Gilera GP 800 i.e.

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Stores code Description

020565Y Flywheel lock calliper spanner

020659Y Tool to remove clutch and re-

place belt

020660Y Driving pulley lock

020713Y Flywheel extractor

020527Y Engine support base

020658Y Engine plate

Tooling GP 800 i.e.

TOOL - 4

Main Page

Symbols Meaning3
Index of Topics5
Characteristics8
Maintenance Rules8
Safety Rules8
Dimensions and Mass9
Vehicle Identification9
Engine10
Capacities12
Electrical System12
Transmission12
"Mode" Button13
Checking Remote Controls "A" Operating as Circuit Breakers13
Checking Remote Controls "B" Operating as Switches13
Helmet Compartment Light Button14
Horn Button14
Windshield "Down" Button14
Windshield "Up" Button14
Engine Stop Switch15
Light Switch15
Starter Button15
Turn Indicator Switch15
Fuel Injector16
Intake Air Temperature Sensor16
Stepper Motor16
Throttle Position Sensor16
Engine Temperature Sensor17
Fuel Pump Unit17
H.V. Coil17
Revolution Timing Sensor17
Brakes18
Frame and Suspensions18
Minimum Oil Pressure Sensor18
Stator18
Tightening Torques19
Wheels and Tyres19
Table of Contents20
Assembly Clearances22
Cylinder - Piston Assy22
Overhaul Data22
Piston Rings24
Crankcase - Crankshaft - Connecting Rod25
Cylinder Head29
Slot Packing System35
Products36
Appropriate Tools38
Tooling38
Maintenance Chart50
Maintenance Table50
Checking the Spark Advance51
Spark Plug51
Air Filter53
Air Deflector Filter56
Engine Oil Replacement57
Engine Oil Check59
Engine Oil Filter60
Oil Pressure Warning Light60
Checking the Valve Clearance61
Braking System62
Cooling System62
Level Check62
Headlight Adjustment63
Top-Up63
Drive Chain64
Pinion Unit66
Excessive Oil Consumption/Exhaust Smoke68
Insufficient Lubrication Pressure68
Transmission and Brakes68
Troubleshooting68
Brakes Overheating69
Heavy Steering69
Insufficient Braking69
Steering and Suspensions69
Noisy Suspension70
Suspension Oil Leakage70
Components Arrangement75
Ground Points80
Instrument Panel82
Electrical System Installation83
Front Side83
Back Side86
Conceptual Diagrams90
Ignition90
Battery Recharge and Starting91
Level Indicators and Enable Signals Section93
Devices and Accessories94
Lights and Turn Indicators96
Checks and Inspections97
Immobiliser97
Virgin Circuit98
Diagnostic Code - 1 Flash100
Diagnostic Codes100
Diagnostic Code - 2 Flashes101
Diagnostic Code - 3 Flashes102
Ignition Circuit102
No Spark Plug102
Battery Recharge Circuit104
Stator Check104
Voltage Regulator Check104
Recharge System Voltage Check105
Starter Motor106
- Horn Control108
- Turn Signals System Check110
- Fuel Gauge111
- Level Indicators111
- Lights List112
- Low-Beam Light Check113
- Tail Light Check113
- High-Beam Light Check114
- Stop Light Check114
- Light Bulbs Table115
- Fuses116
- Instructions for Battery Refresh after Open Circuit Storage117
- Sealed Battery117
- Instructions for Renewal Recharge after Open-Circuit Storage118
- Remote Controls Check119
- Switches Check120
- Electrical Windshield Check122
- Connectors123
- Engine Control Unit Connector124
- Vehicle Control Unit Connector124
- Instrument Panel Connector "A"125
- Instrument Panel Connector "B"125
- Front Cylinder HV Coil Connector126
- Immobilizer Decoder Connector126
- Rear Cylinder HV Coil Connector126
- Rear Cylinder Injector Connector126
- Antitheft Device Pre-Installation Connector127
- Front Cylinder Injector Connector127
- Saddle Opening Receiver Connector127
- Turn Indcator Control Device Connector127
- Diagnostic Socket Connector128
- GPS Wiring Connector128
- Voltage Regulator Connector128
- Wiring for Accessories - Connector128
- Fuel Level Transmitter Connector129
- Fuel Pump Connector129
- Idle Adjustment Motor Connector129
- Stand Switch Connector129
- Air Temperature Sensor Connector130
- Lambda Probe Connector130
- Vehicle Speed Sensor Connector130
- Water Temperature Sensor Connector130
- Barometric Pressure Sensor Connector131
- Engine RPM Sensor Connector131
- External Temperature Sensor Connector131
- Throttle Sensor Connector131
- Battery Replacement132
- Remote Seat Opening132
- Programming133
- Zeroing133
- Engine from Vehicle136
- Exhaust Assy. Removal136
- Muffler Tightening Torques142
Nut Fixing Head - Exhaust Manifold142
- Removal of the Engine from the Vehicle143
- Front Support Service148
- Rear Support Service148
- End Gear Shaft149
- Fitting149
- Nut Fixing Silent-Block Plate - Chassis149
- Engine to Chassis Locking Torques150
Nut Fixing Silent-Block Plate150
- Automatic Transmission152
- Transmission Cover152
- Air Duct Filter154
- Refitting the Driven Pulley Shaft Bearing155
- Removing the Driven Pulley Shaft Bearing155
- Driving Pulley Shaft Supporting Bearing Fitting156
- Driving Pulley Shaft Supporting Bearing Removal156
- Inspecting the Clutch Drum157
- Removing the Clutch157
- Removing the Driven Pulley157
- Inspecting the Clutch158
- Pin Retaining Collar159
- Removing the Driven Half-Pulley Bearing159
- Inspecting the Driven Fixed Half-Pulley160
- Inspecting the Driven Sliding Half-Pulley161
- Refitting the Driven Half-Pulley Bearing161
- Refitting the Driven Pulley162
- Inspecting the Clutch Spring163
- Refitting the Clutch163
- Clutch Ring Nut164
  - Drive-Belt165
  - Removing the Driving Pulley166
  - Inspecting the Rollers Case168
- Air Switch Screw169
  - Refitting the Driving Pulley169
  - Pinion Unit Service171
  - Pinion Unit Fitting177
  - Chain Replacement178
  - Crown Replacement178
  - Refitting the Transmission Cover178
Internal Transmission Cover Screws178
- End Gear179
- Pinion Unit Shaft Bearing Removal179
- Pinion Unit Shaft Bearing Fitting180
- Inspecting the Hub Shaft183
- Flywheel Cover185
- Refitting the Hub Bearings185
- Inspecting the Cover Components186
- Removing the Hub Cover186
- Removing the Stator186
- Refitting the Stator187
- Stator Retainers187
- Flywheel and Starting188
- Flywheel Cover Screws188
Screw Fixing Freewheel to Flywheel194
- Refitting the Starter Motor195
- Cylinder Assy. and Timing System196
- Removing the Intake Manifold196
- Removing the Rocker-Arms Cover197
- Removing the Timing System Drive197
- Removing the Cam Shaft198
- Removing the Cylinder Head199
- Removing the Valves201
- Inspecting the Small End203
- Removing the Cylinder - Piston Assy203
- Inspecting the Piston204
- Inspecting the Piston Rings204
- Inspecting the Wrist Pin204
- Removing the Piston204
- Choosing the Gasket205
- Refitting the Piston Rings206
- Refitting the Cylinder207
- Inspecting the Cylinder Head208
- Inspecting the Timing System Components209
- Inspecting the Valve Sealings209
- Inspecting the Springs and Half-Cones210
- Inspecting the Valve Stem Guide Clearance210
- Inspecting the Valves210
- Refitting the Valves211
- Inspecting the Cam Shaft212
- Refitting the Head and Timing System Components212
- Refitting the Timing Chain218
- Refitting the Rocker-Arms Cover219
- Refitting the Intake Manifold220
- Crankcase - Crankshaft221
- Splitting the Crankcase Halves222
- Inspecting the Crankshaft Alignment225
- Inspecting the Crankshaft Components225
- Inspecting the Crankcase Halves226
- Inspecting the Crankshaft Plain Bearings226
- Coupling Chart227
- Refitting the Crankcase Halves227
Engine Crankcase Coupling Screws (M6)231
- Lubrication232
- Lubrication Circuit232
- General Characteristics233
- Diagnosis Guide234
- Oil Pressure Check236
- Oil Pump Removal237
- Oil Pump Inspection240
- Oil Pump Refitting244
- Water Pump Removal246
- Water Pump Fitting251
- Lubricate the Rotor Shaft with Engine Oil252
- Water Pump Impeller253
- Front Wheel Pin Nut291
- Hydraulic Rod Fixing Screw300
- Fork Locking Screws Cap303
Screw Fixing Three-Way Union to Fork Head310
- Rear Wheel Hub Service311
- Refitting the Rear Wheel313
- Shock Absorbers Refitting313
- Shock Absorbers Removal313
- Fork Removal314
- Fork Service315
- Fork Fitting320
- Side Stand Fitting323
- Side Stand Removal323
- Front Brake Calliper Removal326
- Rear Brake Calliper Refitting326
- Rear Brake Calliper Removal326
- Front Brake Calliper Refitting327
- Rear Brake Disc Removal327
- Disc Inspection328
- Front Brake Disc328
- Rear Brake Disc Refitting328
- Front Brake Disc Refitting329
- Front Brake Disc Removal329
- Front Brake Pads330
- Front Brake Pads Removal331
- Front Brake Pads Refitting332
- Rear Brake Pads Refitting333
- Rear Brake Pads Removal333
- Bleed Screw334
  - Rear - Combined334
  - Front335
  - Brake Fluid Level Check336
  - Removal336
  - Refitting337
- Brake Pipes / Brake Pump Coupling338
  - Front Brake Pipe Fitting338
  - Rear Brake Pipe Fitting339
  - Parking Brake Transmission Fitting341
  - Parking Brake Calliper Removal343
Screw Fixing Parking Brake Calliper to Supporting343
- Brake Pad Replacement344
- Pin Fixing Parking Brake Pads344
Parking Brake Control Removal344
Screws Fixing Half-Handlebars - Supporting Plate378
- Levels Check379
- Functional Inspection380
- Road Test380
- Static Test380
- Time382
- Crankcase383
- Crankshaft384
- Cylinder Assy385
- Cylinder Group385
- Cylinder Head Assy386
- Head Unit386
- Rocker Arms Support Assy387
- Rocking Lever Unit387
- Cylinder Head Cover388
- Head Cover388
- Driven Pulley390
- Front Suspension427

Gilera GP 800 i.e. - Page 40

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