🏷️ Basic Information

Make:

Gilera

Model:

GP800

Model Years Covered:

2006, 2007, 2008, 2009, 2010

Engine Code:

GPR00

Chassis Code:

Not specified in provided information, but typically related to the GP800 platform.

👋 Introduction

Target Audience:

Do-it-yourself enthusiasts and experienced mechanics seeking comprehensive repair and service information.

Value Proposition:

An inexpensive and efficient way to keep the vehicle working properly, offering in-depth knowledge typically found only in professional workshops.

Uniqueness:

Positioned as 'The only service repair workshop manual you will ever need,' highlighting its comprehensive coverage and detailed nature.

Download Benefit:

Instant download eliminates shipping costs and waiting times, providing immediate access to critical service information.

Illustration Quality:

Emphasis on high-quality illustrations, drawings, and photos to facilitate understanding of complex procedures.

Navigation Tools:

User-friendly features like a numbered table of contents and searchable text enhance the efficiency of using the manual.

📋 Manual Details

Model Variants:

All versions and model year variants from 2006-2010

Estimated Page Count:

Not explicitly stated, but described as comprehensive with hundreds of photos and illustrations, implying a substantial document.

Type:

Workshop Service and Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, diagnostics, performance tuning, lubrication, cooling, fuel delivery, ignition.

Transmission:

Automatic transmission (CVT) operation, maintenance, repair, fluid specifications, and troubleshooting.

Brakes:

Front and rear brake system maintenance, component replacement, bleeding procedures, ABS system (if applicable).

Electrical:

Wiring diagrams, lighting systems, starting and charging systems, ignition system, electronic control units (ECU), instrumentation.

Chassis:

Frame inspection and repair, suspension system (front and rear), steering system, wheels, and tires.

Bodywork:

Fairing removal and installation, body panel repair, seat, storage compartments.

Cooling System:

Radiator, coolant, fan, hoses, temperature sensor diagnostics and replacement.

Fuel System:

Fuel pump, injectors, fuel filter, fuel tank, throttle body servicing.

Exhaust System:

Exhaust pipe and muffler inspection and replacement.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug replacement, chain adjustment (if applicable, though GP800 is belt drive), brake pad replacement.

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon issues, including electrical faults and engine performance problems.

Repair:

Step-by-step instructions for complete disassembly and reassembly of all major components and systems.

Installation:

Procedures for installing replacement parts and performing adjustments.

Diagnostics:

Detailed diagnostic flowcharts and procedures for identifying the root cause of problems.

Depth:

From basic do-it-yourself maintenance to advanced mechanical and electrical repair, suitable for both novice and experienced technicians.

Illustrations:

Hundreds of detailed photos, drawings, and diagrams, including enlarged insets for detailed examination of parts.

Instructions Format:

Numbered, step-by-step instructions with bold figure numbers for easy cross-referencing with illustrations.

Notes Cautions Warnings:

Critical information is highlighted through notes, cautions, and warnings throughout each chapter.

📊 Manual Specifications

Format:

PDF

Printable:

All pages are printable, allowing users to print specific sections for workshop use.

Image Scaling:

Images can be blown up and printed in enlarged copies for better detail.

Binding:

Digital Download (PDF)

Paper Type:

Not Applicable (Digital Format)

Operating Systems:

Compatible with all Windows (7, Vista 32/64, XP, ME, 98, NT, 2000 etc.) and Mac computers.

Reader:

Requires Adobe PDF Reader.

Delivery:

Instant Download

Text Search:

Searchable text into document for quick information retrieval.

Indexing:

Fully indexed for easy navigation and quick access to information.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 4-stroke, V-twin (90°)

Displacement:

799 cc (48.8 cu. in.)

Bore X Stroke:

90.0 mm x 63.0 mm (3.54 in x 2.48 in)

Compression Ratio:

10.5:1

Horsepower:

Approx. 75 HP (55 kW) at 7,000 RPM (Note: specific manufacturer claims may vary slightly by region/year).

Torque:

Approx. 80 Nm (59 lb-ft) at 5,000 RPM (Note: specific manufacturer claims may vary slightly by region/year).

Fuel Delivery:

Electronic Fuel Injection (EFI)

Throttle Body:

Single throttle body, likely 50mm or similar diameter.

Fuel Type:

Unleaded gasoline, 95 octane (RON) or higher recommended.

Ignition System:

Digital electronic ignition.

Oil Type:

Semi-synthetic or fully synthetic motorcycle oil meeting API SG, SH, SJ, SL or JASO MA/MA2 specifications. Viscosity typically 10W-40 or 15W-50 depending on climate.

Oil Capacity:

Approximately 1.8 - 2.0 liters (1.9 - 2.1 US quarts) with oil filter change.

🔧 Transmission

Transmission Type:

Automatic (CVT - Continuously Variable Transmission)

Drive Type:

Belt drive to rear wheel.

Clutch Type:

Automatic centrifugal clutch.

Transmission Fluid:

Specific CVT fluid recommended by Gilera, or a high-quality automatic transmission fluid (ATF) that meets specified standards (detailed in manual).

📐 Dimensions

Length:

Approx. 2,270 mm (89.4 in)

Width:

Approx. 800 mm (31.5 in) (over handlebars)

Height:

Approx. 1,420 mm (55.9 in) (over windscreen)

Wheelbase:

Approx. 1,590 mm (62.6 in)

Dry Weight:

Approx. 245 kg (540 lbs)

Gross Vehicle Weight Rating:

Not specified in provided information.

Fuel Capacity:

Approx. 18.5 liters (4.9 US gallons)

🛡️ Safety Features

Crash Test Results:

Not applicable to motorcycle safety ratings in the same way as cars.

Brakes:

Front: Dual 260 mm discs with 4-piston calipers. Rear: 280 mm disc with 2-piston caliper. Linked braking system likely present.

ABS:

Optional ABS system available on some models.

Lighting:

Halogen headlights, LED taillight and indicators.

Instruments:

Digital and analog instrument cluster providing speed, RPM, fuel level, engine temperature, and warning lights.

💡 Technology Features

Instrument Cluster:

Combination analog tachometer and digital display for speed, odometer, trip meters, fuel gauge, engine temperature, clock, and warning indicators.

ABS:

Optional Anti-lock Braking System (ABS) for enhanced safety during braking.

Diagnostics Port:

On-board diagnostics (OBD) port for electronic fault code retrieval and system analysis.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first. Refer to manual for exact recommendation.

Air Filter Replacement:

Inspect every 5,000 km (3,000 miles), replace as needed or at approximately 15,000 km (9,000 miles).

Spark Plug Replacement:

Typically around 10,000 - 15,000 km (6,000 - 9,000 miles).

Belt Drive Inspection:

Inspect belt for wear and tension at regular intervals, typically every 5,000 km (3,000 miles). Replace belt as per manual recommendations (often around 20,000 - 30,000 km).

Engine Oil:

See engine_specs for oil_type.

Coolant:

Ethylene glycol-based antifreeze, mixed with distilled water at a 50/50 ratio. Capacity approx. 1.2 liters.

Brake Fluid:

DOT 4 or DOT 5.1 brake fluid (check manual for specific designation).

Common Problems:

Potential issues may include stator failure, regulator/rectifier issues, CVT belt wear, and occasional electrical gremlins. Regular maintenance is key to longevity.

Preventative Measures:

Adherence to the maintenance schedule, using correct fluids and parts, and addressing minor issues promptly can prevent major failures.

📚 Vehicle History

Manufacturer:

Gilera is an Italian manufacturer of motorcycles, scooters, and mopeds, known for its sporting heritage.

Ownership:

Gilera is part of the Piaggio Group, which also owns Vespa, Aprilia, and Moto Guzzi.

Development Concept:

The GP800 was designed as a high-performance maxi-scooter, blending the practicality of a scooter with the power and handling characteristics of a motorcycle.

Key Innovations:

Featured a powerful V-twin engine in a scooter platform, offering significant acceleration and top speed, as well as motorcycle-like chassis components.

Manufacturing Location:

Primarily manufactured in Italy.

🏆 Awards & Recognition

Industry Accolades:

While specific awards are not listed in the provided text, the GP800 was recognized for its innovative blend of scooter convenience and motorcycle performance, creating a new segment for high-power maxi-scooters.

Performance Reviews:

Generally praised by automotive journalists and riders for its potent engine, comfortable riding position for long distances, and impressive acceleration.