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Gilera GP800 i.e. 2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Gilera Model: GP800 i.e. Year: 2007 Codes Engine Type Code: V2, 4-stroke, liquid-cooled, 8-valve 👋 Introduction Market Position Segment: Maxi-scooter / Sport-scooter Target Audience: Riders seeking a powerful, versatile scooter for commuting and touring, with a focus on performance and comfort. Competitive Analysis Key Competitors: Yamaha TMAX, Suzuki Burgman, BMW C650 GT, Aprilia SRV850 (later model). Key Features Unique Selling Points: Large displacement V-twin engine, motorcycle-like performance, advanced braking system (potentially with ABS), comfortable riding position, significant under-seat storage. Design Philosophy: Bridging the gap between scooter practicality and motorcycle performance, offering a sporty and capable urban and touring machine. 📋 Manual Details Coverage Areas Primary Coverage: Service and Repair Page Count Total Pages: 431 Manual Type Manual Classification: Factory Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive engine overhaul, including disassembly, inspection, and reassembly of all internal components, valve timing, cooling system, lubrication system. Fuel System: Detailed coverage of the electronic fuel injection (i.e.) system, including injectors, throttle body, fuel pump, pressure regulator, ECU diagnostics, and sensor calibration. Transmission: Service and repair procedures for the automatic CVT (Continuously Variable Transmission) system, including belt inspection and replacement, variator, clutch assembly, and final drive. Brakes: Complete brake system service, including hydraulic components, ABS (Anti-lock Braking System) operation and troubleshooting, disc and pad replacement, bleeding procedures. Electrical System: Extensive coverage of the electrical system, including wiring diagrams, starter system, charging system (alternator, regulator/rectifier), battery, ignition system, lighting, and all sensors. Chassis Suspension: Front and rear suspension servicing, including fork oil change, seal replacement, shock absorber adjustment and overhaul, swingarm, bearings, and steering head assembly. Cooling System: Radiator service, coolant replacement, thermostat operation, fan control, and troubleshooting of leaks or overheating issues. Exhaust System: Exhaust pipe and silencer inspection, gasket replacement, and emissions control system components. Bodywork: Fairing removal and installation, seat, storage compartment, and other body panel servicing. Procedures Included Maintenance: Detailed maintenance schedule, oil and filter changes, air filter servicing, spark plug replacement, drive belt inspection, brake fluid replacement, coolant replacement. Repair: Step-by-step repair procedures for all major and minor components, including engine rebuilds, transmission overhauls, electrical diagnostics, and suspension repairs. Troubleshooting: Systematic troubleshooting guides for common and complex issues, including diagnostic flowcharts and fault code interpretation for the EFI system. Diagnostics: Procedures for diagnosing electronic faults using diagnostic tools (if applicable), sensor testing, and ECU parameter checks. Assembly Disassembly: Complete instructions for the removal and installation of all major components and sub-assemblies. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic fluid changes and inspections to complete engine and transmission rebuilds, electrical system diagnostics, and chassis overhaul. 📊 Manual Specifications File Format PDF Quality: Readable print, though original source material had light print. Text is generally searchable if OCR was applied during conversion. Printability: Printable, allowing users to print specific sections for workshop use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Manufacturer: Piaggio (Gilera is part of Piaggio Group) Engine Layout: V-twin (90-degree) Displacement: 799 cc Bore X Stroke: 88 mm x 66.1 mm (estimated, to be confirmed in manual) Valvetrain: DOHC, 8 valves (4 valves per cylinder) Cooling System: Liquid-cooled Performance Horsepower: Approx. 75 HP (55 kW) @ 7,000 RPM (estimated, to be confirmed in manual) Torque: Approx. 78 Nm (57.5 lb-ft) @ 6,000 RPM (estimated, to be confirmed in manual) Fuel System Fuel Delivery: Electronic Fuel Injection (i.e.) Fuel Type: Unleaded gasoline (95 RON recommended) Lubrication System Oil Type: SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA approved) Oil Capacity With Filter: Approx. 2.0 Liters (to be confirmed in manual) Ignition System Ignition Type: Electronic ignition with variable timing 🔧 Transmission Standard Transmission Type: Automatic CVT (Continuously Variable Transmission) Optional Optional Transmission: N/A Features Drive Type: Belt drive to rear wheel Clutch Type: Automatic centrifugal clutch 📐 Dimensions Exterior Length: Approx. 2,235 mm (to be confirmed in manual) Width: Approx. 780 mm (to be confirmed in manual) Height: Approx. 1,420 mm (to be confirmed in manual) Wheelbase: Approx. 1,585 mm (to be confirmed in manual) Weights Dry Weight: Approx. 232 kg (to be confirmed in manual) Wet Weight: Approx. 247 kg (to be confirmed in manual) Fuel Tank Capacity: Approx. 18.5 Liters (including reserve) (to be confirmed in manual) 🛡️ Safety Features Ratings ABS: Available (model dependent, check specific vehicle specification) Active Features Braking System: Dual front discs with radial calipers, rear disc brake. ABS system for enhanced safety. Passive Features Lighting: Halogen headlights, LED taillight and brake light. Frame Construction: Double cradle steel frame for rigidity and stability. 💡 Technology Features Infotainment Instrument Cluster: Digital and analog instrumentation including speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature, and warning lights. May include engine diagnostic indicators. Driver Assistance ABS...
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Gilera GP800 i.e. 2007 Service Repair ManualGilera GP800 i.e. 2007 Service Repair ManualGilera GP800 i.e. 2007 Service Repair ManualGilera GP800 i.e. 2007 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Gilera
Model:
GP800 i.e.
Year:
2007
Codes
Engine Type Code:
V2, 4-stroke, liquid-cooled, 8-valve
👋 Introduction
Market Position
Segment:
Maxi-scooter / Sport-scooter
Target Audience:
Riders seeking a powerful, versatile scooter for commuting and touring, with a focus on performance and comfort.
Competitive Analysis
Key Competitors:
Yamaha TMAX, Suzuki Burgman, BMW C650 GT, Aprilia SRV850 (later model).
Key Features
Unique Selling Points:
Large displacement V-twin engine, motorcycle-like performance, advanced braking system (potentially with ABS), comfortable riding position, significant under-seat storage.
Design Philosophy:
Bridging the gap between scooter practicality and motorcycle performance, offering a sporty and capable urban and touring machine.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Page Count
Total Pages:
431
Manual Type
Manual Classification:
Factory Service Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive engine overhaul, including disassembly, inspection, and reassembly of all internal components, valve timing, cooling system, lubrication system.
Fuel System:
Detailed coverage of the electronic fuel injection (i.e.) system, including injectors, throttle body, fuel pump, pressure regulator, ECU diagnostics, and sensor calibration.
Transmission:
Service and repair procedures for the automatic CVT (Continuously Variable Transmission) system, including belt inspection and replacement, variator, clutch assembly, and final drive.
Brakes:
Complete brake system service, including hydraulic components, ABS (Anti-lock Braking System) operation and troubleshooting, disc and pad replacement, bleeding procedures.
Electrical System:
Extensive coverage of the electrical system, including wiring diagrams, starter system, charging system (alternator, regulator/rectifier), battery, ignition system, lighting, and all sensors.
Chassis Suspension:
Front and rear suspension servicing, including fork oil change, seal replacement, shock absorber adjustment and overhaul, swingarm, bearings, and steering head assembly.
Cooling System:
Radiator service, coolant replacement, thermostat operation, fan control, and troubleshooting of leaks or overheating issues.
Exhaust System:
Exhaust pipe and silencer inspection, gasket replacement, and emissions control system components.
Bodywork:
Fairing removal and installation, seat, storage compartment, and other body panel servicing.
Procedures Included
Maintenance:
Detailed maintenance schedule, oil and filter changes, air filter servicing, spark plug replacement, drive belt inspection, brake fluid replacement, coolant replacement.
Repair:
Step-by-step repair procedures for all major and minor components, including engine rebuilds, transmission overhauls, electrical diagnostics, and suspension repairs.
Troubleshooting:
Systematic troubleshooting guides for common and complex issues, including diagnostic flowcharts and fault code interpretation for the EFI system.
Diagnostics:
Procedures for diagnosing electronic faults using diagnostic tools (if applicable), sensor testing, and ECU parameter checks.
Assembly Disassembly:
Complete instructions for the removal and installation of all major components and sub-assemblies.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic fluid changes and inspections to complete engine and transmission rebuilds, electrical system diagnostics, and chassis overhaul.
📊 Manual Specifications
File Format
PDF Quality:
Readable print, though original source material had light print. Text is generally searchable if OCR was applied during conversion.
Printability:
Printable, allowing users to print specific sections for workshop use.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Manufacturer:
Piaggio (Gilera is part of Piaggio Group)
Engine Layout:
V-twin (90-degree)
Displacement:
799 cc
Bore X Stroke:
88 mm x 66.1 mm (estimated, to be confirmed in manual)
Valvetrain:
DOHC, 8 valves (4 valves per cylinder)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 75 HP (55 kW) @ 7,000 RPM (estimated, to be confirmed in manual)
Torque:
Approx. 78 Nm (57.5 lb-ft) @ 6,000 RPM (estimated, to be confirmed in manual)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (i.e.)
Fuel Type:
Unleaded gasoline (95 RON recommended)
Lubrication System
Oil Type:
SAE 5W-40 Synthetic Motorcycle Oil (API SG or higher, JASO MA approved)
Oil Capacity With Filter:
Approx. 2.0 Liters (to be confirmed in manual)
Ignition System
Ignition Type:
Electronic ignition with variable timing
🔧 Transmission
Standard
Transmission Type:
Automatic CVT (Continuously Variable Transmission)
Optional
Optional Transmission:
N/A
Features
Drive Type:
Belt drive to rear wheel
Clutch Type:
Automatic centrifugal clutch
📐 Dimensions
Exterior
Length:
Approx. 2,235 mm (to be confirmed in manual)
Width:
Approx. 780 mm (to be confirmed in manual)
Height:
Approx. 1,420 mm (to be confirmed in manual)
Wheelbase:
Approx. 1,585 mm (to be confirmed in manual)
Weights
Dry Weight:
Approx. 232 kg (to be confirmed in manual)
Wet Weight:
Approx. 247 kg (to be confirmed in manual)
Fuel Tank Capacity:
Approx. 18.5 Liters (including reserve) (to be confirmed in manual)
🛡️ Safety Features
Ratings
ABS:
Available (model dependent, check specific vehicle specification)
Active Features
Braking System:
Dual front discs with radial calipers, rear disc brake. ABS system for enhanced safety.
Passive Features
Lighting:
Halogen headlights, LED taillight and brake light.
Frame Construction:
Double cradle steel frame for rigidity and stability.
💡 Technology Features
Infotainment
Instrument Cluster:
Digital and analog instrumentation including speedometer, tachometer, fuel gauge, odometer, trip meter, coolant temperature, and warning lights. May include engine diagnostic indicators.
Driver Assistance
ABS System:
The availability of an Anti-lock Braking System (ABS) significantly enhances rider safety by preventing wheel lock-up during heavy braking.
Connectivity
Diagnostic Port:
A diagnostic port for connecting electronic diagnostic tools to read fault codes and monitor engine parameters.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 6,000 km or 12 months, whichever comes first. (Consult manual for exact details)
Oil Filter Replacement:
At every engine oil change. (Part Number: 851079 - Piaggio/Aprilia)
Air Filter Cleaning Replacement:
Inspect every 6,000 km, clean or replace as needed. (Part Number: 829485 - Piaggio/Aprilia)
Spark Plug Replacement:
Every 12,000 km. (Recommended: NGK CR9EB or equivalent)
Drive Belt Inspection:
Inspect every 12,000 km. Replace based on wear and condition. (Part Number: 851192 - Piaggio/Aprilia)
Coolant Replacement:
Every 24,000 km or 24 months. (Use a high-quality ethylene glycol-based coolant)
Brake Fluid Replacement:
Every 24,000 km or 24 months. (DOT 4 recommended)
Fluid Specifications
Transmission Fluid:
N/A (CVT system uses engine oil for clutch lubrication, no separate transmission fluid)
Known Issues
Common Wear Items:
Drive belt, clutch shoes, variator rollers, brake pads, suspension components due to high performance.
Potential Electrical Issues:
Regulator/rectifier failure (common in many Piaggio products of this era), stator issues, wiring harness wear.
Fuel System Considerations:
Potential for injector clogging if fuel quality is poor; regular maintenance of the fuel filter is crucial.
📚 Vehicle History
Brand Heritage
Gilera Legacy:
Gilera is an historic Italian motorcycle manufacturer, known for performance-oriented models and racing heritage, now part of the Piaggio Group.
Model Evolution
Gp800 Introduction:
The GP800 was introduced as Gilera's flagship maxi-scooter, aiming to offer a powerful and sporty alternative to conventional scooters and entry-level motorcycles.
Gp800 Successor:
The GP800 served as the platform for the later Aprilia SRV850, sharing many of its core components and powertrain.
Production
Manufacturing Location:
Italy (Piaggio Group manufacturing facilities)
🏆 Awards & Recognition
Recognitions
Award Status:
Specific industry awards for the 2007 Gilera GP800 are not widely documented in general automotive history, but it was recognized for its class-leading performance within the maxi-scooter segment at its launch.
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