Gilera Fuoco 500 - Engine Removal

Gilera Fuoco 500

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Table of Contents

Index of Topics5
Characteristics7
Safety Rules8
Maintenance Rules8
Vehicle Identification9
Dimensions and Mass9
Electrical System11
Wheels and Tyres11
Table of Contents12
Upper Shock Absorber Clamp13
- Overhaul Data15
- Assembly Clearances15
- Cylinder - Piston Assy.15
- Coupling Categories16
- Height to Measure the Piston16
- Piston Rings16
- Cylinder - Piston16
- Rings/Housing Coupling Clearances17
- Crankcase - Crankshaft - Connecting Rod18
- Axial Clearance between Crankshaft and Connecting Rod18
- Diameter of Crankshaft Bearings19
- Max. Admissible Displacement19
- Slot Packing System20
- Recommended Products Table21
- Products21
- Base Gasket Thickness21
- Tooling23
- Specific Tools24
- Maintenance35
- Maintenance Chart36
- Every 2 Years36
- After 1,000 Km36
- After 10,000 Km; 50,000 Km; 70,000 Km37
- After 15,000 Km; 45,000 Km; 75,000 Km37
- After 20,000 Km; 40,000 Km; 60,000 Km and 80,000 Km37
- Checking the Spark Advance38
- 30,000 Km38
- Spark Plug40
- Hub Oil41
- Replacement41
- Air Filter42
- Engine Oil42
- Engine Oil Filter45
- Oil Pressure Warning Light45
- Oil Top up45
- Adding Engine Coolant46
- Cooling System46
- Checking the Ignition Timing46
- Braking System Level Check47
- Top-Up47
- Headlight Adjustment48
- To Access the Headlight Adjusting Screws48
- Troubleshooting51
- Engine52
- Excessive Oil Consumption/Exhaust Smoke52
- Insufficient Lubrication Pressure52
- Clutch Grabbing or Performing Inadequately52
- Excessive Steering Play53
- Heavy Steering53
- Brakes Overheating53
- Insufficient Braking53
- Noisy Suspension54
- Suspension Oil Leakage54
- Electrical System55
- Components Arrangement58
- Ignition64
- Battery Recharge and Starting65
- Level Indicators and Enable Signals Section66
- Devices and Accessories67
- Lights and Turn Indicators68
- Checks and Inspections69
- Immobiliser70
- With the Key Switch Set to off71
- With the Key Switch in the off Position71
- Virgin Circuit72
- Diagnostic Codes73
- Diagnostic Code - 1 Flash74
- Diagnostic Code - 2 Flashes75
- Diagnostic Code - 3 Flashes75
- Battery Recharge Circuit75
- Stator Check75
- Voltage Regulator/Rectifier76
- Recharge System Voltage Check76
- Fuses77
- Fuse Table78
- Dashboard79
- Sealed Battery80
- Connectors81
- Injection Electronic Control Unit81
- Pick-Up Connector81
- Voltage Regulator Connector82
- Saddle Opening Receiver Connector82
- Turn Indicator Control Device Connector82
- Instrument Panel Connector "A"83
- Hv Coil Connector83
- Fuel Pump Connector83
- Anti-Theft Device Pre-Installation Connector83
- Instrument Panel Connector "B"84
- Parking Control Ecu Connector84
- Remote Seat Opening85
- Zeroing85
- Programming86
- Engine from Vehicle87
- Exhaust Assy. Removal88
- Removal of the Engine from the Vehicle88
- Transmission Cover94
- Automatic Transmission94
- Air Duct95
- Air Duct Filter96
- Removing the Driven Pulley Shaft Bearing96
- Refitting the Driven Pulley Shaft Bearing97
- Baffle Roller97
- Plastic Roller97
- Removing the Driven Pulley98
- Inspecting the Clutch Drum98
- Removing the Clutch99
- Inspecting the Clutch99
- Removing the Driven Half-Pulley Bearing100
- Pin Retaining Collar100
- Inspecting the Driven Fixed Half-Pulley101
- Inspecting the Driven Sliding Half-Pulley102
- Refitting the Driven Half-Pulley Bearing102
- Refitting the Driven Pulley103
- Inspecting the Clutch Spring103
- Refitting the Clutch104
- Drive-Belt105
- Removing the Driving Pulley105
- Inspecting the Rollers Case106
- Refitting the Driving Pulley107
- Refitting the Transmission Cover109
- End Gear111
- Removing the Hub Cover111
- Removing the Wheel Axle112
- Removing the Hub Bearings112
- Removing the Wheel Axle Bearings113
- Inspecting the Hub Shaft114
- Inspecting the Hub Cover115
- Refitting the Hub Cover Bearings117
- Refitting the Hub Bearings118
- Refitting the Ub Cover118
- Flywheel Cover119
- Removing the Flywheel Cover Components120
- Removing the Stator121
- Inspecting the Cover Components121
- Refitting the Stator124
- Refitting the Flywheel Cover Components124
- Refitting the Flywheel Cover126
- Flywheel and Starting128
- Starter Motor130
- Battery130
- Start-Up Remote Control Switch130
- Starter Transmission130
- Removing the Flywheel Magneto131
- Removing the Starter Motor131
- Refitting the Intermediate Gear137
- Refitting the Flywheel Magneto138
- Refitting the Starter Motor140
- Cylinder Assy. and Timing System140
- Removing the Intake Manifold141
- Removing the Rocker-Arms Cover141
- Removing the Timing System Drive141
- Removing the Cam Shaft143
- Removing the Cylinder Head144
- Removing the Valves145
- Removing the Cylinder - Piston Assy.146
- Inspecting the Small End147
- Inspecting the Wrist Pin147
- Inspecting the Piston148
- Inspecting the Piston Rings149
- Removing the Piston150
- Choosing the Gasket151
- Refitting the Piston Rings153
- Refitting the Cylinder153
- Inspecting the Cylinder Head153
- Maximum Allowable Run-Out154
- Inspecting the Valve Sealings154
- Inspecting the Timing System Components154
- Inspecting the Valve Housings155
- Inspecting the Valves155
- Standard Diameter155
- Minimum Admissible Diameter156
- Inspecting the Valve Stem Guide Clearance156
- Inlet157
- Outlet157
- Standard Valve Length157
- Inspecting the Springs and Half-Cones158
- Refitting the Valves158
- Admissible Limits159
- Standard Height159
- Inspecting the Cam Shaft159
- Refitting the Head and Timing System Components161
- Prescribed Clearance167
- Refitting the Timing Chain167
- 020460Y Scooter Diagnosis and Tester168
- 020330Y Stroboscopic Light for Timing Control168
- Refitting the Rocker-Arms Cover169
- Refitting the Intake Manifold170
- Crankcase - Crankshaft170
- 020335Y Magnetic Support for Dial Gauge171
- 020262Y Crankcase Splitting Strip171
- Splitting the Crankcase Halves171
- Removing the Crankshaft172
- Removing the Countershaft173
- Replacing the Countershaft Bearings173
- Inspecting the Crankshaft Components176
- Inspecting the Crankshaft Alignment177
- Max Admissible Displacement177
- Inspecting the Crankcase Halves178
- Inspecting the Crankshaft Plain Bearings179
- Check the Bench Bush180
- Coupling Chart180
- Countershaft182
- Refitting the Crankshaft182
- Refitting the Crankcase Halves184
- Lubrication185
- Technical Specifications185
- Sump Capacity185
- Recommended Engine Oil185
- Pre-Filter186
- Oil Filter186
- Oil Minimum Pressure Indicator Light Switch186
- Head Lubrication Control Jet186
- General Characteristics187
- Conceptual Diagrams187
- Diagnosis Guide188
- Standard Values189
- Oil Pressure Check190
- Oil Pump191
- Injection197
- Precautions200
- Terminals Setup202
- Terminal Layout202
- EMS Circuit Diagram203
- System Schematic203
- Troubleshooting Procedure204
- Engine Does Not Start204
- Starting Difficulties205
- Engine Start-Up Problems205
- Engine Stops at Idle205
- Engine Does Not Rev down206
- Exhaust Backfires in Deceleration206
- Engine Revs Irregularly207
- Poor Performance at Full Throttle207
- Engine Knocking208
- Fuel Supply System208
- Presence of Knocking (Overhead Knocking)208
- Removing the Butterfly Valve209
- Pump Supply Circuit211
- Injection Loads212
- Electrical Data212
- Fuel Filter Check216
- Inspecting the Injector Circuit218
- Code 1228
- Code 2229
- Code 3229
- Tachometer230
- HT Coil231
- Spark Advance236
- Inspecting the Spark Plug Shielded Cap236
- Coolant Temperature Sensor238
- Temperature Sensor238
- Zeroing the Throttle239
- Resetting the Throttle Valve Position Signal (TPS Reset)239
- Lambda Probe242
- Suspensions247
- Removing the Front Wheel248
- Front Wheel Hub Overhaul248
- The Tilt Mechanism250
Handlebar Fixing Screw250
- Steering Tubes251
- Hydraulic System Layout251
- Parallelogram Device257
Side Headstock Lower Ring Nut257
Fixing Nuts for Constant-Velocity Universal Joints257
Arm Coupling Screws261
Screws Fixing Arms to Side Headstocks261
Screws Fixing Arms to Central Headstock261
Screws Fixing the Half-Arm Coupling Flange261
Geared Motor and Suspension Locking System262
Fixing Screws for Tilt Locking Disc Section262
Clamp Fixing Pump Bolt to Anti-Tilting Device264
- 020376Y Adaptor Handle271
- Pressure Switch275
- Electrical Devices Test275
- Geared Motor278
- Tilt Locking-Unlocking Switch279
- Tilt Locking Calliper Sensor281
- Potentiometer282
- Rider Presence Sensor283
- Tone Wheel Sensor284
- Wheel Alignment287
- Tool Fitting287
- Removing the Rear Wheel291
- Refitting the Rear Wheel293
- Swing-Arm293
- Overhaul295
- Shock Absorbers299
- Swinging Arm Fitting299
Centre Stand Bolt300
- Braking System301
- Rear Brake Calliper302
- Front Brake Calliper304
- Rear Brake Disc305
- Disc Inspection307
- Front Brake Disc307
- Front Brake Pads309
- Rear Brake Pads310
- Rear - Combined311
- Brake Pipes312
- Parking Brake313
- Circuit Diagram316
- Electric Fan Check317
- System Sealing Check318
- Coolant Replacement319
- System Top-Up Rules319
- Pompa Acqua319
- Water Pump319
- Removing the Water Pump Cover320
- Oil in the Fluid321
- Cooling Fluid Consumption321
- Excessive System Pressure321
- Chassis323
- Instrument Panel324
- Front Handlebar Cover325
- Headlight Assy.325
- Frame Central Cover327
- Legshield328
- Knee-Guard329
- Taillight Assy.331
- Footrest332
- Side Fairings332
- License Plate Holder333
- Helmet Bay333
- Fuel Tank335
- Handles and Top Side Fairings337
- Radiator Cover337
- Lower Cover339
- Pre-Delivery343
- Aesthetic Inspection344
- Tightening Torques Inspection344
- Front Wheel Fixing Screws345
- Static Control after the Test Ride346
- Static Test346
- Road Test346
- Functional Inspection347
- Time349
- Crankcase351
- Crankshaft352
- Cylinder Assy.353
- Cylinder Head Assy.354
- Rocker Arms Support Assy.355
- Cylinder Head Cover356
- Driven Pulley358
- Final Gear Assy.360
- Driving Pulley361
- Flywheel Magneto363
- Butterfly Valve364
- Exhaust Pipe365
- Air Cleaner366
- Frame367
- Legshield Spoiler369
- Central Cover371
- Mudguard372
- Fuel Tank373
- Rear Shock-Absorber374
- Handlebar Covers375
- Handlebar Components376
- Seat378
- Locks380
Front Wheel383
- Rear Wheel384
- Electric Start385
- Electric Devices386
- Electronic Controls387
- Cable Harness387
- Transmissions388
- Helmet Compartment389
Front Suspension390
Stickers393

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