Gilera GP 800 i.e. User Manual

Removal
Proceed as follows:
- Remove the rear brake calliper
- Loosen the two pins shown in the figure that lock
the two pads.
- Remove the pads, being careful with the pad
spring clamp.
- Check the thickness of the friction material of the
pads.
- Replace the pads if the thickness is below the
minimum value.
- The replacement must be made with greater re-
sidual thickness if the pad has not worn evenly. A
0.5 mm thickness difference in the residual friction
material is permitted.
Characteristic
Minimum value
1.5 mm
Refitting
To fit, proceed as follows:
- Insert the two pads in the callipers.
- Screw the two pad lock pins to the correct torque, and apply the recommended product.
- Fit the calliper on its support, tightening the two screws to the prescribed torque.
N.B.
IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER ON THE DISC DURING FIT-
TING, GENTLY EXPAND THE PADS.
Recommended products
Loctite 243 Medium strength threadlock
Loctite 243 medium-strength threadlock
Locking torques (N*m)
GP 800 i.e. Braking system
BRAK SYS - 9

Gilera GP 800 i.e. Specifications

General

Brand	Gilera
Model	GP 800 i.e.
Category	Scooter
Language	English

Summary

Characteristics

General Information and Rules

Engine Specifications

Details on engine type, capacity, performance, lubrication, cooling, and fuel supply.

Electrical System Components

Details on electrical system parts, including ignition, battery, sensors, and wiring.

Chassis and Suspension Components

Maintenance

Service Indicator Reset and Chart

Procedure for resetting service icons and the comprehensive maintenance schedule.

Air Filter and Engine Oil Maintenance

Steps for air filter cleaning/replacement and engine oil/filter change.

Valve Clearance and Cooling System

Procedures for valve clearance adjustment and cooling system checks.

Troubleshooting

Engine and Drivetrain Issues

Diagnosing engine oil consumption, lubrication pressure, and clutch problems.

Braking System Faults

Troubleshooting inefficient braking and brake overheating issues.

Steering and Suspension Problems

Electrical System

System Overview and Components

Lists and diagrams of electrical components, wiring, and connectors.

Immobiliser and Anti-theft System

Checks and troubleshooting for the immobiliser system and its components.

Ignition, Charging, and Starting Systems

Procedures for checking battery, stator, regulator, starter motor, and flywheel.

Lighting, Indicators, and Controls

Fuel and Sensor Systems

Covers injection system, fuel pump, injectors, and various sensors.

Engine Removal from Vehicle

Exhaust System Removal

Engine Removal Procedure

Step-by-step guide to detach the engine, including coolant, fuel, and electrical connections.

Engine

Automatic Transmission Components

Clutch and Belt System

Inspection and removal/refitting of the clutch drum, clutch, and drive belt.

Pinion Unit Service

Crankcase and Crankshaft

Procedures for splitting crankcase halves, inspecting bearings, and crankshaft alignment.

Lubrication System

Oil Pump Service

Removal, inspection, and refitting of the pressure and scavenge oil pumps.

Injection System

EMS System Overview

Description of the EMS injection and ignition system, its components, and functions.

Control Unit and Diagnostics

Troubleshooting Hints and Procedures

Common EMS failures, connection checks, and troubleshooting steps.

Sensor and Actuator Checks

Fuel Pump and Injector Circuit

Details on the fuel supply system, pump unit, circuit leak tests, and injector checks.

Immobiliser Circuit and Troubleshooting

Information on the immobiliser system, virgin circuit, programming, and diagnostic codes.

Suspensions

Front Wheel Removal and Hub Overhaul

Handlebar Removal and Refitting

Front Fork Overhaul

Procedures for overhauling and refitting the front fork components.

Steering Column Removal and Overhaul

Rear Wheel Hub Service

Shock Absorbers

Braking System

Rear and Front Brake Caliper Service

Brake Disc Inspection and Replacement

Front and Rear Brake Pad Replacement

Steps for checking and replacing front and rear brake pads.

Brake Fluid System

Parking Brake System

Cooling System

Circuit Diagram and Specifications

Electric Fan and Thermostat Checks

System Sealing and Coolant Replacement

Water Pump Service

Cooling System Diagnosis

Troubleshooting common cooling system issues like excessive pressure and fluid consumption.