Primary Coverage:
Engine, chassis, electrical systems, bodywork, maintenance, troubleshooting, and repair of Gilera motorcycles with 350cc, 500cc, and 600cc 4-stroke engines.
Estimated Page Count:
Detailed page count not specified in product description, but expected to be comprehensive for a service manual covering multiple displacements. Likely 300+ pages.
Manual Type:
Service Manual / Repair Manual
Language:
Likely English, based on product description and typical market availability. May also include Italian originals or translations.
Format:
Downloadable Digital File (e.g., PDF)
Engine Mechanical:
Cylinder head, valves, camshafts, piston, connecting rod, crankshaft, lubrication system (oil pump, filter, passages), cooling system (if applicable, usually air-cooled for this era), timing system (chain, gears).
Fuel System:
Carburetor(s) (identification, disassembly, cleaning, adjustment, tuning), fuel pump (if equipped), fuel lines, fuel filter.
Ignition System:
Spark plugs, ignition coils, CDI unit, stator, rotor, wiring diagrams, ignition timing adjustment.
Exhaust System:
Exhaust pipes, mufflers, gaskets, mounting hardware, and troubleshooting of leaks or performance issues.
Transmission And Drivetrain:
Clutch (operation, adjustment, replacement), gearbox (gear selection, internal components, lubrication), final drive (chain, sprockets, lubrication).
Suspension:
Front forks (oil changes, seal replacement, spring replacement, damping adjustments), rear shock absorber(s) (adjustment, replacement, linkage maintenance).
Braking System:
Front and rear brake mechanisms (disc or drum), brake calipers, master cylinders, brake lines, brake fluid replacement, bleeding procedures, pad/shoe replacement.
Electrical System:
Wiring diagrams, battery, charging system (alternator/stator, rectifier/regulator), lighting (headlight, taillight, indicators), starter motor, horn, instrument cluster, fuses.
Chassis And Frame:
Frame inspection, steering head bearings, wheel bearings, swingarm bushings, mounting points.
Bodywork:
Fairings, fuel tank, seat, fenders, instrument panel mounting, graphics, and related fasteners.
Preventive Maintenance:
Oil changes, filter replacement, spark plug checks/replacement, chain adjustment/lubrication, brake checks, tire pressure checks, general lubrication points.
Troubleshooting:
Diagnostic procedures for common starting, running, electrical, and mechanical issues. Symptom-based troubleshooting guides.
Engine Rebuild:
Detailed steps for engine disassembly, component inspection, measurement of wear tolerances, reassembly, and initial start-up procedures.
Component Overhaul:
Specific instructions for overhauling carburetors, brake systems, suspension forks, and other key components.
Electrical Diagnostics:
Testing of charging system, ignition system components, starter circuits, and lighting circuits using multimeters and diagnostic tools.
Wheel And Tire Service:
Wheel bearing replacement, tire mounting/demounting, and wheel balancing (if applicable).
Diagnostic Capability:
Advanced diagnostics with detailed troubleshooting flowcharts and specific component testing procedures.
Repair Scope:
Covers routine maintenance, minor repairs, significant overhauls, and complete engine rebuilds.
Information Detail:
Illustrated with clear, step-by-step instructions, often including torque specifications, clearances, and diagrams.
Engine Configuration:
Single-cylinder, 4-stroke (likely overhead camshaft - OHC or possibly double overhead camshaft - DOHC for some variants).
Bore Stroke Variation:
Specific bore and stroke dimensions will vary between the 350cc, 500cc, and 600cc variants. These will be detailed in the manual.
Cooling System:
Predominantly air-cooled, though some later or specific models might incorporate oil-cooling elements. Manual will specify.
Horsepower Range:
Typically ranging from approximately 25-35 HP for 350cc, 35-45 HP for 500cc, and 40-50 HP for 600cc models, depending on specific tune and model. Exact figures will be in the manual.
Torque Characteristics:
Emphasis on mid-range torque delivery for spirited riding, characteristic of Gilera's sporty design philosophy.
Carburetor Types:
Likely utilizes downdraft or side-draft carburetors, commonly from manufacturers like Dell'Orto or Mikuni. Manual will specify models and settings (e.g., PHM, VM, TMR).
Fuel Delivery:
Gravity feed from the fuel tank, potentially with an inline fuel filter. Some models might feature a vacuum-operated fuel tap.
Oil Change Interval:
Typically every 3,000-5,000 km or annually. Manual will provide precise recommendations based on oil type and operating conditions.
Valve Clearance Check:
Likely every 6,000-10,000 km. Precise intervals and adjustment procedures are critical and detailed in the manual.
Spark Plug Replacement:
Every 10,000-15,000 km, depending on plug type and condition. Manual will specify recommended plugs.
Engine Oil Type:
Likely SAE 10W-40 or 20W-50, API SG or higher, suitable for 4-stroke motorcycles. Manual will specify exact viscosity and API classification.
Engine Oil Capacity:
Typically around 1.5 - 2.5 liters. Manual will provide exact capacity for each engine variant.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid for hydraulic systems. Manual will confirm and specify replacement intervals.
Fork Oil Type And Viscosity:
Likely ATF Dexron II or a dedicated 5W or 10W fork oil. Manual will specify type and quantity per fork leg.
Gearbox Oil Type:
Separate gearbox lubrication, often SAE 80W or 85W gear oil. Manual will confirm.
Common Wear Items:
Valve seat wear, camshaft wear, clutch plate wear, fork seal leaks, carburetor jetting issues due to age/gumming.
Electrical Gremlins:
Corrosion on electrical connectors, stator coil failure, rectifier/regulator issues are common in older bikes.
Carburetor Performance:
Sensitivity to fuel quality and atmospheric conditions, requiring regular cleaning and adjustment for optimal performance.
