Gilera Fuoco Workshop 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 CHAS

PRE-DELIVERY PRE DE

TIME 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

Characteristics Fuoco 500 i.e.

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 Four valves, single overhead camshaft, chain driv-

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) controlled by a chain with 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

Capacities

CHAR - 4

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.

CAPACITY

Specification Desc./Quantity

Engine oil 1.7 l

Fuoco 500 i.e. Characteristics

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

Specification Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The tilt mechanism is composed of an articulated

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to

Rear suspension travel 110 mm

Brakes

Specification Desc./Quantity

Front brake Ø 240 mm double disk with hydraulic control acti-

Rear brake disc brake, diameter 240 mm, with hydraulic servo

FRAME AND SUSPENSIONS

parallelogram suspension with die-cast aluminium
control arms and two side headstocks plus shock

absorbers with hydraulic locking system.

four positions at preloading.

BRAKES

vated by the handlebar right-hand lever.

operated from the handlebar with the left-hand lev-

er.

Wheels and tyres

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 12'' x 3.00

WHEELS AND TYRES

CHAR - 5

Characteristics Fuoco 500 i.e.

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

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

7 ÷ 10

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

CHAR - 6

Fuoco 500 i.e. Characteristics

Name Torque in Nm

Lower fitting for shock absorber sliding locking

clamp pipes

Upper fitting for shock absorber sliding locking

clamp pipes

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

20 ÷ 25
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

CHAR - 7

Characteristics Fuoco 500 i.e.

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

CHAR - 8

Fuoco 500 i.e. Characteristics

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.

CHAR - 9

Characteristics Fuoco 500 i.e.

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

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

Characteristics Fuoco 500 i.e.

Crankcase - crankshaft - connecting rod

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Transmission-side

shoulder

Half-shaft, trans-

mission side

Connecting rod 22 0.10 - 0.15 C D = 0.20 ÷ 0.50

Flywheel-side

shoulder

Flywheel side half-

shaft

Complete crank-

shaft

1 ± 0.025 A D = 0.20 ÷ 0.50

20.9 - 0.05 B D = 0.20 ÷ 0.50

1.8 ± 0.025 F 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

CHAR - 12

Fuoco 500 i.e. Characteristics

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

CHAR - 13

Characteristics Fuoco 500 i.e.

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. Characteristics

Characteristic

Compression ratio

10.5: 1

BASE GASKET THICKNESS

Name Measure A Thickness

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05
«A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05
«A» MEASURE TAKEN + 0.10 - + 0.185 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 Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the

requirements of API GL3 specifi-

cations

AGIP CITY HI TEC 4T Oil to lubricate flexible transmis-

sions (throttle control)

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3,

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

SPECIAL AGIP PERMANENT

fluid

coolant Monoethylene glycol-based anti-

Oil for 4-stroke engines

for increased adhesiveness

based spray grease with NLGI 2;

ISO-L-XBCIB2

JASO MA Synthetic oil

freeze fluid, CUNA NC 956-16

CHAR - 15

Characteristics Fuoco 500 i.e.

CHAR - 16

INDEX OF TOPICS

TOOLING TOOL

Tooling Fuoco 500 i.e.

SPECIFIC TOOLS CORRECT

Stores code Description

001330Y Tool for fitting steering seats

001467Y002 Driver for OD 73 mm bearing

001467Y006 Extraction pliers for 20 mm bear-

ings

001467Y007 Driver for OD 54 mm bearing

001467Y008 Extraction pliers for ø 17 mm

bearings

001467Y014 Extraction pliers for ø 15 mm

bearings

TOOL - 2

Fuoco 500 i.e. Tooling

Stores code Description

001467Y031 Bell

001467Y034 Extraction pliers for ø 15 mm

bearings

001467Y035 Bearing housing outside diame-

ter 47 mm

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

Tooling Fuoco 500 i.e.

Stores code Description

020151Y Air heater

020193Y Oil pressure gauge

020201Y Spacer bushing driving tube
020262Y Crankcase splitting strip

020306Y Punch for assembling valve seal

rings

020329Y Mity-Vac vacuum operated

pump

TOOL - 4

020330Y Stroboscopic light for timing con-

trol

Fuoco 500 i.e. Tooling

Stores code Description

020331Y Digital multimeter

020333Y Single battery charger

020334Y Multiple battery charger

020335Y Magnetic support for dial gauge

020357Y 32 x 35 mm adaptor
020358Y 37x40 mm adaptor
020359Y 42 x 47 mm adaptor

TOOL - 5

Tooling Fuoco 500 i.e.

Stores code Description

020360Y 52 x 55 mm adaptor

020364Y 25 mm guide

020376Y Adaptor handle

020382Y012 bush (valve removing tool)

020412Y 15 mm guide

020424Y Driven pulley roller casing fitting

punch

020431Y Valve oil seal extractor

TOOL - 6

Fuoco 500 i.e. Tooling

Stores code Description

020434Y Oil pressure control fitting

020439Y 17 mm guide

020444Y Tool for fitting/ removing the driv-

en pulley clutch

020456Y Ø 24 mm adaptor

020458Y Puller for lower bearing on steer-

ing tube

TOOL - 7

Tooling Fuoco 500 i.e.

Stores code Description

020459Y Punch for fitting bearing on steer-

ing tube

020460Y Scooter diagnosis and tester

020467Y Flywheel extractor

020468Y Piston fitting band

020469Y Reprogramming kit for scooter

diagnosis tester

TOOL - 8

Fuoco 500 i.e. Tooling

Stores code Description

020470Y 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

Tooling Fuoco 500 i.e.

Stores code Description

020478Y Punch for driven pulley roller cas-

ing

020479Y Countershaft lock wrench

020480Y Petrol pressure check set

020481Y Control unit interface wiring

020482Y Engine support

020483Y 30 mm guide

TOOL - 10

Fuoco 500 i.e. Tooling

Stores code Description

020512Y Piston fitting fork

020527Y Engine support base

020604Y011 Fitting adapter

020565Y Flywheel lock calliper spanner

Marelli MIU diagnosis software Marelli MIU diagnosis software

020640y software euro3

TOOL - 11

Tooling Fuoco 500 i.e.

TOOL - 12

INDEX OF TOPICS

MAINTENANCE MAIN

Maintenance Fuoco 500 i.e.

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

60'

Coolant - change
Brake fluid - change

60'

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

EVERY 2 YEARS

Action

AFTER 1,000 KM

Action

AFTER 5,000 KM; 25,000 KM; 35,000 KM; 55,000 KM; 65,000 KM

10'

Engine oil - level check/top-up
Brake pads - check condition and wear
Centre stand - lubrication

MAIN - 2

Action

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

Maintenance Fuoco 500 i.e.

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 Fuoco 500 i.e.

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 sup-

plied;

- Upon refitting, place the spark plugs at the re-

quired 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 inser-

ted.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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 border-

line 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. 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 Fuoco 500 i.e.

MAIN - 16

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Troubleshooting Fuoco 500 i.e.

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 Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves 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

have not been fitted properly

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Replace the piston cylinder unit or just the piston

rings

pling seal

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch 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 anom-

fully clean the By-Pass area.

components

type

alous way

TROUBL - 2

Fuoco 500 i.e. Troubleshooting

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation

Inefficient braking system 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.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Brake disc slack or distorted 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 Operation

Defective sliding of pistons Check calliper and replace any damaged part.

Brake disc slack or distorted 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.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Re-inflated or glued rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing 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 Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

TROUBL - 3

Troubleshooting Fuoco 500 i.e.

Possible Cause Operation

if they are recessed or if the balls are squashed,

replace them.

Noisy suspension

NOISY SUSPENSION

Possible Cause Operation

Malfunctions in the suspension system If the front suspension is noisy, check: the efficien-

cy 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 Operation

Seal fault or breakage Replace the shock absorber Check the condition

of wear of the steering covers and the adjust-

ments.

TROUBL - 4

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Electrical system Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 per-

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

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

Electrical system Fuoco 500 i.e.

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 Desc./Quantity

Type Non-adjustable three-phase transistor

ELE SYS - 22

Fuoco 500 i.e. Electrical system

Specification Desc./Quantity

Voltage 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

Electrical system Fuoco 500 i.e.

FUSE TABLE

Specification Desc./Quantity

1 Fuse No. 1 Capacity: 7.5 A

Protected circuits:Injection ECU battery

power

2 Fuse No. 2 Capacity: 15 A

Protected circuits:Battery-powered injec-

tion loads, electrical fan

3 Fuse No. 3 Capacity: 15 A

Protected circuits:Battery-powered saddle

opening switch, glove-box lighting, light

switch, turn indicator switch, antitheft instal-

lation, fuse No. 12

4 Fuse No. 4 Capacity: 20A

Protected circuits:battery-powered ECU for

parking control

5 Fuse No. 5 Capacity: 20A

Protected circuits:battery-powered fuse

No. 7, live fuses No. 8 - No. 9 - No.10 - No.

11

6 Fuse No. 6 Capacity: 15 A

Protected circuits:L.V. socket.

7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:Battery-powered instru-

ment panel

8 Fuse No. 8 Capacity: 10A

Protected circuits:Live stop, start-up and

start-up enabling switch and start-up circuit.

9 Fuse No. 9 Capacity: 7.5 A

Protected circuits:live passing and horn

10 Fuse No. 10 Capacity: 7.5A

Protected circuits:Live injection ECU, im-

mobilizer aerial, electric fan remote control,

injection loads remote control

11 Fuse No. 11 Capacity: 7.5A

Protected circuits:Live ECU parking lever,

antitheft installation, instrument panel, head-

light remote control, horn

12 Fuse No. 12 Capacity: 7.5A

Protected circuits:Live turn indicator con-

trol, saddle opening switch, tail lights, panel

lighting

ELE SYS - 24

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 sen-

sor (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 Fuoco 500 i.e.

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 CON-

NECTOR

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. 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 Fuoco 500 i.e.

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 (Brown-

White)

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 (Grey-

Black)

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 (Grey-

Black)

6A. Headlight remote control (White-Black)
7A. Potentiometer ground lead, rpm sensor, rider

presence sensor (Yellow)

ELE SYS - 30

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 Fuoco 500 i.e.

- 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. 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 Fuoco 500 i.e.

ENG VE - 6

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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

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. 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 Fuoco 500 i.e.

- 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