Gilera Gp 800 Service manual

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SERVICE STATION MANUAL

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

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

(EL)

GP 800 i.e.

Page 2

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)

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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.

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Page 5

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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

Page 8

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

Page 9

GP 800 i.e. Characteristics

Vehicle identification

Chassis prefix (A):

ZAPM55100

Engine prefix (B):

M554M

Dimensions and mass

CHAR - 3

Page 10

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

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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

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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

Page 13

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

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Characteristics GP 800 i.e.

WINDSHIELD «UP» BUTTON

WINDSHIELD «DOWN» BUTTON

HELMET COMPARTMENT LIGHT BUTTON

HORN BUTTON

CHAR - 8

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GP 800 i.e. Characteristics

STARTER BUTTON

LIGHT SWITCH

ENGINE STOP SWITCH

TURN INDICATOR SWITCH

CHAR - 9

Page 16

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

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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

Page 18

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

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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

Page 20

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

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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

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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

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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

Page 24

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

Page 25

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

Page 26

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

Page 27

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

Page 28

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

Page 29

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

Page 30

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

Page 31

GP 800 i.e. Characteristics

- Clean the valve seats of any carbon residues.

- Using the Prussian blue, check the width of the impression on the valve seat "V".

Characteristic

Standard value:

1 - 1.3 mm

Admissible limit:

1.6 mm

- If the impression width on the valve seat is larger than the prescribed limits, true the seats with a 45° mill and then grind.

- In case of excessive wear or damages, replace the head.

STANDARD VALVE LENGTH

Specification Desc./Quantity

Inlet: 95.0 ± 0.3 mm

Outlet: 94.2 ± 0.3 mm

- Measure the diameter of the valve stems in the three positions indicated in the diagram.

STANDARD DIAMETER

Specification Desc./Quantity

Inlet: 4.987 - 4.972 mm

Outlet: 4.975 - 4.960 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity

Inlet: 4.96 mm

Outlet: 4.945 mm

CHAR - 25

Page 32

Characteristics GP 800 i.e.

- Calculate the clearance between valve and valve guide.

- Check the deviation of the valve stem by resting it on a "V" shaped abutment and measuring the extent of the deformation with a comparator.

Characteristic

Limit values admitted:

0.1 mm

- Check the concentricity of the valve head by arranging a comparator at right angle relative to the valve head and rotate it on a "V" shaped abutment.

Characteristic

Admissible limit:

0.03 mm

Measure the valve guide.

Characteristic

Valve guide:

5 +0.012 mm

CHAR - 26

Page 33

GP 800 i.e. Characteristics

- After measuring the valve guide diameter and the valve stem diameter, check the clearance between guide and stem.

OUTLET

Specification Desc./Quantity

Standard clearance: 0.025 ÷ 0.052 mm

Admissible limit: 0.09 mm

INLET

Specification Desc./Quantity

Standard clearance: 0.013 - 0.04 mm

Admissible limit: 0.08 mm

- Check that there are no signs of wear on the surface of contact with the articulated register terminal.

- If the checks above give no failures, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping compound. During the grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem and the guide (see figure).

CAUTION

TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.

CAUTION

CHAR - 27

Page 34

Characteristics GP 800 i.e.

DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).

- Check that the camshaft ends exhibit no scores or irregular wear.

- Using a micrometer, measure the camshaft capacity.

STANDARD DIAMETER

Specification Desc./Quantity

Bearing A Ø: 42 - 0.060 -0.085 mm

Bearing B diameter: 20 - 0.020 -0.041 mm

MINIMUM ADMISSIBLE DIAMETER

Specification Desc./Quantity

Bearing A Ø: 41.910 mm

Bearing B diameter: 19.940 mm

-Using a gauge, measure the cam height.

STANDARD HEIGHT

Specification Desc./Quantity

intake 33.988 mm

discharge 33.417 mm

ADMISSIBLE LIMITS

Specification Desc./Quantity

intake 33.740 mm

discharge 33.170 mm

Standard axial clearance: 0 - 0.22 mm

Maximum admissible axial clearance: 0.3 mm

- Check that the cam contact sliding block and the articulated register plate is free from wear.

- In case of wear, replace the component.

CHAR - 28

Page 35

GP 800 i.e. Characteristics

- Check that the rocking lever pins exhibit no scores or wear.

Characteristic

Standard diameter:

13 - 0.010 -0.018 mm

- Measure the inside diameter of each rocking lever.

Characteristic

Standard diameter:

13 + 0.026 +0.015 mm

Slot packing system

Shimming system to control compression ratio

DISTANCE «A» IS A PROTRUSION OR RECESS VALUE OF THE PISTON CROWN WITH RESPECT TO THE CYLINDER PLANE. DISTANCE «A» HELPS DETERMINE THE THICKNESS OF GASKET «B» THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE COMPRESSION RATIO. BASE GASKET «B» MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.

Characteristic

Compression ratio

10.5 ± 0.5 : 1

BASE GASKET THICKNESS

Name Measure A Thickness

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05 «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 ÷ + 0.185 0.8 ± 0.05

N.B.

VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.

N.B.

DISTANCE «A» MUST BE MEASURED WITHOUT ANY GASKET FITTED AT «B»

CHAR - 29

Page 36

Characteristics GP 800 i.e.

Products

See also

Refitting the timing chain

Spark plug

To replace the rear cylinder spark plugs:

- Tip the saddle forwards, undo the five screws «A» and remove cover «B».

- Disconnect caps «C» of the HV wire of the spark plugs.

- Unscrew the spark plugs using the wrench supplied.

- Upon refitting, place the spark plugs into the hole at the due inclination and tighten them by hand.

- Only use the wrench to lock spark plugs in place.

- Place caps «C» fully over the spark plugs.

- Refit cover «B».

CAUTION

SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD. SPARK PLUGS MAINTENANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE. USING NON-CONFORMING ELECTRONIC CENTRAL UNITS AND ELECTRONIC IGNITIONS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE.

N.B.

THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR OF SHIELDLESS SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEM FAILURES.

MAIN - 3

Page 52

Maintenance GP 800 i.e.

To replace the front cylinder spark plugs:

- Undo screw «D» and remove lid «E».

- Disconnect caps «F» of the HV wire of the spark plugs.

- Unscrew the spark plugs using the wrench supplied.

- Upon refitting, place the spark plugs into the hole at the due inclination and tighten them using the supplied spark plug wrench.

- Tighten the two spark plugs.

- Place caps «F» fully over the spark plugs.

- Refit the lid «E».

CAUTION

N.B.

THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR OF SHIELDLESS SPARK PLUG CAPS CAN CAUSE ELECTRICAL SYSTEM FAILURES.

Characteristic

Spark plug

NGK CR7EKB

Electrode gap

0.7 ÷ 0.9 mm

MAIN - 4

Page 53

GP 800 i.e. Maintenance

Air filter

- Rimuovere la copertura laterale telaio da entrambi i lati del veicolo.

- Rimuovere la copertura centrale anteriore.

- Operando dal lato destro del veicolo, svitare la vite indicata.

- Disimpegnare dalla fascetta di ritegno la tubazione blow-by.

- Operando dal lato sinistro del veicolo, svitare le sei viti indicate e rimuovere la fascetta di ritegno del manicotto.

- Rimuovere l'elemento filtrante dalla parte interna del depuratore aria.

- Sfilare la tubazione di recupero vapori blow-by.

MAIN - 5

Page 54

Maintenance GP 800 i.e.

- Rimuovere la parte esterna del depuratore aria.

- Disimpegnare da entrambi i lati del veicolo gli occhielli della molla di chiusura e rimuoverla.

- Ruotare la parte interna del depuratore aria in modo da disimpegnare l'incastro sul telaio.

- Rimuovere la parte interna del depuratore aria.

MAIN - 6

Page 55

GP 800 i.e. Maintenance

To access the air filter:

- Tip the saddle forwards, undo the five screws «A» and remove cover «B».

- Remove the battery compartment access cover «C» by undoing the four screws «D ».

- Remove the access cover to the cap of expansion tank «E» by undoing the four screws «F».

- Undo the two screws «G».

- Remove the central cover «H» holding it as shown in the figure and pulling it towards the rear part of the vehicle.

MAIN - 7

Page 56

Maintenance GP 800 i.e.

- Release clip «I» and remove the filter housing cover «L».

For filter cleaning:

- Hold the air filter upright and tap it several times on a clean cloth.

- If required, clean the air filter with a blast of compressed air (direct the air from the inside to the outside of the filter) opposite to the sense the air flow travels under regular operation.

- Clean the external side of the air filter with a clean cloth

- Remove the cap «M» regularly, drain the content into a container and send it to a recycling bank.

AIR DEFLECTOR FILTER

For filter removal:

- Remove the side fairings.

- Undo the three indicated screws and remove the air deflector.

MAIN - 8

Page 57

GP 800 i.e. Maintenance

- Remove the filter.

For filter cleaning:

- Wash the sponge with water and mild soap.

- Dry it with a clean cloth and short blasts of compressed air.

- Soak it in a mixture of 50% petrol and 50% specific oil.

- Gently squeeze the filtering element with your hands without wringing it; let it drip dry and then refit.

Recommended products

AGIP FILTER OIL Air filter

Mineral oil with specific tackifier additive ISO VG 150

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Replace oil and filter as indicated in the scheduled maintenance table.

In order to facilitate oil drainage, remove lid «A» and loosen the cap/dipstick «B».

MAIN - 9

Page 58

Maintenance GP 800 i.e.

The engine should be emptied by draining the oil through the drainage plug «C» placed under the engine crankcase.

Since a certain quantity of oil still remains in the circuit, refill with approx. 2600 cm³ of oil through the cap «A». The engine has a reference «G» indicating that the maximum oil level has been reached inside the crankcase. This reference must be used only when changing oil, whereas the cap/ dipstick «B» must be used when checking oil level. Then start up the vehicle, let it run for a few minutes and shut it off. After about 5 minutes, check the level and, if necessary, top-up but never exceeding the MAX level reference mark «G» sight glass on the right crankcase. For top-ups and oil changes, use new oil of the recommended type.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

Always check the oil level before carrying out top-ups. For topping-up:

- Unscrew and remove cap «B».

- Top up the oil in the reservoir until you reach the correct level.

MAIN - 10

Page 59

GP 800 i.e. Maintenance

- Pour oil in small quantities and wait until it is distributed throughout the engine before checking the level through the right crankcase sight glass «G». The oil must reach the "MAX oil level" reference mark on the corresponding sight glass «G» on the right crankcase.

WARNING

PROCEED TO TOP-UP WITH ENGINE OIL WHILE THE ENGINE IS WARM. DO NOT GO BEYOND THE "MAX" MARK ON THE CRANKCASE OR BELOW THE "MIN" LEVEL MARK ON THE DIPSTICK TO AVOID SEVERE ENGINE DAMAGE.

Check

For oil level check:

- Keep the vehicle perfectly upright, with both wheels on the ground.

- Remove cover «A» holding it and pulling it out.

- Unscrew the dipstick cap «B» and check that the oil level exceeds the «MIN» mark. In order to check oil level properly, keep the engine running for about 2 minutes and then wait at least 5 minutes once the engine is off.

MAIN - 11

Page 60

Maintenance GP 800 i.e.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. To access the oil cartridge filter:

- Remove mat «D».

- Undo the six screws «E» and remove the spoiler.

- Remove the cartridge filter «F» and fit a new one taking care to lubricate the sealing O-rings of the filter with engine oil.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

Oil pressure warning light

The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been started.

If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.

MAIN - 12

Page 61

GP 800 i.e. Maintenance

Checking the valve clearance

Front head

- Remove the plastic parts in order to free the head cover access.

- Undo the six fixing screws and remove the tappet cover together with the gasket.

- Check the valve clearance, and if necessary, restore the correct clearance.

Characteristic

Valve clearance

Inlet: 0.15 mm Outlet: 0.15 mm

See also

Side fairings Air filter

Rear head

- Remove the plastic parts in order to free the head cover access.

- Undo the six fixing screws and remove the tappet cover together with the gasket.

- Check the valve clearance, and if necessary, restore the correct clearance.

Characteristic

Valve clearance

Inlet: 0.15 mm Outlet: 0.15 mm

See also

Helmet bay

- According to the procedure described in the «Engine Chapter» fit the tappet cover.

See also

Refitting the rocker-arms cover

MAIN - 13

Page 62

Maintenance GP 800 i.e.

Cooling system

Check coolant when the engine is cold as indicated in the scheduled maintenance table. To check:

- Rest the vehicle upright on the stand, undo the four screws «A» and remove cover «B» partially.

- The fluid level should always be between the «MIN» and «MAX» level marks indicated on the knee-guard panel.

- If the coolant level is close to the minimum mark «MIN», top-up when the engine is cold.

CAUTION

THE RECOMMENDED COOLANT MUST BE USED FOR TOP-UPS TO AVOID DAMAGING THE ENGINE.

Recommended products

AGIP PERMANENT SPEZIAL coolant

Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 (*)

Braking system

Level check

The front and rear brake fluid reservoirs are both positioned on the handlebars. Proceed as follows:

- Rest the vehicle onto the centre stand, with the handlebar centred.

- Check the fluid through the specific sight glass.

- Top-up whenever the level is below the MIN reference «C» for the left reservoir, and reference «D» for the right reservoir.

MAIN - 14

Page 63

GP 800 i.e. Maintenance

A certain lowering of the level is caused by wear on the pads.

Top-up

- Undo screws «B» and remove the reservoir cap «A». Top-up using only the fluid specified, without exceeding the maximum level. This procedure applies to the rear brake pump topup operation; follow the same procedure for the front brake pump. Under standard climatic conditions, replace coolant as indicated in the scheduled maintenance table.

Recommended products

AGIP BRAKE 4 Brake fluid

FMVSS DOT 4 Synthetic fluid

Headlight adjustment

Proceed as follows:

- Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen;

- Turn on the headlight and check that the limit of the light beam projected on the screen is not higher than 9/10 or lower than 7/10 of the height of the centre of the headlight from the ground.

MAIN - 15

Page 64

Maintenance GP 800 i.e.

Adjustment:

- Undo screw «A» and remove the grille.

- Act on the screw «L». Turn it anticlockwise to raise the light beam and turn it clockwise to lower it.

Drive chain

To check the drive chain clearance:

- Stop the engine.

- Position the scooter on centre stand.

MAIN - 16

Page 65

GP 800 i.e. Maintenance

- Remove the chain guard.

- Act on the rear wheel so that a link notch matches point «A».

- Tighten the chain and check that the distance between the chain link lower notch and point «A» is 38 mm ± 2 mm.

- Rotate the wheel to check the vertical oscillation of the chain in other positions; clearance should remain constant for all the wheel rotation phases. Adjust the chain if clearance is uniform but out of the specified limit.

To adjust the drive chain clearance:

- Loosen the wheel axle lock nut «B».

- Loosen the two screws «C» on both sides.

- Insert a pin through the holes on the planetary gears supporting the axle and rotate them to obtain the ideal chain tension. There are references on the planetary gears supporting the axle, proceed so that the reference indicated is the same on both sides of the fork.

Drive chain cleaning

Do not wash the chain with water jets, vapour jets, high-pressure water jets and highly flammable solvents. Wash the chain with fuel oil or kerosene. Maintenance operations should be more frequent if there are signs of early rust. Lubricate the chain with a recommended product whenever necessary after washing and drying it.

Recommended products

AGIP CHAIN SPRAY Spray lubricating grease

MAIN - 17

Page 66

Maintenance GP 800 i.e.

Spray lubricating grease for chains and gears

PINION UNIT

The pinion unit oil should be checked and changed as indicated in the scheduled maintenance table. The oil level should never be below the "MAX" reference mark indicated in the figure. Otherwise:

- Undo screw «D».

- Restore the level by adding recommended oil

with a syringe taking care not to exceed the "MAX" reference mark indicated in the figure.

WARNING

DO NOT EXCEED THE "MAX" LEVEL WHEN TOPPING UP.

Recommended products

AGIP ROTRA MP 80W-90 Transmission oil

SAE 80W-90, API GL-5

- Tighten the drain screw to the prescribed torque.

Locking torques (N*m)

Pinion unit oil filling screw 13 ÷ 15

MAIN - 18

Page 67

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

Page 68

Troubleshooting GP 800 i.e.

This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTION

Possible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace

the valves

Misshapen/worn valve seats Replace the head assembly

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston

rings

Worn or broken piston rings or piston rings that

have not been fitted properly

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the cou-

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Replace the piston cylinder unit or just the piston

rings

pling seal

Insufficient lubrication pressure

POOR LUBRICATION PRESSURE

Possible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Care-

Oil pump with excessive clearance Perform the dimensional checks on the oil pump

Oil filter too dirty Replace the cartridge filter

Oil level too low Restore the level adding the recommended oil

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch Check that there is no grease on the masses.

Check that the clutch mass contact surface with

the casing is mainly in the centre with equivalent

characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anom-

fully clean the By-Pass area.

components

type

alous way

TROUBL - 2

Page 69

GP 800 i.e. Troubleshooting

Insufficient braking

INEFFICIENT BRAKING SYSTEM

Possible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the

brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace

brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump

seals, replace

Brake disc slack or distorted Check the brake disc screws are locked; measure

the axial shift of the disc with a dial gauge and with

wheel mounted on the scooter.

Brakes overheating

BRAKES OVERHEATING

Possible Cause Operation

Defective sliding of pistons Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial

gauge and a wheel mounted on the vehicle to

measure the axial shift of the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or glued rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENING

Possible Cause Operation

Steering hardening Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

if they are recessed or if the balls are squashed,

replace them.

Excessive steering play

EXCESSIVE STEERING CLEARANCE

Possible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring

nuts. If irregularities continue in turning the steer-

ing even after making the above adjustments,

check the seats in which the ball bearings rotate:

TROUBL - 3

Page 70

Troubleshooting GP 800 i.e.

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.

TROUBL - 4

Page 71

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

Page 72

Electrical system GP 800 i.e.

1. Immobilizer decoder

2. Immobilizer aerial

3. Magneto flywheel

4. Roll-over sensor

5. Diagnostics socket

6. Resistance 120 Ohm - 2W

7. 1A diode

8.Stand button

9. 1A diode

10. Resistance 120 Ohm - 2W

11. Engine stop switch

12. 40A fuse

13. Voltage regulator

14. Main fuses

15. Main relay

16. Key switch contacts

17. Start-up remote control switch relay

18. Start-up maintenance relay

19. 1A diode

20. Key switch contacts

ELE SYS - 2

Page 73

GP 800 i.e. Electrical system

21. Auxiliary fuses

22. 12V - 14Ah battery

23. Starter motor

24. Start-up remote control switch

25. Starter button

26. Resistance 120 Ohm - 2W

27. 1A diode

28. 1A diode

29. Saddle opening actuator

30.GPS wiring

31. LV coil - max.180W

32. Saddle opening receiver

33. Pre-installation for antitheft device

34. Turn indicator switch

35. Stop button on rear brake

36. Stop button on front brake

37. Turn indicator control device

38. Light switch

39. Helmet compartment light bulb

40. License plate bulb

41. Rear left turn indicator bulb

42. Rear light A. Stop light LEDs B. Rear position light LEDs

43. Rear right turn indicator bulb

44. Front left turn indicator bulb

45. Headlight A. Front position light bulb B. Low-beam light bulb C. High-beam light bulb

46. Front right turn indicator bulb

47. MODE button

48. Instrument panel

49. Vehicle speed sensor

50. Barometric pressure sensor

51.Electronic ignition device (Engine connector)

52. Front cylinder HV coil

53. Rear cylinder HV coil

ELE SYS - 3

Page 74

Electrical system GP 800 i.e.

54. Electronic ignition device (Vehicle connector)

55. Front cylinder fuel injector

56. Rear cylinder fuel injector

57. Electric fan relay

58. Electric fan

59. Wiring for accessories

60. Horn button

61. Horn

62. Helmet compartment light switch

63. Windshield DOWN button

64. Windshield UP button

65. Windshield limit switch

66. Windshield limit switch

67. Low-beam light relay

68. High-beam light relay

69. Resistance 120 Ohm - 2W

70. Hand brake

71. Fuel level transmitter

72. Windshield motor

73. Windshield relay

74. Windshield relay

75. Injection load relay

76. Fuel pump

77. Engine temperature sensor

78. Lambda probe

79. Throttle valve potentiometer

80. Air temperature sensor

81. Idle speed regulator

82. Revolution sensor

83. Monostable

84. External temperature sensor

85. Oil pressure sensor Key

Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

ELE SYS - 4

Page 75

GP 800 i.e. Electrical system

Components arrangement

1. Pre-installation for antitheft device : to reach it,

remove the front shield.

2. Wiring for accessories: to reach it, remove the front shield.

ELE SYS - 5

Page 76

Electrical system GP 800 i.e.

3. Saddle opening receiver: to reach it, remove the front shield.

4. Control unit: to reach it, remove the front shield.

5. Barometric pressure sensor: to reach it, remove

the front shield.

6. Turn indicator control device: to reach it, remove the front shield.

ELE SYS - 6

Page 77

GP 800 i.e. Electrical system

7. Diagnostics socket: to reach it, remove the bat-

tery cover.

8. Battery: to reach it, remove the battery cover.

Characteristic

Battery

12 V / 14 Ah, SEALED BATTERY

9. Remote controls: to reach them, remove the front shield.

KEY A. Electric fan relay B. Start-up remote control switch relay C. Main relay D. Injection load relay E. Start-up maintenance relay F. Low-beam light relay G. High-beam light relay H. Start-up remote control switch I-L. Windshield relay M. Electric control management device

10. Fuses: to reach it, remove the battery cover.

ELE SYS - 7

Page 78

Electrical system GP 800 i.e.

11. Front Cylinder HV coil: to reach it, remove the left fairing;

12. Stand button: to reach it, remove the left footrest.

13. Rear Cylinder HV coil: to reach it, remove the right fairing.

14. Fuel level transmitter: to reach it, remove the right fairing.

Electric characteristic

Full tank position

<= 5 Ohm

Empty tank position

98 ± 5 Ohm

ELE SYS - 8

Page 79

GP 800 i.e. Electrical system

15. Plug socket: to reach it, open the helmet com-

partment.

Electric characteristic

Plug socket

12 V - 180 W MAX

16. Immobilizer aerial: to reach it, remove the shield back plate.

17. Immobilizer decoder: to reach it, remove the front shield.

18. GPS wiring: to reach it, remove the handlebar central cover.

ELE SYS - 9

Page 80

Electrical system GP 800 i.e.

19. Windshield motor: to reach it, remove the front shield.

20. Roll-over sensor: to reach it, remove the front shield.

21. Voltage regulator: to reach it, remove the front shield.

Electric characteristic

Control voltage

14 ÷ 14.7 V at 1000÷8000 rpm

22. Horn: to reach it, remove the front shield.

Ground points

There are three ground points in the electrical system:

ELE SYS - 10

Page 81

GP 800 i.e. Electrical system

A. Located on the left part of the chassis. To reach

it, remove the shield back plate.

B. Located on the control unit in the front part of the vehicle. To reach it, remove the front shield.

C. Located on the engine in the right part of the vehicle. To reach it, remove the right side fairing.

ELE SYS - 11

Page 82

Electrical system GP 800 i.e.

Instrument panel

KEY A = Immobilizer / antitheft LED B= Speedometer with twin scale (km/h and mph) C = CLOCK switch D = Digital display E= SET switch F= Rpm indicator G = Fuel gauge H = Warning light for parking brake engaged I = Engine control telltale light and injection system failure warning light L = Low fuel warning light M = Engine stop warning light N= Turn indicator warning light O = Low oil pressure warning light P = High-beam warning light

ELE SYS - 12

Page 83

GP 800 i.e. Electrical system

Electrical system installation

Front side

1. Remote control unit

2. To the left turn indicator

3. To the regulator

4. HV coil

5. To the side stand switch

6. Engine wire unit

7. Ground point

8. To the battery

9. Start-up remote control switch

10.Remote control switches - electric windshield switches

ELE SYS - 13

Page 84

Electrical system GP 800 i.e.

1. Saddle opening actuator

2. To the right control unit on the handlebar

3. Voltage regulator

4. To the right turn indicator

5. Snail horn

6. Electric fan connection

7. Starter motor cable

8. Regulator - flywheel connector

9. Parking brake switch

10.To the left control unit on the handlebar

11.GPS wiring

12.To the immobilizer aerial

13.Immobilizer ECU

14.Saddle opening receiver

ELE SYS - 14

Page 85

GP 800 i.e. Electrical system

1. Saddle opening receiver

2. To the right turn indicator

3. External temperature sensor

4. To the side stand switch

5. To the instrument panel

6. Remote control switches - electric windshield switches

7. Electric windshield motor

8. Injection electronic control unit

9. Overturn sensor

10.Connection between main system and the system on the engine

11.GPS wiring

12.Buttons control device on the handlebar

13.Turn indicator control device

14.To the battery negative

15.To the battery positive

16.Diagnostic socket for hand-held computer

ELE SYS - 15

Page 86

Electrical system GP 800 i.e.

17.Battery

18.Cable from engine control unit

19.Starter motor cable

20.Electric windshield motor cable

21.Chassis wire unit

22.Voltage regulator cable

Back side

1. To the license plate light

2. To the right turn indicator

3. To the fuel level transmitter

4. To the fuel pump

5. Rear cylinder HV coil

6. Ground point

7. Helmet compartment light switch

ELE SYS - 16

Page 87

GP 800 i.e. Electrical system

1. Helmet compartment light switch

2. Rear cylinder coil

3. Plug socket and helmet compartment light

ELE SYS - 17

Page 88

Electrical system GP 800 i.e.

1. Left turn indicator connection

2. To the left turn indicator

3. Fuel level transmitter

ELE SYS - 18

Page 89

GP 800 i.e. Electrical system

1. Plug socket for accessories

2. Helmet compartment light

3. Rear turn indicators

1. Air temperature sensor

2. Throttle valve sensor

ELE SYS - 19

Page 90

Electrical system GP 800 i.e.

3. Stepper motor

4. Rear cylinder fuel injector

5. Rpm timing sensor

6. Engine temperature sensor

7. To the front cylinder fuel injector

8. To the rear cylinder HV coil

9. Oil pressure sensor

10.To the voltage regulator

11.Starter motor cable

12.Rear cylinder fuel injector

13.To the front cylinder fuel injector

14.Speed sensor connector

15.Lambda probe connector

16.Lambda probe

Conceptual diagrams

Ignition

KEY

1. Immobilizer decoder

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GP 800 i.e. Electrical system

2. Immobilizer aerial

14. Main fuses

15. Main relay

16. Key switch contacts

19. 1A diode

21. Auxiliary fuses

22. 12V - 14Ah battery

48. Instrument panel

51.Electronic ignition device (Engine connector)

52.Front cylinder HV coil

53. Rear cylinder HV coil

54. Electronic ignition device (Vehicle connector)

75. Injection load relay

Battery recharge and starting

KEY

3. Magneto flywheel

6. Resistance 120 Ohm - 2W

7. 1A diode

8. Stand button

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Electrical system GP 800 i.e.

9. 1A diode

10. Resistance 120 Ohm - 2W

11. Engine stop switch

12. 40A fuse

13. Voltage regulator

14. Main fuses

15. Main relay

16. Key switch contacts

17. Start-up remote control switch relay

18. Start-up maintenance relay

19. 1A diode

21. Auxiliary fuses

22. 12V - 14Ah battery

23. Starter motor

24. Start-up remote control switch

25. Starter button

26. Resistance 120 Ohm - 2W

27. 1A diode

28. 1A diode

35. Stop button on rear brake

36. Stop button on front brake

42. Rear light A. Stop light LEDs

48. Instrument panel

54. Electronic ignition device (Vehicle connector)

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GP 800 i.e. Electrical system

Level indicators and enable signals section

KEY

14. Main fuses

15. Main relay

16. Key switch contacts

19. 1A diode

20. Key switch contacts

21. Auxiliary fuses

22. 12V - 14Ah battery

48. Instrument panel

49. Vehicle speed sensor

50. Barometric pressure sensor

51.Electronic ignition device (Engine connector)

54. Electronic ignition device (Vehicle connector)

55. Front cylinder fuel injector

56. Rear cylinder fuel injector

71. Fuel level transmitter

75. Injection load relay

77. Engine temperature sensor

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Electrical system GP 800 i.e.

78. Lambda probe

79. Throttle valve potentiometer

80. Air temperature sensor

81. Idle speed regulator

82. Engine rpm sensor

83. Monostable

84. External temperature sensor

85. Oil pressure sensor

Devices and accessories

KEY

4. Roll-over sensor

5. Diagnostics socket

14. Main fuses

15. Main relay

16. Key switch contacts

19. 1A diode

20. Key switch contacts

21. Auxiliary fuses

22. 12V - 14Ah battery

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GP 800 i.e. Electrical system

29. Saddle opening actuator

30.GPS wiring

31. LV coil - max.180W

32. Saddle opening receiver

33. Pre-installation for antitheft device

39. Helmet compartment light bulb

41. Rear left turn indicator bulb

43. Rear right turn indicator bulb

44. Front left turn indicator bulb

46. Front right turn indicator bulb

47. MODE button

48. Instrument panel

54. Electronic ignition device (Vehicle connector)

57. Electric fan relay

58. Electric fan

59. Wiring for accessories

60. Horn button

61. Horn

62. Helmet compartment light switch

63. Windshield DOWN button

64. Windshield UP button

65. Windshield limit switch

66. Windshield limit switch

70. Hand brake

72. Windshield motor

73. Windshield relay

74. Windshield relay

75. Injection load relay

76. Fuel pump

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Electrical system GP 800 i.e.

Lights and turn indicators

KEY

14. Main fuses

15. Main relay

16. Key switch contacts

19. 1A diode

20. Key switch contacts

21. Auxiliary fuses

22. 12V - 14Ah battery

34. Turn indicator switch

37. Turn indicator control device

38. Light switch

40. License plate bulb

41. Rear left turn indicator bulb

42. Rear light B. Rear position light LEDs

43. Rear right turn indicator bulb

44. Front left turn indicator bulb

45. Headlight

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GP 800 i.e. Electrical system

A. Front position light bulb B. Low-beam light bulb C. High-beam light bulb

46. Front right turn indicator bulb

48. Instrument panel

54. Electronic ignition device (Vehicle connector)

67. Low-beam light relay

68. High-beam light relay

69. Resistance 120 Ohm - 2W

Checks and inspections

This section is devoted to the checks on the electrical system components.

Immobiliser

The EMS system is independent from the immobilizer antitheft device. Its functions are:

- Start-up enabled by key recognition.

- Deterrent flashing.

The system consists of:

-EMS system control unit

- Decoder

- Aerial

- master key

- service key

- Deterrent and diagnosis LED

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Electrical system GP 800 i.e.

Virgin circuit

When control unit (ECU) and decoder are not programmed, the following conditions occur:

- Key switch set to «OFF»: Deterrent flashing inactive.

- Key switch set to «ON»: Ignition and injection disabled and LED on with solid light. When the key switch is set to "ON", the LED switches on as shown in the figure. The LED is turned on by the decoder.

Specific tooling

020460Y Scooter diagnosis and tester

To connect the diagnostic tester, open the battery inspection port and pull out the EMS diagnosis socket. Remove the protection cap and connect the tester terminal.

Power the diagnostic tester by connecting the terminals to the battery poles, or the specific connector to the socket inside the helmet compartment.

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GP 800 i.e. Electrical system

Set the switch to "ON" and select the diagnostic tester menu to the immobiliser function. Scroll the pages to display the control unit data.

N.B.

AN UNPROGRAMMED SYSTEM CANNOT BE DETECTED UPON FIRST FITTING, OR IN CASE THE DECODER AND THE CONTROL UNIT ARE REPLACED CONCURRENTLY.

The information will be as follows: Unprogrammed control unit «ON» Start-up disabled «ON» Key number Zero › 250

1 Replacing the small cylinder

- Remove the original master key transponder and install it on the master key of the new cylinder.

- Program the system again as described in the injection chapter.

2 Decoder replacement

When the decoder is replaced it is necessary to program the system again. Programming is indispensable for the engine start-up. (see injection chapter).

3 Control unit replacement

Programming is indispensable when the control unit is replaced to enable the engine start-up. In this case it is sufficient to switch to "ON" using the master key.

N.B.

THE SERVICE KEY IS NOT USED FOR PROGRAMMING.

- WHEN NOT PROGRAMMED, THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIAGNOSIS ON THE ENGINE.

4 Replacing or duplicating service keys

Keys can be duplicated using the blank keys and the original master key.

WITH MASTER KEY

When the key switch is set to "ON" and programming is performed normally, the LED switches on as shown in the figure. After the confirmation flash when switching to "ON", a number of flashes are emitted, equal to the number of keys used for programming.

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Electrical system GP 800 i.e.

WITH SERVICE KEYS

After the confirmation flash when switching to «ON», the LED remains off.

Switching from «ON» to «OFF» with programmed system causes the intermittent switching on of the LED, with an antitheft effect. This occurs with any key used for programming.

If the scooter is not used, the deterrent light stops automatically after 48 hours to prevent discharging the battery. A new 48-h cycle starts by switching from "OFF" to "ON" and "OFF" again.

Diagnostic codes

The LED indication is divided into 3 steps: 1st step: A flash: "ON" switching recognition 2nd step: Series of flashes: diagnosis code indication 3rd step: Steady light on or off: on = start-up disabled off = start-up enabled

Diagnostic code - 1 flash

Code 1 indicates a non-programmed system. If the code is still displayed after having carried out the programming procedure, repeat the procedure carefully observing the "ON" times of each key.

If the code is still displayed, proceed as follows:

- Disconnect the battery negative.

- Remove the control unit connector.

- Remove the main decoder connector.

N.B.

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Gilera Gp 800 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual