Gilera GP 800 i.e. Manuals

Manuals and User Guides for Gilera GP 800 i.e.. We have 1 Gilera GP 800 i.e. manual available for free PDF download: Service Station Manual

Gilera GP 800 i.e. Service Station Manual (432 pages)

Brand: Gilera | Category: Scooter | Size: 18.06 MB

Symbols Meaning
3
Index of Topics
5
Characteristics
8
Maintenance Rules
8
Safety Rules
8
Dimensions and Mass
9
Vehicle Identification
9
Engine
10
Capacities
12
Electrical System
12
Transmission
12
"Mode" Button
13
Checking Remote Controls "A" Operating as Circuit Breakers
13
Checking Remote Controls "B" Operating as Switches
13
Helmet Compartment Light Button
14
Horn Button
14
Windshield "Down" Button
14
Windshield "Up" Button
14
Engine Stop Switch
15
Light Switch
15
Starter Button
15
Turn Indicator Switch
15
Fuel Injector
16
Intake Air Temperature Sensor
16
Stepper Motor
16
Throttle Position Sensor
16
Engine Temperature Sensor
17
Fuel Pump Unit
17
H.V. Coil
17
Revolution Timing Sensor
17
Brakes
18
Frame and Suspensions
18
Minimum Oil Pressure Sensor
18
Stator
18
Tightening Torques
19
Wheels and Tyres
19
Table of Contents
20
Assembly Clearances
22
Cylinder - Piston Assy
22
Overhaul Data
22
Piston Rings
24
Crankcase - Crankshaft - Connecting Rod
25
Cylinder Head
29
Slot Packing System
35
Products
36
Appropriate Tools
38
Tooling
38
Maintenance Chart
50
Maintenance Table
50
Checking the Spark Advance
51
Spark Plug
51
Air Filter
53
Air Deflector Filter
56
Engine Oil Replacement
57
Engine Oil Check
59
Engine Oil Filter
60
Oil Pressure Warning Light
60
Checking the Valve Clearance
61
Braking System
62
Cooling System
62
Level Check
62
Headlight Adjustment
63
Top-Up
63
Drive Chain
64
Pinion Unit
66
Excessive Oil Consumption/Exhaust Smoke
68
Insufficient Lubrication Pressure
68
Transmission and Brakes
68
Troubleshooting
68
Brakes Overheating
69
Heavy Steering
69
Insufficient Braking
69
Steering and Suspensions
69
Noisy Suspension
70
Suspension Oil Leakage
70
Components Arrangement
75
Ground Points
80
Instrument Panel
82
Electrical System Installation
83
Front Side
83
Back Side
86
Conceptual Diagrams
90
Ignition
90
Battery Recharge and Starting
91
Level Indicators and Enable Signals Section
93
Devices and Accessories
94
Lights and Turn Indicators
96
Checks and Inspections
97
Immobiliser
97
Virgin Circuit
98
Diagnostic Code - 1 Flash
100
Diagnostic Codes
100
Diagnostic Code - 2 Flashes
101
Diagnostic Code - 3 Flashes
102
Ignition Circuit
102
No Spark Plug
102
Battery Recharge Circuit
104
Stator Check
104
Voltage Regulator Check
104
Recharge System Voltage Check
105
Starter Motor
106
- Horn Control
  108
- Turn Signals System Check
  110
- Fuel Gauge
  111
- Level Indicators
  111
- Lights List
  112
- Low-Beam Light Check
  113
- Tail Light Check
  113
- High-Beam Light Check
  114
- Stop Light Check
  114
- Light Bulbs Table
  115
- Fuses
  116
- Instructions for Battery Refresh after Open Circuit Storage
  117
- Sealed Battery
  117
- Instructions for Renewal Recharge after Open-Circuit Storage
  118
- Remote Controls Check
  119
- Switches Check
  120
- Electrical Windshield Check
  122
- Connectors
  123
- Engine Control Unit Connector
  124
- Vehicle Control Unit Connector
  124
- Instrument Panel Connector "A"
  125
- Instrument Panel Connector "B"
  125
- Front Cylinder HV Coil Connector
  126
- Immobilizer Decoder Connector
  126
- Rear Cylinder HV Coil Connector
  126
- Rear Cylinder Injector Connector
  126
- Antitheft Device Pre-Installation Connector
  127
- Front Cylinder Injector Connector
  127
- Saddle Opening Receiver Connector
  127
- Turn Indcator Control Device Connector
  127
- Diagnostic Socket Connector
  128
- GPS Wiring Connector
  128
- Voltage Regulator Connector
  128
- Wiring for Accessories - Connector
  128
- Fuel Level Transmitter Connector
  129
- Fuel Pump Connector
  129
- Idle Adjustment Motor Connector
  129
- Stand Switch Connector
  129
- Air Temperature Sensor Connector
  130
- Lambda Probe Connector
  130
- Vehicle Speed Sensor Connector
  130
- Water Temperature Sensor Connector
  130
- Barometric Pressure Sensor Connector
  131
- Engine RPM Sensor Connector
  131
- External Temperature Sensor Connector
  131
- Throttle Sensor Connector
  131
- Battery Replacement
  132
- Remote Seat Opening
  132
- Programming
  133
- Zeroing
  133
- Engine from Vehicle
  136
- Exhaust Assy. Removal
  136
- Muffler Tightening Torques
  142
Nut Fixing Head - Exhaust Manifold
142
- Removal of the Engine from the Vehicle
  143
- Front Support Service
  148
- Rear Support Service
  148
- End Gear Shaft
  149
- Fitting
  149
- Nut Fixing Silent-Block Plate - Chassis
  149
- Engine to Chassis Locking Torques
  150
Nut Fixing Silent-Block Plate
150
- Automatic Transmission
  152
- Transmission Cover
  152
- Air Duct Filter
  154
- Refitting the Driven Pulley Shaft Bearing
  155
- Removing the Driven Pulley Shaft Bearing
  155
- Driving Pulley Shaft Supporting Bearing Fitting
  156
- Driving Pulley Shaft Supporting Bearing Removal
  156
- Inspecting the Clutch Drum
  157
- Removing the Clutch
  157
- Removing the Driven Pulley
  157
- Inspecting the Clutch
  158
- Pin Retaining Collar
  159
- Removing the Driven Half-Pulley Bearing
  159
- Inspecting the Driven Fixed Half-Pulley
  160
- Inspecting the Driven Sliding Half-Pulley
  161
- Refitting the Driven Half-Pulley Bearing
  161
- Refitting the Driven Pulley
  162
- Inspecting the Clutch Spring
  163
- Refitting the Clutch
  163
- Clutch Ring Nut
  164
  - Drive-Belt
    165
  - Removing the Driving Pulley
    166
  - Inspecting the Rollers Case
    168
- Air Switch Screw
  169
  - Refitting the Driving Pulley
    169
  - Pinion Unit Service
    171
  - Pinion Unit Fitting
    177
  - Chain Replacement
    178
  - Crown Replacement
    178
  - Refitting the Transmission Cover
    178
Internal Transmission Cover Screws
178
- End Gear
  179
- Pinion Unit Shaft Bearing Removal
  179
- Pinion Unit Shaft Bearing Fitting
  180
- Inspecting the Hub Shaft
  183
- Flywheel Cover
  185
- Refitting the Hub Bearings
  185
- Inspecting the Cover Components
  186
- Removing the Hub Cover
  186
- Removing the Stator
  186
- Refitting the Stator
  187
- Stator Retainers
  187
- Flywheel and Starting
  188
- Flywheel Cover Screws
  188
  - Refitting the Flywheel Cover
    188
  - Removing the Flywheel Magneto
    189
  - Removing the Starter Motor
    189
  - Inspecting the Flywheel Components
    191
  - Starter Gear Rim
    191
  - Intermediate Gear
    192
  - Refitting the Free Wheel
    193
  - Refitting the Intermediate Gear
    194
Screw Fixing Freewheel to Flywheel
194
- Refitting the Starter Motor
  195
- Cylinder Assy. and Timing System
  196
- Removing the Intake Manifold
  196
- Removing the Rocker-Arms Cover
  197
- Removing the Timing System Drive
  197
- Removing the Cam Shaft
  198
- Removing the Cylinder Head
  199
- Removing the Valves
  201
- Inspecting the Small End
  203
- Removing the Cylinder - Piston Assy
  203
- Inspecting the Piston
  204
- Inspecting the Piston Rings
  204
- Inspecting the Wrist Pin
  204
- Removing the Piston
  204
- Choosing the Gasket
  205
- Refitting the Piston Rings
  206
- Refitting the Cylinder
  207
- Inspecting the Cylinder Head
  208
- Inspecting the Timing System Components
  209
- Inspecting the Valve Sealings
  209
- Inspecting the Springs and Half-Cones
  210
- Inspecting the Valve Stem Guide Clearance
  210
- Inspecting the Valves
  210
- Refitting the Valves
  211
- Inspecting the Cam Shaft
  212
- Refitting the Head and Timing System Components
  212
- Refitting the Timing Chain
  218
- Refitting the Rocker-Arms Cover
  219
- Refitting the Intake Manifold
  220
- Crankcase - Crankshaft
  221
- Splitting the Crankcase Halves
  222
- Inspecting the Crankshaft Alignment
  225
- Inspecting the Crankshaft Components
  225
- Inspecting the Crankcase Halves
  226
- Inspecting the Crankshaft Plain Bearings
  226
- Coupling Chart
  227
- Refitting the Crankcase Halves
  227
Engine Crankcase Coupling Screws (M6)
231
- Lubrication
  232
- Lubrication Circuit
  232
- General Characteristics
  233
- Diagnosis Guide
  234
- Oil Pressure Check
  236
- Oil Pump Removal
  237
- Oil Pump Inspection
  240
- Oil Pump Refitting
  244
- Water Pump Removal
  246
- Water Pump Fitting
  251
- Lubricate the Rotor Shaft with Engine Oil
  252
- Water Pump Impeller
  253
  - Injection
    257
  - Injection Precautions
    258
  - Injection Troubleshooting Hints
    259
  - Terminals Setup
    260
  - Vehicle Contol Unit Connector
    260
  - EMS Circuit Diagram
    261
  - Troubleshooting Procedure
    261
  - Engine Does Not Start
    262
  - Starting Difficulties
    262
  - Engine Does Not Rev down
    263
  - Engine Stops at Idle
    263
  - Engine Revs Irregularly
    264
  - Exhaust Backfires in Deceleration
    264
  - Engine Knocking
    265
  - Poor Performance at Full Throttle
    265
  - Fuel Supply System
    266
  - Pump Supply Circuit
    267
  - Circuit Leak Test
    268
  - Inspecting the Injector Circuit
    269
  - Immobiliser Circuit
    270
  - Code 1
    273
  - Code 2
    274
  - Code 3
    275
  - Tachometer
    275
  - HT Coil
    277
  - Front Cylinder HV Coil Connector
    278
  - HV Coil
    278
  - Inspecting the Spark Plug Shielded Cap
    278
  - Spark Advance
    278
  - Coolant Temperature Sensor
    279
  - Throttle Valve Opening Sensor
    282
  - Zeroing the Throttle
    283
  - Step Motor
    285
  - Front Suspensions
    288
  - Removing the Front Wheel
    288
- Front Wheel Pin Nut
  291
  - Handlebar Removal
    291
  - Refitting the Front Wheel
    291
  - Handlebar Refitting
    293
  - Front Fork Removal
    295
  - Handlebar Cover Fixing Screw 2
    295
  - Front Fork Overhaul
    296
  - Cleaning of the Components
    298
  - Component Check
    298
  - Front Fork Refitting
    299
- Hydraulic Rod Fixing Screw
  300
- Fork Locking Screws Cap
  303
  - Steering Column Removal
    303
  - Steering Column Overhaul
    304
  - Steering Fifth Wheel Track Removal
    305
  - Steering Fifth Wheel Track Fitting
    306
  - Steering Column Refitting
    307
  - Rear Suspensions
    310
  - Removing the Rear Wheel
    310
Screw Fixing Three-Way Union to Fork Head
310
- Rear Wheel Hub Service
  311
- Refitting the Rear Wheel
  313
- Shock Absorbers Refitting
  313
- Shock Absorbers Removal
  313
- Fork Removal
  314
- Fork Service
  315
- Fork Fitting
  320
- Side Stand Fitting
  323
- Side Stand Removal
  323
- Front Brake Calliper Removal
  326
- Rear Brake Calliper Refitting
  326
- Rear Brake Calliper Removal
  326
- Front Brake Calliper Refitting
  327
- Rear Brake Disc Removal
  327
- Disc Inspection
  328
- Front Brake Disc
  328
- Rear Brake Disc Refitting
  328
- Front Brake Disc Refitting
  329
- Front Brake Disc Removal
  329
- Front Brake Pads
  330
- Front Brake Pads Removal
  331
- Front Brake Pads Refitting
  332
- Rear Brake Pads Refitting
  333
- Rear Brake Pads Removal
  333
- Bleed Screw
  334
  - Rear - Combined
    334
  - Front
    335
  - Brake Fluid Level Check
    336
  - Removal
    336
  - Refitting
    337
- Brake Pipes / Brake Pump Coupling
  338
  - Front Brake Pipe Fitting
    338
  - Rear Brake Pipe Fitting
    339
  - Parking Brake Transmission Fitting
    341
  - Parking Brake Calliper Removal
    343
Screw Fixing Parking Brake Calliper to Supporting
343
- Brake Pad Replacement
  344
- Pin Fixing Parking Brake Pads
  344
  - Cooling System Circuit Diagram
    346
  - Electric Fan Check
    348
  - Coolant Replacement
    349
  - System Sealing Check
    349
  - Water Pump
    350
  - Cooling Fluid Consumption
    352
  - Cooling System Diagnosis
    352
  - Excessive System Pressure
    352
  - Oil in the Fluid
    352
  - Chassis
    354
  - Driving Mirrors
    355
  - Seat
    355
  - Headlight Assy
    356
  - Legshield
    357
  - Knee-Guard
    359
  - Front Wheel Housing
    362
  - Taillight Assy
    362
  - Footrest
    363
  - Side Fairings
    364
  - License Plate Holder
    365
  - Helmet Bay
    366
  - Spoiler
    367
  - Fuel Tank
    368
  - Front Mudguard
    370
  - Rear Central Cover
    370
  - Radiator Fan
    371
  - Handles and Top Side Fairings
    372
  - Rear Chassis
    372
  - Front Central Cover
    373
  - Flyscreen
    374
  - Radiator Cover
    374
  - Battery
    375
  - Aesthetic Inspection
    378
  - Pre-Delivery
    378
  - Tightening Torques Inspection
    378
Parking Brake Control Removal
344
Screws Fixing Half-Handlebars - Supporting Plate
378
- Levels Check
  379
- Functional Inspection
  380
- Road Test
  380
- Static Test
  380
- Time
  382
- Crankcase
  383
- Crankshaft
  384
- Cylinder Assy
  385
- Cylinder Group
  385
- Cylinder Head Assy
  386
- Head Unit
  386
- Rocker Arms Support Assy
  387
- Rocking Lever Unit
  387
- Cylinder Head Cover
  388
- Head Cover
  388
- Driven Pulley
  390
  - Oil Pump
    391
  - Final Gear Assy
    392
  - Final Reduction Gear Assembly
    392
  - Driving Pulley
    393
  - Final Drive
    394
  - Transmission Cover
    395
  - Flywheel Magneto
    397
  - Butterfly Valve
    398
  - Throttle Body
    398
  - Exhaust Pipe
    399
  - Muffler
    399
  - Air Cleaner
    400
  - Frame
    401
  - Centre-Stand
    402
  - Front Shield
    403
  - Legshield Spoiler
    403
  - Side Covers
    404
  - Rear Cover
    405
  - Rear Shield
    405
  - Central Cover
    406
  - Mudguard
    407
  - Rear Shock-Absorber
    409
  - Handlebar Components
    410
  - Braccio Oscillante
    411
  - Swing-Arm
    411
  - Saddle
    412
  - Locks
    414
  - Turn Signal Lights
    414
  - Front Turn Indicators Indicator Lights
    415
  - Rear Turn Indicators Indicator Lights
    416
  - Front Wheel
    417
  - Rear Wheel
    418
  - Electric Start
    419
  - Electrical Start-Up
    419
  - Electric Devices
    420
  - Remote Controls
    421
  - Wire Unit
    422
  - Electronic Controls
    423
  - Handlebar Controls
    423
  - Transmissions
    424
  - Helmet Compartment
    425
  - Rear Covers
    426
  - Rear Side Fairings
    426
- Front Suspension
  427
  - Windscreen
    430
  - Windshield
    430
  - Stickers
    431
  - Transfers
    431

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Gilera GP 800 i.e. Manuals

Gilera GP 800 i.e. Service Station Manual (432 pages)

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