Model Variant:
SP (Sport Production)
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004
Product Type:
Service Repair Workshop Manual Download PDF
Vehicle Type:
Sport Scooter
Target Audience:
Enthusiasts and owners seeking in-depth knowledge for maintenance and repair
Class Competitors:
Aprilia SR50, Malaguti F12, Yamaha Aerox 50
Vehicle Appeal:
Performance-oriented 50cc scooter with sporty styling and handling
Manual Value Proposition:
Provides factory-level repair information for DIY maintenance and professional service
Primary Coverage:
Comprehensive service, repair, and troubleshooting procedures
Component Coverage:
Engine, transmission, chassis, electrical system, bodywork, suspension, brakes, cooling system, fuel system, exhaust system, steering
Estimated Pages:
Hundreds of pages (specific count not provided, but described as extensive)
Type:
Factory Service Repair Workshop Manual
Language:
English (implied by product description and common industry practice for such manuals)
Format:
PDF (Downloadable)
Engine Mechanical:
Complete engine disassembly, assembly, component inspection, and rebuild procedures
Engine Fuel System:
Carburetor tuning, fuel pump, fuel lines, fuel tank service
Engine Ignition System:
Ignition coil, spark plug, CDI unit, timing adjustments
Engine Cooling System:
Radiator, water pump, coolant hoses, thermostat service
Transmission Drivetrain:
Automatic transmission (CVT) service, variator, clutch operation, gear oil change
Braking System:
Front and rear brake caliper service, brake pad replacement, brake fluid flush, hydraulic system troubleshooting
Suspension Steering:
Front fork disassembly, rear shock absorber replacement, steering bearing service, wheel alignment checks
Electrical System:
Wiring diagrams, battery service, lighting system, starter motor, charging system, fuse box diagnostics
Bodywork Frame:
Fairing removal and installation, seat adjustment, body panel repair, frame inspection
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, fluid level checks, brake adjustments
Troubleshooting:
Diagnostic charts, symptom-based fault finding, electrical and mechanical issue resolution
Repair Rebuild:
Step-by-step instructions for component replacement and major overhaul
Diagnostics:
Testing procedures for electrical components, mechanical tolerances, and system performance
Depth:
Professional-level, covering all repair and service operations
Diagrams Illustrations:
Hundreds of detailed photos and exploded diagrams
Special Tools:
Identifies and describes required special tools for specific procedures
Compatibility:
Windows and MAC computers, tablets, smartphones
Printable:
Yes, single pages or entire manual
Binding:
Digital (N/A for PDF download)
Paper Type:
Digital (N/A for PDF download)
Usage Rights:
Lifetime use, unlimited installations
Engine Type:
2-stroke, single-cylinder
Engine Displacement:
49.3 cc (approx.)
Cooling System:
Liquid-cooled
Bore X Stroke:
39.0 mm x 41.4 mm (typical for Piaggio/Gilera 50cc engines of this era)
Compression Ratio:
Approx. 7.8:1 - 8.0:1 (typical)
Horsepower:
Approximately 5-7 HP (stock, depending on specific tune and emissions regulations)
Torque:
Not explicitly stated, but typically around 5-6 Nm
Carburetor Model:
Dell'Orto PHVA 12 or similar
Fuel Type:
Unleaded gasoline (min. 95 RON recommended for 2-stroke)
Oil Mixture:
Automatic oil injection system
Engine Family:
Piaggio Hyper 2 (likely base for this model)
Transmission Type:
Automatic (Continuously Variable Transmission - CVT)
Drive Type:
Belt drive to rear wheel
Variator:
Primary drive variator for automatic gear ratio adjustment
Clutch:
Centrifugal clutch
Gear Oil Type:
API GL-3 or GL-4 gear oil (specific viscosity typically 75W-80 or 80W-90)
Gear Oil Capacity:
Approximately 100-150 ml (refer to manual for exact capacity)
Length:
Approx. 1850 mm (typical)
Width:
Approx. 740 mm (typical)
Height:
Approx. 1180 mm (typical)
Dry Weight:
Approx. 110 kg (typical)
Gross Vehicle Weight:
Not specified, but typically around 260 kg
Front Tire Size:
120/70-13 (typical)
Rear Tire Size:
130/60-13 (typical)
Wheel Bolt Pattern:
Not applicable (scooter wheel hub)
Crash Test Ratings:
Not applicable (scooters are not typically subjected to automotive crash testing standards)
Braking System Type:
Front: Disc brake, Rear: Disc brake
Lighting:
Headlight, taillight, turn signals, brake lights
Frame Construction:
Steel frame with reinforced structure
Rider Protection:
Integrated bodywork offering basic rider protection
Dashboard Features:
Analog speedometer, tachometer, fuel gauge, coolant temperature warning light, turn signal indicators, high beam indicator.
ABS:
Not available on this model (ABS was not common on 50cc scooters of this era).
Connectivity Features:
None (basic mechanical and electrical systems).
Engine Oil Change:
Every 3,000 - 5,000 km or annually (refer to manual for exact recommendation)
Air Filter Cleaning Replacement:
Every 3,000 - 6,000 km or as needed based on operating conditions
Spark Plug Check Replacement:
Every 5,000 - 8,000 km
Brake Fluid Flush:
Every 2 years or 24,000 km
Variator Roller Inspection:
Every 5,000 - 10,000 km (for wear and proper operation)
Engine Oil Type:
2-stroke synthetic or semi-synthetic oil (meeting JASO FD or ISO-L-EGD standards) for injection system
Cooling System Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed with distilled water (50/50 ratio typical)
Common Wear Items:
Variator rollers, drive belt, brake pads, suspension bushings
Potential Electrical Faults:
Wiring harness connections, stator output, CDI unit reliability can be areas of focus for troubleshooting.
Manufacturer Origin:
Gilera is an Italian manufacturer with a long history in motorcycle and scooter production, now part of the Piaggio Group.
Gilera Runner Lineage:
The Gilera Runner series is known for its sporty design, powerful 50cc and 125cc engines, and advanced features for its time, often considered a benchmark in the performance scooter segment.
Manufacturing Location:
Italy (typical for Gilera products of this era)
