The Gilera GP 800 IE, introduced around 2007, is a performance-oriented maxi-scooter known for its powerful 799 cc V-twin engine and sportbike-like handling. Manufactured in Italy, this model offers a unique blend of scooter convenience and motorcycle performance, making it a distinct option in its class. Its engineering prioritizes a dynamic riding experience, supported by a robust steel twin-spar frame and an automatic continuously variable transmission (CVT) for smooth power delivery. This workshop service manual provides comprehensive guidance for the mechanical maintenance and repair of the Gilera GP 800 IE. It covers essential systems including the engine, fuel injection, cooling, transmission, brakes, suspension, and bodywork. Detailed procedures for routine maintenance, component overhaul, and troubleshooting are included, along with critical technical specifications such as torque values and fluid requirements. This manual is designed to assist owners and technicians in understanding, maintaining, and repairing the vehicle effectively. 🏷️ Basic Information Identification Make: Gilera Model: GP 800 IE Frame Number Prefix: ZAPM55100 Codes Engine Code Prefix: M55 👋 Introduction Market Position Segment: Maxi-scooter, performance-oriented Competitive Analysis Competitors: Suzuki Burgman 650, Yamaha TMAX 500/530, BMW C 600 Sport/C 650 GT Key Features Uniqueness: Powerful engine for a scooter, sportbike-like handling for its class Target Audience Primary Users: Motorcycle owners seeking detailed DIY maintenance and repair knowledge, professional mechanics Manual Value Proposition Benefit: Enables cost-effective DIY maintenance, deeper understanding of vehicle operation 📋 Manual Details Coverage Areas Primary Coverage: Mechanical maintenance and repair for Gilera GP 800 IE Excluded Coverage: Electrical diagrams Page Count Estimated Page Count: Varies (Digital PDF, typically 300-500 pages for comprehensive manuals) Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, tuning Fuel System: Fuel injection system (mechanical components), fuel pump, injectors Cooling System: Radiator, water pump, thermostat, hoses Transmission: Automatic transmission (CVT) operation, maintenance, and repair Brakes: Brake system components, fluid, pad replacement, caliper service Suspension: Front fork (telescopic), rear shock absorber, linkage maintenance Frame And Bodywork: Chassis inspection, body panel removal/installation Wheels And Tires: Tire replacement, wheel balancing, bearing service Exhaust System: Exhaust manifold, muffler, catalytic converter maintenance Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air), spark plug service, chain adjustment (if applicable to rear drive) Component Overhaul: Engine rebuild, transmission service, brake caliper overhaul Troubleshooting: Diagnostic procedures for common mechanical issues Adjustment: Throttle cable, clutch adjustment (if applicable), suspension pre-load Technical Depth Depth: Comprehensive workshop level, covering routine maintenance to major repairs Data Accuracy: Includes critical torque specifications, measurements, and clearances 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Reproducibility: High-resolution, suitable for printing individual sections or the entire manual Binding Type Digital Binding: N/A (Digital download, binding is user-defined upon printing) Paper Type Digital Paper: N/A (Digital PDF, user chooses paper type if printed) ⚙️ Engine Specifications Primary Engine Configuration: V-twin, 4-stroke, liquid-cooled Displacement: 799 cc Bore X Stroke: 75 mm x 79 mm Compression Ratio: 10.5:1 (approximate, check manual for exact) Performance Horsepower: 54.4 HP (40 kW) @ 7,000 rpm (approximate, check manual) Torque: 70 Nm (51.6 lb-ft) @ 6,000 rpm (approximate, check manual) Fuel System Injection: Electronic Fuel Injection (IE) Fuel Type: Unleaded gasoline (minimum 95 RON) Lubrication Oil Type: SAE 10W-40 API SG or higher (specific API/JASO rating to be confirmed in manual) Oil Capacity: Approx. 1.7 liters (check manual for exact, with filter change) 🔧 Transmission Standard Type: Automatic continuously variable transmission (CVT) Features Drive System: Belt drive to rear wheel Transmission Fluid Type: Specific CVT fluid (refer to manual for part number and specification) 📐 Dimensions Exterior Length: Approx. 2,160 mm Width: Approx. 790 mm Height: Approx. 1,490 mm (seat height variable) Weights Dry Weight: Approx. 215 kg Gross Vehicle Weight: Approx. 380 kg Payload Capacity: Approx. 165 kg 🛡️ Safety Features Active Features Braking System: Dual front disc brakes, single rear disc brake. ABS optional/standard depending on market. (Manual will detail ABS service if equipped) Lighting: Halogen headlights, LED taillight (likely) Passive Features Frame Construction: Steel twin-spar frame 💡 Technology Features Infotainment Instrument Cluster: Digital-analog combination, speed, RPM, fuel level, engine temperature, odometer, trip meter Driver Assistance ABS: Optional (check specific model configuration), detailed in manual if present Connectivity Immobilizer: Likely equipped as standard for anti-theft 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months (check manual for precise intervals and conditions) Air Filter Replacement: Every 12,000 km or 24 months (check manual) Spark Plug Replacement: Every 18,000 km or 36 months (check manual for specific plug type) Brake Fluid Change: Every 24 months (DOT 4 recommended, check manual for specific) Cvt Belt Inspection: Every 12,000 km (check for wear and tension) Fluid Specifications Coolant: Ethylene glycol-based antifreeze with corrosion inhibitors (check manual for mix ratio and specification) Brake Fluid: DOT 4 (minimum) Known Issues...