Category:
Performance Motorcycles (late 1980s / early 1990s era)
Target Audience:
Owners and mechanics of Gilera 350, 500, and 600 Master models seeking detailed repair and maintenance guidance.
Competitors:
Manuals for contemporary Italian motorcycles from brands like Moto Guzzi, Ducati, and Laverda, as well as comparable Japanese performance bikes of the era.
Completeness:
Stated as 'FULL/COMPLETE Version', indicating comprehensive coverage rather than partial or workshop bulletins.
Downloadability:
Convenient PDF download format for immediate access.
Models Covered:
Gilera 350 Master, Gilera 500 Master, Gilera 600 Master
Estimated Page Count:
Comprehensive, estimated 500+ pages (typical for a full service manual of this era)
Type:
Master Service and Repair Manual
Language:
Likely English (primary, with potential for Italian and other European languages depending on original publication)
Engine:
Detailed engine overhaul, tuning, carburetor systems, ignition systems, cooling systems, lubrication systems, fuel delivery (specific to model variants like single cylinder vs. twin cylinder, if applicable across the Master range).
Transmission:
Gearbox inspection, repair, clutch operation and replacement, lubrication, shift mechanism.
Chassis And Suspension:
Front fork assembly and rebuild (including damping, seals), rear shock absorber systems, swingarm maintenance, wheel bearings, steering head bearings.
Braking System:
Hydraulic brake systems (front and rear calipers, master cylinders), brake fluid replacement, bleeding procedures, pad and disc inspection/replacement.
Electrical System:
Wiring diagrams, starter motor, charging system (stator, regulator/rectifier), lighting circuits, battery maintenance, fuse identification and replacement, ignition system components.
Fuel System:
Carburetor tuning and rebuilding (e.g., Dell'Orto, Mikuni, depending on specific models), fuel tank servicing, fuel lines, petcock operation.
Exhaust System:
Exhaust pipe and muffler inspection, maintenance, and potential replacement procedures.
Bodywork And Frame:
Fairing removal/installation, seat servicing, fuel tank mounting, frame inspection and basic repairs, body panel alignment.
Maintenance:
Regular service intervals, oil changes, filter replacements (oil, air), spark plug service, chain adjustment and lubrication, brake pad checks, tire pressure checks, valve clearance adjustment.
Troubleshooting:
Diagnostic charts for common starting issues, engine running problems, electrical faults, braking system issues, and suspension performance.
Repair And Rebuild:
Step-by-step instructions for engine disassembly and reassembly, transmission overhauls, carburetor rebuilding, suspension fork servicing, brake caliper overhaul, electrical component replacement.
Specifications And Data:
Torque specifications for all fasteners, engine clearances (piston to cylinder, valve clearances), fluid capacities, ignition timing settings, carburetor jetting recommendations.
Wiring Diagrams:
Detailed and clearly labeled electrical schematics for all model variants covered.
Level Of Detail:
Comprehensive, covering routine maintenance through to full engine and transmission rebuilds. Suitable for both amateur enthusiasts and professional mechanics.
Engine Type:
Likely single-cylinder, four-stroke (for 350, 500, 600 Master variants) with potential for variations in bore, stroke, and compression ratio across displacements. Some models might have been twins.
Power Output:
Specific figures vary by model: 350cc (approx. 30-35 HP), 500cc (approx. 35-40 HP), 600cc (approx. 40-45 HP). Exact figures would be detailed in the manual.
Torque Output:
Torque figures vary by model and RPM. Manual will specify peak torque and torque curves if available.
Carburetion:
Likely single or dual carburetor setup (e.g., Dell'Orto PHM or similar) with specific jetting and adjustment procedures.
Ignition Type:
Electronic ignition (CDI or similar) with specific timing and component testing procedures.
Cooling Method:
Air-cooled
Oil Type Capacity:
Manual will specify recommended oil grade (e.g., SAE 20W-50 or similar) and total oil capacity, including filter.
Valve Clearance:
Specific intake and exhaust valve clearances (cold) for each model will be detailed, along with adjustment procedures.
Crash Test Ratings:
N/A (Motorcycle safety testing standards were less formalized and standardized compared to automobiles during this period).
Braking System:
Disc brakes front and rear (specific caliper arrangements, e.g., single or dual piston, will be detailed). ABS was not common on these models.
Lighting:
Headlight, taillight, brake lights, turn signals. Manual covers their function and troubleshooting.
Oil Change Interval:
Typically every 3,000-5,000 km or annually, whichever comes first. Manual will specify exact interval and oil type.
Valve Check Interval:
Generally around 6,000-12,000 km. Manual will provide the precise interval.
Engine Oil Grade:
Likely SAE 20W-50, but manual will confirm the exact specification and API service rating.
Brake Fluid Type:
DOT 4 or DOT 3 hydraulic brake fluid. Manual will specify the correct type and replacement interval.
Gearbox Oil Type:
Manual will specify the recommended gear oil grade and quantity.
Common Wear Items:
Carburetor diaphragm degradation, fork seal leaks, drive chain wear, clutch wear, and electrical component reliability can be common on older bikes. Manual provides diagnostics and repair.
Carburetor Synchronization:
Detailed instructions for synchronizing carburetors (if applicable) and setting idle speed.
