🏷️ Basic Information

Make:

Gilera

Model:

GP800 I.E.

Year:

2009

Product Type:

Factory Service Repair Manual

Chassis Code:

Not specified in product data

Engine Code:

Not specified in product data, but indicative of an 800cc Gilera V-twin

👋 Introduction

Segment:

Sport-touring scooter, high-performance maxi-scooter.

Target Audience:

Owners, independent repair shops, mechanics seeking in-depth knowledge of the Gilera GP800.

Key Competitors:

Suzuki Burgman 650, Yamaha TMAX 500, Aprilia SRV 850 (later model, but sharing platform), BMW C650GT.

Vehicle Highlights:

Powerful V-twin engine, advanced CVT transmission, substantial underseat storage, touring comfort.

Benefit To User:

Empowers owners and technicians to perform accurate diagnostics, maintenance, and repairs, saving time and money while ensuring optimal performance and longevity.

📋 Manual Details

Overall Coverage:

Comprehensive repair and maintenance for the Gilera GP800 I.E. 2009 model.

Estimated Page Count:

Estimated 300-400 pages (typical for this type of comprehensive service manual).

Type:

Factory Service Repair Manual

Language:

Likely English (based on product description and common availability for international markets).

Format:

PDF Download

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, inspection, tuning, lubrication, cooling system, fuel injection system (I.E.), exhaust system.

Transmission:

Automatic CVT transmission overhaul, belt inspection and replacement, clutch operation, gearbox oil.

Chassis:

Frame inspection, steering system, front fork and suspension, rear shock absorber, swingarm, bearings.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake pads, brake fluid specifications and bleeding procedures.

Electrical:

Wiring diagrams, battery, starter system, charging system, ignition system, lighting, indicators, instrumentation, ECU, sensors.

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel tank, fuel pressure regulation.

Bodywork:

Fairings, seat removal, panel fitting, storage compartment access.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, chain adjustment (if applicable, though likely belt-driven CVT), coolant checks.

Troubleshooting:

Diagnostic charts, common problems and solutions, error code interpretation (if applicable).

Repair:

Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Diagnostics:

Procedures for checking component operation, electrical system testing, fuel system checks.

Depth:

Comprehensive, covering everything from basic adjustments and fluid changes to full engine and transmission rebuilds, including electrical system diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable PDF (standard for most service manuals).

Quality:

Professional, factory-level documentation with clear diagrams and illustrations.

Binding:

N/A (Digital PDF Download)

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 90-degree V-twin, 4-stroke

Displacement:

799 cc

Bore X Stroke:

88 mm x 65.5 mm

Compression Ratio:

10.5:1

Valve Train:

SOHC, 4 valves per cylinder

Horsepower:

Approximately 75 HP (55 kW) @ 7,750 rpm

Torque:

Approximately 77 Nm (57 lb-ft) @ 6,000 rpm

Fuel Delivery:

Electronic Fuel Injection (I.E.) with Keihin throttle body

Fuel Type:

Unleaded gasoline (min 95 RON recommended)

Oil Type:

Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 API SG or higher, JASO MA certified.

Oil Capacity:

Approx. 2.6 liters (with filter change)

Coolant Type:

Mixture of ethylene glycol and distilled water (50/50 ratio), with anti-corrosion additives.

🔧 Transmission

Type:

Automatic Continuously Variable Transmission (CVT)

Optional Transmissions:

None (CVT is standard)

Clutch:

Automatic centrifugal clutch

Final Drive:

Belt drive

Transmission Oil Type:

Specific CVT fluid or SAE 80W-90 API GL-5 gear oil (check manual for exact specification).

Transmission Oil Capacity:

Approx. 0.3 liters (check manual for exact specification).

📐 Dimensions

Length:

Approx. 2,230 mm

Width:

Approx. 790 mm

Height:

Approx. 1,450 mm (seat height approx. 800 mm)

Dry Weight:

Approx. 240 kg

Gross Vehicle Weight Rating:

Not specified, but substantial due to engine size and chassis.

Fuel Tank Capacity:

18.7 Liters

🛡️ Safety Features

Crash Safety Ratings:

Not applicable in the same way as cars; focus is on design integrity and rider protection.

Braking System:

Dual front disc brakes (likely 300mm+ diameter) with 2-piston calipers, Rear disc brake (likely 280mm+ diameter) with 2-piston caliper. Optional ABS (Anti-lock Braking System) available.

Lighting:

Halogen headlights, LED taillight and brake lights, front and rear turn signals.

Frame Construction:

Steel frame for rigidity and durability.

Ride Stability:

Large diameter front forks and robust rear suspension contribute to stability.

💡 Technology Features

Instrument Cluster:

Digital and analog combination display, including speedometer, tachometer, fuel gauge, coolant temperature, odometer, trip meters, and warning lights.

ABS:

Available as an option on some models, covered in manual's brake system section.

Connectivity Features:

Not typically found on this model; focus is on mechanical and electrical systems.

ECU Capabilities:

Engine Control Unit managing fuel injection, ignition timing, and potentially other engine parameters. Manual will detail sensor inputs and diagnostic procedures.

🔧 Maintenance

Oil Change Interval:

Every 5,000 km or 6 months, whichever comes first.

Filter Replacement:

Oil filter at every oil change. Air filter check at 10,000 km, replacement as needed. CVT belt inspection at 10,000 km, replacement generally recommended around 20,000-30,000 km.

Spark Plug Service:

Check and gap at 10,000 km, replacement recommended around 20,000 km.

Coolant Replacement:

Every 2 years or 40,000 km.

Brake Fluid:

DOT 4 (check manual for specific recommendations).

Common Wear Items:

CVT belt, brake pads, tires, wheel bearings.

Potential Electrical Issues:

Wiring harness connections, voltage regulator (common in some Piaggio Group products of this era, manual will detail diagnostics).

Engine Specific Considerations:

Proper maintenance of the fuel injection system and regular oil changes are crucial for the longevity of the V-twin.

📚 Vehicle History

Manufacturer Origin:

Gilera is an Italian manufacturer with a long history in motorcycle racing and production, now part of the Piaggio Group.

Gp800 Development:

Developed by Gilera, leveraging Piaggio Group's engineering capabilities, particularly the powerful 800cc V-twin engine previously used in Aprilia models and later adapted for the Aprilia SRV 850.

Manufacturing Location:

Likely Italy (Piaggio Group manufacturing facilities).

Production Years:

Produced from 2007 to approximately 2011.

🏆 Awards & Recognition

Industry Awards:

The Gilera GP800 was recognized for its powerful engine and sport-touring capabilities, often lauded for its performance in the maxi-scooter segment at its release.

Performance Reviews:

Generally received positive reviews for its acceleration, top speed, and comfortable ride for longer distances.

Emissions Standards:

Complies with Euro 3 emissions standards for motorcycles.