2006-2010 Gilera Fuoco 500 Service Repair Manual – PDF Download

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2006-2010 Gilera Fuoco 500 Service Repair Manual

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2006-2010 Gilera Fuoco 500 Service Repair Manual

LANGUAGE:ENGLISH
PAGES:502
DOWNLOADABLE:YES
FILE TYPE:PDF

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DESCRIPTION:

2006-2010 Gilera Fuoco 500 Service Repair Manual

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

TABLE OF CONTENTS:

2006-2010 Gilera Fuoco 500 Service Repair Manual

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

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