Target Audience:
Owners seeking to perform their own maintenance and repairs, as well as professional mechanics working on Gilera scooters.
Visual Guidance:
Includes comprehensive pictures to aid in understanding disassembly and assembly procedures.
Technical Data Accuracy:
Provides critical technical data such as bolt tightening torques and special tool requirements.
Diy Focus:
Specifically highlights its utility for DIY maintenance tasks like oil changes and brake servicing.
Electrical Diagrams:
Explicitly states that electrical diagrams are NOT included in this manual.
Engine:
Detailed disassembly, assembly, inspection, and repair of the Purejet engine, including cooling system, lubrication, and fuel injection.
Transmission:
Coverage of the automatic transmission (CVT), including variator, clutch, and reduction gears.
Brakes:
Front and rear brake system service, including caliper, master cylinder, brake lines, and fluid replacement.
Suspension:
Front fork and rear shock absorber inspection, maintenance, and replacement.
Chassis:
Frame inspection, steering head bearing service, and general chassis component maintenance.
Fuel System:
Details on the fuel injection system, including fuel pump, injectors, and fuel lines. Excludes electrical diagrams for fuel system components.
Routine Maintenance:
Oil changes, air filter replacement, oil filter replacement, spark plug service, brake pad replacement, fluid level checks.
Major Repairs:
Engine disassembly and reassembly, transmission overhaul, suspension rebuild, brake system bleeding.
Troubleshooting:
Diagnostic guidance for common mechanical issues and operational problems.
Diagnostic Level:
Suitable for intermediate to advanced DIY mechanics and professional technicians. Focuses on mechanical diagnosis.
Rebuild Capability:
Enables complete engine and transmission rebuilds with detailed part specifications and torque values.
Engine Type:
Liquid-cooled, 2-stroke, single-cylinder (Piaggio LEADER engine variant, likely)
Displacement:
Typically 49cc or 50cc for Purejet models, though variations may exist. Refer to specific model VIN for exact specs.
Bore X Stroke:
Specific dimensions available within the manual. For 50cc Purejet, often around 39.0 mm x 41.4 mm.
Horsepower:
Typically around 5-6 HP for 50cc models, subject to emissions regulations and tuning. Specific figures in manual.
Torque:
Specific torque figures for engine components will be detailed in the manual. Peak torque often achieved at mid-RPM range.
Fuel Delivery:
Electronic Fuel Injection (EFI) - Piaggio's 'Purejet' system.
Ignition System:
Electronic ignition. Specific details on timing and components would be in the manual (excluding electrical diagrams).
Oil Type:
Two-stroke oil, specific API TC or JASO FD classification required. Capacity and change intervals in manual.
Recommendation:
Specific spark plug type (e.g., NGK BR9ES or similar) and gap specification will be provided in the manual.
Type:
Automatic Continuously Variable Transmission (CVT)
Clutch Type:
Centrifugal automatic clutch
Variator:
Covers inspection, roller weight analysis, and belt replacement for the variator.
Reduction Gear:
Details on the reduction gear assembly and its lubrication.
Reduction Gear Oil:
Specific gearbox oil viscosity and capacity will be detailed in the manual (e.g., SAE 80W/90).
Length:
Approx. 1800-1850 mm (varies by specific generation, check manual for exact)
Width:
Approx. 730-750 mm (at handlebars)
Height:
Approx. 1200-1250 mm (to top of windscreen)
Dry Weight:
Approx. 110-120 kg (varies by model year and specification)
Fuel Tank Capacity:
Typically around 7-8 Liters
Brakes:
Front and rear disc brakes, typically with hydraulic actuation. Specific caliper and disc sizes in manual.
Tires:
Tubeless tires. Common sizes: Front 120/70-14, Rear 140/60-13 (check manual for specific fitment).
Lighting:
Headlight, taillight, turn signals. Manual covers bulb types and replacement procedures.
Frame Structure:
High-tensile steel frame, detailed inspection points will be in the manual.
Dashboard:
Digital/analog combination dashboard displaying speed, RPM, fuel level, temperature, and warning lights. Manual covers indicator light functions.
N/A:
Scooters of this era typically do not feature advanced driver assistance systems.
Engine Oil Change:
Typically every 3,000-5,000 km or annually. Specific interval and oil capacity in manual.
Air Filter Check:
Regular inspection, usually every 3,000-5,000 km. Replacement interval specified in manual.
Spark Plug Replacement:
Typically every 6,000-10,000 km. Refer to manual for exact type and gap.
Brake Fluid Change:
Recommended every 2 years or as per manual's guideline, to maintain braking performance.
Engine Oil Type:
Full synthetic 2-stroke oil, JASO FD or API TC rated. Capacity approximately 1-1.2 Liters (refer to manual for exact).
Cooling System Coolant:
Ethylene glycol-based coolant with anti-corrosion additives. Capacity and type specified in manual.
Fuel Injector Clogging:
Potential for injector clogging with poor quality fuel or extended storage. Manual provides cleaning procedures.
Variator Roller Wear:
Normal wear and tear of variator rollers can affect acceleration and top speed. Manual guides inspection and replacement.
Water Pump Seals:
Potential for water pump seal leaks over time. Manual details seal replacement procedures.
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and performance-oriented scooters.
Runner Lineup:
The Runner platform is a long-standing and popular model for Gilera, known for its sporty handling and distinctive styling. The Purejet variant signifies the adoption of fuel injection for improved performance and emissions.
Model Years Covered:
While not explicitly stated, the ZAPC462 frame number prefix suggests models from the mid-2000s onwards (e.g., 2005-2010+). The manual should cover this specific production era.
