Gilera GP800 i.e. 2007-Onward Service Repair Workshop Manual Download PDF

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Stichworte: 2007 Gilera GP800 GP800 i.e. Motorcycle Motorcycles

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Beschreibung

This manual covers the Gilera GP800 i.e., a maxi-scooter produced from 2007 onwards, recognized for its powerful parallel-twin engine and automatic CVT transmission. Developed with a focus on combining motorcycle performance with scooter practicality, the GP800 i.e. offers a unique riding experience. Its engineering quality and reliability are supported by its Italian heritage, being part of a larger automotive group and sharing components with other performance-oriented models. This model is designed for riders seeking a capable and comfortable machine for both urban commuting and longer journeys, standing out among its competitors with its robust engine and advanced features for its class. This factory service repair workshop manual provides comprehensive guidance for the Gilera GP800 i.e. It details all aspects of maintenance, from scheduled servicing and fluid changes to complete engine and transmission overhauls. The manual includes in-depth troubleshooting procedures, diagnostic information for the fuel injection and electrical systems, and step-by-step repair instructions for all major components, including the engine, brakes, chassis, and bodywork. With extensive wiring diagrams and technical specifications, this resource is an essential tool for owners, mechanics, and technicians aiming to maintain, diagnose, and repair the vehicle effectively, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

GP800 i.e.

Year:

2007 onwards

Codes

Engine Code Identifier:

GP800 i.e. (Fuel Injection)

👋 Introduction

Market Position

Vehicle Segment:

Maxi-scooter / Sport Scooter

Competitive Analysis

Competitors:

Suzuki Burgman 650, Yamaha TMAX 500/530, Honda Silver Wing 600/650.

Key Features

Engine Configuration:

Parallel-twin cylinder, liquid-cooled.

Transmission Type:

Automatic Continuously Variable Transmission (CVT).

Braking System:

Dual front discs, single rear disc; likely with ABS as an option/standard on some models.

📋 Manual Details

Coverage Areas

Countries Of Sale Covered:

Global (assumed based on common manual distribution)

Page Count

Estimated Pages:

Hundreds (as stated in description)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English (implied by product description language)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnosis, tuning, fuel injection system, ignition system, lubrication system, cooling system.

Transmission:

Automatic transmission (CVT) overhaul, fluid checks and changes, drive belt inspection and replacement, gear reduction unit.

Brakes:

Hydraulic brake system, front and rear brake caliper service, brake pad replacement, brake fluid flushing and bleeding, ABS system (if equipped).

Electrical:

Wiring diagrams, battery system, charging system (alternator/stator), starter motor, lighting system (headlights, taillights, signals), instrumentation, ECU diagnosis, sensor testing.

Chassis And Suspension:

Front fork (telescopic) service, rear shock absorber inspection and replacement, swingarm maintenance, steering system overhaul, wheel bearing replacement.

Bodywork And Trim:

Fairing removal and installation, seat adjustment, storage compartment access, panel fitting, lighting component access.

Procedures Included

Maintenance:

Scheduled maintenance, oil and filter changes, spark plug replacement, air filter service, coolant checks and changes, drive belt inspection and replacement, brake fluid service.

Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, braking system anomalies, starting problems, and general operational issues.

Repair:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Diagnostics:

Fault code interpretation, sensor data analysis, electrical circuit testing, fuel system pressure testing, ignition timing checks.

Engine Rebuild:

Detailed procedures for complete engine disassembly, piston/cylinder inspection and replacement, crankshaft inspection, valve timing and adjustment, and reassembly.

Suspension Overhaul:

Front fork oil change and seal replacement, rear shock absorber inspection and mounting bolt torque values.

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance and fluid checks to full engine and transmission rebuilds, including detailed electrical diagnostics and troubleshooting.

Electrical Diagnostics Detail:

Extensive wiring diagrams with component identification, pinout data, voltage drop testing procedures, and troubleshooting charts for common electrical faults.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF (common for professional manuals)

Print Quality

Printability:

Printable (single pages or entire manual)

Binding Type

Binding:

N/A (Digital download)

Paper Type

Paper Quality:

N/A (Digital download)

Licensing

Usage Rights:

Unlimited usage on multiple devices, lifetime access, no expiry.

⚙️ Engine Specifications

Primary Engine

Engine Type:

839cc, Liquid-cooled, 4-stroke, DOHC, 4-valve per cylinder, Parallel-Twin

Performance

Bore X Stroke:

Not specified in product info, but typically around 74 mm x 70 mm for this engine.

Horsepower:

Approximately 50-55 HP (based on typical output for this engine configuration).

Torque:

Approximately 70-75 Nm (based on typical output for this engine configuration).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (i.e.)

Ignition System:

Electronic Ignition

Lubrication System

Oil Type:

Likely SAE 10W-40 or 15W-50 Motorcycle Specific Synthetic/Mineral Blend (Requires specific verification in manual).

Cooling System

Coolant Type:

Ethylene Glycol based antifreeze/coolant (typically 50/50 mix).

🔧 Transmission

Standard

Transmission Type:

Automatic CVT (Continuously Variable Transmission)

Optional

Optional Transmissions:

N/A (CVT is standard)

Features

Drive Belt:

V-belt drive system with automatic clutch and variator.

Final Drive:

Chain drive to rear wheel (via gear reduction unit).

📐 Dimensions

Exterior

Length:

Approximately 2200-2300 mm (typical for maxi-scooters).

Width:

Approximately 800-850 mm.

Height:

Approximately 1350-1450 mm (seat height around 800 mm).

Weights

Dry Weight:

Approximately 220-230 kg (curb weight will be higher).

Fuel Tank Capacity:

Approximately 16-18 Liters.

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle-specific safety ratings differ from automotive standards)

Active Features

Available (likely optional or standard depending on market/trim).

Braking System Performance:

Dual front discs with multi-piston calipers, single rear disc. Excellent stopping power expected.

Passive Features

Lighting:

Dual Halogen or HID Headlights, LED Tail/Brake Lights (depending on specific model year updates).

💡 Technology Features

Infotainment

Dashboard Instrumentation:

Digital/Analog combination dashboard with speedometer, tachometer, fuel gauge, odometer, trip meters, engine temperature, and warning lights.

Driver Assistance

Anti-lock Braking System (Optional/Standard)

Connectivity

ECU Diagnosis:

OBD-II compatible diagnostic port (likely specific connector for motorcycle ECU) for fault code retrieval and live data.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km or 12 months (typical for Gilera/Aprilia motorcycles).

Oil Filter Change:

With every oil change.

Spark Plug Replacement:

Every 12,000 - 18,000 km (specific type: Iridium recommended).

Air Filter Service:

Inspect every 6,000 km, replace as needed or every 12,000 km.

Coolant Change:

Every 24,000 km or 24 months.

Drive Belt Inspection:

Inspect every 12,000 km, replace as recommended (typically 24,000 - 36,000 km).

Fluid Specifications

Engine Oil Capacity:

Approximately 2.0 - 2.2 Liters (with filter change). Exact capacity must be verified in manual.

Brake Fluid Type:

DOT 4 (or DOT 5.1 if specified for ABS models).

Coolant Capacity:

Approximately 1.2 - 1.5 Liters. Exact capacity must be verified in manual.

Final Drive Oil Type:

Hypoid Gear Oil SAE 80W-90 (typical specification).

Known Issues

Common Wear Items:

Drive belt, clutch plates (CVT), brake pads, fork seals, wheel bearings.

Electrical Gremlins:

Some owners report minor electrical issues, often related to sensor connections or battery terminals. Comprehensive electrical diagnosis is key.

Fuel System Maintenance:

Regular fuel system cleaner and quality fuel are recommended to maintain the integrity of the fuel injection system.

📚 Vehicle History

Brand Heritage

Brand Origin:

Gilera is an Italian motorcycle manufacturer, historically known for performance and racing heritage, now part of the Piaggio Group.

Model Evolution

Development Basis:

The GP800 was developed in collaboration with Aprilia (also part of Piaggio Group), sharing its engine and many components with the Aprilia Mana 850 GT.

Production

Production Period:

Introduced around 2007, with updates and revisions throughout its production run.

Manufacturing Location:

Italy (likely Piaggio Group manufacturing facilities).

🏆 Awards & Recognition

Recognitions

Industry Accolades:

No specific awards are widely documented for the GP800; it was known for its unique blend of motorcycle performance and scooter practicality.