GILERA GP 800 IE Service Manual GP800 Workshop

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Taper: Motorcycle

Distributeur:

UGS: 72700

Mots clés: Gilera GP 800 IE GP800 Motorcycle Motorcycles

Variantes de produits

Description

The Gilera GP 800 IE, introduced around 2007, is a performance-oriented maxi-scooter known for its powerful 799 cc V-twin engine and sportbike-like handling. Manufactured in Italy, this model offers a unique blend of scooter convenience and motorcycle performance, making it a distinct option in its class. Its engineering prioritizes a dynamic riding experience, supported by a robust steel twin-spar frame and an automatic continuously variable transmission (CVT) for smooth power delivery. This workshop service manual provides comprehensive guidance for the mechanical maintenance and repair of the Gilera GP 800 IE. It covers essential systems including the engine, fuel injection, cooling, transmission, brakes, suspension, and bodywork. Detailed procedures for routine maintenance, component overhaul, and troubleshooting are included, along with critical technical specifications such as torque values and fluid requirements. This manual is designed to assist owners and technicians in understanding, maintaining, and repairing the vehicle effectively.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

GP 800 IE

Frame Number Prefix:

ZAPM55100

Codes

Engine Code Prefix:

👋 Introduction

Market Position

Segment:

Maxi-scooter, performance-oriented

Competitive Analysis

Competitors:

Suzuki Burgman 650, Yamaha TMAX 500/530, BMW C 600 Sport/C 650 GT

Key Features

Uniqueness:

Powerful engine for a scooter, sportbike-like handling for its class

Target Audience

Primary Users:

Motorcycle owners seeking detailed DIY maintenance and repair knowledge, professional mechanics

Manual Value Proposition

Benefit:

Enables cost-effective DIY maintenance, deeper understanding of vehicle operation

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical maintenance and repair for Gilera GP 800 IE

Excluded Coverage:

Electrical diagrams

Page Count

Estimated Page Count:

Varies (Digital PDF, typically 300-500 pages for comprehensive manuals)

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, tuning

Fuel System:

Fuel injection system (mechanical components), fuel pump, injectors

Cooling System:

Radiator, water pump, thermostat, hoses

Transmission:

Automatic transmission (CVT) operation, maintenance, and repair

Brakes:

Brake system components, fluid, pad replacement, caliper service

Suspension:

Front fork (telescopic), rear shock absorber, linkage maintenance

Frame And Bodywork:

Chassis inspection, body panel removal/installation

Wheels And Tires:

Tire replacement, wheel balancing, bearing service

Exhaust System:

Exhaust manifold, muffler, catalytic converter maintenance

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air), spark plug service, chain adjustment (if applicable to rear drive)

Component Overhaul:

Engine rebuild, transmission service, brake caliper overhaul

Troubleshooting:

Diagnostic procedures for common mechanical issues

Adjustment:

Throttle cable, clutch adjustment (if applicable), suspension pre-load

Technical Depth

Depth:

Comprehensive workshop level, covering routine maintenance to major repairs

Data Accuracy:

Includes critical torque specifications, measurements, and clearances

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Reproducibility:

High-resolution, suitable for printing individual sections or the entire manual

Binding Type

Digital Binding:

N/A (Digital download, binding is user-defined upon printing)

Paper Type

Digital Paper:

N/A (Digital PDF, user chooses paper type if printed)

⚙️ Engine Specifications

Primary Engine

Configuration:

V-twin, 4-stroke, liquid-cooled

Displacement:

799 cc

Bore X Stroke:

75 mm x 79 mm

Compression Ratio:

10.5:1 (approximate, check manual for exact)

Performance

Horsepower:

54.4 HP (40 kW) @ 7,000 rpm (approximate, check manual)

Torque:

70 Nm (51.6 lb-ft) @ 6,000 rpm (approximate, check manual)

Fuel System

Injection:

Electronic Fuel Injection (IE)

Fuel Type:

Unleaded gasoline (minimum 95 RON)

Lubrication

Oil Type:

SAE 10W-40 API SG or higher (specific API/JASO rating to be confirmed in manual)

Oil Capacity:

Approx. 1.7 liters (check manual for exact, with filter change)

🔧 Transmission

Standard

Type:

Automatic continuously variable transmission (CVT)

Features

Drive System:

Belt drive to rear wheel

Transmission Fluid Type:

Specific CVT fluid (refer to manual for part number and specification)

📐 Dimensions

Exterior

Length:

Approx. 2,160 mm

Width:

Approx. 790 mm

Height:

Approx. 1,490 mm (seat height variable)

Weights

Dry Weight:

Approx. 215 kg

Gross Vehicle Weight:

Approx. 380 kg

Payload Capacity:

Approx. 165 kg

🛡️ Safety Features

Active Features

Braking System:

Dual front disc brakes, single rear disc brake. ABS optional/standard depending on market. (Manual will detail ABS service if equipped)

Lighting:

Halogen headlights, LED taillight (likely)

Passive Features

Frame Construction:

Steel twin-spar frame

💡 Technology Features

Infotainment

Instrument Cluster:

Digital-analog combination, speed, RPM, fuel level, engine temperature, odometer, trip meter

Driver Assistance

Optional (check specific model configuration), detailed in manual if present

Connectivity

Immobilizer:

Likely equipped as standard for anti-theft

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 6,000 km or 12 months (check manual for precise intervals and conditions)

Air Filter Replacement:

Every 12,000 km or 24 months (check manual)

Spark Plug Replacement:

Every 18,000 km or 36 months (check manual for specific plug type)

Brake Fluid Change:

Every 24 months (DOT 4 recommended, check manual for specific)

Cvt Belt Inspection:

Every 12,000 km (check for wear and tension)

Fluid Specifications

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitors (check manual for mix ratio and specification)

Brake Fluid:

DOT 4 (minimum)

Known Issues

Common Concerns:

CVT belt wear, potential fuel injection sensor issues (as with many FI systems), water pump seal leaks (typical for liquid-cooled engines). Manual will provide diagnostic steps.

📚 Vehicle History

Brand Heritage

Manufacturer:

Piaggio Group (owns Gilera brand)

Model Evolution

Introduction Year:

Introduced around 2007

Production

Manufacturing Location:

Italy (Piaggio plants)

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

Praised for its performance and motorcycle-like riding dynamics within the maxi-scooter segment.