Gilera GP 800 - Workshop Manual, Repair Manual

GILERA GP 800 - WORKSHOP, SERVICE, REPAIR MANUAL - PARTS - WIRING

- English Workshop Manual, Parts Manual and Wiring Schematics to motorcycles Gilera GP 800.



INDEX:


GILERA GP800 WORKSHOP MANUAL

CHARACTERISTICS

- Rules
- Safety rules
- Maintenance rules
- Vehicle identification
- Dimensions and mass
- Engine
- Transmission
- Capacities
- Electrical system
- Frame and suspensions
- Brakes
- Wheels and tyres
- Tightening Torques
- Overhaul data
- Assembly clearances
- Cylinder - piston assy.
- Piston rings
- Crankcase - crankshaft - connecting rod
- Cylinder Head
- Slot packing system
- Products

TOOLING

MAINTENANCE

- Maintenance chart
- Checking the spark advance
- Spark plug
- Air filter
- Engine oil
- Replacement
- Check
- Engine oil filter
- Oil pressure warning light
- Checking the valve clearance
- Cooling system
- Braking system
- Level check
- Top-up
- Headlight adjustment
- Drive chain

TROUBLESHOOTING

- Engine
- Excessive oil consumption/Exhaust smoke
- Insufficient lubrication pressure
- Transmission and brakes
- Clutch grabbing or performing inadequately
- Insufficient braking
- Brakes overheating
- Steering and suspensions
- Heavy steering
- Excessive steering play
- Noisy suspension
- Suspension oil leakage

ELECTRICAL SYSTEM

- Components arrangement
- Ground points
- Instrument panel
- Electrical system installation
- Front side
- Back side
- Conceptual diagrams
- Ignition
- Battery recharge and starting
- Level indicators and enable signals section
- Devices and accessories
- Lights and turn indicators
- Checks and inspections
- Immobiliser
- Virgin circuit
- Diagnostic codes
- Diagnostic code - 1 flash
- Diagnostic code - 2 flashes
- Diagnostic code - 3 flashes
- Ignition circuit
- No spark plug
- Battery recharge circuit
- Stator check
- Voltage regulator check
- Recharge system voltage check
- Starter motor
- Horn control
- Turn signals system check
- level indicators
- Lights list
- Fuses
- Sealed battery
- Remote controls check
- Switches check
- Electrical windshield check
- Connectors
- Remote seat opening
- Battery replacement
- Zeroing
- Programming

ENGINE FROM VEHICLE

- Exhaust assy. Removal
- Removal of the engine from the vehicle

ENGINE

- Automatic transmission
- Transmission cover
- Air duct filter
- Removing the driven pulley shaft bearing
- Refitting the driven pulley shaft bearing
- Driving pulley shaft supporting bearing removal
- Driving pulley shaft supporting bearing fitting
- Removing the driven pulley
- Inspecting the clutch drum
- Removing the clutch
- Inspecting the clutch
- Pin retaining collar
- Removing the driven half-pulley bearing
- Inspecting the driven fixed half-pulley
- Inspecting the driven sliding half-pulley
- Refitting the driven half-pulley bearing
- Refitting the driven pulley
- Inspecting the clutch spring
- Refitting the clutch
- Refitting the driven pulley
- Drive-belt
- Removing the driving pulley
- Inspecting the rollers case
- Refitting the driving pulley
- End gear shaft
- Refitting the transmission cover
- End gear
- Removing the driven pulley shaft bearing
- Inspecting the hub shaft
- Refitting the driven pulley shaft bearing
- Refitting the hub bearings
- Flywheel cover
- Removing the hub cover
- Removing the stator
- Inspecting the cover components
- Refitting the stator
- Refitting the flywheel cover
- Flywheel and starting
- Removing the starter motor
- Removing the flywheel magneto
- Inspecting the flywheel components
- Starter gear rim
- Intermediate gear
- Refitting the free wheel
- Refitting the intermediate gear
- Refitting the starter motor
- Cylinder assy. and timing system
- Removing the intake manifold
- Removing the rocker-arms cover
- Removing the timing system drive
- Removing the cam shaft
- Removing the cylinder head
- Removing the valves
- Removing the cylinder - piston assy.
- Inspecting the small end
- Inspecting the wrist pin
- Inspecting the piston
- Inspecting the piston rings
- Removing the piston
- Choosing the gasket
- Refitting the piston rings
- Refitting the cylinder
- Inspecting the cylinder head
- Inspecting the timing system components
- Inspecting the valve sealings
- Inspecting the valves
- Inspecting the valve stem guide clearance
- Inspecting the springs and half-cones
- Refitting the valves
- Inspecting the cam shaft
- Refitting the head and timing system components
- Refitting the timing chain
- Refitting the rocker-arms cover
- Refitting the intake manifold
- Crankcase - crankshaft
- Splitting the crankcase halves
- Inspecting the crankshaft components
- Inspecting the crankshaft alignment
- Inspecting the crankcase halves
- Inspecting the crankshaft plain bearings
- Coupling chart
- Refitting the crankcase halves
- Lubrication
- Conceptual diagrams
- General characteristics
- Diagnosis guide
- Oil pressure check
- Oil pump
- Removal
- Inspection
- Refitting
- Water pump
- Removal
- Fitting

INJECTION

- Precautions
- Terminals setup
- EMS circuit diagram
- Troubleshooting procedure
- Engine does not start
- Starting difficulties
- Engine stops at idle
- Engine does not rev down
- Exhaust backfires in deceleration
- Engine revs irregularly
- Poor performance at full throttle
- Engine knocking
- Fuel supply system
- Pump supply circuit
- Circuit leak test
- Inspecting the injector circuit
- Immobiliser circuit
- Virgin circuit
- Diagnostic codes
- Code 1
- Code 2
- Code 3
- Tachometer
- HT coil
- Inspecting the spark plug shielded cap
- Spark advance
- Coolant temperature sensor
- Intake air temperature sensor
- Throttle valve opening sensor
- Zeroing the throttle
- Step motor

SUSPENSIONS

- Front
- Removing the front wheel
- Front wheel hub overhaul
- Refitting the front wheel
- Handlebar
- Removal
- Refitting
- Front fork
- Removal
- Overhaul
- Refitting
- Steering column
- Removal
- Overhaul
- Refitting
- Rear
- Removing the rear wheel
- Refitting the rear wheel
- Shock absorbers
- Removal
- Refitting
- Removal
- Refitting
- Fork
- Removal
- Service
- Fitting
- Centre-stand
- Side stand

BRAKING SYSTEM

- Rear brake calliper
- Removal
- Refitting
- Front brake calliper
- Removal
- Refitting
- Rear brake disc
- Removal
- Refitting
- Disc Inspection
- Front brake disc
- Removal
- Refitting
- Disc Inspection
- Front brake pads
- Removal
- Refitting
- Rear brake pads
- Removal
- Refitting
- Fill
- Rear - combined
- Front
- Brake fluid level check
- Removal
- Refitting
- Removal
- Refitting
- Brake pipes
- Parking brake

COOLING SYSTEM

- Circuit diagram
- Electric fan check
- System sealing check
- Coolant replacement
- Water pump
- diagnosis
- Excessive system pressure
- Cooling fluid consumption
- Oil in the fluid

CHASSIS

- Seat
- Driving mirrors
- Instrument panel
- Headlight assy.
- Legshield
- Knee-guard
- Front wheel housing
- Taillight assy.
- Footrest
- Side fairings
- License plate holder
- Helmet bay
- spoiler
- Fuel tank
- Rear central cover
- Front mudguard
- Radiator fan
- Rear
- Handles and top side fairings
- Front central cover
- Flyscreen
- Radiator cover
- Battery

PRE-DELIVERY

- Aesthetic inspection
- Tightening torques inspection
- Electrical system
- Levels check
- Road test
- Static test
- Functional inspection

TIME

- Engine
- Crankcase
- Crankshaft
- Cylinder assy.
- Cylinder head assy.
- Rocker arms support assy.
- Cylinder head cover
- Flywheel cover
- Driven pulley
- Oil pump
- Final gear assy.
- Driving pulley
- Final drive
- Transmission cover
- Water pump
- Flywheel magneto
- Butterfly valve
- Exhaust pipe
- Air cleaner
- Frame
- Centre-stand
- Legshield spoiler
- Side fairings
- Rear cover
- Central cover
- Mudguard
- Fuel tank
- Rear shock-absorber
- Handlebar components
- Swing-arm
- Seat
- Instrument panel
- Locks
- Turn signal lights
- Front wheel
- Rear wheel
- Electric start
- Electric devices
- Electronic controls
- Transmissions
- Helmet bay
- Rear side fairings
- Front suspension
- Cooling system
- Braking system
- Windscreen
- Stickers

GILERA GP800 PARTS MANUAL

GILERA GP800 WIRING DIAGRAM
 
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GILERA GP800 INJECTION WIRING DIAGRAM