Gilera Runner Purejet 50 2003-2004 Service Repair Workshop Manual Download PDF

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The Runner Purejet 50, produced for the 2003-2004 model years, represents a sporty and agile option in the 50cc scooter segment. Known for its aggressive styling and the advanced Purejet...

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Taper: Motorcycle

Distributeur:

UGS: 86798

Mots clés: 2003 2004 Gilera Motorcycle Motorcycles Runner Runner Purejet 50

Variantes de produits

Description

The Runner Purejet 50, produced for the 2003-2004 model years, represents a sporty and agile option in the 50cc scooter segment. Known for its aggressive styling and the advanced Purejet 50cc direct injection 2-stroke engine, this model offers enhanced performance and fuel efficiency compared to its carbureted predecessors. An Italian brand with a rich heritage in performance motorcycling, engineered the Runner series for dynamic handling and a responsive riding experience, making it a popular choice for urban commuting and spirited riding. This comprehensive service repair workshop manual provides detailed guidance for owners and technicians working on the Runner Purejet 50cc (Fuel Injection) models from 2003 and 2004. It covers a vast array of systems, including complete engine service, fuel injection, ignition, cooling, transmission, brakes, suspension, steering, and electrical systems. The manual includes routine maintenance procedures, troubleshooting guides for common issues, step-by-step repair instructions, diagnostic procedures, and essential technical specifications, all presented with clarity to ensure proper upkeep and repair of the vehicle.

🏷️ Basic Information

Identification

Make:

Gilera

Model:

Runner Purejet 50

Year:

2003-2004

👋 Introduction

Market Position

Scooter Segment:

Sporty 50cc scooter segment, popular in urban environments

Competitive Analysis

Key Competitors:

Aprilia SR50, Piaggio Zip SP, Yamaha Aerox 50, Malaguti F12R

Key Features

Engine Technology:

Purejet 50cc direct injection 2-stroke engine, offering improved performance and fuel efficiency over carbureted models

Design:

Aggressive, sporty design with advanced features for its class

📋 Manual Details

Coverage Areas

Model Years Covered:

2003, 2004

Engine Variants Covered:

Purejet 50cc (Fuel Injection)

Page Count

Estimated Page Count:

Hundreds of pages (specific number not provided, but described as extensive)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English (implied by product description, common for international manuals)

Format

Digital Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Service:

Complete overhaul, disassembly, assembly, tuning, and component diagnostics

Fuel System:

Detailed coverage of the Purejet fuel injection system, including components, testing, and calibration

Ignition System:

Spark plug specifications, ignition coil testing, CDI unit diagnostics

Cooling System:

Radiator, water pump, thermostat, coolant type, and bleeding procedures

Exhaust System:

Catalytic converter information, silencer, and header pipe maintenance

Transmission And Drivetrain:

CVT (Continuously Variable Transmission) disassembly, component inspection (variator, clutch, belt), and lubrication

Brakes:

Front and rear brake system service, hydraulic lines, caliper maintenance, pad replacement, and bleeding

Suspension:

Front telescopic forks, rear shock absorber service, and adjustment procedures

Steering:

Handlebar, steering stem, and bearing maintenance

Electrical System:

Wiring diagrams, lighting, battery, starter motor, charging system, and ECU diagnostics

Bodywork And Chassis:

Panel removal, fairing maintenance, seat and storage compartment service

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, brake fluid flushes, and general inspections

Troubleshooting:

Diagnostic procedures for common starting, running, and electrical issues

Repair Procedures:

Step-by-step guides for component replacement and repair across all covered systems

Diagnostic Guides:

Fault code interpretation and systematic diagnostic flowcharts for the Purejet system

Wiring Diagrams:

Comprehensive electrical schematics for accurate troubleshooting

Exploded Diagrams:

Highly detailed visual aids for part identification and assembly sequence

Technical Depth

Depth Of Coverage:

Professional-level repair and overhaul, suitable for experienced DIY mechanics and technicians

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, enhancing usability for finding specific information

Print Quality

Print Capability:

Printable pages (single or entire manual)

Binding Type

Digital Binding:

N/A (Digital Download)

Paper Type

Digital Paper Type:

N/A (Digital Download)

Licensing

Usage License:

Lifetime use, unlimited computer installations

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled, Piaggio Hi-Per 2 Pro (Purejet)

Displacement:

49.4 cc (3.01 cu in)

Bore X Stroke:

39 mm x 41.4 mm (typical for this engine family)

Performance

Horsepower:

Approximately 4.5 - 5.0 HP (stock, subject to variations)

Torque:

Specific torque figures not commonly published for 50cc scooters, but optimized for urban acceleration

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with digital ignition

Recommended Fuel:

Unleaded Gasoline (Octane rating 95 RON recommended)

Lubrication

Oil System:

Automatic oil injection system (separate reservoir for 2-stroke oil)

Recommended 2T Oil:

High-quality, low-smoke, fully synthetic 2-stroke scooter oil

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Features

Gear Reduction:

Integrated final drive with helical gears

Transmission Fluid:

N/A (CVT does not use a transmission fluid in the automotive sense; requires occasional inspection and replacement of belt and rollers)

📐 Dimensions

Exterior

Wheelbase:

Approximately 1350 mm (135 cm)

Weights

Dry Weight:

Approximately 105 kg

Max Payload:

Typically around 150 kg (rider + passenger + cargo)

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable for this vehicle class and era in standard automotive crash testing protocols.

Active Features

Braking System:

Hydraulic disc brakes front and rear

Lighting:

Halogen headlamp, taillight, brake light, turn signals

Passive Features

Frame Construction:

Steel tube frame

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, digital odometer, fuel gauge, coolant temperature warning light, and indicator lights.

Driver Assistance

No ABS typically offered on the 50cc model of this era.

Connectivity

Charging Port:

12V auxiliary power outlet (not a USB charging port)

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000 km or annually, whichever comes first (refer to manual for precise details on 2-stroke oil level check)

Transmission Belt Inspection:

Check at 6,000 km, replace as needed based on wear

Spark Plug Replacement:

Inspect every 3,000 km, replace at recommended intervals (e.g., 6,000 km or based on condition)

Brake Fluid Flush:

Every 2 years or as per manual recommendations

Fluid Specifications

Engine Oil Type:

Refer to manual for specific Piaggio recommendations, typically a grade suitable for liquid-cooled 2-stroke engines, e.g., SAE 5W-40 for the engine oil (if separate from injection oil)

2 Stroke Oil Type:

Fully synthetic, low-smoke, JASO FD, API TC certified 2-stroke oil

Coolant Type:

Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Items:

CVT belt, rollers, brake pads, spark plug, air filter

Purejet Specific Concerns:

Potential for injector clogging or fuel pump issues if fuel quality is poor or maintenance is neglected. Electrical connectors can be susceptible to corrosion in damp conditions.

📚 Vehicle History

Brand Heritage

Gilera Legacy:

Gilera is an Italian brand with a long history in motorcycling, known for performance-oriented scooters and motorcycles.

Model Evolution

Runner Series:

The Gilera Runner is a long-standing and popular model, known for its sporty handling and performance, evolving through various engine options and body styles. The Purejet variant introduced direct injection for improved efficiency and emissions.

Production

Manufacturing Location:

Italy (part of the Piaggio Group)