Road side help! Long beep and the scooter won't start at all
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Enthusiast
MP3 500
Joined: 16 May 2008
Posts: 72
Location: New York City!
Wed Jun 01, 2011 5:35 pm quote
I had a nice long ride with my MP3 500 over the long weekend and was planning to put a happy post, but it was not to be.
I went on a short ride this afternoon about 30 miles out, everything seems fine on the highway but after I got to the destination and I was coming off the exit ramp I noticed something weird. When I roll the throttle the scooter would back fire but I would get no power. After repeating it a few time it would "catch". But when I let go of the throttle I would again not be able to engage the engine.
This went on for about a mile and at the first stop light, the engine just stopped. This is when I really get stucked. The scooter makes a long 6 second long beep sound stops for 2-3 seconds and then the beep sounds again. The oil light came on for some reason, even though I just got the scooter serviced. Also the seat sensor also lights up and stayed lit even though I was still sitting on the scooter.
Having encounter something similar before, I tried switching the scooter off and switching it back on. The seat sensor light would go off momentarily but I still couldn't start the scooter. When I try to start the scooter it makes the same sound as if the battery is dead.
I had to leave her by the side of the road and get a ride back home.. Something is wrong but I am not sure what, if I can at least get her back home and to the dealer whom did the service recently I am sure they can solve the problem, just hoping that I can avoid the hassle and expense of getting her towed...
Any suggestion would be great, perhaps the alternator is not charging the battery and its dead?
Ossessionato
Red MP3 500 RUBY DRAGON
Joined: 29 Nov 2008
Posts: 2571
Location: Northern CA
Wed Jun 01, 2011 5:39 pm quote
Sounds like that tricky fuse is at it again. Easy fix too.
Ossessionato
MP3 400 / BV200
Joined: 02 Jun 2009
Posts: 2998
Location: San Diego, California
Wed Jun 01, 2011 5:55 pm quote
So your speaking of the 30 amp hidden fuse right? Not sure of the location on a 500. Please give details.
Enthusiast
MP3 500
Joined: 16 May 2008
Posts: 72
Location: New York City!
Wed Jun 01, 2011 6:45 pm quote
Quick update on the situation and a bit more info, I went back to the scooter and managed to start it with out any problem, but I immediately noticed that the lights are dim and it appears that the battery is dead.
Would the hidden fuse cause the battery to not charge while the scooter is running?
Ossessionato
Red MP3 500 RUBY DRAGON
Joined: 29 Nov 2008
Posts: 2571
Location: Northern CA
Wed Jun 01, 2011 7:00 pm quote
frostbite wrote:
Quick update on the situation and a bit more info, I went back to the scooter and managed to start it with out any problem, but I immediately noticed that the lights are dim and it appears that the battery is dead.
Would the hidden fuse cause the battery to not charge while the scooter is running?
I believe so!
Enthusiast
2008 Piaggio MP3-400
Joined: 11 Feb 2011
Posts: 77
Location: Rochester, NY
Wed Jun 01, 2011 7:11 pm quote
30A "hidden fuse"
yes, i just had the same issue a week ago. The 30A "hidden fuse" runs the alternator. Once the fuse is blown you are running on battery.

see pix in this link:
Break down on Mp3 500
Veni, Vidi, Posti
MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5052
Location: Austin, TX
Wed Jun 01, 2011 7:44 pm quote
Yup - that's 98% probable the issue. Jerry had some great pics of the location - so without further ado - Location of hidden fuse on the 500
Ossessionato
MP3 400 / BV200
Joined: 02 Jun 2009
Posts: 2998
Location: San Diego, California
Wed Jun 01, 2011 7:56 pm quote
The hidden fuse feeds the Voltage Regulator which feeds the altenator. Fuse connectors are problems, as is the connector between alt and VR

http://www.scootermanuals.us/manuals/Gilera%20Fuoco/MP3%20500-Fuoco%20Wiring%20Diagram%20(USA%20ONLY).pdf
Molto Verboso
MP3 500, Honda PCX
Joined: 20 Jul 2008
Posts: 1123
Location: Dallas, TX
Wed Jun 01, 2011 8:26 pm quote
The hidden fuse is under the seat on the right side (rider's right when going forward) against the wall. The whole thing is shown in a post I did at:

Hidden Fuse DONE - pictures and all

The pictures are not in the best order but they are there as well as the explanation of how to get to the fuse.
Enthusiast
MP3 500
Joined: 16 May 2008
Posts: 72
Location: New York City!
Thu Jun 02, 2011 3:58 am quote
Thanks for all the replies! I open her up to look for the fuse this morning and indeed it was the fuse that cause the problem. However the fix isn't quite that easy.

It took some work to pull the cover off but while I was trying to wriggle the cover free I noticed that there's a hole on one side of the housing and it appears to be burned, not good.

So I managed to pull the cover off and the fuse that was there was in pieces and partially melted. I had to extract it in pieces. But after removing the bad fuse this is what it looks like:



Another view:



Looks like the housing will need to be replaced, but the more immediate problem is that I can't plug in the fuse, since the what's inside the slot is two male prone (the shorter copper color ones) just like what's on the fuse. Did something go missing?
Ossessionato
Red MP3 500 RUBY DRAGON
Joined: 29 Nov 2008
Posts: 2571
Location: Northern CA
Thu Jun 02, 2011 4:05 am quote
Those prongs are still part of the old fuse. You can pull them out with needlenose pliers.
Banned
MP3 500
Joined: 20 Aug 2008
Posts: 4530
Location: Ashburn, Va
Thu Jun 02, 2011 4:08 am quote
Looks like you pulled the hole relay off. Was the black square relay melted too?

If you are in the US. I can have a spare used one in the mail to you by tomorrow. I have 3 spares.
PM me if you want to buy one.
Enthusiast
MP3 500
Joined: 16 May 2008
Posts: 72
Location: New York City!
Thu Jun 02, 2011 4:45 am quote
StooterBoy wrote:
Looks like you pulled the hole relay off. Was the black square relay melted too?

If you are in the US. I can have a spare used one in the mail to you by tomorrow. I have 3 spares.
PM me if you want to buy one.
Hmm.. What is a relay? The plastic "case" around the prong melted a bit and there's also a small hole in the plastic divider between where the fuse plug in and the adjacent place where the red cover plug in. But the wires around it looks okay.

Looking at the fuse box and how the fuse plug in, it appears that there are metal snaps that bridge the prongs coming out of the box and the fuses. Is this the relay you are referring to?

I thought that perhaps I can just go to a auto store and buy it so I can plug the fuse in?
Ossessionato
MP3 400 / BV200
Joined: 02 Jun 2009
Posts: 2998
Location: San Diego, California
Thu Jun 02, 2011 8:57 pm quote
That looks like the starter relay.

http://www.athensscooterco.com/eshopprod_cat_4797-48548-48426_product_603081.604_STARTER_RELAY_12V-30Amp.htm

STARTER MAGNETIC SWITCH
2 - 640692-2 $28.00

12V-150A relay switch
2 - 582690-2 $45.89

Fuse 3 amp
3 - 581440-3 $0.01

Thats not the hidden 30amp fuseholder

Look at page 101 on the parts catalog for the Gilera Fuoco
Molto Verboso
MP3 500 08
Joined: 08 Aug 2009
Posts: 1531
Location: Toms River area, New Jersey
Fri Jun 03, 2011 1:12 am quote
What is the approx. milage? Just for referances.
Banned
MP3 500
Joined: 20 Aug 2008
Posts: 4530
Location: Ashburn, Va
Fri Jun 03, 2011 3:33 am quote
14perry wrote:
That looks like the starter relay.

http://www.athensscooterco.com/eshopprod_cat_4797-48548-48426_product_603081.604_STARTER_RELAY_12V-30Amp.htm

STARTER MAGNETIC SWITCH
2 - 640692-2 $28.00

12V-150A relay switch
2 - 582690-2 $45.89

Fuse 3 amp
3 - 581440-3 $0.01

Thats not the hidden 30amp fuseholder

Look at page 101 on the parts catalog for the Gilera Fuoco
"12V-150A relay switch
2 - 582690-2 $45.89 "
This is the relay that has the Hidden fuse in it. I have two of these in my parts cabinet in my garage.
Ossessionato
MP3 400 / BV200
Joined: 02 Jun 2009
Posts: 2998
Location: San Diego, California
Fri Jun 03, 2011 5:39 am quote
So the wiring diagram identifies Fuse # 13 as a 30 amp fuse, but the parts catalog says the fuse with the starter relay is a 3amp. There are no 3amp fuses listed on the wiring diagram so there is a typo in the parts book. Thanks for the correction Stooterboy!
Enthusiast
MP3 500
Joined: 16 May 2008
Posts: 72
Location: New York City!
Sun Jun 05, 2011 9:33 am quote
G03 wrote:
What is the approx. milage? Just for referances.
I got about 25,000 miles on her.

I actually found the plastic part that plugs into fuse box, its a small black rectangle with two copper clips that plugs into the exposed prong and allow the fuse to be plug into it. Is this the fuse relay that every one is referring to? I only manage to find half of it since its partially melted, so I ended up making a makeshift plug using a wire harness. I do need to get this part but I am not really sure what its called.

According to the diagram provided on the above link, the part looks to be #3 shown as "CALL FOR AVAILABILITY" what is it called? May be I can get it through my dealership?
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