2006-2010 Gilera Fuoco 500 Service Repair Manual
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2006-2010 Gilera Fuoco 500 Service Repair Manual
LANGUAGE:ENGLISH
PAGES:502
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
2006-2010 Gilera Fuoco 500 Service Repair Manual
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.
TABLE OF CONTENTS:
2006-2010 Gilera Fuoco 500 Service Repair Manual
Man: Fuoco 500 i.e............................................. 5 Cap:Characteristics........................................ 7 Sez:Rules.............................................. 8 Sez:Safety rules....................................... 8 Sez:Maintenance rules.................................. 8 Sez:Vehicle identification............................. 8 Sez:Dimensions and mass................................ 9 Sez:Engine............................................. 10 Sez:Transmission....................................... 10 Sez:Capacities......................................... 10 Sez:Electrical system.................................. 11 Sez:Frame and suspensions.............................. 11 Sez:Brakes............................................. 11 Sez:Wheels and tyres................................... 11 Sez:Tightening Torques................................. 12 Sez:Overhaul data...................................... 15 Sez:Assembly clearances................................ 15 Sez:Cylinder - piston assy............................. 15 Sez:Piston rings....................................... 16 Sez:Crankcase - crankshaft - connecting rod............ 17 Sez:Slot packing system................................ 20 Sez:Products........................................... 21 Cap:Tooling................................................ 23 Cap:Maintenance............................................ 35 Sez:Maintenance chart.................................. 36 Sez:Checking the spark advance......................... 38 Sez:Spark plug......................................... 39 Sez:Hub oil............................................ 40 Sez:Check.............................................. 41 Sez:Replacement........................................ 41 Sez:Air filter......................................... 42 Sez:Engine oil......................................... 42 Sez:Replacement........................................ 43 Sez:Check.............................................. 44 Sez:Engine oil filter.................................. 45 Sez:Oil pressure warning light......................... 45 Sez:Checking the ignition timing....................... 45 Sez:Cooling system..................................... 46 Sez:Braking system..................................... 47 Sez:Level check........................................ 47 Sez:Top-up............................................. 47 Sez:Headlight adjustment............................... 48 Cap:Troubleshooting........................................ 51 Sez:Engine............................................. 52 Sez:Excessive oil consumption/Exhaust smoke............ 52 Sez:Insufficient lubrication pressure.................. 52 Sez:Transmission and brakes............................ 52 Sez:Clutch grabbing or performing inadequately......... 52 Sez:Insufficient braking............................... 52 Sez:Brakes overheating................................. 53 Sez:Steering and suspensions........................... 53 Sez:Heavy steering..................................... 53 Sez:Excessive steering play............................ 53 Sez:Noisy suspension................................... 54 Sez:Suspension oil leakage............................. 54 Cap:Electrical system...................................... 0 Sez:Components arrangement............................. 58 Sez:Conceptual diagrams................................ 63 Sez:Ignition........................................... 63 Sez:Battery recharge and starting...................... 64 Sez:Level indicators and enable signals section........ 66 Sez:Devices and accessories............................ 67 Sez:Lights and turn indicators......................... 68 Sez:Checks and inspections............................. 69 Sez:Immobiliser........................................ 69 Sez:Virgin circuit..................................... 72 Sez:Diagnostic codes................................... 73 Sez:Diagnostic code - 1 flash.......................... 74 Sez:Diagnostic code - 2 flashes........................ 74 Sez:Diagnostic code - 3 flashes........................ 75 Sez:Battery recharge circuit........................... 75 Sez:Stator check....................................... 75 Sez:Recharge system voltage check...................... 76 Sez:Fuses.............................................. 77 Sez:Dashboard.......................................... 78 Sez:Sealed battery..................................... 80 Sez:Connectors......................................... 80 Sez:Remote seat opening................................ 85 Sez:Zeroing............................................ 85 Sez:Programming........................................ 86 Cap:Engine from vehicle.................................... 0 Sez:Exhaust assy. Removal.............................. 88 Sez:Removal of the engine from the vehicle............. 88 Cap:Engine................................................. 93 Sez:Automatic transmission............................. 94 Sez:Transmission cover................................. 94 Sez:Air duct........................................... 95 Sez:Air duct filter.................................... 95 Sez:Removing the driven pulley shaft bearing........... 96 Sez:Refitting the driven pulley shaft bearing.......... 96 Sez:Baffle roller...................................... 97 Sez:Plastic roller..................................... 97 Sez:Removing the driven pulley......................... 98 Sez:Inspecting the clutch drum......................... 98 Sez:Removing the clutch................................ 98 Sez:Inspecting the clutch.............................. 99 Sez:Pin retaining collar...............................100 Sez:Removing the driven half-pulley bearing............100 Sez:Inspecting the driven fixed half-pulley............101 Sez:Inspecting the driven sliding half-pulley..........101 Sez:Refitting the driven half-pulley bearing...........102 Sez:Refitting the driven pulley........................103 Sez:Inspecting the clutch spring.......................103 Sez:Refitting the clutch...............................103 Sez:Refitting the driven pulley........................104 Sez:Drive-belt.........................................104 Sez:Removing the driving pulley........................105 Sez:Inspecting the rollers case........................106 Sez:Refitting the driving pulley.......................107 Sez:Refitting the transmission cover...................109 Sez:End gear...........................................111 Sez:Removing the hub cover.............................111 Sez:Removing the wheel axle............................111 Sez:Removing the hub bearings..........................112 Sez:Removing the wheel axle bearings...................113 Sez:Removing the driven pulley shaft bearing...........113 Sez:Inspecting the hub shaft...........................114 Sez:Inspecting the hub cover...........................115 Sez:Refitting the driven pulley shaft bearing..........115 Sez:Refitting the hub cover bearings...................117 Sez:Refitting the hub bearings.........................118 Sez:Refitting the ub cover.............................118 Sez:Flywheel cover.....................................119 Sez:Removing the hub cover.............................119 Sez:Removing the flywheel cover components.............120 Sez:Removing the stator................................121 Sez:Inspecting the cover components....................121 Sez:Refitting the stator...............................123 Sez:Refitting the flywheel cover components............124 Sez:Refitting the flywheel cover.......................126 Sez:Flywheel and starting..............................128 Sez:Removing the starter motor.........................131 Sez:Removing the flywheel magneto......................131 Sez:Inspecting the flywheel components.................134 Sez:Starter gear rim...................................135 Sez:Intermediate gear..................................135 Sez:Refitting the free wheel...........................136 Sez:Refitting the intermediate gear....................137 Sez:Refitting the flywheel magneto.....................138 Sez:Refitting the starter motor........................140 Sez:Cylinder assy. and timing system...................140 Sez:Removing the intake manifold.......................140 Sez:Removing the rocker-arms cover.....................141 Sez:Removing the timing system drive...................141 Sez:Removing the cam shaft.............................143 Sez:Removing the cylinder head.........................144 Sez:Removing the valves................................145 Sez:Removing the cylinder - piston assy................146 Sez:Inspecting the small end...........................147 Sez:Inspecting the wrist pin...........................147 Sez:Inspecting the piston..............................148 Sez:Inspecting the piston rings........................149 Sez:Removing the piston................................150 Sez:Choosing the gasket................................151 Sez:Refitting the piston rings.........................152 Sez:Refitting the cylinder.............................153 Sez:Inspecting the cylinder head.......................153 Sez:Inspecting the timing system components............154 Sez:Inspecting the valve sealings......................154 Sez:Inspecting the valve housings......................155 Sez:Inspecting the valves..............................155 Sez:Inspecting the valve stem guide clearance..........156 Sez:Inspecting the springs and half-cones..............158 Sez:Refitting the valves...............................158 Sez:Inspecting the cam shaft...........................159 Sez:Refitting the head and timing system components....161 Sez:Refitting the timing chain.........................167 Sez:Refitting the rocker-arms cover....................169 Sez:Refitting the intake manifold......................170 Sez:Crankcase - crankshaft.............................170 Sez:Splitting the crankcase halves.....................171 Sez:Removing the crankshaft............................172 Sez:Removing the countershaft..........................172 Sez:Replacing the countershaft bearings................173 Sez:Inspecting the crankshaft components...............175 Sez:Inspecting the crankshaft alignment................177 Sez:Inspecting the crankcase halves....................178 Sez:Inspecting the crankshaft plain bearings...........179 Sez:Coupling chart.....................................180 Sez:Countershaft.......................................182 Sez:Refitting the crankshaft...........................182 Sez:Refitting the crankcase halves.....................183 Sez:Lubrication........................................185 Sez:Conceptual diagrams................................186 Sez:General characteristics............................187 Sez:Diagnosis guide....................................188 Sez:Oil pressure check.................................190 Sez:Oil pump...........................................191 Sez:Removal............................................191 Sez:Refitting..........................................194 Cap:Injection..............................................197 Sez:Precautions........................................200 Sez:Terminals setup....................................202 Sez:EMS circuit diagram................................203 Sez:Troubleshooting procedure..........................204 Sez:Engine does not start..............................204 Sez:Starting difficulties..............................204 Sez:Engine stops at idle...............................205 Sez:Engine does not rev down...........................206 Sez:Exhaust backfires in deceleration..................206 Sez:Engine revs irregularly............................207 Sez:Poor performance at full throttle..................207 Sez:Engine knocking....................................208 Sez:Fuel supply system.................................208 Sez:Removing the butterfly valve.......................209 Sez:Pump supply circuit................................211 Sez:Circuit leak test..................................215 Sez:Fuel filter check..................................216 Sez:Inspecting the injector circuit....................217 Sez:Inspecting the injector hydraulics.................222 Sez:Immobiliser circuit................................223 Sez:Virgin circuit.....................................226 Sez:Diagnostic codes...................................227 Sez:Code 1.............................................228 Sez:Code 2.............................................229 Sez:Code 3.............................................229 Sez:Tachometer.........................................229 Sez:HT coil............................................231 Sez:Inspecting the spark plug shielded cap.............236 Sez:Spark advance......................................236 Sez:Coolant temperature sensor.........................238 Sez:Zeroing the throttle...............................239 Sez:Lambda probe.......................................241 Cap:Suspensions............................................247 Sez:Front..............................................248 Sez:Removing the front wheel...........................248 Sez:Front wheel hub overhaul...........................248 Sez:Handlebar..........................................250 Sez:Removal............................................250 Sez:Refitting..........................................250 Sez:The tilt mechanism.................................250 Sez:Hydraulic system layout............................250 Sez:Steering tubes.....................................251 Sez:Parallelogram device...............................257 Sez:Geared motor and Suspension locking system.........262 Sez:Electrical devices test............................275 Sez:Wheel alignment....................................287 Sez:Rear...............................................291 Sez:Removing the rear wheel............................291 Sez:Refitting the rear wheel...........................293 Sez:Swing-arm..........................................293 Sez:Removal............................................293 Sez:Overhaul...........................................295 Sez:Refitting..........................................298 Sez:Shock absorbers....................................299 Sez:Removal............................................299 Sez:Refitting..........................................300 Sez:Centre-stand.......................................300 Cap:Braking system......................................... 0 Sez:Rear brake calliper................................302 Sez:Removal............................................302 Sez:Overhaul...........................................302 Sez:Refitting..........................................304 Sez:Front brake calliper...............................304 Sez:Removal............................................304 Sez:Overhaul...........................................304 Sez:Refitting..........................................305 Sez:Rear brake disc....................................305 Sez:Removal............................................305 Sez:Refitting..........................................306 Sez:Disc Inspection....................................306 Sez:Front brake disc...................................307 Sez:Removal............................................307 Sez:Refitting..........................................308 Sez:Disc Inspection....................................308 Sez:Front brake pads...................................309 Sez:Removal............................................309 Sez:Refitting..........................................310 Sez:Rear brake pads....................................310 Sez:Removal............................................310 Sez:Refitting..........................................310 Sez:Fill...............................................310 Sez:Rear - combined....................................310 Sez:Front..............................................311 Sez:Brake pipes........................................312 Sez:Parking brake......................................313 Cap:Cooling system......................................... 0 Sez:Circuit diagram....................................316 Sez:Electric fan check.................................317 Sez:System sealing check...............................318 Sez:Coolant replacement................................318 Sez:Pompa acqua........................................319 Sez:diagnosis..........................................320 Sez:Excessive system pressure..........................321 Sez:Cooling fluid consumption..........................321 Sez:Oil in the fluid...................................321 Cap:Chassis................................................323 Sez:Seat...............................................324 Sez:Instrument panel...................................324 Sez:Front handlebar cover..............................324 Sez:Headlight assy.....................................325 Sez:Frame central cover................................326 Sez:Legshield..........................................327 Sez:Knee-guard.........................................328 Sez:Taillight assy.....................................331 Sez:Footrest...........................................332 Sez:Side fairings......................................332 Sez:License plate holder...............................332 Sez:Helmet bay.........................................333 Sez:spoiler............................................335 Sez:Fuel tank..........................................335 Sez:Rear...............................................336 Sez:Handles and top side fairings......................336 Sez:Radiator cover.....................................337 Sez:Battery............................................339 Sez:Lower cover........................................339 Cap:Pre-delivery........................................... 0 Sez:Aesthetic inspection...............................344 Sez:Tightening torques inspection......................344 Sez:Electrical system..................................345 Sez:Levels check.......................................346 Sez:Road test..........................................346 Sez:Static test........................................346 Sez:Functional inspection..............................347 Cap:Time...................................................349 Sez:Engine.............................................350 Sez:Crankcase..........................................350 Sez:Crankshaft.........................................351 Sez:Cylinder assy......................................352 Sez:Cylinder head assy.................................353 Sez:Rocker arms support assy...........................354 Sez:Cylinder head cover................................355 Sez:Flywheel cover.....................................356 Sez:Driven pulley......................................357 Sez:Oil pump...........................................358 Sez:Final gear assy....................................359 Sez:Driving pulley.....................................360 Sez:Transmission cover.................................361 Sez:Flywheel magneto...................................362 Sez:Butterfly valve....................................363 Sez:Exhaust pipe.......................................364 Sez:Air cleaner........................................365 Sez:Frame..............................................366 Sez:Centre-stand.......................................367 Sez:Legshield spoiler..................................368 Sez:Side fairings......................................369 Sez:Rear cover.........................................370 Sez:Central cover......................................370 Sez:Mudguard...........................................371 Sez:Fuel tank..........................................372 Sez:Rear shock-absorber................................373 Sez:Handlebar covers...................................374 Sez:Handlebar components...............................375 Sez:Swing-arm..........................................376 Sez:Seat...............................................377 Sez:Instrument panel...................................378 Sez:Locks..............................................379 Sez:Turn signal lights.................................380 Sez:Front wheel........................................382 Sez:Rear wheel.........................................383 Sez:Electric start.....................................384 Sez:Electric devices...................................385 Sez:Electronic controls................................387 Sez:Transmissions......................................388 Sez:Helmet bay.........................................389 Sez:Front suspension...................................389 Sez:Cooling system.....................................390 Sez:Braking system.....................................391 Sez:Stickers...........................................393 Sez:The tilt mechanism.................................393 Sez:Geared motor.......................................394 PARTS CATALOGUE ...........................................397
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