE IS COLD.
•
Remove the water pump cover shown
in the figure by loosening the 6 fastening screws.
•
Proceed to partially drain the circuit as
described in the "Engine" Chapter.
•
Once the fault has been fixed and all
components have been replaced, fill
and purge the system again.
N.B.
FOR CHANGING THE COOLANT AND BLEEDING 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 come into contact with grease or oil.
CAUTION
FAILURE TO OBSERVE THIS ADVICE CAN IRRETRIEVABLY DEFORM THE O-RING.
- Refit the water pump cover and tighten the 6 fixing screws to the prescribed torque.
Locking torques (N*m)
Water pump cover screws 3 ÷ 4
See also
Flywheel cover
Engine
COOL SYS - 6
Fuoco 500 i.e.
Cooling system
diagnosis
Excessive system pressure
1 - Check the expansion tank cap efficiency.
N.B.
THE CAP IS PROVIDED WITH AN OVERPRESSURE VALVE CALIBRATED AT 0.9 BAR.
There is also a valve that must allow air inlet during the cooling step.
YES go to 2 NO go to 3
2 - Check the head gasket seal (see "Thermal unit 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 gasket seal (see "Thermal unit and timing system" chapter)
COOL SYS - 7
Cooling system
COOL SYS - 8
Fuoco 500 i.e.
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Fuoco 500 i.e.
This section è is devoted to the operations that can be carried out on the vehicle's bodywork.
Seat
- Raise the saddle.
- Undo the screw shown in the figure, remove the
cover and disconnect the rider presence sensor
connector.
- Remove the three fixing screws shown in the figure.
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.
CHAS - 2
Fuoco 500 i.e.
Chassis
Front handlebar cover
- Unscrew the six screws and remove the upper
cap and the rear handlebar cover.
- Unscrew the two screws fixing the handlebar to
remove the front part of the handlebar cover.
Headlight assy.
- Remove the front shield.
- Unscrew the screw of the tail light support.
- Disconnect the electrical terminals and remove
the support.
CHAS - 3
Chassis
- Undo the two screws fixing it to the frame.
- Undo the two screws fixing it to the upper part of
the shield back plate.
- Disconnect the assembly connectors at both
sides and remove the support.
- Undo the ten screws fixing it to the support and
remove the headlight assemblies.
CHAS - 4
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
Frame central cover
- Unscrew the fuel tank cap.
- Remove the saddle.
- Remove the side fairings
Working from both sides:
- Undo the screw indicated and remove the cap lid.
- Undo the two screws.
- Undo the screw connecting it to the helmet compartment.
- Lift it so that the refuelling compartment opening
cable can be released.
- Remove the central frame cover.
CHAS - 5
Chassis
Legshield
- Remove the spoiler.
- Unscrew the four screws indicated and remove
the lower part from the headlight assembly support.
Working from both sides, remove the lateral sections 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.
CHAS - 6
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
Knee-guard
- Remove the front shield.
- Remove the handlebar covers.
- Remove the spoiler.
- Remove the two central screws and the coolant
cap cover screw.
- Remove the expansion tank fixing screw and the
frame from the instrument panel and manually release 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.
CHAS - 7
Chassis
- Remove the key switch plastic ring and the two
plastic covers near the footrest.
- Remove the five screws on the shield back plate
rear part.
- Remove the two shield back plate front screws,
see figure.
CHAS - 8
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
- Remove the two shield back plate lower screws.
- Remove the external temperature sensor connection.
See also
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 support.
- Undo the three screws and remove the light unit.
CHAS - 9
Chassis
Footrest
Remove the central cover.
Remove the four screws and extract the half-footrest.
Follow the same procedure for both half-footrests.
Release the fuse-box
See also
Frame central cover
Side fairings
- These operations are described once but apply
to both side fairings.
- 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.
CHAS - 10
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
License plate holder
- Undo the two upper screws fixing it to the rear
plastic element and the three screws fixing it to the
frame.
Helmet bay
- Remove the side fairings.
- Remove the side handgrips.
- Remove the central frame cover.
- Undo the two screws on the battery compartment, 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.
CHAS - 11
Chassis
- Undo the screws fixing the voltage regulator to
the helmet compartment internal side.
- Undo the two screws of the saddle lock, disconnect 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.
CHAS - 12
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
- Remove the helmet compartment.
spoiler
- Remove the GILERA clip-on badge paying attention 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.
CHAS - 13
Chassis
Remove the two lower bracket retainers indicated
in the figure.
Disconnect the electric wiring and the fuel pipes.
See also
Footrest
Rear
Remove the four fixing screws of the cover and
release it from the two leverages.
CHAS - 14
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
Handles and top side fairings
- Remove the side fairings.
- Undo the seven screws fixing the turn indicator
arrows.
- Disconnect the license plate light connector.
- Undo the three screws indicated at both sides
and remove the handgrip clamp.
Radiator cover
- Remove the front shield.
- Remove the headlight assembly.
- Disconnect the turn indicators wirings.
- Undo the two screws indicated.
CHAS - 15
Chassis
- Undo the two screws indicated.
- Undo the two screws of the supporting clamp.
- Remove the supporting clamp.
- Remove the two protective screws that fix the radiator 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.
CHAS - 16
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
Battery
- Raise the saddle.
- Undo the two screws of the battery cover.
Lower cover
Montaggio
- Dalle viti di corredo prendere: tre viti con rondelle,
tre piastrine elastiche e tre distanziali.
- Inserire i distanziali nei tre fori indicati.
CHAS - 17
Chassis
- Inserire dove indicato le tre piastrine elastiche.
- Montare il paracolpi inferiore, avvitando le tre viti
complete di rondelle.
Smontaggio
- Svitare le tre viti complete di rondelle di fissaggio
al telaio, e recuperare il distanziale.
CHAS - 18
Fuoco 500 i.e.
Fuoco 500 i.e.
Chassis
CHAS - 19
Chassis
CHAS - 20
Fuoco 500 i.e.
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Fuoco 500 i.e.
Pre-delivery
Carry out the listed tests before delivering the vehicle.
Warning- be very careful when handling fuel.
Position the plastic cover supplied with the coupling on the steering tube as shown in the figure.
If a customer wishes to have mudflaps installed,
proceed as follows:
•
Place the flap in the mudguard inner
side as shown in the figure, making the
4 securing holes coincide.
•
Fit the 4 washers on the mudguard outer 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
Safety locks
•
Rear shock absorber upper fixing
•
Rear shock absorber lower fixing
PRE DE - 2
Fuoco 500 i.e.
•
Front shock absorber upper fixing
•
Front shock absorber lower fixing
•
Sliding stems fixing
•
Break callipers fixing
•
Front wheels fixing screws
•
Front wheels axle nut
•
Rear wheel axle nut
•
Chassis - engine swinging arm fixing
•
Handlebar lock nut
•
Lower ring nut for side steering tubes
•
Upper ring nut for side steering tubes
•
Lower ring nut for central steering tube
•
Upper ring nut for central steering tubes
•
Constant-velocity universal joints
Pre-delivery
Electrical system
• Battery
• Main switch
• Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights
- Regulating the headlights according to the regulations 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 BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
PRE DE - 3
Pre-delivery
Fuoco 500 i.e.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES,
SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE
TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING
CLOSE TO BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN 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 brake efficiency
- Parking brake efficiency
- Rear and front suspension efficiency
- Abnormal noise
- Tilting system locking - unlocking efficiency
Static test
Static control after the test ride:
• Hot engine restart
• Minimum seal (turning the handlebar)
• Uniform steering rotation
• Possible losses
• electric radiator fan operation
CAUTION
PRE DE - 4
Fuoco 500 i.e.
Pre-delivery
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Verifica Funzionale:
• Impianto frenante idraulico: corsa della leva
• Frizione: verifica corretto funzionamento
• 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 inferiore ed eventuali accessori
PRE DE - 5
Pre-delivery
PRE DE - 6
Fuoco 500 i.e.
INDEX OF TOPICS
TIME
TIME
Fuoco 500 i.e.
Time
This section is devoted to the time necessary to carry out repairs.
For each operation, the description, code and time envisages are specified.
Engine
ENGINE
1
TIME - 2
Code
001001
Action
Engine to chassis - Replacement
Duration
Fuoco 500 i.e.
Time
Crankcase
CRANKCASE
1
Code
001100
2
001133
3
001153
Action
Oil seal, clutch side - Replacement
Engine crankcase- Replacement
Half crankcase gasket - Replacement
Duration
TIME - 3
Fuoco 500 i.e.
Time
Crankshaft
CRANKSHAFT
1
2
TIME - 4
Code
001117
001098
Action
Crankshaft - Replacement
Countershaft - Replacement
Duration
Fuoco 500 i.e.
Time
Cylinder assy.
CYLINDER GROUP
1
Code
001002
2
3
001154
001129
Action
Cylinder piston - Replacement
Pin ring piston unit - Service
Chain tensioner - Service and
Replacement
Duration
TIME - 5
Fuoco 500 i.e.
Time
Cylinder head assy.
GRUPPO TESTA
1
2
3
4
5
6
Code
001045
001049
001056
001126
001083
007012
7
001057
TIME - 6
Action
Valves - Replacement
Valves - Adjustments
Head gasket - Replacement
Head - Replacement
Thermistor - Replacement
Coolant bleed valve - Replacement
Thermostat - Replacement
Duration
Fuoco 500 i.e.
Time
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT
1
2
Code
001044
001148
3
001169
Action
Camshaft - Replacement
Rocking lever valve - Replacement
Decompressor - Replacement
Duration
TIME - 7
Fuoco 500 i.e.
Time
Cylinder head cover
HEAD COVER
1
2
3
TIME - 8
Code
001089
001093
001088
Action
Head cover - Replacement
Spark plug - Replacement
Head cover gasket - Replacement
Duration
Fuoco 500 i.e.
Time
Flywheel cover
COPERCHIO VOLANO
1
2
3
4
5
Code
001087
001113
001123
001124
001150
6
001160
7
001102
8
003064
Action
Flywheel cover - replace
Water pump - Replacement
Oil filter -Replacement
By-pass valve - Replacement
Flywheel cover gasket - Replacement
Minimum oil pressure sensor
- Replacement
Net oil filter - Replacement /
Cleaning
Engine oil - change
Duration
TIME - 9
Fuoco 500 i.e.
Time
Driven pulley
DRIVEN PULLEY
1
2
3
4
TIME - 10
Code
001022
001012
001110
001155
Action
Clutch - Replacement
Driven pulley - Overhaul
Driven pulley - Replacement
Clutch bell housing - Replacement
Duration
Fuoco 500 i.e.
Time
Oil pump
POMPA OLIO
1
2
Code
001042
001051
3
4
001112
001125
Action
Oil pump - overhaul
Belt/ Timing chain - Replacement
Oil pump - change
Chain guide pads - change
Duration
TIME - 11
Fuoco 500 i.e.
Time
Final gear assy.
FINAL REDUCTION GEAR ASSEMBLY
1
Code
001010
2
001156
3
4
003065
004125
5
002031
TIME - 12
Action
Geared reduction unit - Service
Gear reduction unit cover Replacement
Gear box oil - Replacement
Rear gear shaft - Replacement
Rear wheel hub bearings Replacement
Duration
Fuoco 500 i.e.
Time
Driving pulley
DRIVING PULLEY
1
Code
001086
2
3
4
001011
001006
001141
5
6
001066
001177
Action
Driving half-pulley - Replacement
Driving belt - Replacement
driving pulley - Service
Belt anti-flapping roller - Replacement
driving pulley - Replacement
Variator rollers / shoes - Replacement
Duration
TIME - 13
Fuoco 500 i.e.
Time
Transmission cover
TRANSMISSION COVER
1
Code
001065
2
001096
3
001131
4
001135
5
001170
TIME - 14
Action
Internal transmission cover Replacement
External transmission cover Replacement
Transmission air intake - Replacement
Transmission cover bearing Replacement
Air manifold - replacement
Duration
Fuoco 500 i.e.
Time
Flywheel magneto
VOLANO MAGNETE
1
2
3
4
Code
001173
001067
001058
001104
Action
Rotor - replace
Stator - Replacement
Flywheel - Replacement
Start-up freewheel - Replacement
Duration
TIME - 15
Fuoco 500 i.e.
Time
Butterfly valve
THROTTLE BODY
1
2
3
TIME - 16
Code
001013
001047
001023
Action
Intake manifold - change
Injector - Replacement
Control unit - Replacement
Duration
Fuoco 500 i.e.
Time
Exhaust pipe
MUFFLER
1
2
Code
001009
001092
3
4
5
001095
004169
005138
Action
Muffler - Replacement
Exhaust manifold - Replacement
Muffler guard - Replacement
Muffler guard - Replacement
Lambda probe - Replacement
Duration
TIME - 17
Fuoco 500 i.e.
Time
Air cleaner
DEPURATORE ARIA
1
2
Code
001015
001014
3
004122
4
001027
TIME - 18
Action
Air filter box - Replacement
Air filter - Replacement /
cleaning
Cleaner / Throttle body union
- Replacement
Body / air cleaner union - Replacement
Duration
Fuoco 500 i.e.
Time
Frame
CHASSIS
1
2
3
Code
004146
004001
004147
4
5
6
004143
004116
004148
7
902003
Action
Front frame - Replacement
Frame - replace
footboard support bracket
one side - Replacement
Footrest support - replace
Rear frame - Replacement
footboard support bracket
two sides - Replacement
Supporto fanale anteriore Sostituzione
Duration
TIME - 19
Fuoco 500 i.e.
Time
Centre-stand
STAND
1
2
TIME - 20
Code
004004
004179
Action
Stand - Replacement
Stand buffer - Replacement
Duration
Fuoco 500 i.e.
Time
Legshield spoiler
FRONT SHIELD
1
Code
004021
2
004022
3
4
5
004020
004085
004064
Action
Shield upper section - Replacement
Shield lower section - Replacement
Headlight rim - Replacement
Fairing (1) - Replacement
Front shield - Replacement
Duration
TIME - 21
Fuoco 500 i.e.
Time
Side fairings
COPERTURE LATERALI
1
Code
004036
2
3
4
004129
004037
004121
Action
Lower chassis cover - Replacement
Rear fairing - Replacement
Side aprons-Replacement
Fianchetto sella (1) - Sostituzione
Duration
Rear cover
SCUDO POSTERIORE
1
TIME - 22
Code
004065
Action
Front shield rear section - removal and installation
Duration
Fuoco 500 i.e.
Time
Central cover
CENTRAL COVER
1
Code
004059
2
3
004135
004011
4
004012
5
004015
6
004075
Action
Spark plug inspection flap Replacement
Fuel tank port - Replacement
Central chassis cover - replace
Rear fairings - Removal and
refitting
Footrest - Removal and Refitting
Front mat - Replacement
Duration
TIME - 23
Fuoco 500 i.e.
Time
Mudguard
MUDGUARDS
1
Code
007015
2
004009
3
4
004181
004184
5
004002
TIME - 24
Action
Radiator air intake - Replacement
Rear mudguard - Replacement
Lower cover - Replacement
Front mudguard support - replacement
Front mudguard - Replacement
Duration
Fuoco 500 i.e.
Time
Fuel tank
FUEL TANK
1
Code
004137
2
3
4
5
6
005010
004109
004168
004005
004073
Action
Injector pump pipe - Replacement
Tank float - Replacement
Fuel tank breather - change
Fuel tank cap - Replacement
Fuel tank - Replacement
Fuel pump - Replacement
Duration
TIME - 25
Fuoco 500 i.e.
Time
Rear shock-absorber
REAR SHOCK ABSORBERS
1
Code
003007
2
003035
3
003077
TIME - 26
Action
Rear shock absorber - Removal and Refitting
Shock absorber support and
brake calliper - Replacement
muffler/rear shock absorber
support arm - Service
Duration
Fuoco 500 i.e.
Time
Handlebar covers
HANDLEBAR COVERS
1
Code
000307
2
004026
Action
RIGHT OR LEFT CONTROL
ASSEMBLY REPLACEMENT
Handlebar cover - Replacement
Duration
TIME - 27
Fuoco 500 i.e.
Time
Handlebar components
COMPONENTI MANUBRIO
1
2
Code
002059
002060
3
002063
4
5
6
003001
002071
003059
7
8
002037
002067
9
002080
10
004162
11
12
002024
002047
TIME - 28
Action
Right-hand knob - change
Complete gas command Replacement
Complete gas transmission Replacement
Handlebar - Replacement
LHS knob - Replacement
Counterweight - Replacement
Brake lever - Replacement
Rear brake pump - Replacement
Rear brake oil bleeding system - Replacement
Mirror support and/or brake
pump fitting u-bolt - Replacement
Front brake pump - replace
Front brake fluid and air
bleeding system - Replacement
Duration
Fuoco 500 i.e.
Time
Swing-arm
SWINGING ARM
1
2
Code
004058
003081
3
001072
4
003080
Action
Silent block - Replacement
Swinging arm support flange
- replace
Swinging arm - Engine-chassis connection - Replacement
Swinging arm on frame - Replacement
Duration
TIME - 29
Fuoco 500 i.e.
Time
Seat
SADDLE
1
TIME - 30
Code
004003
Action
Saddle - Replacement
Duration
Fuoco 500 i.e.
Time
Instrument panel
GRUPPO STRUMENTI
1
2
Code
005014
004099
3
004035
Action
Odometer - Replacement
Odometer housing - Replacement
Instrument panel - Replacement
Duration
TIME - 31
Fuoco 500 i.e.
Time
Locks
LOCKS
1
Code
005146
2
004054
3
005072
4
004010
Turn signal lights
Front lights
TIME - 32
Action
Elettroattuatore apertura
sella - Sostituzione
Saddle lock catch - Replacement
Immobilizer aerial - Replacement
Anti-theft lock - Replacement
Duration
Fuoco 500 i.e.
Time
FANALERIA LAMPEGGIATORI ANT
1
Code
005067
2
005012
3
4
5
6
005002
005008
005139
005140
Action
Front direction indicator bulb
- Replacement
Front direction indicators Replacement
Front light - Replacement
Light bulbs - Replacement
Tail light bulb - Replacement
Front light - Replacement
Duration
Rear lights
TIME - 33
Fuoco 500 i.e.
Time
REAR TURN INDICATORS INDICATOR LIGHTS
1
2
3
Code
005005
005022
005031
4
005032
5
005131
6
005066
7
005068
TIME - 34
Action
Taillight - Replacement
Rear turn indicators - replace
Licence plate light bulb - Replacement
Transparent licence plate
cover - replace
Licence plate light support Replacement
Rear light bulbs - Replacement
Rear turn indicator bulb - Replacement
Duration
Fuoco 500 i.e.
Time
Front wheel
FRONT WHEELS
1
2
Code
003047
003033
3
003037
4
5
005089
002041
6
004123
Action
Front tyre - replace
Front wheel hub- Replacement
Front wheel rim- Replacement
Tone wheel - Replacement
Front brake disc - Replacement
Front wheel - Replacement
Duration
TIME - 35
Fuoco 500 i.e.
Time
Rear wheel
REAR WHEEL
1
Code
002070
2
3
001016
001071
4
004126
TIME - 36
Action
Rear brake disc - Replacement
Rear wheel - Replacement
Front wheel rim - Removal
and refitting
Rear wheel tyre - Replacement
Duration
Fuoco 500 i.e.
Time
Electric start
AVVIAMENTO
1
Code
001017
2
3
001020
001151
Action
Start-up pinion - Replacement
Starter motor - Replacement
Start-up driven gearing - Replacement
Duration
TIME - 37
Fuoco 500 i.e.
Time
Electric devices
DISPOSITIVI ELETTRICI
1
Code
005035
2
005011
3
4
5
005007
005003
005096
6
005117
7
xxxxxx
8
9
005052
832311
TIME - 38
Action
Headlight remote control Replacement
Start-up remote control
switch - Replacement
Battery - Replacement
Horn - Replacement
Remote control for injection
components - Replacement
Electrical fan remote control Replacement
Teleruttore consenso avviamento - sostituzione
Fuse - Replacement
Turn indicator blinker - Replacement
Duration
Fuoco 500 i.e.
Time
CABLE HARNESS
1
2
Code
005001
005114
Action
electric system - change
Electrical system - Service
Duration
Electronic controls
TIME - 39
Fuoco 500 i.e.
Time
COMANDI AL MANUBRIO
1
2
Code
005017
005077
3
4
5
005041
005040
005006
6
7
005039
005142
8
005084
9
10
005143
888126
Action
Stop switch - Replacement
Emergency stop switch - Replacement
Starter button - replace
Horn button - Replacement
Light switch or turn indicators
- Replacement
Headlight switch - replace
Unlocking switch - Replacement
Emergency light switch - Replacement
MODE button - Replacement
Pulsante sottosella - sostituzione
Duration
Transmissions
TRASMISSIONI SERRATURE
1
Code
003094
2
002082
3
002083
TIME - 40
Action
Tilt locking calliper control cable - replacement
Fuel tank cap opening drive Replacement
Saddle opening transmission
- Replacement
Duration
Fuoco 500 i.e.
Time
4
Code
002026
5
002092
Action
Trasmissione freno di stazionamento - sostituzione
Transmission splitter/ hook
transmission - Replacement
Duration
Helmet bay
HELMET COMPARTMENT
1
2
Code
005046
005026
3
005027
4
004016
5
004142
Action
Battery cover - change
Helmet compartment bulb Replacement
Helmet compartment bulb
support - Replacement
Helmet compartment - replace
Plug socket - Replacement
Duration
TIME - 41
Fuoco 500 i.e.
Time
Front suspension
FRONT SUSPENSION
1
2
Code
003010
003111
3
003038
4
003040
5
6
003107
003113
TIME - 42
Action
Front suspension - Service
Side steering tube - replacement
Front wheel axle - Remov.
and Refitt.
Front wheel bearings - Replacement
Sliding stems - replacement
Front shock absorber - replacement
Duration
Fuoco 500 i.e.
Time
Cooling system
IMPIANTO DI RAFFREDDAMENTO
1
Code
007013
2
001052
3
007001
4
007024
5
007003
6
007016
7
8
007002
007014
9
004167
Action
Radiator expansion tank connection pipe - Replacement
Coolant and air bleed - Replacement
Expansion tank - Replacement
Expansion tank cap - Replacement
Coolant delivery and return
pipe - Replacement
Fan with support - Replacement
Water radiator - replacement
Radiator thermal switch - Replacement
Grill / radiator cover - Replacement
Duration
TIME - 43
Fuoco 500 i.e.
Time
Braking system
IMPIANTO FRENANTE
1
2
Code
002025
003096
3
003100
4
003109
5
002002
6
002020
7
002081
8
003118
9
003103
10
003102
11
003088
12
002021
TIME - 44
Action
Brake piping - Replacement
Tilt locking calliper- replacement
Tilt locking calliper pads - replacement
Parking brake mechanical
calliper - replacement
Shoes - Rear brake pads Replacement
Rear brake pipes - Removal
and refitting
Rear brake disc piping - Replacement
Tilt locking disc section - replacement
Splitter for suspension locking system hoses- replacement
Hoses for the splitter-calliper
suspension locking system replacement
Tilt locking hydraulic pump replacement
Front brake piping - Replacement
Duration
Fuoco 500 i.e.
Time
13
Code
002007
14
002039
15
003104
16
003119
17
003105
18
003106
19
003121
20
003122
21
002048
Action
Front brake pads - Replacement
Front brake calliper - Replacement
Suspension system locking
calliper- replacement
Hoses for the pump-splitter
suspension locking system replacement
Suspension locking system
brake fluid - repl.
Suspension locking system
pressure sensor-Replacement
Parking brake control lever replacement
Parking brake control lever
micro-switch - replacement
Rear brake calliper - Replacement
Duration
Stickers
TRANSFERS
1
2
Code
004066
004159
Action
Driving mirror - Replacement
Plates / Stickers - Replacement
Duration
TIME - 45
Fuoco 500 i.e.
Time
The tilt mechanism
TILT MECHANISM
1
Code
003073
2
003112
3
003002
4
003115
5
003114
6
7
003116
003117
TIME - 46
Action
Steering clearance - Adjustment
Central steering tube - replacement
Steering fifth wheel - Replacement
Parallelogram arms - replacement
Parallelogram bearings - replacement
Steering rod - replacement
Constant-velocity universal
joint - replacement
Duration
Fuoco 500 i.e.
Time
Geared motor
MOTORIDUTTORE
1
Code
003101
2
3
005009
003095
4
5
001069
001094
6
003120
7
003093
8
003090
9
003092
10
003091
11
003089
12
003097
13
XXXXXX
14
005099
Action
Tilt locking calliper control
lever - replacement
Voltage regulator - replace
Tilt locking calliper support
bracket - replacement
HV coil - replace
Spark plug cap - Replacement
Tilt locking control unit - replacement
Geared motor crankcase - replacement
Geared electric motor - replacement
Geared motor bearings - replacement
Geared motor pinion - replacement
Geared motor potentiometer
- replacement
Tilt locking calliper microswitch - replacement
Centralina alimentazione
MIU - Sostituzione
Electric saddle opening device - Replacement
Duration
TIME - 47
Time
TIME - 48
Fuoco 500 i.e.
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