Gilera GP800 2008 Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 49988

Mots clés: 2008 Gilera GP800 Motorcycle Motorcycles

Variantes de produits

Description

The Gilera GP800, introduced in 2007, represents a premium maxi-scooter designed for discerning riders seeking a blend of performance and comfort. This model is distinguished by its powerful V-twin engine, offering robust acceleration and a dynamic riding experience, complemented by car-like ergonomics for enhanced rider comfort during extended journeys. Its high-quality chassis and suspension components contribute to precise handling and stability, making it suitable for both spirited riding and daily commuting. The GP800 aims to provide a sophisticated and engaging ride, positioning itself as a capable alternative in the performance maxi-scooter segment. This comprehensive Factory Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the Gilera GP800. It covers all essential systems, including engine mechanics, fuel, cooling, lubrication, exhaust, transmission, electrical systems, braking, suspension, and chassis components. The manual offers step-by-step procedures for routine maintenance tasks, in-depth repair processes, and diagnostic strategies for identifying and resolving issues. With its extensive coverage and technical detail, this workshop manual serves as an indispensable resource for owners, technicians, and mechanics to ensure the optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

GP800

Year:

Vehicle Type:

Maxi-scooter

Codes

Chassis Code:

GP800 (exact chassis codes may vary by market, consult manual for specifics)

👋 Introduction

Market Position

Segment:

Premium Maxi-scooter

Target Audience:

Scooter enthusiasts, commuters, performance-oriented riders seeking advanced features

Competitive Analysis

Key Competitors Approx:

Yamaha TMAX, Suzuki Burgman 650, Honda Silver Wing

Key Features

Vehicle Highlight 1:

Powerful V-twin engine for its class

Vehicle Highlight 2:

Car-like ergonomics and comfort

Vehicle Highlight 3:

High-quality chassis and suspension components

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and maintenance

Secondary Coverage:

Diagnostics, troubleshooting, electrical systems, wiring diagrams

Page Count

Page Count:

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

File Format:

Compatibility:

Windows & Mac (all versions)

Required Software:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanics:

Engine removal/installation, internal component inspection and repair, cylinder head, pistons, crankshaft, camshafts, valve timing

Fuel System:

Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel filter, fuel tank service

Cooling System:

Radiator, coolant pump, thermostat, cooling fan, coolant flow, system pressure testing, bleeding procedures

Lubrication System:

Oil pump, oil filter, oil passages, oil capacity, oil change procedures

Exhaust System:

Muffler, catalytic converter, exhaust pipes, gaskets, mounting hardware

Transmission:

Automatic transmission (CVT), variator operation, belt replacement, clutch assembly, final drive, gearbox oil

Electrical System:

Battery, charging system (alternator/stator, regulator/rectifier), starter motor, ignition system, lighting (headlights, taillights, indicators), horn, sensors, ECU

Wiring Diagrams:

Detailed wiring schematics for all electrical circuits, component identification, connector pinouts

Braking System:

Front and rear disc brakes, hydraulic system, brake calipers, master cylinders, brake lines, brake fluid, ABS system (if equipped)

Suspension:

Front telescopic forks, rear shock absorber, linkages, adjustments, fork oil specifications and change procedures

Chassis:

Frame inspection, steering head bearings, wheel bearings, swingarm, general chassis components

Bodywork:

Fairings, seat, handlebars, instrumentation, storage compartments, disassembly and reassembly

Wheels Tires:

Wheel specifications, tire sizes, tire pressure, wheel balancing, tire replacement

Special Tools:

Listing and usage of specialized tools required for specific repair and maintenance tasks

Procedures Included

Maintenance:

Scheduled maintenance tasks, fluid checks and changes, filter replacements, spark plug replacement, drive belt inspection/replacement

Troubleshooting:

Systematic diagnostic procedures for common problems, fault codes, symptom-based troubleshooting guides

Diagnostics:

Engine management diagnostics, electrical system diagnostics, ABS diagnostics (if applicable)

Engine Repair:

Complete engine overhaul, valve adjustments, piston ring replacement, gasket replacement

Transmission Service:

Variator maintenance, belt replacement, clutch service, gearbox oil replacement

Electrical Repair:

Component testing and replacement (alternator, starter, ignition coils, sensors), wiring harness repair

Brake System Service:

Brake bleeding, pad replacement, caliper service, master cylinder replacement, ABS bleeding procedures

Suspension Overhaul:

Fork seal replacement, fork oil change, rear shock absorber service

Bodywork Disassembly:

Panel removal and installation, seat removal, fairing repair

Pre Delivery Inspection:

Checklist and procedures for preparing a new vehicle for customer delivery

Technical Depth

Depth Level:

Comprehensive: from basic maintenance to in-depth engine and component overhauls

Diagnostic Capability:

Advanced diagnostic procedures and troubleshooting, including electrical systems and fuel injection

Rebuild Procedures:

Detailed instructions for complete engine and transmission rebuilds

Schematic Detail:

High level of detail in diagrams, including exploded views and torque specifications

📊 Manual Specifications

File Format

File Type:

Digital (PDF Download)

Print Quality

Print Recommendation:

Printable on demand, suitable for professional workshop use

Binding Type

Binding Type:

N/A (Digital File)

Paper Type

Paper Type:

N/A (Digital File)

Searchability

Text Search:

Likely text-searchable PDF for quick information retrieval

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, four-stroke, liquid-cooled, DOHC, 8 valves

Engine Displacement:

799 cc

Bore X Stroke:

75.8 mm x 72.2 mm

Compression Ratio:

10.5:1 (typical, verify in manual)

Performance

Horsepower:

Approx. 55 HP @ 7,250 RPM (verify in manual)

Torque:

Approx. 70 Nm @ 6,000 RPM (verify in manual)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) - Likely Marelli system

Fuel Type:

Unleaded gasoline

Engine Cooling

Cooling Medium:

Liquid (Coolant)

Engine Lubrication

Oil Type:

High-quality synthetic motorcycle oil, SAE 10W-40 or 15W-50 (refer to manual for specific API and JASO ratings)

Oil Capacity:

Approx. 2.5 - 2.8 liters (with filter change, verify in manual)

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Optional

Optional Transmission:

N/A (CVT is standard)

Features

Drive Type:

Belt drive to rear wheel

Final Drive Gear Oil:

API GL-4 or GL-5, SAE 75W-90 hypoid gear oil (verify in manual)

📐 Dimensions

Exterior

Length:

Approx. 2,235 mm (verify in manual)

Width:

Approx. 810 mm (verify in manual)

Height:

Approx. 1,460 mm (verify in manual)

Wheelbase:

Approx. 1,590 mm (verify in manual)

Weights

Dry Weight:

Approx. 235 kg (verify in manual)

Curb Weight:

Approx. 245 kg (verify in manual, includes fluids)

Max Load Capacity:

Typically around 180-200 kg rider + cargo (verify in manual)

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable in the same way as cars, but structural integrity is covered in the manual.

Active Features

ABS Availability:

Optional (check specific model variant)

Braking System Type:

Dual front disc brakes, single rear disc brake. Linked braking system may be present (verify in manual).

Passive Features

Lighting:

Halogen headlights, LED taillights/brake lights, turn signals

Instrumentation:

Digital/analog combination with essential warning lights

💡 Technology Features

Infotainment

Instrument Cluster:

Combination analog tachometer and digital display for speed, fuel level, temperature, odometer, trip meters, and warning lights.

Driver Assistance

Optional Anti-lock Braking System (ABS) for enhanced safety, the manual will cover its operation and service.

Connectivity

Vehicle Diagnostics:

On-board diagnostics (OBD) for engine and electrical system fault detection, covered extensively in the manual.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

Check every 5,000 km, replace as needed (refer to manual)

Spark Plug Replacement:

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

Drive Belt Inspection Replacement:

Inspect periodically, replace typically every 20,000 - 30,000 km (refer to manual for exact interval and procedures)

Brake Fluid Change:

Recommended every 2 years (DOT 4, verify in manual)

Coolant Change:

Typically every 2-3 years or as specified (refer to manual for type)

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant, mix ratio 50/50 with distilled water (refer to manual for specific additive package)

Brake Fluid Type:

DOT 4 (verify in manual)

Known Issues

Common Issues General:

While the GP800 is generally robust, common maxi-scooter issues can include CVT belt wear over time, potential electrical gremlins if wiring is compromised, and regular maintenance needs for the V-twin engine. Specific issues will be detailed in the troubleshooting section of the manual.

📚 Vehicle History

Brand Heritage

Parent Company:

Piaggio & C. S.p.A. (Gilera is a historic Italian brand under Piaggio)

Model Evolution

Introduction Year:

Introduced in 2007

Development Basis:

Shared platform and powertrain with the Piaggio X8/X9 maxi-scooters and Aprilia RSV Mille based V-twin engines.

Production

Manufacturing Location:

Italy