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GILERA RUNNER RST PUREJET Service Manual Workshop

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🏷️ Basic Information Identification Make: Gilera Model: Runner RST Purejet Codes Frame Number Prefix: ZAPC462 👋 Introduction Market Position Target Audience: Owners seeking to perform their own maintenance and repairs, as well as professional mechanics working on Gilera scooters. Key Features 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. Limitations Electrical Diagrams: Explicitly states that electrical diagrams are NOT included in this manual. 📋 Manual Details Coverage Areas Language: English Format: PDF Download Manual Type: Service Manual / Workshop Manual Page Count Estimated Page Count: Information not explicitly stated, but typical for a comprehensive workshop manual covering mechanical systems. Likely 200-400 pages. 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable within the PDF, allowing for quick access to specific topics. Print Quality Printability: Designed for printing individual sections or the entire manual for workshop use. Binding Type Binding Type Physical: N/A (Digital Download) Paper Type Paper Type Physical: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 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. Performance 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 System 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). Cooling System Type: Liquid-cooled Lubrication Oil Type: Two-stroke oil, specific API TC or JASO FD classification required. Capacity and change intervals in manual. Spark Plug Recommendation: Specific spark plug type (e.g., NGK BR9ES or similar) and gap specification will be provided in the manual. 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) Clutch Type: Centrifugal automatic clutch Features Variator: Covers inspection, roller weight analysis, and belt replacement for the variator. Reduction Gear: Details on the reduction gear assembly and its lubrication. Fluid Specifications Reduction Gear Oil: Specific gearbox oil viscosity and capacity will be detailed in the manual (e.g., SAE 80W/90). 📐 Dimensions Exterior 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) Weights Dry Weight: Approx. 110-120 kg (varies by model year and specification) Fuel Tank Capacity: Typically around 7-8 Liters 🛡️ Safety Features Active Features 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). Passive Features 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. 💡 Technology Features Infotainment Dashboard: Digital/analog combination dashboard displaying speed, RPM, fuel level, temperature, and warning lights. Manual covers indicator light functions. Driver Assistance N/A: Scooters of this era typically do not feature advanced driver assistance systems. 🔧 Maintenance Service Intervals 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...
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GILERA RUNNER RST PUREJET Service Manual Workshop
🏷️ Basic Information
Identification
Make:
Gilera
Model:
Runner RST Purejet
Codes
Frame Number Prefix:
ZAPC462
👋 Introduction
Market Position
Target Audience:
Owners seeking to perform their own maintenance and repairs, as well as professional mechanics working on Gilera scooters.
Key Features
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.
Limitations
Electrical Diagrams:
Explicitly states that electrical diagrams are NOT included in this manual.
📋 Manual Details
Coverage Areas
Language:
English
Format:
PDF Download
Manual Type:
Service Manual / Workshop Manual
Page Count
Estimated Page Count:
Information not explicitly stated, but typical for a comprehensive workshop manual covering mechanical systems. Likely 200-400 pages.
📖 Manual Coverage
Systems Covered
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.
Procedures Included
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.
Technical Depth
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.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable within the PDF, allowing for quick access to specific topics.
Print Quality
Printability:
Designed for printing individual sections or the entire manual for workshop use.
Binding Type
Binding Type Physical:
N/A (Digital Download)
Paper Type
Paper Type Physical:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
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.
Performance
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 System
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).
Cooling System
Type:
Liquid-cooled
Lubrication
Oil Type:
Two-stroke oil, specific API TC or JASO FD classification required. Capacity and change intervals in manual.
Spark Plug
Recommendation:
Specific spark plug type (e.g., NGK BR9ES or similar) and gap specification will be provided in the manual.
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT)
Clutch Type:
Centrifugal automatic clutch
Features
Variator:
Covers inspection, roller weight analysis, and belt replacement for the variator.
Reduction Gear:
Details on the reduction gear assembly and its lubrication.
Fluid Specifications
Reduction Gear Oil:
Specific gearbox oil viscosity and capacity will be detailed in the manual (e.g., SAE 80W/90).
📐 Dimensions
Exterior
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)
Weights
Dry Weight:
Approx. 110-120 kg (varies by model year and specification)
Fuel Tank Capacity:
Typically around 7-8 Liters
🛡️ Safety Features
Active Features
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).
Passive Features
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.
💡 Technology Features
Infotainment
Dashboard:
Digital/analog combination dashboard displaying speed, RPM, fuel level, temperature, and warning lights. Manual covers indicator light functions.
Driver Assistance
N/A:
Scooters of this era typically do not feature advanced driver assistance systems.
🔧 Maintenance
Service Intervals
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.
Fluid Specifications
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.
Known Issues
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.
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycle production, known for sporty and performance-oriented scooters.
Model Evolution
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.
Production
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.
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Gilera Runner range has historically received acclaim for its sporty design and agile handling, making it a popular choice in its segment. Specific awards for the RST Purejet variant may exist but are not detailed in the product description.
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