Gilera GP800 I.E. 2007 Factory Service Repair Manual

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Stichworte: 2007 Gilera GP800 GP800 I.E. Motorcycle Motorcycles

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Beschreibung

The Gilera GP800, introduced in 2007, represents a unique fusion of motorcycle performance and maxi-scooter practicality. Featuring a potent 799 cc V-twin engine, this Grand Tourer scooter offers an aggressive, sporty design and handling characteristics typically found in larger motorcycles. Its advanced electronic fuel injection system and robust chassis, engineered for stability at higher speeds, position it as a distinctive option in the performance scooter market. The GP800 was designed to bridge the gap between traditional scooters and sportbikes, providing an exhilarating riding experience. This comprehensive service repair manual offers factory-level guidance for the Gilera GP800 I.E. (Injection Electronique). It covers essential maintenance procedures, including routine servicing, fluid changes, and component replacements, alongside detailed instructions for engine disassembly, transmission servicing, and chassis component repair. The manual also provides in-depth troubleshooting guidance for the electronic fuel injection system, braking, and electrical systems, making it an indispensable resource for mechanics and DIY enthusiasts alike. Access to this information ensures proper upkeep and efficient repair of your Gilera GP800.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

GP800

Year:

Model Variant:

I.E. (Injection Electronique)

👋 Introduction

Market Position

Vehicle Segment:

Maxi-scooter, GT (Grand Tourer) Scooter

Unique Selling Proposition:

Performance-oriented maxi-scooter bridging motorcycle and scooter characteristics.

Competitive Analysis

Key Competitors 2007:

Yamaha TMAX, Suzuki Burgman 650, Aprilia Atlantic 500, BMW C1 (earlier, but in a similar niche).

Key Features

Engine Architecture:

Large displacement V-twin engine for a scooter.

Styling:

Sporty, aggressive styling reminiscent of motorcycles.

Handling:

Chassis and suspension tuned for agile handling and stability at higher speeds.

Technology Integration:

Electronic fuel injection for performance and emissions.

📋 Manual Details

Coverage Areas

Primary Coverage:

Factory Service Repair

Intended Audience:

Mechanics and DIY enthusiasts

Page Count

Estimated Page Count:

Extensive (typical factory service manuals range from 300-1000+ pages)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

Likely English (based on product description, though original may vary)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, assembly, inspection, repair of engine components (pistons, cylinders, crankshaft, valve train).

Engine Management I E:

Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnostics and programming.

Transmission Drivetrain:

Removal, disassembly, assembly, and inspection of the automatic transmission and final drive.

Chassis Suspension:

Front and rear suspension systems, fork assembly, shock absorbers, steering system.

Braking System:

Front and rear brake system components, hydraulic lines, master cylinders, calipers, discs, ABS system (if equipped).

Electrical System:

Wiring diagrams, lighting, starting and charging system, battery, fuses, relays, horn, instrument panel.

Bodywork Fairings:

Fairing removal, installation, and repair; seat, luggage compartment access.

Cooling System:

Radiator, coolant flow, thermostat, fan operation.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter servicing, chain/belt adjustment (if applicable).

Diagnostic Troubleshooting:

Systematic identification and resolution of common and uncommon faults and performance issues.

Component Removal Installation:

Detailed steps for removing and reinstalling all major and minor components.

Disassembly Assembly:

Step-by-step instructions for taking apart and putting back together various sub-assemblies.

Adjustments Calibration:

Procedures for adjusting brakes, clutch, throttle, and other systems as needed.

Torque Specifications:

Essential torque values for critical fasteners across all systems.

Technical Depth

Depth Level:

Comprehensive factory-level repair and maintenance information.

Diagnostic Tools:

Likely references diagnostic tools or procedures requiring specific equipment for EFI systems.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Typically searchable text within a well-digitized PDF.

Print Quality

Printability:

Designed for easy printing of specific sections or the entire manual.

Binding Type

Physical Binding:

N/A (Digital PDF Download)

Paper Type

Physical Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke, liquid-cooled

Displacement:

799 cc

Bore X Stroke:

88 mm x 66 mm

Compression Ratio:

9.3:1

Valve Train:

SOHC, 4 valves per cylinder (likely actuation via cam chain).

Performance

Horsepower Claimed:

Approx. 50-55 HP (at crankshaft)

Torque Claimed:

Approx. 70-75 Nm (at crankshaft)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (I.E.)

Fuel Type:

Unleaded Petrol (Gasoline)

Fuel Tank Capacity:

Approx. 16 Liters

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Drive Type:

Belt drive to rear wheel

Features

Transmission Fluid:

Specific CVT fluid (refer to manual for exact type and capacity, e.g., Motul Scooter Gear Oil Expert 80W90 or equivalent).

📐 Dimensions

Exterior

Length:

Approx. 2250 mm

Width:

Approx. 800 mm

Height:

Approx. 1450 mm

Wheelbase:

Approx. 1590 mm

Weights

Dry Weight:

Approx. 230-240 kg

Gross Vehicle Weight Rating Gvwr:

Approx. 430-450 kg

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycle/Scooter segment typically not subjected to automotive crash testing standards).

Active Features

Braking System Type:

Disc brakes front and rear, likely with ABS as an option or standard on some variants.

Anti Lock Braking System ABS:

Optional or standard depending on market/trim. Manual will detail ABS system operation and service.

Passive Features

Lighting:

Halogen headlights, LED taillight/indicators (depending on specific execution).

💡 Technology Features

Infotainment

Instrument Cluster:

Digital and analog combination display with speed, RPM, fuel level, coolant temperature, odometer, trip meters, and warning lights.

Driver Assistance

ABS Integration:

ABS module and sensor operation for enhanced braking stability.

Connectivity

Diagnostics Port:

On-board diagnostics (OBD) port or proprietary diagnostic connector for engine management system access.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 5,000 - 7,500 km or annually (refer to manual for exact interval).

Air Filter Inspection:

Every 7,500 km, replace as needed.

Spark Plug Replacement:

Typically every 10,000 - 15,000 km (refer to manual for plug type and gap).

Transmission Fluid Change:

Every 10,000 - 15,000 km or every two years.

Fluid Specifications

Engine Oil Type:

High-quality synthetic motorcycle engine oil, e.g., API SG/SH/SJ or higher, JASO MA/MA2 rated. Viscosity: 10W-40 or 15W-50 depending on climate (refer to manual for exact spec).

Coolant Type:

Ethylene glycol based antifreeze coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 or DOT 5.1 (refer to manual for precise specification, especially if ABS is present).

Known Issues

Potential Issues Reported:

Some owners have reported occasional issues with the CVT drive system's longevity, electrical gremlins, or specific sensor failures. The manual is crucial for diagnosing and addressing these.

Maintenance Priority Areas:

Regular checks of the CVT belt condition, variator rollers, and proper functioning of the EFI system are paramount for longevity and performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

Gilera is an Italian manufacturer with a long history in motorcycling, known for performance-oriented models.

Model Evolution

Gp800 Development:

The GP800 was developed to offer motorcycle-like performance in a maxi-scooter platform, leveraging Piaggio Group's engine technology.

Production

Manufacturing Location:

Italy (under Piaggio Group ownership)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

While specific awards for the 2007 model are not widely publicized, the GP800 was recognized for its unique V-twin engine and sporty performance in the maxi-scooter segment.