GILERA GP800 IE Workshop Repair Manual Download All 2007-ONWARDS ModelS COVERED PDF
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🏷️ Basic Information Identification Make: Gilera Model: GP800 IE Codes Engine Code Family: Piaggio Quasar 👋 Introduction Market Position Segment: Performance Scooter/Maxi-scooter Competitive Analysis Competitors: Suzuki Burgman 650, Yamaha TMAX 500/530, BMW C600 Sport/C650 GT Key Features Appeal: Powerful engine, sporty handling, touring capability, distinctive Italian design Manual Value Utility: Essential tool for maintaining performance, diagnosing issues, and executing repairs on the Gilera GP800 IE 📋 Manual Details Coverage Areas Covered Model Years: 2007 onwards Global Markets Covered: All models Page Count Estimated Page Count: Comprehensive (specific number not provided, but implied to be extensive for workshop repair) Manual Type Type: Workshop Repair Manual Language Language: English (implied by product description and common industry practice for this type of manual) Format Format: PDF 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, tuning, fuel injection, ignition, cooling, lubrication, starting, charging Transmission System: Automatic transmission (CVT), clutch, drive belts, final drive maintenance and repair Chassis System: Frame, suspension (front and rear), steering, wheels, tires Braking System: Hydraulic braking system, brake pads, discs, calipers, lines, ABS system (if applicable) Electrical System: Wiring diagrams, battery, starter, alternator, lighting, indicators, dashboard instrumentation, sensors, ECU diagnostics Fuel System: Fuel tank, fuel pump, fuel lines, injectors, throttle body, fuel pressure regulation Bodywork And Fittings: Fairings, seat, handlebars, controls, lighting fixtures, body panel removal and installation Diagnostic Procedures: Troubleshooting guides, error code interpretation, diagnostic tool usage (if applicable) Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug inspection/replacement, drive belt inspection/replacement, chain adjustment (if applicable), brake fluid flush, coolant checks Disassembly And Assembly: Detailed step-by-step instructions with exploded views for all major components Repair And Rebuild: Complete overhaul procedures for engine, transmission, and other major systems Adjustments: Carburetor/throttle body synchronization, valve clearance adjustment (if applicable), suspension settings Electrical Troubleshooting: Fault finding for electrical circuits and components Technical Depth Depth: Comprehensive workshop level, suitable for professional technicians and advanced DIY enthusiasts Diagnostic Capabilities: Includes troubleshooting guides, diagnostic flowcharts, and likely references to diagnostic codes 📊 Manual Specifications File Format Compatibility: PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.) Searchability: Likely searchable PDF text for quick information retrieval Print Quality Quality: High-quality digital reproduction of original workshop manual content Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, Four-stroke, Liquid-cooled Displacement: 799 cc Bore X Stroke: 71.5 mm x 50.8 mm (Approximate for Piaggio Quasar V-Twin, specific to GP800 might vary slightly) Valve Train: SOHC, 4 valves per cylinder Performance Horsepower: Approximately 54 HP (40 kW) @ 6,250 rpm (spec varies slightly by year/market) Torque: Approximately 7.7 kgm (75.5 Nm; 55.7 lb-ft) @ 4,250 rpm (spec varies slightly by year/market) Fuel System Fuel Delivery: Electronic Fuel Injection (IE) Ignition System: Electronic ignition with variable timing Cooling System Cooling Type: Liquid-cooled Lubrication System Oil Type Specification: Refer to manual for specific SAE viscosity grade (e.g., SAE 5W-40 or 10W-40) and API classification (e.g., API SG or higher) and JASO MA certification for wet clutch compatibility. Emissions Standard Standard: Euro 3 (likely for models post-2007) 🔧 Transmission Standard Type: Automatic Continuously Variable Transmission (CVT) with dry multi-plate clutch Optional Optional Transmission: N/A (CVT is standard) Features Drive Type: Belt drive to rear wheel Final Drive: Chain and sprockets (typical for many motorcycles of this era, though scooters often use enclosed belt drive - confirm for GP800) 📐 Dimensions Exterior Length: Refer to manual for precise dimensions (typically around 2200-2300 mm) Width: Refer to manual for precise dimensions (typically around 780-800 mm) Height: Refer to manual for precise dimensions (typically around 1300-1400 mm) Weights Dry Weight: Approximately 220-230 kg Gross Vehicle Weight Rating: Refer to manual Fuel Tank Capacity: Approximately 18 Liters (including reserve) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle/Scooter, not typically subjected to automotive crash tests) Active Features Braking System: Disc brakes front and rear, ABS available as an option on some models Lighting: Dual Halogen headlights, LED taillight/brake light Passive Features Frame Construction: Steel trellis frame for rigidity and stability Ergonomics: Designed for comfortable rider positioning and control 💡 Technology Features Infotainment Dashboard Display: Digital LCD display with analog speedometer, tachometer, fuel gauge, engine temperature, trip meters, clock, and warning lights. Driver Assistance ABS System: Optional Anti-lock Braking System (ABS) available on certain configurations, providing enhanced safety during braking. Connectivity Diagnostic Ports: Diagnostic connectors for ECU access and fault code reading, crucial for advanced troubleshooting. Engine Management ECU Features: Electronic Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions. 🔧 Maintenance Service Intervals Engine Oil Change: Every 6,000 km or 12 months, whichever comes first (typical for this class, confirm in manual) Spark Plug Replacement: Every 12,000 km (typical, confirm in manual) Drive Belt Inspection: Every 12,000 km, replacement...
Detailed step-by-step instructions with exploded views for all major components
Repair And Rebuild:
Complete overhaul procedures for engine, transmission, and other major systems
Adjustments:
Carburetor/throttle body synchronization, valve clearance adjustment (if applicable), suspension settings
Electrical Troubleshooting:
Fault finding for electrical circuits and components
Technical Depth
Depth:
Comprehensive workshop level, suitable for professional technicians and advanced DIY enthusiasts
Diagnostic Capabilities:
Includes troubleshooting guides, diagnostic flowcharts, and likely references to diagnostic codes
📊 Manual Specifications
File Format
Compatibility:
PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, etc.)
Searchability:
Likely searchable PDF text for quick information retrieval
Print Quality
Quality:
High-quality digital reproduction of original workshop manual content
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke, Liquid-cooled
Displacement:
799 cc
Bore X Stroke:
71.5 mm x 50.8 mm (Approximate for Piaggio Quasar V-Twin, specific to GP800 might vary slightly)
Valve Train:
SOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 54 HP (40 kW) @ 6,250 rpm (spec varies slightly by year/market)
Torque:
Approximately 7.7 kgm (75.5 Nm; 55.7 lb-ft) @ 4,250 rpm (spec varies slightly by year/market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (IE)
Ignition System:
Electronic ignition with variable timing
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Oil Type Specification:
Refer to manual for specific SAE viscosity grade (e.g., SAE 5W-40 or 10W-40) and API classification (e.g., API SG or higher) and JASO MA certification for wet clutch compatibility.
Emissions Standard
Standard:
Euro 3 (likely for models post-2007)
🔧 Transmission
Standard
Type:
Automatic Continuously Variable Transmission (CVT) with dry multi-plate clutch
Optional
Optional Transmission:
N/A (CVT is standard)
Features
Drive Type:
Belt drive to rear wheel
Final Drive:
Chain and sprockets (typical for many motorcycles of this era, though scooters often use enclosed belt drive - confirm for GP800)
📐 Dimensions
Exterior
Length:
Refer to manual for precise dimensions (typically around 2200-2300 mm)
Width:
Refer to manual for precise dimensions (typically around 780-800 mm)
Height:
Refer to manual for precise dimensions (typically around 1300-1400 mm)
Weights
Dry Weight:
Approximately 220-230 kg
Gross Vehicle Weight Rating:
Refer to manual
Fuel Tank Capacity:
Approximately 18 Liters (including reserve)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle/Scooter, not typically subjected to automotive crash tests)
Active Features
Braking System:
Disc brakes front and rear, ABS available as an option on some models
Lighting:
Dual Halogen headlights, LED taillight/brake light
Passive Features
Frame Construction:
Steel trellis frame for rigidity and stability
Ergonomics:
Designed for comfortable rider positioning and control
💡 Technology Features
Infotainment
Dashboard Display:
Digital LCD display with analog speedometer, tachometer, fuel gauge, engine temperature, trip meters, clock, and warning lights.
Driver Assistance
ABS System:
Optional Anti-lock Braking System (ABS) available on certain configurations, providing enhanced safety during braking.
Connectivity
Diagnostic Ports:
Diagnostic connectors for ECU access and fault code reading, crucial for advanced troubleshooting.
Engine Management
ECU Features:
Electronic Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters for optimal performance and emissions.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km or 12 months, whichever comes first (typical for this class, confirm in manual)
Spark Plug Replacement:
Every 12,000 km (typical, confirm in manual)
Drive Belt Inspection:
Every 12,000 km, replacement recommended around 24,000 km or as needed based on wear (confirm in manual)
Valve Clearance Check:
Every 18,000 km (typical, confirm in manual)
Fluid Specifications
Engine Oil:
Refer to manual for specific SAE viscosity grade and API/JASO classification (e.g., SAE 5W-40, API SG/SH, JASO MA)
Coolant:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio recommended, specific type in manual)
Brake Fluid:
DOT 4 brake fluid (confirm in manual)
Transmission Oil:
Gear oil for final drive, specific API GL rating and viscosity (e.g., GL-4 or GL-5 SAE 75W-90) as per manual
Wiring harness connectors (especially on older models), stator/regulator issues can occur with high mileage
Engine Reliability:
Generally reliable Piaggio V-twin engine, but regular maintenance is crucial for longevity. Issues can arise with neglected cooling systems or fuel delivery components.
📚 Vehicle History
Brand Heritage
Brand Origin:
Gilera is an Italian motorcycle manufacturer with a long history dating back to 1909, known for performance and racing heritage.
Model Evolution
Development:
The GP800 was developed to offer maxi-scooter practicality with a powerful engine and sporty motorcycle-like performance and handling.
Engine Development:
Utilizes Piaggio's robust and powerful Quasar engine platform, adapted for the GP800's performance goals.
Production
Manufacturing Location:
Italy
Production Start:
2007
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
Praised for its unique blend of scooter convenience and motorcycle performance upon release, though niche market positioning limited widespread awards.
Ratings
Owner Satisfaction:
Owner satisfaction often tied to timely maintenance and the specific features appreciated by riders who value its power and handling.
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