GILERA GP800 Service Repair Manual 2006 2007 2008 2009 2010
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🏷️ Basic Information Identification Make: Gilera Model: GP800 Generation Model Years Covered: 2006, 2007, 2008, 2009, 2010 Codes Engine Code: GPR00 Chassis Code: Not specified in provided information, but typically related to the GP800 platform. 👋 Introduction Market Position 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. Competitive Analysis Uniqueness: Positioned as 'The only service repair workshop manual you will ever need,' highlighting its comprehensive coverage and detailed nature. Key Features 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 Coverage Areas Model Variants: All versions and model year variants from 2006-2010 Page Count Estimated Page Count: Not explicitly stated, but described as comprehensive with hundreds of photos and illustrations, implying a substantial document. Manual Type Type: Workshop Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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 File Format Format: PDF Print Quality 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 Type Binding: Digital Download (PDF) Paper Type Paper Type: Not Applicable (Digital Format) Compatibility Operating Systems: Compatible with all Windows (7, Vista 32/64, XP, ME, 98, NT, 2000 etc.) and Mac computers. Software Requirements Reader: Requires Adobe PDF Reader. Delivery Method Delivery: Instant Download Searchability Text Search: Searchable text into document for quick information retrieval. Navigation Indexing: Fully indexed for easy navigation and quick access to information. ⚙️ Engine Specifications Primary Engine 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 Performance 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 System 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 Ignition System: Digital electronic ignition. Lubrication 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 Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive Type: Belt drive to rear wheel. Features 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 Exterior 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) Weights Dry Weight: Approx. 245 kg (540 lbs) Gross Vehicle...
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.
Procedures Included
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.
Technical Depth
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
File Format
Format:
PDF
Print Quality
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 Type
Binding:
Digital Download (PDF)
Paper Type
Paper Type:
Not Applicable (Digital Format)
Compatibility
Operating Systems:
Compatible with all Windows (7, Vista 32/64, XP, ME, 98, NT, 2000 etc.) and Mac computers.
Software Requirements
Reader:
Requires Adobe PDF Reader.
Delivery Method
Delivery:
Instant Download
Searchability
Text Search:
Searchable text into document for quick information retrieval.
Navigation
Indexing:
Fully indexed for easy navigation and quick access to information.
⚙️ Engine Specifications
Primary Engine
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
Performance
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 System
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
Ignition System:
Digital electronic ignition.
Lubrication
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.
Specific CVT fluid recommended by Gilera, or a high-quality automatic transmission fluid (ATF) that meets specified standards (detailed in manual).
📐 Dimensions
Exterior
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)
Weights
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
Ratings
Crash Test Results:
Not applicable to motorcycle safety ratings in the same way as cars.
Active Features
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.
Passive Features
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
Infotainment
Instrument Cluster:
Combination analog tachometer and digital display for speed, odometer, trip meters, fuel gauge, engine temperature, clock, and warning indicators.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) for enhanced safety during braking.
Connectivity
Diagnostics Port:
On-board diagnostics (OBD) port for electronic fault code retrieval and system analysis.
🔧 Maintenance
Service Intervals
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).
Fluid Specifications
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).
Known Issues
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
Brand Heritage
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.
Model Evolution
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.
Production
Manufacturing Location:
Primarily manufactured in Italy.
🏆 Awards & Recognition
Recognitions
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.
Ratings
Performance Reviews:
Generally praised by automotive journalists and riders for its potent engine, comfortable riding position for long distances, and impressive acceleration.