Vehicle Class:
Maxi-scooter, sport scooter
Target Audience:
Performance-oriented scooter enthusiasts, owners seeking detailed DIY repair capabilities
Competitors:
Suzuki Burgman 650, Yamaha TMAX 500/530, BMW C650GT/C600 Sport
Manual Advantage:
Comprehensive, detailed, easy-to-follow with diagrams, instant access
Vehicle Usp:
Powerful engine for a scooter, sporty handling, comfortable for long distances
Language:
English (implied by typical workshop manual content)
Models Covered:
All Gilera GP800 IE models
Page Count Estimate:
Likely extensive, typical for workshop manuals (e.g., 300-800+ pages, exact count not provided)
Manual Type:
Workshop Repair Manual
Purpose:
Perform all repairs, service, maintenance, teardowns, overhauls, and adjustments
Engine:
Detailed engine repair, overhaul, tuning, and diagnostics
Fuel System:
Injection system (IE), fuel pump, injectors, fuel lines, fuel tank, fuel filter
Ignition System:
Spark plugs, ignition coils, ECU control
Cooling System:
Radiator, water pump, thermostat, coolant lines, fan
Transmission Drivetrain:
Automatic transmission (CVT likely), clutch, drive belts, final drive
Chassis Frame:
Frame construction, component mounting, alignment
Suspension Front:
Fork assembly, steering head bearings, wheel alignment
Suspension Rear:
Shock absorber, swingarm, linkage (if applicable)
Braking System:
Front and rear brakes, hydraulic system, brake pads, rotors, calipers, master cylinders
Wheels Tires:
Wheel removal/installation, tire pressure, tire replacement
Electrical System:
Battery, charging system, starter motor, lighting, instrumentation, wiring diagrams
Bodywork Fairings:
Fairing removal/installation, body panel repair, trim
Controls:
Handlebars, levers, pedals, throttle control, brake controls
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable)
Preventative Maintenance:
Scheduled maintenance, inspections, lubrication, adjustments
Troubleshooting:
Diagnosis of common problems, fault finding procedures
Repair Overhaul:
Step-by-step instructions for component repair and complete rebuilds
Disassembly Reassembly:
Detailed procedures for taking apart and putting back together all major systems
Adjustment:
Precise adjustments for various systems (e.g., chain tension, valve clearance if applicable, throttle cable)
Replacement:
Instructions for replacing wear items and faulty components
Wiring Diagrams:
Comprehensive electrical system schematics for fault diagnosis and repair
Depth:
Comprehensive (covers all repairs, diagnostics, and specifications)
Detail Level:
High, with exploded views, diagrams, and step-by-step instructions
Engine Type:
Liquid-cooled, 4-stroke, 8-valve, SOHC V-twin
Bore X Stroke:
83 mm x 73.5 mm
Fuel Delivery:
Electronic fuel injection (IE)
Compression Ratio:
10.2:1 (typical for this engine)
Horsepower Output:
Approximately 50-55 HP (at crankshaft)
Torque Output:
Approximately 65-70 Nm (at crankshaft)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 18 liters
Spark Plug Type:
Specify based on service manual (e.g., NGK CR9EKB or similar)
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Piaggio/Gilera specific coolant or equivalent)
Instrumentation:
Digital and analog display including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meters, clock.
ABS:
Available as an option on certain models, providing enhanced braking safety.
Diagnostic Port:
On-board diagnostic (OBD) port for engine management system diagnostics.
Oil Change Interval:
Typically every 5,000-6,000 km or annually (refer to manual for exact intervals).
Spark Plug Replacement:
Every 10,000-12,000 km (refer to manual for specific recommendation).
Air Filter Replacement:
Check every 5,000 km, replace as needed or every 10,000 km.
Drive Belt Inspection Replacement:
Inspect annually, replace typically every 20,000-30,000 km or as wear dictates.
Engine Oil Type:
API SG/SH/SJ or higher, SAE 5W-40 synthetic or semi-synthetic motorcycle oil (verify with manual for exact grade).
Engine Oil Capacity:
Approx. 1.7 - 1.9 liters (with filter change, refer to manual).
Coolant Capacity:
Approx. 1.5 - 1.7 liters (refer to manual).
Brake Fluid Type:
DOT 4 (refer to manual for specific recommendations and replacement intervals).
Common Wear Items:
Drive belt, brake pads, tires, front fork seals, starter motor solenoid.
Potential Electrical Gremlins:
Can occur with age, especially concerning charging system or ECU connections (manual will guide diagnosis).
Engine Vibration:
Some owners report higher vibration levels than expected for a V-twin, often mitigated by proper maintenance and engine mounts.
