Gilera Gp 800 Service manual

SERVICE STATION MANUAL

664841(IT)-664842(EN)-664843(FR)-664844

(DE)-664845(ES)-664846(PT)-664847(NL)-664848

(EL)

GP 800 i.e.

SERVICE STATION

GP 800 i.e.

MANUAL

The descriptions and illustrations given in this publication are not binding. While the basic features as described and illustrated in this manual remain unchanged, PIAGGIO - GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessory supplies, which it considers necessary to improve the product or which

are required for manufacturing or construction reasons.

Not all versions shown in this publication are available in all Countries. The availability of individual

versions should be confirmed with the official Piaggio sales network.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL

GP 800 i.e.

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any significant changes to vehicle characteristics or to specific repair operations will be communicated by updates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual concerning special tools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

Characteristics GP 800 i.e.

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid open flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electric connections have been made properly, particularly the ground and battery connections.

CHAR - 2

GP 800 i.e. Characteristics

Vehicle identification

Chassis prefix (A):

ZAPM55100

Engine prefix (B):

M554M

Dimensions and mass

CHAR - 3

Characteristics GP 800 i.e.

WEIGHTS AND DIMENSIONS

Specification Desc./Quantity

Kerb weight 248 ± 10 kg

Maximum weight allowed 450 kg

Maximum height 1300 ÷ 1370 mm

Width 790 mm

Wheelbase 1585 mm

Length 2230 mm

Engine

ENGINE

Specification Desc./Quantity

Type 90° V-twin engine, 4-stroke, with double spark plug

Cubic capacity 839 cm3

Bore x stroke 88 x 69 mm

Compression ratio 10.5 ± 0.5 : 1

Engine idle speed 1,250 ± 100 rpm

Timing system 4 valves, single overhead camshaft, driven.

Valve clearance Inlet: 0.15 mm

Outlet: 0.15 mm MAX. Power 50.5 kW at 7,750 rpm MAX. torque 71 Nm at 4,500 rpm

Lubrication Engine lubrication by a dry sump system, with

double lobe pump (one for delivery and one for re-

turn), controlled by a chain and paper filter.

Lubrication pressure 3.5 ÷ 4 bar

Minimum lubrication pressure (100° C) 0.8 bar

Fuel supply Multipoint electronic injection with single Ø 38-mm

throttle body and electric fuel pump.

Cooling Forced liquid circulation cooling.

Fuel Unleaded petrol (95 RON)

TECHNICAL SPECIFICATIONS

Specification Desc./Quantity

Type Trochoidal

Rotor washers Delivery pump: 12 mm

Assembly clearances Lobe ends: 0.04 ÷ 0.1 mm

External rotor radial clearance 0.05- 0.12 mm

Levelness 0.1 mm

Specification Desc./Quantity

Type with piston

Plunger diameter Ø 14-0.016 -0.043 mm

Unloaded spring length 52 mm

Calibration pressure 4.5 bar

CHAR - 4

OIL PUMP

Scavenge pump: 22 mm

BY-PASS

GP 800 i.e. Characteristics

OIL FILTER

Specification Desc./Quantity

Type Paper with pressure relief and anti-drain back by-

pass valves

OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH

Specification Desc./Quantity

Calibration 0.3 - 0.6 bar

HEAD LUBRICATION CONTROL JET

Specification Desc./Quantity

Diameter 1 ± 0.05 mm *

* Tightening torque 5÷7 N·m

PISTON COOLING NOZZLE

Specification Desc./Quantity

Diameter Ø 1 ± 0.05 mm

CRANKCASE VENTILATION CHECK

Specification Desc./Quantity

Device metal reed valve and decantation chamber

TECHNICAL SPECIFICATIONS

Specification Desc./Quantity

Cooling system capacity 2.4 l

Prescribed fluid AGIP PERMANENT SPEZIAL

Sealing pressure Cap calibrated at 0.9 bar

THERMOSTAT

Specification Desc./Quantity

Type Wax-type, with deviator

Starts opening 85±2°C

ELECTRIC VENTILATION

Specification Desc./Quantity

Type With piston Electric ventilation starts at 105°C Electric ventilation stops at 100°C

WATER PUMP

Specification Desc./Quantity

Type Centrifugal

Control Gear on oil delivery pump

RADIATOR

Specification Desc./Quantity

Type Aluminium, with horizontal circulation

CHAR - 5

Characteristics GP 800 i.e.

EXPANSION TANK

Specification Desc./Quantity

Calibration Automatic bleeding, in parallel with the radiator

Transmission

TRANSMISSION

Specification Desc./Quantity

Main drive Automatic expandable pulley variator with torque

server, V-belt, automatic dry self-ventilating

clutch.

Secondary reduction

Final transmission Chain-driven

Gear reduction unit in oil bath.

Capacities

CAPACITY

Specification Desc./Quantity

Engine oil 2.5 l (without oil filter replacement)

Transmission oil ~ ----- cm³

Cooling system fluid ~ 2.4 l

Fuel tank (reserve) ~14 l ± 0.5 l (~1.8 l)

Electrical system

ELECTRICAL SYSTEM

Specification Desc./Quantity

Start-up Electric

Ignition High efficiency electronic inductive ignition, inte-

Ignition advance Three-dimensional map managed by control unit

Spark plug NGK CR7EKB

Alternative spark plug -

Battery 12 V / 14 Ah, SEALED BATTERY

Generator Three-phase alternating current, 450W.

There are two types of remote controls in the elec-

2.6 l (with oil filter replacement)

grated with the injection system, with variable ad-

vance and separate HV coil.

trical system, those operating as "circuit breakers" «A», and those operating as a "switches" «B».

CHAR - 6

GP 800 i.e. Characteristics

CHECKING REMOTE CONTROLS «A» OPERATING AS CIRCUIT BREAKERS

1) Check that, given regular conditions, there is no continuity between terminals 30 and 87.

2) Apply 12V voltage to power terminals 85 and 86 of the remote control.

3) With the remote control powered, check that there is continuity between terminals 30 and 87.

4) If these conditions are not fulfilled, the remote control is damaged and must be replaced.

CHECKING REMOTE CONTROLS «B» OPERATING AS SWITCHES

1) Check that, given regular conditions, there is no continuity between terminals 30 and 87 but that there is continuity between terminals 30 and 87a.

2) Apply 12V voltage to power terminals 85 and 86 of the remote control.

3) With the remote control powered, check that there is continuity between terminals 30 and 87. However, there must be no continuity between terminals 30 and 87a.

4) If these conditions are not fulfilled, the remote control is damaged and must be replaced.

To check buttons and switches make sure that, according to their position, the continuity of contacts is correct, as indicated in the following tables.

«MODE» BUTTON

CHAR - 7

Characteristics GP 800 i.e.

WINDSHIELD «UP» BUTTON

WINDSHIELD «DOWN» BUTTON

HELMET COMPARTMENT LIGHT BUTTON

HORN BUTTON

CHAR - 8

GP 800 i.e. Characteristics

STARTER BUTTON

LIGHT SWITCH

ENGINE STOP SWITCH

TURN INDICATOR SWITCH

CHAR - 9

Characteristics GP 800 i.e.

INTAKE AIR TEMPERATURE SENSOR

-10° = 9600 Ohm 0° = 5900 Ohm +10° = 3800 Ohm +20° = 2500 Ohm

-30° = 1700 Ohm

THROTTLE POSITION SENSOR

With the switch set to "ON" at a variable voltage between 0.7V and > 4V between pins 23 - 3 on engine-side wiring. Ground insulation of pins 29 - 32 - 3 on engine-side wiring

STEPPER MOTOR

Resistance engine-side connector between pins 19 - 9 ~ 51 Ohm Resistance engine-side connector between pins

18 - 17 ~ 51 Ohm

FUEL INJECTOR

Type: 4 holes Conicity of the nozzle: 24° Resistance at terminals: 13.7 ÷ 15.2 Ohm

CHAR - 10

GP 800 i.e. Characteristics

FUEL PUMP UNIT

Mechanical type pressure regulator operating at a pressure of 3 BAR Pump winding resistance: ~ 1,5 Ohm

REVOLUTION TIMING SENSOR Resistance between "+ and -" = 890 ± Ohm (pins 35 - 25 , engine-side wiring) Insulation between "+ and S" and between "- and S" (pins 35 - 34 and 25 - 34, engine-side wiring)

ENGINE TEMPERATURE SENSOR

0° = 5900 Ohm +10° = 3800 Ohm +20° = 2500 Ohm +30° = 1700 Ohm +80° = 300 Ohm

H.V. COIL

Primary winding resistance: 520 ÷ 620 mOhm Secondary resistance: 6830 ÷ 7830 Ohm

CHAR - 11

Characteristics GP 800 i.e.

MINIMUM OIL PRESSURE SENSOR

Normally closed switch Activation threshold: 0.3 - 0.6 bar With the engine off: continuity between terminal and ground

STATOR

Resistance between terminals: 0.2 ÷ 1 Ohm Terminal insulation from ground

Frame and suspensions

Specification Desc./Quantity

Chassis Double cradle with tubular and steel stamped

Front suspension Hydraulic telescopic fork, single plate, ø 41-mm

Front suspension travel 126 mm

Oil quantity for stem 295 ± 3 cm³

Unloaded spring length ----- mm

Rear suspension Single shock absorber that acts directly on the

Rear suspension travel 135 mm

Brakes

Specification Desc./Quantity

Front brake Ø 300-mm double disc brake with hydraulic control

Rear brake Ø 280-mm disc brake, with hydraulic servo oper-

FRAME AND SUSPENSIONS

plates

straight stems.

fork.

BRAKES

activated by the handlebar right-hand lever.

Two floating callipers, ø 28 double plunger

ated from the handlebar with the left-hand lever.

One floating calliper with a single plunger

CHAR - 12

GP 800 i.e. Characteristics

Wheels and tyres

WHEELS AND TYRES

Specification Desc./Quantity

Wheel rim type Light alloy rims.

Front rim 16'' x 3.50

Rear rim 15'' x 4.50

Front tyre Tubeless, 120/70 - 16" 57H

Rear tyre Tubeless, 160/60 - 15" 67H

Front tyre pressure (with passenger) 2.5 bar (-)

Rear tyre pressure (with passenger) 2.75 bar (-)

Tightening Torques

LUBRICATION

Name Torque in Nm

Engine oil drainage plug 21 ÷ 29

Bulkhead screws for oil pump housing cover 3 ÷ 4

Engine oil filter 12 - 16

Oil pump chain tensioner pad 2 ÷ 3

Oil pump screws 5 - 6

By-pass scavenge duct fixing screws 11 ÷ 13

Lubrication circuit upper bulkhead 3 ÷ 4

Oil pump crown screw 10 ÷ 14

Screws fixing oil pump to the crankcase 5 - 6

Minimum oil pressure sensor 10

Water pump gear fixing screw 5 - 6

THERMAL GROUP AND TIMING SYSTEM

Name Torque in Nm

Spark plug 12 ÷ 14

Head fixing stud bolts: ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts: 10 - 12

Head lubrication control jet 5 - 7

Tensioner sliding block fixing screw: 10 - 14

injector fixing screw 3 ÷ 4

inlet manifold fixing screws 11 - 13

Tappet cover fixing screws: 7 - 9

Throttle body fixing screws 11 ÷ 13

camshaft retaining bracket fixing screws 4 - 6

Head fixing screws 10 - 12

Coolant temperature sensor 21 ÷ 23 Revolution timing sensor fixing screw 7.5 ÷ 8.5 Timing system chain tensioner screw 11 ÷ 13

Timing system gear on camshaft screw 12 ÷ 14

*** Apply a preliminary torque of 10 Nm in a criss-crossed sequence. - tighten with a torque of 13 Nm + 90° in a criss-crossed sequence. - tighten again by 90° in a criss-crossed sequence.

TRANSMISSION COVER

Name Torque in Nm

Drive pulley nut 252 ÷ 278

CHAR - 13

Characteristics GP 800 i.e.

Name Torque in Nm

Driven pulley nut 153 ÷ 187

Clutch ring nut 65 - 75

External transmission cover screws 5 ÷ 7

Internal transmission cover screws 11 ÷ 13

Air switch screw 3 ÷ 4

Air outlet grille screws 3 ÷ 4

FLYWHEEL COVER

Name Torque in Nm

Flywheel fixing nut 116 ÷ 128

Stator retainers 8 - 10

Screw fixing freewheel to flywheel 13 ÷ 15

Flywheel cover screws 11 - 13

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Starting ring gear retaining plate 3 ÷ 4 Engine crankcase coupling screws (M6) 11 ÷ 13 Engine crankcase coupling screws (M8) 25 ÷ 28

COOLING

Name Torque in Nm

Water pump rotor cover 3 ÷ 4

bleed screw 3 ÷ 4

Water pump impeller 4 ÷ 5

Screws tightening water pump gear protection

plate

3 ÷ 4

CHASSIS

Name Torque in Nm

Side stand bolt nut 37

Screws fixing side stand button 6

Screw fixing electric fan - radiator 2 ÷ 3

Screw fixing radiator - chassis 5 ÷ 7

Nut fixing silent-block plate - chassis 22 ÷ 25

Nut fixing silent-block plate 33 ÷ 41

Pin fixing nut - M14 124 ÷ 153

Pin fixing nut - M10 47 ÷ 52 Upper nut fixing engine support link rods - chassis 33 ÷ 41 Lower nut fixing engine support link rods - chassis 33 ÷ 41

Nut fixing head - exhaust manifold 16 ÷ 18

Centre stand front bolt nut 34 ÷ 39

Centre stand rear bolt nut 74 ÷ 81

Screw fixing silencer - muffler support arm 11

Screw fixing catalytic converter - catalytic convert-

er support

Screw fixing muffler support arm - engine 24 ÷ 27

Silencer fixing screw 22

Manifold retainer clamp 16 ÷ 18

22 ÷ 24

CHAR - 14

GP 800 i.e. Characteristics

PINION UNIT

Name Torque in Nm

Screw for plate locking pinion driving bushing 4 ÷ 6*

Screws fixing pinion unit cover 4 ÷ 5*

Screws fixing pinion unit - chassis 50

Pinion unit oil drain screw 13 ÷ 15

Pinion unit oil filling screw 13 ÷ 15

Oil sealing casing clamp 3 ÷ 5

(*) Apply LOCTITE 243 threadlock

HANDLEBAR

Name Torque in Nm

Screws fixing handlebar supporting plate - steer-

ing tube

Screws fixing frame - supporting plate 4.5 ÷ 7

Screws fixing half-handlebars - supporting plate 20 ÷ 25*

Screw fixing half-handlebar insert - half-handlebar 20 ÷ 25*

Handlebar cover fixing screw 2.5 ÷ 4

Brake pump stand fixing screws 7 ÷ 10

(*) Apply LOCTITE 243 threadlock

50 ÷ 55

MISCELLANEOUS

Name Torque in Nm

starter motor retainers 11 - 13

BRAKE SYSTEM

Name Torque in Nm

Brake pipes / rear brake calliper coupling 20 ÷ 25

Brake pipes / brake pump coupling 16 ÷ 20

Screws fixing front brake disc to rim 25

Screws fixing rear brake disc to rim 25

Screws fixing brake pump to handlebar 7 ÷ 10

Screw fixing three-way union to fork head 10 ÷ 12

Screws fixing front brake calliper to fork 20 ÷ 25

Screw fixing rear brake calliper to supporting plate 20 ÷ 25

Screw fixing parking brake calliper to supporting

plate

Brake calliper bleed screw 4 ÷ 7

Parking brake adjusting nut 10

Nut fixing rear brake pipe retaining clip 11 ÷ 13

Pin fixing parking brake pads 15 ÷ 20

Brake pipes / three-way union coupling 18 ÷ 23

Brake pipes / front brake calliper coupling 16 ÷ 20

Rear brake pad fixing pins 15 ÷ 20

24 ÷ 27

FRONT SUSPENSION

Name Torque in Nm

Screw fixing wheel pin on right fork leg 6 ÷ 7

Front wheel pin nut 60 ÷ 70

Hydraulic rod fixing screw 25 ÷ 35*

Fork locking screws cap 35 - 55

Stem support clamp tightening screws 20 ÷ 25

CHAR - 15

Characteristics GP 800 i.e.

Name Torque in Nm

Steering tube lower ring nut 20 ÷ 22

Steering tube upper ring nut 48 ÷ 54

(*) Apply LOCTITE 243 threadlock

REAR SUSPENSION

Name Torque in Nm

Nut fixing shock absorber - fork 38 - 46

Screw fixing shock absorber - fork 38 - 46

Screw fixing chain stop slider - fork 5 ÷ 7

Screw fixing centre stand stop buffer - fork 5 ÷ 7

Crown fixing screws 22.5 ÷ 27.5*

Rear wheel pin nut 70

Fork locking ring nut 60 ± 3 Nm

Fork pin set screw 0.5

Fork pin nut 90 ± 5

(*) Apply LOCTITE 243 threadlock

Overhaul data

Assembly clearances

Cylinder - piston assy.

CHAR - 16

GP 800 i.e. Characteristics

HEIGHT TO MEASURE THE PISTON

Specification Desc./Quantity

A 10 mm B 43 mm

CYLINDER - PISTON

Specification Desc./Quantity

Cylinder diameter C 88 +0.018-0.01 mm

Piston Ø P 87.968 ±0.014 mm

COUPLING CATEGORIES

Name Initials Cylinder Piston Play on fitting

Cylinder- Piston A 87.990÷87.997 87.954÷87.961 0.029÷0.043 Cylinder- Piston B 87.997 ÷ 87.004 87.961 ÷ 87.968 0.029÷0.043 Cylinder- Piston C 88.004÷88.011 87.968÷87.975 0.029÷0.043 Cylinder- Piston D 88.011÷88.018 87.975 ÷ 87.982 0.029÷0.043

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

- Calculate the coupling clearance between pin and connecting rod end.

Characteristic

Standard clearance:

0.015 ÷ 0.029 mm

- Measure the capacity diameter on the piston.

Characteristic

Standard diameter:

22 + 0.006 + 0.001 mm

- Calculate the piston pin coupling clearance.

N.B.

THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT MUST BE MADE ACCORDING TO THE PISTON AXIS.

Characteristic

Standard clearance:

0.001 ÷ 0.010 mm

CHAR - 17

Characteristics GP 800 i.e.

- Check that coating is free from flakes.

- Check that the head matching surface exhibits no deformations or wear.

Characteristic

Maximum allowable run-out:

0.05 mm

- Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).

Piston rings

*Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the openings in the rings as shown here. ***Value «A» of sealing ring inside the cylinder.

Check the size of the sealing ring opening: Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm

CHAR - 18

GP 800 i.e. Characteristics

Rings/housing coupling clearances:

Carefully clean the sealing ring housings. Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances.

Top ring Standard coupling clearance:

0.01÷0.06 mm Maximum clearances allowed after use: 0.10 mm

Intermediate ring Standard coupling clearance:0.02÷0.07 mm Maximum clearances allowed after use: 0.10

mm Oil scraper ring Standard coupling clearance:

0.01÷0.06 mm Maximum clearances allowed after use: 0.10 mm Replace the piston if clearances exceed the maximum limits specified in the table.

Crankcase - crankshaft - connecting rod

Diameter of crankshaft bearings.

Measure the capacity on both axes x-y.

CHAR - 19

Characteristics GP 800 i.e.

CRANKSHAFT

Specification Desc./Quantity

Cat. 1 Standard diameter: 45.010 ÷ 45.016 Cat. 2 Standard diameter: 45.016 ÷ 45.022

Crankshaft alignment

Specific tooling

020335Y Magnetic support for dial gauge

CHAR - 20

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

GP 800 i.e. Characteristics

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Half-shaft, trans-

mission side

Flywheel-side half-

shaft

Connecting rod 22 -0.10 - 0.15 C D = 0.20 ÷ 0.55

Complete crank-

shaft

23.8 +0.1 A D = 0.20 ÷ 0.55

23.8 + 0.1 B D = 0.20 ÷ 0.55

91.8 +0.05 E D = 0.20 ÷ 0.55

Characteristic

Crankshaft-crankcase axial clearance (H)

CHAR - 21

Characteristics GP 800 i.e.

0.1 ÷ 0.45 mm (when cold)

- Using a bore gauge, measure the connecting rod small end diameter.

N.B.

IF THE CONNECTING ROD SMALL END DIAMETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT.

Characteristic

Standard diameter:

22 + 0.025 +0.015 mm

- Check the inside diameter of the main bushings in the three directions indicated in the diagram.

- Repeat the measurements for the other bushing half. see diagram.

N.B.

DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.

Before assembling, check that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits.

Characteristic

Crankshaft-bushing maximum clearance admitted:

0.08 mm

- The standard bushing diameter after driving is variable on the basis of a coupling selection.

- The bushing seats in the crankcase and the crankshaft are classified into 2 categories.

- Bushings are subdivided into 3 categories according to their thickness (see the table). The following kinds of bushings indicated in the table must be used according to the kind of coupling

between the crankshaft and the crankcase.

CHAR - 22

GP 800 i.e. Characteristics

KEY X = Crankshaft category Y = Crankcase half-shell category A = Red B = Blue C = Yellow

Cylinder Head

Before performing head service operations, thoroughly clean all coupling surfaces. Note the position of the springs and the valves so as not to change the original position during refitting

- Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted.

Characteristic

Maximum allowable run-out:

0.1 mm

- In case of irregularities, replace the head.

- Check the sealing surfaces for the intake and exhaust manifold.

- Check that the camshaft and the rocker pin capacities exhibit no wear.

- Check that the head cover surface is not worn.

- Check that the coolant sealing pad exhibits no oxidation.

CHAR - 23

Characteristics GP 800 i.e.

- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust valves.

- The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.

Measure the camshaft bearing seats and rocking lever support pins with a bore meter

Specification Desc./Quantity

Bearing "A" 42 +0.025 Bearing "B" 19.5 -0.2

Bearing "C" 13 +0.018

- Measure the unloaded spring length.

Characteristic

Standard length:

44.4 mm

Admissible limit after use:

42.4 mm

HEAD BEARINGS

CHAR - 24

+ 401 hidden pages