The Gilera GP800, introduced in 2007, represents a premium maxi-scooter designed for discerning riders seeking a blend of performance and comfort. This model is distinguished by its powerful V-twin engine, offering robust acceleration and a dynamic riding experience, complemented by car-like ergonomics for enhanced rider comfort during extended journeys. Its high-quality chassis and suspension components contribute to precise handling and stability, making it suitable for both spirited riding and daily commuting. The GP800 aims to provide a sophisticated and engaging ride, positioning itself as a capable alternative in the performance maxi-scooter segment. This comprehensive Factory Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the Gilera GP800. It covers all essential systems, including engine mechanics, fuel, cooling, lubrication, exhaust, transmission, electrical systems, braking, suspension, and chassis components. The manual offers step-by-step procedures for routine maintenance tasks, in-depth repair processes, and diagnostic strategies for identifying and resolving issues. With its extensive coverage and technical detail, this workshop manual serves as an indispensable resource for owners, technicians, and mechanics to ensure the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: Gilera Model: GP800 Year: 2008 Vehicle Type: Maxi-scooter Codes Chassis Code: GP800 (exact chassis codes may vary by market, consult manual for specifics) 👋 Introduction Market Position Segment: Premium Maxi-scooter Target Audience: Scooter enthusiasts, commuters, performance-oriented riders seeking advanced features Competitive Analysis Key Competitors Approx: Yamaha TMAX, Suzuki Burgman 650, Honda Silver Wing Key Features Vehicle Highlight 1: Powerful V-twin engine for its class Vehicle Highlight 2: Car-like ergonomics and comfort Vehicle Highlight 3: High-quality chassis and suspension components 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance Secondary Coverage: Diagnostics, troubleshooting, electrical systems, wiring diagrams Page Count Page Count: 429 Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format File Format: PDF Compatibility: Windows & Mac (all versions) Required Software: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine Mechanics: Engine removal/installation, internal component inspection and repair, cylinder head, pistons, crankshaft, camshafts, valve timing Fuel System: Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel filter, fuel tank service Cooling System: Radiator, coolant pump, thermostat, cooling fan, coolant flow, system pressure testing, bleeding procedures Lubrication System: Oil pump, oil filter, oil passages, oil capacity, oil change procedures Exhaust System: Muffler, catalytic converter, exhaust pipes, gaskets, mounting hardware Transmission: Automatic transmission (CVT), variator operation, belt replacement, clutch assembly, final drive, gearbox oil Electrical System: Battery, charging system (alternator/stator, regulator/rectifier), starter motor, ignition system, lighting (headlights, taillights, indicators), horn, sensors, ECU Wiring Diagrams: Detailed wiring schematics for all electrical circuits, component identification, connector pinouts Braking System: Front and rear disc brakes, hydraulic system, brake calipers, master cylinders, brake lines, brake fluid, ABS system (if equipped) Suspension: Front telescopic forks, rear shock absorber, linkages, adjustments, fork oil specifications and change procedures Chassis: Frame inspection, steering head bearings, wheel bearings, swingarm, general chassis components Bodywork: Fairings, seat, handlebars, instrumentation, storage compartments, disassembly and reassembly Wheels Tires: Wheel specifications, tire sizes, tire pressure, wheel balancing, tire replacement Special Tools: Listing and usage of specialized tools required for specific repair and maintenance tasks Procedures Included Maintenance: Scheduled maintenance tasks, fluid checks and changes, filter replacements, spark plug replacement, drive belt inspection/replacement Troubleshooting: Systematic diagnostic procedures for common problems, fault codes, symptom-based troubleshooting guides Diagnostics: Engine management diagnostics, electrical system diagnostics, ABS diagnostics (if applicable) Engine Repair: Complete engine overhaul, valve adjustments, piston ring replacement, gasket replacement Transmission Service: Variator maintenance, belt replacement, clutch service, gearbox oil replacement Electrical Repair: Component testing and replacement (alternator, starter, ignition coils, sensors), wiring harness repair Brake System Service: Brake bleeding, pad replacement, caliper service, master cylinder replacement, ABS bleeding procedures Suspension Overhaul: Fork seal replacement, fork oil change, rear shock absorber service Bodywork Disassembly: Panel removal and installation, seat removal, fairing repair Pre Delivery Inspection: Checklist and procedures for preparing a new vehicle for customer delivery Technical Depth Depth Level: Comprehensive: from basic maintenance to in-depth engine and component overhauls Diagnostic Capability: Advanced diagnostic procedures and troubleshooting, including electrical systems and fuel injection Rebuild Procedures: Detailed instructions for complete engine and transmission rebuilds Schematic Detail: High level of detail in diagrams, including exploded views and torque specifications 📊 Manual Specifications File Format File Type: Digital (PDF Download) Print Quality Print Recommendation: Printable on demand, suitable for professional workshop use Binding Type Binding Type: N/A (Digital File) Paper Type Paper Type: N/A (Digital File) Searchability Text Search: Likely text-searchable PDF for quick information retrieval ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke, liquid-cooled, DOHC, 8 valves Engine Displacement: 799 cc Bore X Stroke: 75.8 mm x 72.2 mm Compression Ratio: 10.5:1 (typical, verify in manual) Performance Horsepower: Approx. 55 HP @ 7,250 RPM (verify in manual) Torque: Approx. 70 Nm @ 6,000 RPM (verify in...