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GP 800 i.e.
Gilera GP 800 i.e. User Manual
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R
EAR
TURN
INDICATORS
INDICATOR
LIGHTS
Code
Action
Duration
1
005005
Taillight - Replacement
2
005022
Rear turn indicators - Re-
placement
3
005031
Licence plate light bulb - Re-
placement
4
005131
Licence plate light support -
Replacement
5
005068
Rear turn indicator bulb - Re-
placement
Time
GP 800 i.e.
TIME - 36
415
417
Table of Contents
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
5
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Gilera GP 800 i.e. Specifications
General
Brand
Gilera
Model
GP 800 i.e.
Category
Scooter
Language
English
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