Gilera GP800 I.E. 2007 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Gilera Model: GP800 Year: 2007 Model Variant: I.E. (Injection Electronique) 👋 Introduction Market Position Vehicle Segment: Maxi-scooter, GT (Grand Tourer) Scooter Unique Selling Proposition: Performance-oriented maxi-scooter bridging motorcycle and scooter characteristics. Competitive Analysis Key Competitors 2007: Yamaha TMAX, Suzuki Burgman 650, Aprilia Atlantic 500, BMW C1 (earlier, but in a similar niche). Key Features Engine Architecture: Large displacement V-twin engine for a scooter. Styling: Sporty, aggressive styling reminiscent of motorcycles. Handling: Chassis and suspension tuned for agile handling and stability at higher speeds. Technology Integration: Electronic fuel injection for performance and emissions. 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Intended Audience: Mechanics and DIY enthusiasts Page Count Estimated Page Count: Extensive (typical factory service manuals range from 300-1000+ pages) Manual Type Manual Type: Service Repair Manual Language Language: Likely English (based on product description, though original may vary) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, repair of engine components (pistons, cylinders, crankshaft, valve train). Engine Management I E: Fuel injection system (EFI), ignition system, sensors, actuators, ECU diagnostics and programming. Transmission Drivetrain: Removal, disassembly, assembly, and inspection of the automatic transmission and final drive. Chassis Suspension: Front and rear suspension systems, fork assembly, shock absorbers, steering system. Braking System: Front and rear brake system components, hydraulic lines, master cylinders, calipers, discs, ABS system (if equipped). Electrical System: Wiring diagrams, lighting, starting and charging system, battery, fuses, relays, horn, instrument panel. Bodywork Fairings: Fairing removal, installation, and repair; seat, luggage compartment access. Cooling System: Radiator, coolant flow, thermostat, fan operation. Exhaust System: Exhaust manifold, catalytic converter (if applicable), muffler removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug checks, air filter servicing, chain/belt adjustment (if applicable). Diagnostic Troubleshooting: Systematic identification and resolution of common and uncommon faults and performance issues. Component Removal Installation: Detailed steps for removing and reinstalling all major and minor components. Disassembly Assembly: Step-by-step instructions for taking apart and putting back together various sub-assemblies. Adjustments Calibration: Procedures for adjusting brakes, clutch, throttle, and other systems as needed. Torque Specifications: Essential torque values for critical fasteners across all systems. Technical Depth Depth Level: Comprehensive factory-level repair and maintenance information. Diagnostic Tools: Likely references diagnostic tools or procedures requiring specific equipment for EFI systems. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Typically searchable text within a well-digitized PDF. Print Quality Printability: Designed for easy printing of specific sections or the entire manual. Binding Type Physical Binding: N/A (Digital PDF Download) Paper Type Physical Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke, liquid-cooled Displacement: 799 cc Bore X Stroke: 88 mm x 66 mm Compression Ratio: 9.3:1 Valve Train: SOHC, 4 valves per cylinder (likely actuation via cam chain). Performance Horsepower Claimed: Approx. 50-55 HP (at crankshaft) Torque Claimed: Approx. 70-75 Nm (at crankshaft) Fuel System Fuel Delivery: Electronic Fuel Injection (I.E.) Fuel Type: Unleaded Petrol (Gasoline) Fuel Tank Capacity: Approx. 16 Liters 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Drive Type: Belt drive to rear wheel Features Transmission Fluid: Specific CVT fluid (refer to manual for exact type and capacity, e.g., Motul Scooter Gear Oil Expert 80W90 or equivalent). 📐 Dimensions Exterior Length: Approx. 2250 mm Width: Approx. 800 mm Height: Approx. 1450 mm Wheelbase: Approx. 1590 mm Weights Dry Weight: Approx. 230-240 kg Gross Vehicle Weight Rating Gvwr: Approx. 430-450 kg 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle/Scooter segment typically not subjected to automotive crash testing standards). Active Features Braking System Type: Disc brakes front and rear, likely with ABS as an option or standard on some variants. Anti Lock Braking System ABS: Optional or standard depending on market/trim. Manual will detail ABS system operation and service. Passive Features Lighting: Halogen headlights, LED taillight/indicators (depending on specific execution). 💡 Technology Features Infotainment Instrument Cluster: Digital and analog combination display with speed, RPM, fuel level, coolant temperature, odometer, trip meters, and warning lights. Driver Assistance ABS Integration: ABS module and sensor operation for enhanced braking stability. Connectivity Diagnostics Port: On-board diagnostics (OBD) port or proprietary diagnostic connector for engine management system access. 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 5,000 - 7,500 km or annually (refer to manual for exact interval). Air Filter Inspection: Every 7,500 km, replace as needed. Spark Plug Replacement: Typically every 10,000 - 15,000 km (refer to manual for plug type and gap). Transmission Fluid Change: Every 10,000 - 15,000 km or every two years. Fluid Specifications Engine Oil Type: High-quality synthetic motorcycle engine oil, e.g., API SG/SH/SJ or higher, JASO MA/MA2 rated. Viscosity: 10W-40 or 15W-50 depending on climate (refer to manual for exact spec). Coolant Type: Ethylene glycol based antifreeze coolant, 50/50 mix with distilled water. Brake Fluid Type: DOT...
Specific CVT fluid (refer to manual for exact type and capacity, e.g., Motul Scooter Gear Oil Expert 80W90 or equivalent).
📐 Dimensions
Exterior
Length:
Approx. 2250 mm
Width:
Approx. 800 mm
Height:
Approx. 1450 mm
Wheelbase:
Approx. 1590 mm
Weights
Dry Weight:
Approx. 230-240 kg
Gross Vehicle Weight Rating Gvwr:
Approx. 430-450 kg
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle/Scooter segment typically not subjected to automotive crash testing standards).
Active Features
Braking System Type:
Disc brakes front and rear, likely with ABS as an option or standard on some variants.
Anti Lock Braking System ABS:
Optional or standard depending on market/trim. Manual will detail ABS system operation and service.
Passive Features
Lighting:
Halogen headlights, LED taillight/indicators (depending on specific execution).
💡 Technology Features
Infotainment
Instrument Cluster:
Digital and analog combination display with speed, RPM, fuel level, coolant temperature, odometer, trip meters, and warning lights.
Driver Assistance
ABS Integration:
ABS module and sensor operation for enhanced braking stability.
Connectivity
Diagnostics Port:
On-board diagnostics (OBD) port or proprietary diagnostic connector for engine management system access.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000 - 7,500 km or annually (refer to manual for exact interval).
Air Filter Inspection:
Every 7,500 km, replace as needed.
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (refer to manual for plug type and gap).
Transmission Fluid Change:
Every 10,000 - 15,000 km or every two years.
Fluid Specifications
Engine Oil Type:
High-quality synthetic motorcycle engine oil, e.g., API SG/SH/SJ or higher, JASO MA/MA2 rated. Viscosity: 10W-40 or 15W-50 depending on climate (refer to manual for exact spec).
Coolant Type:
Ethylene glycol based antifreeze coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for precise specification, especially if ABS is present).
Known Issues
Potential Issues Reported:
Some owners have reported occasional issues with the CVT drive system's longevity, electrical gremlins, or specific sensor failures. The manual is crucial for diagnosing and addressing these.
Maintenance Priority Areas:
Regular checks of the CVT belt condition, variator rollers, and proper functioning of the EFI system are paramount for longevity and performance.
📚 Vehicle History
Brand Heritage
Manufacturer:
Gilera is an Italian manufacturer with a long history in motorcycling, known for performance-oriented models.
Model Evolution
Gp800 Development:
The GP800 was developed to offer motorcycle-like performance in a maxi-scooter platform, leveraging Piaggio Group's engine technology.
Production
Manufacturing Location:
Italy (under Piaggio Group ownership)
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
While specific awards for the 2007 model are not widely publicized, the GP800 was recognized for its unique V-twin engine and sporty performance in the maxi-scooter segment.
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