Gilera GP 800 i.e. User Manual

Possible Cause Operation
if they are recessed or if the balls are squashed,
replace them.
Noisy suspension
NOISY SUSPENSION
Possible Cause Operation
Malfunctions in the suspension system If the front suspension is noisy, check: the efficien-
cy of the front shock absorbers; the condition of
the ball bearings and relevant lock-nuts, the limit
switch rubber buffers and the movement bushings.
In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber
disk in the attachment to the hub and the steering
tube.
Suspension oil leakage
OIL LEAKAGE FROM SUSPENSION
Possible Cause Operation
Seal fault or breakage Replace the shock absorber Check the condition
of wear of the steering covers and the adjust-
ments.
Troubleshooting GP 800 i.e.
TROUBL - 4

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.