Gilera Runner 500cc.
Post Reply    Forum -> Project Reports 12Next
Author Message
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Nov 04, 2018 5:12 am quote
Hello, my name is Arno.
I live in the Netherlands.
When i was 16 years old, i baught myself a Gilera Runner 50cc.
I modified the engine, and drove it for years with great fun.

I sold it when i was 18, and baught a car.
I alway's liked the Runner, so i started to look for one to buy.
So 13 years later, i baught myself a 125cc Gilera Runner in Germany.
Imported it, and drove it for 2 years.

Since 2 years i took it appart to modify it to a 500cc.
I want to build it like it was build from the factory this way.
And the fairings and stickers will look just like 17 ears ago. (i own it for 4 years now)

First some pictures how i baught it, and how it looked in the 2 years of driving on the Dutch roads.








Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Nov 04, 2018 5:20 am quote
I am collecting parts for it for a while.
And testing how things will look, and fit.

I got the choise of 2 engines :

Piaggio X9 500 460cc Master engine.
Gilera Fuoco 500 493cc Twinspark Master engine.

For the front fork i will use the fork of a Piaggio Beverly 500.
I testfitted it here with the 12 inch wheel.





This is to small in my oppinion, so made a mockup with a 13 inch rear wheel.



This looks mutch better, and has more space for the dual disk brake system.
I want to have 2 brake disks at the front, just like the X9 and the Beverly have.
This looks nice, and stops realy well.

There is no wheel that looks like the original wheel of a Runner with the mounting brackets for 2 disk brakes.
So the front wheel will be costum made.

For brake disks i want to use the 240 disks.

Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Nov 04, 2018 5:34 am quote
To use the Piaggio Beverly 500 front fork, a new steering tube is made.



The 500cc Master engine will never fit the original Runner frame.
So a big part of the frame needs to be changed.
So i made a frame around the Runner frame, to attach the points where the fairings have to be attached.
And to keep the front section, and the rear section exact in line.

i can take sections out, and bolt them back on.
And when all things fit correct, i can weld it back together.

Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Nov 04, 2018 5:39 am quote
Here you see the braked to remove, and later reinstall the side stand.








And made the brackets to remove the footboard.
These are important to place back when the welding of the new frame starts.
When these are in place, i can put the fairings back on to measure several points.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Nov 04, 2018 5:47 am quote
Installed the 125cc 2 stroke engine in the Runner frame for the last time.
This was to measure the engine angle when it is installed.
The plan is to install the new engine in the same angle if this is possible.










Also made a bracked to fix the original wheelbase an wheel hight.




Molto Verboso
Vespa GTS 250ie
Joined: 02 Jun 2015
Posts: 1157
Location: San Francisco Bay Area
Mon Nov 05, 2018 9:05 am quote
I'm confused. Are you installing a 125cc engine or 500cc engine?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Nov 05, 2018 9:23 am quote
If you read the first post you can see i am converting it to a 500cc.
I only installed the original 125cc engine to measure the angle and wheelbase.
Molto Verboso
Vespa GTS 250ie
Joined: 02 Jun 2015
Posts: 1157
Location: San Francisco Bay Area
Mon Nov 05, 2018 9:39 am quote
I did read it but when you started using the 125 for fitment it through me off the scent. How does fitting the 125 help with the fitment of the much larger 500?
Molto Verboso
99 & 01 honda elite 50, 06 yamaha vino 125, 07 suzuki burgman 400 , 84 Aero 125, 05 Vespa LX 150, 2010 Honda Elite 110
Joined: 17 Dec 2006
Posts: 1384
Location: Maui Hawaii
Mon Nov 05, 2018 1:24 pm quote
I am so jealous... I always want a runner!!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Wed Nov 07, 2018 1:52 pm quote
Made a rolling dolly, with 2 car jacks.
With this i can move the engine below the frame.
And adjust the engine hight and angle.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Thu Nov 08, 2018 9:03 am quote
Took the Runner frame apart today.
Now you can clearly see why i made all these brackets.





Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Thu Nov 08, 2018 9:07 am quote
At this moment it looks like the original engine angle and wheelbase is possible.







Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Thu Nov 08, 2018 9:11 am quote
It looks like some of the engine parts need to be modified.
I want to try to keep the fairings in the original shape.











Molto Verboso
Vespa LX150 GTS250ie GTS300x2
Joined: 11 Dec 2009
Posts: 1980
Location: St. Pete, Fla
Thu Nov 08, 2018 1:06 pm quote
WOW!!!!
This is a amazing project with great pictures. Keep posting pictures and info Please.
Ken
Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 688
Location: Toronto
Thu Nov 08, 2018 4:08 pm quote
I really like your staging rig! Did you fabricate it all yourself?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Thu Nov 08, 2018 10:44 pm quote
berto wrote:
I really like your staging rig! Did you fabricate it all yourself?
Yes, me and my welding machine
Hooked
GTS 250
Joined: 26 Apr 2008
Posts: 218
Location: California
Fri Nov 09, 2018 11:04 am quote
Nice work!
Lurker
Gilera Runner FX 125
Joined: 10 Nov 2018
Posts: 3
Location: Croatia
Sat Nov 10, 2018 4:24 am quote
Very nice project!

Quite professional angel, reminds me of 240z build by b is for build.
Keeping same wheelbase will be difficult, what is difference in engine lengths(original BB and master)?
What about shocks, master has 2...Do you plan to use original shock mounts positions on frame or move them? Old vx/vxr frames already have 2 mounts standard but geometry is not the same like on fx/fxr/sp (tested ).
With engine in this position cooling lines seems like impossible mission. Fuel tank can be problem too, comes quite close to original engine.
Master engine is injection? Fuel pump in tank or?

Enough questions for first post
Good luck and cant wait to se progress!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sat Nov 10, 2018 4:33 am quote
The waterpump will be removed and replaced with a electrical pump.
Fueltank wil be modified.
Rear suspension will be double from a fuoco 500.
Variator cooling will be electric aswel.
New radiator has to be made.
Cooling lines on the cilinderhead will be changed.
Front master brake cilinder must be modified.
Injection system with a stand alone ecu, like KMS.

And the list goes on and on....
Not a easy quick build.
Veni, Vidi, Posti
74 50s x2 78 P200 84 Cosa 58 AllState 68 Sprint 80 50special + projects
Joined: 22 Nov 2010
Posts: 7000
Location: seattle/athens
Mon Nov 12, 2018 4:06 pm quote
Very ambitious build, but looks to be on track. I like your approach.
Should be a very exciting ride.
Arnoh wrote:
...
I got the choice of 2 engines :

Piaggio X9 500 460cc Master engine.
Gilera Fuoco 500 493cc Twinspark Master engine.

...
Do they both fit in the same? Sounds like they are very similar, can you please tell us more? Have you decided which you will use?
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Nov 12, 2018 11:08 pm quote
I will use the Fuoco 493cc engine.
This has the same engine mounting points.
But only the bearings in the lower mounting points are installed.
But this can be swapped.

And the Fuoco engine has a center stand on it.
There are mounting points installed on this engine for the center stand.

The X9 engine doesnt have this.



Hooked
Kawasaki Z1000, Yamaha R1, Honda SH300i, Gilera DNA180
Joined: 08 Oct 2008
Posts: 113
Location: London, UK
Fri Nov 23, 2018 5:47 am quote
Me like
Hooked
GTS 250ie Super, Italjet Velocifero, Scarabeo 150, S50,ET4
Joined: 22 Nov 2016
Posts: 376
Location: Winston-Salem, NC
Fri Nov 23, 2018 1:14 pm quote
Well done Arnoh, this will keep you busy.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Wed Jan 02, 2019 12:08 am quote
Okay, so the engine is hanging freely in the frame now.
And started with building the new frame tubes.



Measuring, bending, measuring, bending...

















And it al fits perfect.
The tubes need some extra work to make them extra strong in the short bends.
It is a lot of work, but it can be done.
The other side is even harder, because the engine is thicker there (distribution chain sits there)
Hooked
GTS 250
Joined: 26 Apr 2008
Posts: 218
Location: California
Thu Jan 03, 2019 5:52 pm quote
Nice work!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Jan 14, 2019 6:17 am quote
Made 2 ribs yesterday.
It all fits how i mentioned.
The floor parts can be welded on the ribs later.



Molto Verboso
GTV300 (wife's)
Joined: 08 Nov 2014
Posts: 1110
Location: Central New York
Thu Jan 17, 2019 6:13 am quote
Very interesting build! More or less hang engine on air and build scooter around it.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Fri Jan 18, 2019 2:07 am quote
kshansen wrote:
Very interesting build! More or less hang engine on air and build scooter around it.
Correct, and by this way the engine can be easy moved.
And i can still put it on the dolly afterwards and roll it away.
Molto Verboso
08 GTS 250, 79 P200E, 62 Allstate
Joined: 11 Jan 2006
Posts: 1181
Location: Florence, OR
Mon Jan 21, 2019 5:43 am quote
You sir, are a wizard! Great job and thanks so much for taking us along.
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Tue Jan 22, 2019 10:52 am quote
On the upper left, the original Runner 220 front brake disk.
On the lower right, the 240 brake disk that i wanted to use in the first time for the front wheel.
That is the Gilera fuoco 500 rear disk.

And the disk i am going to use, is the lower left brake disk.
This is a 240mm disk, and it is the rear brake disk from a 2010 Piagio Beverly 300.

This looks the most like the original front brake disk.

Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Tue Jan 22, 2019 10:55 am quote
And the latest designs for the new double disk 13 inch front wheel for the Runner.





Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Jan 27, 2019 12:35 pm quote
Owww yeah, looking good 😎😎😎



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun Jan 27, 2019 12:42 pm quote
And the new rear adjustable Bitubo shocks arrived.
And for the front, the Bitubo springs and oil.







Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 688
Location: Toronto
Sun Jan 27, 2019 12:56 pm quote
Good stuff!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Feb 18, 2019 4:58 am quote
And some pictures of the progres of the front wheel.







Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Feb 18, 2019 5:02 am quote
And started with the right side.





Making the bends extra strong.



Addicted
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 688
Location: Toronto
Mon Feb 18, 2019 1:23 pm quote
Thanks for the pics!!
Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Feb 25, 2019 6:35 am quote
And the new frame is getting together.
Welded the first tubes today.
Its asymmetric and build around the engine.
A verry tight fit.
The rear is temporarily, wil modify it later.



Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Mon Feb 25, 2019 6:39 am quote
Baught a verry nice Piaggio Beverly cruiser in Germany.
Verry low milage, only 3200Km.
Wil use the engine from this Cruiser (493cc) for the Runner.







Enthusiast
Gilera Runner 500cc.
Joined: 11 Mar 2014
Posts: 64
Location: Netherlands
Sun May 05, 2019 6:29 am quote
Resumed with the frame.
Build the rest of the frame tubes.
Alligned them and welded everything.
And made the engine bracked.
The engine hangs in the frame now, and the next step is to build the shock absorber mounts.













2019 Fall Gathering - September 12 - 15, Hungry Mother State Park, Marion, VA   Vespa Wasp Pin Badges   Cool Ass scooter seat cover
Post Reply    Forum -> Project Reports 12Next
[ Time: 0.9331s ][ Queries: 23 (0.1439s) ][ Debug on ]