OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.




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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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

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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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
To use the Piaggio Beverly 500 front fork, a new steering tube is made.

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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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
Here you see the braked to remove, and later reinstall the side stand.

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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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.



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


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⚠️ Last edited by Arnoh on UTC; edited 1 time
UTC

Molto Verboso
Vespa GTS 250ie
Joined: UTC
Posts: 1229
Location: San Francisco Bay Area
 
Molto Verboso
Vespa GTS 250ie
Joined: UTC
Posts: 1229
Location: San Francisco Bay Area
UTC quote
I'm confused. Are you installing a 125cc engine or 500cc engine?
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.
UTC

Molto Verboso
Vespa GTS 250ie
Joined: UTC
Posts: 1229
Location: San Francisco Bay Area
 
Molto Verboso
Vespa GTS 250ie
Joined: UTC
Posts: 1229
Location: San Francisco Bay Area
UTC 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?
@micbergsma avatar
UTC

Molto Verboso
2003 ET4, 2005 LX 150, 1964 GS 160
Joined: UTC
Posts: 1510
Location: Maui Hawaii
 
Molto Verboso
@micbergsma avatar
2003 ET4, 2005 LX 150, 1964 GS 160
Joined: UTC
Posts: 1510
Location: Maui Hawaii
UTC quote
I am so jealous... I always want a runner!!
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
Took the Runner frame apart today.
Now you can clearly see why i made all these brackets.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
At this moment it looks like the original engine angle and wheelbase is possible.

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⚠️ Last edited by Arnoh on UTC; edited 1 time
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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⚠️ Last edited by Arnoh on UTC; edited 1 time
@lostboater avatar
UTC

Ossessionato
Vespa LX150 GTS250ie GTS300x2 sold 'em
Joined: UTC
Posts: 2380
Location: St. Pete, Fla
 
Ossessionato
@lostboater avatar
Vespa LX150 GTS250ie GTS300x2 sold 'em
Joined: UTC
Posts: 2380
Location: St. Pete, Fla
UTC quote
WOW!!!!
This is a amazing project with great pictures. Keep posting pictures and info Please.
Ken
@berto avatar
UTC

Molto Verboso
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
 
Molto Verboso
@berto avatar
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
UTC quote
I really like your staging rig! Did you fabricate it all yourself?
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
berto wrote:
I really like your staging rig! Did you fabricate it all yourself?
Yes, me and my welding machine
@anndee4444 avatar
UTC

Hooked
GTS 250
Joined: UTC
Posts: 346
Location: California
 
Hooked
@anndee4444 avatar
GTS 250
Joined: UTC
Posts: 346
Location: California
UTC quote
Nice work!
@rodrigoborgia avatar
UTC

Lurker
Gilera Runner FX 125
Joined: UTC
Posts: 3
Location: Croatia
 
Lurker
@rodrigoborgia avatar
Gilera Runner FX 125
Joined: UTC
Posts: 3
Location: Croatia
UTC 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 Laughing emoticon ).
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!
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.
@v_oodoo avatar
UTC

Style Maven
'74 50s x3 '78 P200 E '84 Cosa '91 PK50XL2 - & - '58 AllState '68 Sprint '66(?) Super125 and '72 DanMotor Super150
Joined: UTC
Posts: 9481
Location: seattle/athens
 
Style Maven
@v_oodoo avatar
'74 50s x3 '78 P200 E '84 Cosa '91 PK50XL2 - & - '58 AllState '68 Sprint '66(?) Super125 and '72 DanMotor Super150
Joined: UTC
Posts: 9481
Location: seattle/athens
UTC quote
Very ambitious build, but looks to be on track. I like your approach.
Should be a very exciting ride. Popcorn emoticon
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?
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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UTC

Hooked
Kawasaki Z1000, Yamaha R1, Honda SH300i
Joined: UTC
Posts: 124
Location: London, UK
 
Hooked
Kawasaki Z1000, Yamaha R1, Honda SH300i
Joined: UTC
Posts: 124
Location: London, UK
UTC quote
Me like
@pinkscooter avatar
UTC

Addicted
GTS 250ie Super, Italjet Velocifero, Scarabeo 150, S50, ET4, ET2
Joined: UTC
Posts: 710
Location: Winston-Salem, NC
 
Addicted
@pinkscooter avatar
GTS 250ie Super, Italjet Velocifero, Scarabeo 150, S50, ET4, ET2
Joined: UTC
Posts: 710
Location: Winston-Salem, NC
UTC quote
Well done Arnoh, this will keep you busy.
⬆️    About 1 month elapsed    ⬇️
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
Okay, so the engine is hanging freely in the frame now.
And started with building the new frame tubes.

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Measuring, bending, measuring, bending...

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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)
@anndee4444 avatar
UTC

Hooked
GTS 250
Joined: UTC
Posts: 346
Location: California
 
Hooked
@anndee4444 avatar
GTS 250
Joined: UTC
Posts: 346
Location: California
UTC quote
Nice work!
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
Made 2 ribs yesterday.
It all fits how i mentioned.
The floor parts can be welded on the ribs later.

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@kshansen avatar
UTC

Molto Verboso
GTV300 (wife's)
Joined: UTC
Posts: 1884
Location: Central New York
 
Molto Verboso
@kshansen avatar
GTV300 (wife's)
Joined: UTC
Posts: 1884
Location: Central New York
UTC quote
Very interesting build! More or less hang engine on air and build scooter around it.
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.
@qascooter avatar
UTC

Ossessionato
79 P200E (Ruby), 62 Allstate (B-62)
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Posts: 4102
Location: Florence, OR
 
Ossessionato
@qascooter avatar
79 P200E (Ruby), 62 Allstate (B-62)
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Posts: 4102
Location: Florence, OR
UTC quote
You sir, are a wizard! Great job and thanks so much for taking us along. Clap emoticon Clap emoticon Clap emoticon
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
And the latest designs for the new double disk 13 inch front wheel for the Runner.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
Owww yeah, looking good 😎😎😎

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
And the new rear adjustable Bitubo shocks arrived.
And for the front, the Bitubo springs and oil.

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@berto avatar
UTC

Molto Verboso
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
 
Molto Verboso
@berto avatar
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
UTC quote
Good stuff!
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
And some pictures of the progres of the front wheel.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC quote
And started with the right side.

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Making the bends extra strong.

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@berto avatar
UTC

Molto Verboso
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
 
Molto Verboso
@berto avatar
2006 LX150 (carbed) | 2007 GT200
Joined: UTC
Posts: 1894
Location: Toronto
UTC quote
Thanks for the pics!!
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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⬆️    About 2 months elapsed    ⬇️
OP
@arnoh avatar
UTC

Hooked
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
 
Hooked
@arnoh avatar
Gilera Runner 500cc.
Joined: UTC
Posts: 160
Location: Netherlands
UTC 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.

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