Gilera Fuoco 500 - Vehicle Identification; Dimensions and Mass

Gilera Fuoco 500

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Vehicle identification

Frame prefix (A):

ZAPM61100

Engine prefix (B):

M661M

Dimensions and mass

Fuoco 500 i.e. Characteristics

CHAR - 3

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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