Gilera Fuoco 500 Guide

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.
"©Copyright2007-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
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 Sectionsmarked with this symbol indicatethe correct use of thevehicle
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 CHAS
PRE-DELIVERY PRE DE
TIME TIME

INDEX OF TOPICS
CHARACTERISTICS CHAR

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 connec-
tions.
Characteristics Fuoco 500 i.e.
CHAR - 2

Vehicle identification
Frame prefix (A):
ZAPM61100
Engine prefix (B):
M661M
Dimensions and mass
Fuoco 500 i.e. Characteristics
CHAR - 3

WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Kerb weight 253 ± 5 kg
Maximum weight allowed 445 kg
Maximum height 1.210 mm
Width 790 mm
Wheelbase 1.550 mm
length 2.210 mm
Track 420 mm
Engine
ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke with double spark plug
Cubic capacity 493 cm³
Bore x Stroke 94 x 71 mm
Compression ratio 10.5: 1
Engine idle speed 1,500 ± 100 rpm
Timing system Fourvalves,singleoverheadcamshaft,chaindriv-
en.
Valve clearance Inlet: 0.15 mm
Outlet: 0.15 mm
MAX. power 29 kW at 7,500 rpm
MAX torque 44 Nm at 5,200 rpm
Lubrication Engine lubrication with lobe pump (inside crank-
case)controlledbyachainwith double filter: mesh
and paper.
Lubrication pressure 3.5 ÷ 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Fuel supply Electronic injection with electric fuel pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque
server, V belt, dry self-ventilating automatic cen-
trifugal clutch and transmission housing with
forced air circulation.
Final reduction Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.7 l
Characteristics Fuoco 500 i.e.
CHAR - 4

Specification Desc./Quantity
Transmission oil 250 cm³
Cooling system fluid ~ 1.8 l
Fuel tank (reserve) ~ 12 l (~2 l)
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Start-up Electric
Ignition High efficiency electronic inductive ignition, inte-
grated with the injection system, with variable ad-
vance and separate HV coil.
Ignition advance Three-dimensional map managed by control unit
Spark plug NGK CR7EKB
Alternative spark plug -
Battery 12 V / 14 Ah, SEALED BATTERY
Generator In alternating current
Frame and suspensions
FRAME AND SUSPENSIONS
Specification Desc./Quantity
Chassis Tubular and sheet steel
Front suspension 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.
Front suspension travel 85 mm
Rear suspension Two double-acting shock absorbers, adjustable to
four positions at preloading.
Rear suspension travel 110 mm
Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 240 mm double disk with hydraulic control acti-
vated by the handlebar right-hand lever.
Rear brake disc brake, diameter 240 mm, with hydraulic servo
operatedfromthehandlebarwith theleft-handlev-
er.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy rims.
Front rim 12'' x 3.00
Fuoco 500 i.e. Characteristics
CHAR - 5

Specification Desc./Quantity
Rear rim 14'' x 4.50
Front tyre Tubeless 120/70-12" 51S or 51P
Rear tyre Tubeless 140/70 - 14" 68S or 68P reinf
Front tyre pressure (with passenger) 1.6 bar (1.8 bar)
Rear tyre pressure (with passenger) 2.4 bar (2.6 bar)
Tightening Torques
STEERING
Name Torque in Nm
Steering lower ring nut (central headstock) 22 ÷ 27 loosen by 90°
Steering upper ring nut (central headstock) 27 ÷ 33
Handlebar fixing screw 50 ÷ 55
Fixing screws for handlebar control assembly U-
bolts 7 ÷ 10
CHASSIS
Name Torque in Nm
Swinging arm set screw bushing 5 ÷ 7
Engine arm bolt - frame arm 32.5 ÷ 40
Swinging arm set screw bushing nut 54 ÷ 60
Engine-swinging arm bolt 98 ÷ 118
Frame-swinging arm bolt 54 ÷ 60
Centre stand bolt 31 ÷ 39
FRONT SUSPENSION
Name Torque in Nm
Shock absorber lower clamp 19 ÷ 26
Upper shock absorber clamp 19 ÷ 29
Front wheel fixing screws 19 ÷ 24
Steering arm bolt nut 20 ÷ 25
Tilt calliper fixing screws 20 ÷ 25
Front wheel shaft 74 ÷ 88
Arm coupling screws 45 ÷ 50
Screws fixing arms to side headstocks 45 ÷ 50
Screws fixing arms to central headstock 45 ÷ 50
Screws fixing the half-arm coupling flange 20 ÷ 25
Fixing screws for tilt locking disc section 20 ÷ 25
Side headstock upper ring nut 20 - 24
Side headstock lower ring nut 12 ÷ 15
Screw fixing sliding stem to shock absorber 45 ÷ 50
Clamp for sliding stem locking device 6.5 ÷ 10.5
Fixing nuts for constant-velocity universal joints 18 ÷ 20
Potentiometer to anti-tilting device clamp 8 ÷ 10
Electric motor to anti-tilting device clamp 11 ÷ 13
Clamp fixing pump bolt to anti-tilting device 11 ÷ 13
Pump to anti-tilting device clamp 11 ÷ 13
Pressure switch to distribution frame 18 ÷ 20
Sensor to tilt gripper clamp 2.5 ÷ 2.9
Pipe terminals to fifth wheel check spring 7 ÷ 11
Joint to anti-tilting device pump 20 ÷ 25
Characteristics Fuoco 500 i.e.
CHAR - 6

Name Torque in Nm
Lower fitting for shock absorber sliding locking
clamp pipes 20 ÷ 25
Upper fitting for shock absorber sliding locking
clamp pipes 20 ÷ 25
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 ÷ 41
Shock absorber lower clamp 33 ÷ 41
Shock absorber-crankcase attachment bracket 20 ÷ 25
Rear wheel axle 104 ÷ 126
Muffler arm clamping screws 27 ÷ 30
FRONT BRAKE
Name Torque in Nm
Calliper coupling screw 22 ÷ 27
Oil bleed screw 8÷12
Disc tightening screw (°) 5 - 6
Brake fluid pump - hose fitting 16 ÷ 20
Brake fluid hose-calliper fitting 20 ÷ 25
Screw tightening calliper to the support 20 ÷ 25
Calliper upper pipe fitting 20 ÷ 25
REAR BRAKE
Name Torque in Nm
Oil bleed screw 12÷16
Rear brake disc screws(°) 5 ÷ 6.5
Rear brake calliper-pipe fitting 20 ÷ 25
Rigid / flexible pipe fitting 13 ÷ 18
Rear brake pump-pipe fitting 16 ÷ 20
Rear brake calliper fixing screws 20 ÷ 25
pad fastening pin screws 20 ÷ 25
REAR BRAKE
Product Description Specifications
(°) Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium
strength threadlock
MUFFLER
Name Torque in Nm
Muffler heat guard fixing screw 4 ÷ 5
Screw for fixing muffler to the support arm 20 ÷ 25
Lambda probe clamp on exhaust manifold 40 ÷ 50
Exhaust manifold-muffler joint clamp 12 ÷ 13
Manifold - muffler diaphragm tightening clamp 16 ÷ 18
LUBRICATION
Name Torque in Nm
Oil pump cover screws 0.7 ÷ 0.9
Screws fixing oil pump to the crankcase 5 - 6
Fuoco 500 i.e. Characteristics
CHAR - 7

THERMAL UNIT AND TIMING SYSTEM
Name Torque in Nm
Spark plug 12 ÷ 14
Head fixing stud bolts: ***
Head fixing nuts 10 - 12
Exhaust / intake head fixing nuts: 10 - 12
Head lubrication control jet 5 - 7
Coolant temperature sensor 10 ÷ 12
counterweight mass fixing screw 7 - 8.5
Tensioner sliding block fixing screw: 10 - 14
Rpm timing sensor fixing screw: 3 - 4
injector fixing screw 3 ÷ 4
Rpm timing sensor fixing screw 3 ÷ 4
Valve lifter mass stop bell fixing screws: 30 - 35
inlet manifold fixing screws 11 - 13
Tappet cover fixing screws: 7 - 9
Throttle body fixing screws 11 ÷ 13
Camshaft retaining bracket fixing screws 4 - 6
Head fixing screws 10 - 12
Lambda probe on exhaust manifold 10 - 12
Muffler to bracket fixing screw 14 - 16
*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90° in a crossed sequence. - Tighten again by 90° in
a crossed sequence.
TRANSMISSION COVER
Name Torque in Nm
Driven pulley nut 92 - 100
Drive pulley nut 160 - 175
Anti-vibration roller screw 16.7 - 19.6
M8 retainers for transmission cover 23 - 26
M6 retainer 11 ÷ 13
Anti-vibration roller retainer 17 - 19
Clutch ring nut 65 - 75
Air deflector unit screws 7 ÷ 9
Water pump cover screws 3 ÷ 4
Outside transmission cover screws 7 ÷ 9
Flywheel cover screws 11 - 13
FLYWHEEL COVER
Name Torque in Nm
Flywheel fixing nut 115 - 125
Stator retainers 8 - 10
Blow-by recovery duct fixing screws 3 - 4
Screw fixing freewheel to flywheel 13 - 15
Stator cable harness guide bracket screws 3 - 4
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Countershaft fixing nut 25 - 29
Engine oil filter 12 - 16
Engine oil drainage plug 24 ÷ 30
Engine-crankcase coupling screws 11 ÷ 13
Oil pump screws 5 - 6
Characteristics Fuoco 500 i.e.
CHAR - 8

Name Torque in Nm
Gear mounting on crankshaft screws 10 -12
Bulkhead screws for oil pump housing cover 8 - 10
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Thermostat cover screws 3 ÷ 4
Bleed screw: 3
FINAL REDUCTION
Name Torque in Nm
Rear hub cover screws 24 ÷ 27
ENGINE ASSEMBLY
Name Torque in Nm
starter motor retainers 11 - 13
Overhaul data
Assembly clearances
Cylinder - piston assy.
Fuoco 500 i.e. Characteristics
CHAR - 9

HEIGHT TO MEASURE THE PISTON
Specification Desc./Quantity
A 10 mm
B 43 mm
CYLINDER - PISTON
Specification Desc./Quantity
Cylinder diameter C 94 +0.018-0.01mm
Piston diameter P 93.968 - ±0.014 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
Cylinder- Piston A 93.990÷93.997 93.954÷93.961 0.029÷0.043
Cylinder- Piston B 93.997÷93.004 93.961÷93.968 0.029÷0.043
Cylinder- Piston C 94.004÷94.011 93.968÷93.975 0.029÷0.043
Cylinder- Piston D 94.011÷94.018 93.975÷93.982 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
Characteristics Fuoco 500 i.e.
CHAR - 10

Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Rings/housing coupling clearances:
Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the
housing as shown in the drawing and check the
coupling clearances.
Top ring Standard coupling clearance:
0.01÷0.06 mm
Maximum clearances allowed after use: 0.10
mm
Intermediate ring Standard coupling clear-
ance: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 max-
imum limits specified in the table.
Fuoco 500 i.e. Characteristics
CHAR - 11

Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmission-side
shoulder 1 ± 0.025 A D = 0.20 ÷ 0.50
Half-shaft, trans-
mission side 20.9 - 0.05 B D = 0.20 ÷ 0.50
Connecting rod 22 0.10 - 0.15 C D = 0.20 ÷ 0.50
Flywheel-side
shoulder 1.8 ± 0.025 F D = 0.20 ÷ 0.50
Flywheel side half-
shaft 19.6 + 0.05 E D = 0.20 ÷ 0.50
Complete crank-
shaft 65.5 +0.1 -0.05 G D = 0.20 ÷ 0.50
Characteristics Fuoco 500 i.e.
CHAR - 12

Diameter of crankshaft bearings.
Measure the capacity on both axes x-y.
CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.010 ÷ 40.016
Cat. 2 Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Specific tooling
020335Y Magnetic support for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Fuoco 500 i.e. Characteristics
CHAR - 13

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 RE-
CESS 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 OR-
DER 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.
Characteristics Fuoco 500 i.e.
CHAR - 14