Gilera GP 800 i.e. Service Station 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.

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Page 1 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 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.
Page 3 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.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
GP 800 i.e. Characteristics 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 well- ventilated, using special extractors if necessary;...
Page 9 GP 800 i.e. Characteristics Vehicle identification Chassis prefix (A): ZAPM55100 Engine prefix (B): M554M Dimensions and mass CHAR - 3...
Page 10 GP 800 i.e. Characteristics 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°...
Page 11 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...
Page 12: Electrical System
GP 800 i.e. Characteristics EXPANSION TANK Specification Desc./Quantity Calibration Automatic bleeding, in parallel with the radiator Transmission RANSMISSION Specification Desc./Quantity Main drive Automatic expandable pulley variator with torque server, V-belt, automatic dry self-ventilating clutch. Secondary reduction Gear reduction unit in oil bath. Final transmission Chain-driven Capacities...
Page 13 GP 800 i.e. Characteristics CHECKING REMOTE CONTROLS «A» OPER- ATING 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.
Page 14 GP 800 i.e. Characteristics WINDSHIELD «UP» BUTTON WINDSHIELD «DOWN» BUTTON HELMET COMPARTMENT LIGHT BUTTON HORN BUTTON CHAR - 8...
Page 15 GP 800 i.e. Characteristics STARTER BUTTON LIGHT SWITCH ENGINE STOP SWITCH TURN INDICATOR SWITCH CHAR - 9...
Page 16 GP 800 i.e. Characteristics 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 >...
Page 17 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"...
Page 18 GP 800 i.e. Characteristics 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 FRAME AND SUSPENSIONS Specification Desc./Quantity...
Page 19: Wheels And Tyres
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)
Page 20: Table Of Contents
GP 800 i.e. Characteristics 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 ÷...
Page 21: Table Of Contents
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 Pinion unit oil drain screw 13 ÷ 15 Pinion unit oil filling screw 13 ÷...
Page 22: Assembly Clearances
GP 800 i.e. Characteristics 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...
Page 23 GP 800 i.e. Characteristics HEIGHT TO MEASURE THE PISTON Specification Desc./Quantity 10 mm 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 87.990÷87.997 87.954÷87.961...
Page 24 GP 800 i.e. Characteristics - 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).
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 Intermediate ring Standard coupling clear- ance:0.02÷0.07 mm...
Page 26 GP 800 i.e. Characteristics 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 MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 20...
Page 27 GP 800 i.e. Characteristics AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, trans- 23.8 +0.1 D = 0.20 ÷ 0.55 mission side Flywheel-side half- 23.8 + 0.1 D = 0.20 ÷ 0.55 shaft Connecting rod 22 -0.10 - 0.15 D = 0.20 ÷...
Page 28 GP 800 i.e. Characteristics 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 DIAM- ETER EXCEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PRO- CEED TO REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT.
Page 29: Cylinder Head
GP 800 i.e. Characteristics 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.
Page 30 GP 800 i.e. Characteristics - 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.
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°...
Page 32 GP 800 i.e. Characteristics - 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 ar-...
Page 33 GP 800 i.e. Characteristics - After measuring the valve guide diameter and the valve stem diameter, check the clearance be- tween 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:...
Page 34 GP 800 i.e. Characteristics 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:...
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 lev- Characteristic Standard diameter: 13 + 0.026 +0.015 mm Slot packing system Shimming system to control compression ratio DISTANCE «A»...
Page 36 GP 800 i.e. Characteristics Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil SPECIAL AGIP PERMANENT coolant Monoethylene glycol-based anti- fluid...
Page 37 INDEX OF TOPICS TOOL OOLING...
Page 38 GP 800 i.e. Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001330Y014 Tool for fitting steering seats 001330Y015 Tool for fitting steering seats 020004Y Punch for removing fifth wheels from headstock 020668Y Steering ring nut wrench 020306Y Punch for assembling valve seal rings...
Page 39 GP 800 i.e. Tooling Stores code Description 020431Y Valve oil seal extractor 020128Y Piston fitting band 020470Y Pin retainers installation tool 020475Y Piston position checking tool 020512Y Piston fitting fork 020478Y Punch for driven pulley roller cas- TOOL - 3...
Page 40 GP 800 i.e. Tooling 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 TOOL - 4...
Page 41 GP 800 i.e. Tooling Stores code Description 020664Y Flywheel side crankshaft fitting 020665Y Transmission side crankshaft fit- ting tip 020709Y Engine support 020460Y Scooter diagnosis and tester 020469Y Reprogramming kit for scooter diagnosis tester 020661Y Water pump overall seal replace- ment kit TOOL - 5...
Page 42 GP 800 i.e. Tooling Stores code Description 020663Y Water pump shaft oil seal punch 020193Y Oil pressure gauge 020434Y Oil pressure control fitting 020480Y Petrol pressure check set 020331Y Digital multimeter TOOL - 6...
Page 43 GP 800 i.e. Tooling Stores code Description 020648Y Single battery charger 002465Y Pliers for circlips 020621Y HV cable extraction adaptor 020330Y Stroboscopic light for timing con- trol 020335Y Magnetic support for dial gauge TOOL - 7...
Page 44 GP 800 i.e. Tooling Stores code Description 020262Y Crankcase splitting strip 001467Y007 Driver for OD 54 mm bearing 001467Y031 Bell 001467Y035 Belle for OD 47-mm bearings 001467Y002 Driver for OD 73 mm bearing 020329Y MityVac vacuum-operated pump TOOL - 8...
Page 45 GP 800 i.e. Tooling Stores code Description 020150Y Air heater support 020151Y Air heater 001467Y003 001467Y004 Lug / Taper pin 001467Y005 Screw 001467Y006 Pliers to extract 20 mm bearings 020467Y020 Pliers to extract 30 mm bearings TOOL - 9...
Page 46 GP 800 i.e. Tooling Stores code Description 001467Y001 Pliers to extract 25 mm Ø bear- ings 001467Y008 Pliers to extract 17 mm ø bear- ings 001467Y014 Pliers to extract ø 15-mm bear- ings 020357Y 32 x 35 mm adaptor 020358Y 37x40-mm adaptor 020359Y 42x47-mm adaptor...
Page 47 GP 800 i.e. Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020364Y 25-mm guide 020412Y 15 mm guide 020439Y 17 mm guide 020483Y 30 mm guide TOOL - 11...
Page 48 GP 800 i.e. Tooling Stores code Description 020654Y 35 mm guide 020662Y 50 mm guide 020376Y Adaptor handle 020667Y Wrench for fork pin adjustment ring nut 020632Y 22-mm Hexagonal spanner 020633Y Clamp for sealing ring driving of Kayaba 41-mm and Marzocchi 40-mm forks TOOL - 12...
Page 49 INDEX OF TOPICS MAIN AINTENANCE...
Page 50: Maintenance Chart
GP 800 i.e. Maintenance Follow these steps to reset the service icons: 1. With the key set to OFF, hold down the "SET" button and turn the key to ON : the "BELT" and "SERVICE" icons start flashing. 2. Push the "CLOCK" button for less than 1 second and the icons are displayed sequen- tially.
Page 51: Checking The Spark Advance
GP 800 i.e. Maintenance Km x 1000 1 5 1 ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Suspensions ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■...
Page 52 GP 800 i.e. Maintenance 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 sup- plied.
Page 53: Air Filter
GP 800 i.e. Maintenance Air filter - Rimuovere la copertura laterale telaio da entram- bi 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 tuba- zione blow-by.
Page 54 GP 800 i.e. Maintenance - Rimuovere la parte esterna del depuratore aria. - Disimpegnare da entrambi i lati del veicolo gli oc- chielli 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.
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 expan- sion tank «E»...
Page 56: Air Deflector Filter
GP 800 i.e. Maintenance - 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 com- pressed air (direct the air from the inside to the outside of the filter) opposite to the sense the air flow travels under regular operation.
Page 57: Engine Oil
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;...
Page 58 GP 800 i.e. Maintenance 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».
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.
Page 60: Engine Oil Filter
GP 800 i.e. Maintenance 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.
Page 61: Checking The Valve Clearance
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, re- store the correct clearance.
Page 62: Cooling System
GP 800 i.e. Maintenance Cooling system Check coolant when the engine is cold as indica- ted 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»...
Page 63: Headlight Adjustment
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 top- up operation;...
Page 64: Drive Chain
GP 800 i.e. Maintenance 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 Drive chain To check the drive chain clearance: - Stop the engine.
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 ±...
Page 66 GP 800 i.e. Maintenance 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" ref- erence mark indicated in the figure. Otherwise: - Undo screw «D».
Page 67 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 68 GP 800 i.e. Troubleshooting 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...
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.
Page 70: Noisy Suspension
GP 800 i.e. Troubleshooting 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;...
Page 71 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 72 GP 800 i.e. Electrical system 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.
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.
Page 74 GP 800 i.e. Electrical system 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.
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 GP 800 i.e. Electrical system 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.
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.
Page 78 GP 800 i.e. Electrical system 11. Front Cylinder HV coil: to reach it, remove the left fairing; 12. Stand button: to reach it, remove the left foot- rest. 13. Rear Cylinder HV coil: to reach it, remove the right fairing. 14.
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.
Page 80 GP 800 i.e. Electrical system 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.
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.
Page 82: Instrument Panel
GP 800 i.e. Electrical system Instrument panel 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...
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.
Page 84 GP 800 i.e. Electrical system 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.
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.
Page 86 GP 800 i.e. Electrical system 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.
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 GP 800 i.e. Electrical system 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 GP 800 i.e. Electrical system 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...
Page 91 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.
Page 92 GP 800 i.e. Electrical system 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.
Page 93 GP 800 i.e. Electrical system Level indicators and enable signals section 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.
Page 94 GP 800 i.e. Electrical system 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 4. Roll-over sensor 5.
Page 95 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.
Page 96 GP 800 i.e. Electrical system Lights and turn indicators 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.
Page 97 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.
Page 98 GP 800 i.e. Electrical system Virgin circuit When control unit (ECU) and decoder are not pro- grammed, 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.
Page 99 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.
Page 100 GP 800 i.e. Electrical system 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.
Page 101 GP 800 i.e. Electrical system TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER. 1- With a multimeter, check the continuity between pin 7 of the vehicle side connector control unit and pin 6 of the decoder connector. YES go to 3 NO go to 2 2 - Repair or replace the wiring.
Page 102 GP 800 i.e. Electrical system YES go to 5 NO go to 4 4 - Restore the connection and check the presence of the code 5 - Disconnect the aerial connector and check con- tinuity (8 ± 2 W). YES go to 7 NO go to 6 6 - Replace the aerial.
Page 103 GP 800 i.e. Electrical system Disconnect the connector and measure the resist- ance between coil pins. If values are correct, check wiring continuity. For the front cylinder coil: - Sky Blue cable between coil and pin 10 of the control unit engine-side connector. - Black-Green cable between coil connector and injection load remote control base.
Page 104 GP 800 i.e. Electrical system Battery recharge circuit The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive passing through the 40A protective fuse.
Page 105 GP 800 i.e. Electrical system Recharge system voltage check Look for any leakage 1) Access the battery by removing the specific compartment in the shield back plate. 2) Check that the battery does not show signs of losing fluid before checking the output voltage. 3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole (-) of the battery and the black cable and only then disconnect the black cable from the negative pole (-) of the battery.
Page 106: Starter Motor
GP 800 i.e. Electrical system Starter motor 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 14. Main fuses 15. Main relay 16.
Page 107 GP 800 i.e. Electrical system 27. 1A diode 28. 1A diode 35. Stop button on rear brake 36. Stop button on front brake 54. Electronic ignition device (Vehicle connector) WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
Page 108 GP 800 i.e. Electrical system 12) Check the continuity of the cable harness between fuse No. 9 and the engine stop switch (White- Black cable). Also check continuity between the latter (positive multimeter probe, Yellow-Green cable) and pin 27 of the control unit vehicle-side connector (negative probe, Green cable). 13) Check the contacts of the starter button, stop buttons, stand button and engine stop switch.
Page 109 GP 800 i.e. Electrical system If the horn does not work: 1) Check the working order of fuse No. 1. 2) Check contacts «A» and «B» of the key switch. 3) Check the main relay. 4) Check that the Brown-Black cable of the main relay is earthed.
Page 110 GP 800 i.e. Electrical system Turn signals system check 14. Main fuses 20. Key switch contacts 21. Auxiliary fuses 22. 12V - 14Ah battery 34. Turn indicator switch 37. Turn indicator control device 41. Rear left turn indicator bulb 43. Rear right turn indicator bulb 44.
Page 111 GP 800 i.e. Electrical system If turn indicators do not work: 1) Check the working order of bulbs. 2) Check the working order of fuse No. 4. 3) Check if there is voltage between pin 6 (Orange- Blue) and 9 (Black) of the turn indicator control device connector.
Page 112 GP 800 i.e. Electrical system 48. Instrument panel 71. Fuel level transmitter WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If faults are detected: 1) With a multimeter, check the resistance values between the White-Green cable and the Black ca- ble of the fuel level transmitter by moving the arm with the float.
Page 113 GP 800 i.e. Electrical system 12. 40A fuse 14. Main fuses 15. Main relay 16. Key switch contacts 19. 1A diode 20. Key switch contacts 21. Auxiliary fuses 22. 12V - 14Ah battery 35. Stop button on rear brake 36. Stop button on front brake 38.
Page 114 GP 800 i.e. Electrical system 4) Check the main relay 5) Check that the Brown-Black cable of the main relay is earthed. 6) With the key switch set to «ON», check if there is voltage between the Orange cable of the main relay and the ground connection.
Page 115 GP 800 i.e. Electrical system 2) Check the working order of fuse No. 1. 3) Check contacts «A» and «B» of the key switch. 4) Check the main relay. 5) Check that the main relay and ground Brown-Black cable is earthed. 6) With the key switch set to «ON», check if there is voltage between the Orange cable of the main relay and the ground connection.
Page 116 GP 800 i.e. Electrical system Specification Desc./Quantity Quantity: 2 Fuses The electrical system has twelve fuses distributed in two fuse boxes «A» and «B» to protect the dif- ferent installation circuits. They are placed inside the battery compartment and can be accessed by undoing the four screws «D»...
Page 117 GP 800 i.e. Electrical system Specification Desc./Quantity Protected circuits: Turn indicator control device. Live: Fuses No. 10-11-12. Fuse No. 5 Capacity: 7.5 A Protected circuits: Instrument panel. Fuse No. 6 Capacity: 5A Protected circuits: ECU, decoder. Fuse No. 7 Capacity: 15A Protected circuits:Low-beam light relay, high-beam light (via relay), low-beam light (via relay).
Page 118 GP 800 i.e. Electrical system 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery - Charge time: 5 h Specific tooling 020333Y Single battery charger 020334Y Multiple battery charger Cleaning the battery...
Page 119 GP 800 i.e. Electrical system -Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity - Charge time: 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h Remote controls check There are two types of remote controls in the elec-...
Page 120 GP 800 i.e. Electrical system However, there must be no continuity between ter- minals 30 and 87a. 4) If these conditions are not fulfilled, the remote control is damaged and must be replaced. Switches check To check buttons and switches make sure that, according to their position, the continuity of contacts is correct, as indicated in the following tables.
Page 121 GP 800 i.e. Electrical system STARTER BUTTON HORN BUTTON HELMET COMPARTMENT LIGHT BUTTON WINDSHIELD «DOWN» BUTTON ELE SYS - 51...
Page 122 GP 800 i.e. Electrical system WINDSHIELD «UP» BUTTON «MODE» BUTTON Electrical windshield check 14. Main fuses 20. Key switch contacts ELE SYS - 52...
Page 123 GP 800 i.e. Electrical system 21. Auxiliary fuses 22. 12V - 14Ah battery 63. Windshield DOWN button 64. Windshield UP button 65. Windshield limit switch 66. Windshield limit switch 72. Windshield motor 73. Windshield relay 74. Windshield relay If the windshield motor does not work: 1) Check fuse No.
Page 124 GP 800 i.e. Electrical system ENGINE CONTROL UNIT CONNECTOR 3. Throttle valve potentiometer (Orange-Sky Blue) 5. Engine temperature (Grey-Green) 9. Idle adjustment motor (Sky Blue-Yellow) 10. Cylinder 2 HV coil (Sky Blue) 13. Barometric pressure signal (Orange) 14. Air temperature sensor (White-Grey) 17.
Page 125 GP 800 i.e. Electrical system 24. Vehicle speed signal (Brown-Red) 27. Engine stop switch (Green) 28. Starter button (Grey-White) 32. Lambda probe (Grey-Red) 35. Roll-over sensor (Yellow) 38. Stand switch (White-Blue) INSTRUMENT PANEL CONNECTOR «A» 1. Vehicle speed signal (Brown-Red) 2.
Page 126 GP 800 i.e. Electrical system IMMOBILIZER DECODER CONNECTOR 2. Immobilizer warning light (Red-Green) 3. Battery positive (White-Red) 4. Ground (Black) 6. Control unit (Orange) 8. Live positive (White-Black) REAR CYLINDER HV COIL CONNECTOR 1. Injection load relay (Black-Green) 2. Control unit (Pink-Black) FRONT CYLINDER HV COIL CONNECTOR 1.
Page 127 GP 800 i.e. Electrical system FRONT CYLINDER INJECTOR CONNECTOR 1. Control unit (Blue) 2. Injection load relay (Black-Green) ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Left turn indicators (Pink) 2. Right turn indicators (White-Blue) 3. Ground (Black) 4. Battery positive (Blue) 5. Live positive (Yellow-Black) 6.
Page 128 GP 800 i.e. Electrical system GPS WIRING CONNECTOR 1. Ground (Black) 2. Live positive (Yellow-Red) WIRING FOR ACCESSORIES - CONNECTOR 1. Ground (Black) 2. Live positive (Purple-Black) VOLTAGE REGULATOR CONNECTOR 1. Battery positive (Red-Black) 2. Ground (Black) 3. Battery positive (Red-Black) 4.
Page 129 GP 800 i.e. Electrical system IDLE ADJUSTMENT MOTOR CONNECTOR 1. Control unit (Sky Blue-Red) 2. Control unit (Orange-Red) 3. Control unit (Sky Blue-Yellow) 4. Control unit (Sky Blue-Black) FUEL PUMP CONNECTOR 2. Ground (Black) 5. Injection load relay (Black-Green) FUEL LEVEL TRANSMITTER CONNECTOR 2.
Page 130 GP 800 i.e. Electrical system LAMBDA PROBE CONNECTOR 1. Control unit (White-Green) 2. Control unit (Grey-Red) 3. Control unit (Purple) 4. Injection load relay (Black-Green) AIR TEMPERATURE SENSOR CONNECTOR 1. Control unit (White-Grey) 2. Control unit negative (Sky Blue-Green) WATER TEMPERATURE SENSOR CONNEC- 1.
Page 131 GP 800 i.e. Electrical system ENGINE RPM SENSOR CONNECTOR 1. Control unit (White) 2. Control unit (Red) 3. Sensor shield (Black) THROTTLE SENSOR CONNECTOR 1. Control unit (Grey-Black) 2. Control unit (Brown-Yellow) 3. Control unit (Orange-Sky Blue) EXTERNAL TEMPERATURE SENSOR CON- NECTOR 1.
Page 132: Battery Replacement
GP 800 i.e. Electrical system ROLL-OVER SENSOR CONNECTOR 1. Control unit (Yellow) 2. Ground (Black) Remote seat opening The vehicle is equipped with a remote control to open the saddle. This remote control is supplied together with the keys and at the manufacturing stage, it has been programmed to work together with the ECU that control the opening device.
Page 133 GP 800 i.e. Electrical system Zeroing 1) Remove the front shield in order to reach the control unit that receives/ controls saddle opening. 2) A white cable, that comes from pin 3 of the con- trol unit, goes out from the wiring. Earth it at least 10 seconds in order to delete all the remote con- trols programmed and stored in the control unit.
Page 134 GP 800 i.e. Electrical system ELE SYS - 64...
Page 135 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 136 GP 800 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Support the vehicle adequately. - Remove the helmet compartment. - Remove the rear swingarm. - Undo the three screws indicated, collect the washers and remove the heat-protection cover.
Page 137 GP 800 i.e. Engine from vehicle - Unscrew the two retainers fixing the silencer to the muffler supporting arm. - Remove the silencer together with the gasket. - Remove the return springs of the centre stand. - Unscrew the nut fastening the rear pin. ENG VE - 3...
Page 138 GP 800 i.e. Engine from vehicle - Remove the stand rear pin and collect the wash- - Remove the centre stand plus the four bushings. - Unscrew the nut fastening the front pin. - Unscrew the front pin and collect the washer. - The attachment plate of the centre stand is now free.
Page 139 GP 800 i.e. Engine from vehicle - The stand fixing pins also fasten the muffler sup- porting bracket. - Undo the upper screw fixing it to the engine, and the muffler supporting arm is now free. - Release the muffler supporting arm from the cat- alytic converter.
Page 140 GP 800 i.e. Engine from vehicle - Undo the three screws indicated and remove the rear exhaust manifold cover. - Unscrew the two nuts fixing the rear exhaust manifold. - Loosen the clamp by undoing the screw indica- ted. - Disconnect the lambda probe connector. ENG VE - 6...
Page 141 GP 800 i.e. Engine from vehicle - Undo the screw fixing the catalytic converter to the supporting bracket to the engine. - The catalytic converter is now free. - Release the attachment plate of the centre stand. - Remove the catalytic converter. - Remove rear exhaust manifold together with the gasket and the graphite bushing.
Page 142: Nut Fixing Head - Exhaust Manifold
GP 800 i.e. Engine from vehicle KEY: A: Nut fixing head - exhaust manifold B: Centre stand front bolt nut C. Centre stand rear bolt nut D: Screw fixing silencer - muffler support arm E: Screw fixing catalytic converter - catalytic converter support F: Screw fixing muffler support arm - engine G: Manifold retainer clamp H:Silencer fixing screw...
Page 143 GP 800 i.e. Engine from vehicle Removal of the engine from the vehicle REMOVAL - Support the rear part of the vehicle adequately. - Remove the helmet compartment and the side cases. - Remove the external air cleaner. - Get a container of suitable capacity and empty the cooling system;...
Page 144 GP 800 i.e. Engine from vehicle - Disconnect the blow-by intake pipes from the fil- ter housing. - Remove the spark plug tubes. - Unscrew the nut and disconnect the positive from the starter motor. - Disconnect the engine minimum oil pressure sen- sor connector.
Page 145 GP 800 i.e. Engine from vehicle - Disconnect the ground lead from the retainer on the flywheel cover. - Disconnect the speed sensor connector. - Disconnect the stator connector and release the wiring from the indicated clamps. - Prepare two plates under the engine block so as to create a supporting base.
Page 146 GP 800 i.e. Engine from vehicle - Lower the vehicle so as to rest the engine in a horizontal position on the plates previously placed. - Loosen the six fuel tank retainers to the chassis. - Unscrew the nut indicated from both sides of the engine and remove the fixing pin.
Page 147 GP 800 i.e. Engine from vehicle - Undo the screw fixing the wiring retaining brack- ets on the engine. - Undo the screw fixing the throttle control pipe re- taining bracket. - Lift the rear section of the chassis completely so as to get free access to the throttle body fixing screws.
Page 148 GP 800 i.e. Engine from vehicle REAR SUPPORT SERVICE - Undo the two nuts indicated and collect the wash- ers. - Remove the link rods. - Slide off the pin. - Check the silent-block and the Teflon bushings for wear; replace the components if necessary. FRONT SUPPORT SERVICE - Undo the indicated screw from both sides of the vehicle and remove the supports.
Page 149: Nut Fixing Silent-Block Plate - Chassis
GP 800 i.e. Engine from vehicle End gear shaft FITTING KEY: A: Nut fixing silent-block plate - chassis B: Nut fixing silent-block plate ENG VE - 15...
Page 150: Nut Fixing Silent-Block Plate
GP 800 i.e. Engine from vehicle C. Pin fixing nut - M14 D: Pin fixing nut - M10 E: Upper nut fixing engine support link rods - chassis F: Lower nut fixing engine support link rods - chassis - Follow the removal steps but in reverse order; be careful to tighten to the prescribed torques. ENGINE TO CHASSIS LOCKING TORQUES Name Torque in Nm...
Page 151 INDEX OF TOPICS NGINE...
Page 152: Automatic Transmission
GP 800 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - Undo the four air deflector fixing screws. - Undo the twelve screws fixing it to the engine crankcase.
Page 153 GP 800 i.e. Engine - Loosen the driven pulley shaft fixing nut with an offset wrench and lock pulley shaft rotation using a hex box-spanner. - Remove the nut and collect the washer. - Remove the transmission cover with a mallet to help extracting both shafts from their bearings.
Page 154 GP 800 i.e. Engine - Remove the adjusting ring. - Replace it with a new one. Air duct filter - Undo the three indicated screws and remove the air deflector. - Remove the filter. ENG - 4...
Page 155 GP 800 i.e. Engine Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the seeger ring. - Place transmission cover on a wood surface and use the special tool so that it is adequately sup- ported. - Pull out the bearing using the special tool.
Page 156 GP 800 i.e. Engine - Refit the seeger ring. Driving pulley shaft supporting bearing removal - Remove the transmission cover. - Remove the seeger ring. - Take out the bearing using the specific tool. Specific tooling 001467Y007 Driver for OD 54 mm bearing 001467Y006 Pliers to extract 20 mm bearings Driving pulley shaft supporting bearing fitting - Heat the transmission cover interior using the heat gun.
Page 157: Inspecting The Clutch Drum
GP 800 i.e. Engine - Place the bearing onto the special tool with a little grease to prevent it from coming out. - Install the new bearing using the special tool. Specific tooling 020376Y Adaptor handle 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide - Refit the seeger ring.
Page 158 GP 800 i.e. Engine Specific tooling 020659Y Tool to remove clutch and replace belt - Place the clutch assembly on the tool by inserting the pins in the ventilation holes. - Fit the centring bushing until it stops. - Unscrew the ring nut using the adaptor. - Screw until the clutch is completely disassem- bled.
Page 159 GP 800 i.e. Engine - Do not open the masses using tools to prevent a variation in the return spring load. Pin retaining collar - Extract the collar using 2 screwdrivers. - Remove the 4 guide pins. - Extract the moving driven half-pulley. Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage;...
Page 160 GP 800 i.e. Engine - Using the special tool inserted through the roller bearing, pull out the ball bearing. N.B. PROPERLY SUPPORT THE PULLEY TO PRE- VENT DAMAGING THE THREADING. Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020364Y 25-mm guide N.B.
Page 161 GP 800 i.e. Engine Inspecting the driven sliding half-pulley - Check that the belt contact surface is free from wear. - Remove the 2 inside sealing rings and the 2 out- side O-rings. - Measure the movable half-pulley bushing inside diameter.
Page 162: Refitting The Driven Pulley
GP 800 i.e. Engine - Install a new ball bearing using the special tool. Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020364Y 25-mm guide - Insert the seeger lock ring. Refitting the driven pulley - Insert the new oil guards - Insert the new O-rings N.B.
Page 163 GP 800 i.e. Engine Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring while it is not loaded. Characteristic Standard length: 190.2 mm Admissible limit after use: 182 mm Refitting the clutch - Prepare the specific tool as per the removal phase.
Page 164: Clutch Ring Nut
GP 800 i.e. Engine - Screw the locking ring nut and tighten to the pre- scribed torque. Locking torques (N*m) Clutch ring nut 65 - 75 - With a specific tool, separate the two half-pulleys and fit the belt according to its direction of rotation. CAUTION PLACE THE TWO HALF-RINGS ADEQUATELY SO THAT THEY PERFECTLY ADHERE TO THE...
Page 165 GP 800 i.e. Engine - Position the belt. - Unscrew until the tool frees from the half-pulley and remove it. Refitting the driven pulley - Fit the driving belt in the driven pulley with the specific tool. - Fit the assembled unit on the shaft. See also Refitting the clutch Drive-belt...
Page 166: Removing The Driving Pulley
GP 800 i.e. Engine Removing the driving pulley - Remove the O-ring as shown in the photograph. - Lock the driving pulley using the appropriate tool. - Unscrew the fixing nut and collect the belleville spring and the washer. Specific tooling 020660Y Driving pulley lock - Remove the roller container.
Page 167 GP 800 i.e. Engine - Remove the clutch bell. - Remove the driving half-pulley. - Remove the spacer. N.B. THE SPACER IS CONICAL; UPON REFITTING BE CAREFUL TO INSERT IT WITH THE SMALL- ER DIAMETER FACING THE INSIDE. - Undo the five fixing screws and remove the air switch.
Page 168 GP 800 i.e. Engine Inspecting the rollers case - Check that the inside bushings shown in the fig- ure exhibit no signs of abnormal wear and meas- ure the inside diameter. CAUTION DO NOT LUBRICATE OR CLEAN THE BUSH- INGS Characteristic Maximum admissible diameter: 40.045 mm...
Page 169: Air Switch Screw
GP 800 i.e. Engine - Check the guide shoes for the variator back-plate are not worn. - Check the wear of the roller housings and of the belt contact surfaces on both pulley halves. Characteristic Standard clearance: 0.01 ÷ 0.1 mm Refitting the driving pulley - Follow the removal steps but in reverse order being careful to tighten to the prescribed torques with the specific tool.
Page 170 GP 800 i.e. Engine SMONTAGGIO GRUPPO PIGNONE - Rimuovere l'asse del forcellone posteriore. - Rimuovere la pedana poggiapiedi e la fiancata dal lato destro. - Predisporre un recipiente di capacità adeguata e svitando la vite inferiore scaricare l'olio. CAUTION NON È POSSIBILE SCARICARE TUTTO L'OLIO CONTENUTO DALLA VITE DI SCARICO.
Page 171 GP 800 i.e. Engine - Disimpegnare il pignone dalla catena. CAUTION PRESTARE ATTENZIONE CHE I PATTINI DI TRASCINAMENTO NON CADANO. PINION UNIT SERVICE - Fasten the support in a vice. - Remove both engine-side driving sliders. N.B. THE FOUR DRIVING SLIDERS (TWO ON THE SUPPORT SIDE AND TWO ON THE ENGINE SIDE) ARE INTERCHANGEABLE.
Page 172 GP 800 i.e. Engine - Detach the oil sealing cap together with the fixing ring. N.B. NOTE THE POSITION OF THE FIXING RING. THE MACHINED SURFACE SNAPS ON THE CAP. - Remove the seeger ring. - Remove the shaft together with the driving slid- ers.
Page 173 GP 800 i.e. Engine - Undo the six fixing screws and remove the cover from the opposite side. - Undo the four screws and remove the plate. N.B. THE PLATE FORMS AN INTEGRAL UNIT WITH THE PINION DRIVING BUSHING AND THE SUPPORT.
Page 174 GP 800 i.e. Engine - Remove the oil seal indicated. - Fit the specific tool and pull out the bearing working from inside the pinion unit. Specific tooling 020360Y Adaptor 52x54 mm 020662Y Guide 50 mm 020376Y Adaptor handle - Drive a new bearing with the specific tool working from outside the pinion unit.
Page 175 GP 800 i.e. Engine - Fit the new components on the driving bushing, pinion, bearings and bushing, following the se- quence indicated in the photograph, being careful to place the bushing properly. - In the support, fit the pinion driving bushing plus with the pinion, bearings and spacer previously assembled.
Page 176 GP 800 i.e. Engine - Fit the seeger ring in the seat. - Fit the oil sealing cap with the fixing ring, com- plying with the position indicated during removal. N.B. FIT THE OIL SEALING CAP EDGES UNDER THE SAFETY PLATE. - Tighten the eight screws fixing the pinion to the driving bushing and with a punch fold the tongues of the safety plate.
Page 177 GP 800 i.e. Engine PINION UNIT FITTING - Fit the complete pinion unit in its housing on the engine. - Fit the oil sealing cap over the pinion unit shaft. - Tighten the clamp to the prescribed torque. Locking torques (N*m) Oil sealing casing clamp 3 ÷...
Page 178: Internal Transmission Cover Screws
GP 800 i.e. Engine - Tighten the oil filling screw «D» to the prescribed torque. Locking torques (N*m) Pinion unit oil filling screw 13 ÷ 15 CROWN REPLACEMENT - Remove the rear wheel. - Undo the five screws fixing the crown to the anti- vibration buffer.
Page 179 GP 800 i.e. Engine End gear PINION UNIT SHAFT BEARING REMOVAL - The toothed wheel (pinion unit shaft) rotates on two bearings located on both crankcase halves. To replace, proceed as follows. - Transmission-side crankcase half: - Remove the driven pulley shaft axle and the toothed wheel.
Page 180 GP 800 i.e. Engine - Flywheel-side crankcase half: - Remove the oil seal and the bearing with the specific tool. Specific tooling 020376Y Adaptor handle 020662Y Guide 50 mm 020360Y Adaptor 52x54 mm PINION UNIT SHAFT BEARING FITTING - The toothed wheel (pinion unit shaft) rotates on two bearings located on both crankcase halves.
Page 181 GP 800 i.e. Engine - Fit the oil seal until it stops against the bottom of the seat using the specific tool. Specific tooling 020376Y Adaptor handle 020655Y Adaptor 62x68 mm 020662Y 50 mm guide - Insert the driven pulley shaft bearing until it stops against the bottom of the seat using the specific tool.
Page 182 GP 800 i.e. Engine Removing the driven pulley shaft bearing - Slide off the toothed wheel (pinion unit shaft). - Slide off the driven pulley shaft from one side and with a screwdriver remove the oil seal from the other side. - Remove the seeger ring.
Page 183 GP 800 i.e. Engine - Remove the bearing with the specific tool. Specific tooling 020376Y Adaptor handle 020483Y 30 mm guide 020358Y 37x40-mm adaptor Inspecting the hub shaft - Check the two shafts exhibit no wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.
Page 184 GP 800 i.e. Engine Refitting the driven pulley shaft bearing - Heat the crankcase using the heat gun. Specific tooling 020151Y Air heater - Insert the driven pulley shaft bearing until it stops against the bottom of the seat using the specific tool. Specific tooling 020376Y Adaptor handle 020483Y 30 mm guide...
Page 185 GP 800 i.e. Engine Refitting the hub bearings - Place the two shafts as shown in the figure. Flywheel cover ENG - 35...
Page 186: Removing The Stator
GP 800 i.e. Engine Removing the hub cover - Remove the sixteen screws fixing it to the crank- case. - Remove the flywheel cover. N.B. THE COVER OFFERS RESISTANCE DUE TO THE FLYWHEEL MAGNETIC FIELD. Removing the stator - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
Page 187: Stator Retainers
GP 800 i.e. Engine - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPER- ATURE. A CHECK WITH THE STATOR AT OP- ERATING TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Electric characteristic Resistance: 0.2 - 1 Ω...
Page 188: Flywheel Cover Screws
GP 800 i.e. Engine Refitting the flywheel cover - Follow the removal steps but in reverse order; be careful to tighten to the prescribed torque with the specific tool. CAUTION CLOSING THE COVER MAY POSE A RISK TO THE OPERATOR DUE TO THE STRONG MAG- NETISM OF THE FLYWHEEL.
Page 189 GP 800 i.e. Engine The limiter is calibrated to 100 Nm (10 kgm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting. The starter control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions.
Page 190 GP 800 i.e. Engine - Fit the specific extractor, and unlock the flywheel acting on the tool. CAUTION THE THREAD IS ANTICLOCKWISE. Specific tooling 020713Y Flywheel extractor - Once it is unlocked, remove the flywheel. - Unscrew the plate fixing screw. - Remove the starting ring gear.
Page 191 GP 800 i.e. Engine - Undo the five fixing screws and remove the oil pump compartment closing bulkhead. - Remove the intermediate gear. Inspecting the flywheel components - Check the integrity of the magnets. - Check that the magnet support cage is free from deformation or cracks.
Page 192 GP 800 i.e. Engine - Check the inside diameter of the bushing of the starter gearing. - Check that the toothing is not worn. Characteristic Inside diameter of the bushing: Diameter 27 + 0.020 +0.041 mm N.B. IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND FREEWHEEL.
Page 193 GP 800 i.e. Engine Characteristic Bearing diameter on the engine crankcase: 12 + 0.034 -0.016 mm N.B. THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH DRIVE PLATES. Driven plates consist of 4 Belleville springs provi- ded with grooved profiles;...
Page 194: Screw Fixing Freewheel To Flywheel
GP 800 i.e. Engine - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e. with wheel seeger ring visible. - Lock the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 195 GP 800 i.e. Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the starter motor - Check that the O-ring is in good working order and lubricate it.
Page 196 GP 800 i.e. Engine Cylinder assy. and timing system Removing the intake manifold - Remove the coolant pipes. - Undo the six fixing screws. ENG - 46...
Page 197 GP 800 i.e. Engine - Remove the inlet manifold. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket. Removing the timing system drive - As indicated in the photograph, align the refer- ences on the timing system gear of the rear cylin- der with the reference on the cam cap valves.
Page 198 GP 800 i.e. Engine - Lock the timing system gear with the specific tool, undo the central fixing screw and collect the wash- - Release the chain from the sprocket and be care- ful that it does not fall inside the transmission housing.
Page 199: Removing The Cylinder Head
GP 800 i.e. Engine - Remove pins and rocking levers by the transmis- sion side holes. Removing the cylinder head - The head removal operation is carried out in two separate stages, first on the rear cylinder, then on the front one. - If the heads are removed with the valves and the camshaft, follow the recommendations.
Page 200 GP 800 i.e. Engine - These operations are described once but apply to both heads. - Remove the spark plugs. - Undo the two fixing nuts and collect the washers. - Undo the spark plug side screw. - Undo the two screws inside the timing system side head.
Page 201: Removing The Valves
GP 800 i.e. Engine - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-crossed sequence. - Remove the head, the two centring dowels, the gasket and the lower chain guide slider Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves.
Page 202 GP 800 i.e. Engine - Remove the oil guards using the special tool. Specific tooling 020431Y Valve oil seal extractor - Remove the spring supports. N.B. BLOW THE SEATS WITH COMPRESSED AIR TO FACILITATE THE SPRING SUPPORT RE- MOVAL. ENG - 52...
Page 203: Inspecting The Small End
GP 800 i.e. Engine Removing the cylinder - piston assy. - Remove the coolant inlet pipes. - The described operations refer to one cylinder but apply to both. - Extract the cylinder with the relevant gasket and the centring dowel. N.B.
Page 204: Inspecting The Piston
GP 800 i.e. Engine See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder - piston assy. Inspecting the piston N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 205 GP 800 i.e. Engine - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a punch - Install the pin lock using the key shown in the figure.
Page 206 GP 800 i.e. Engine - Using an abutment plane, reset the comparator with a preload of a few millimetres. - Finally fix the comparator. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the comparator position.
Page 207 GP 800 i.e. Engine - Install the first compression lining in the direction imposed by the housing. - It is advisable to use a fitter to facilitate the in- stallation of the linings. N.B. THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS- SECTION.
Page 208: Inspecting The Cylinder Head
GP 800 i.e. Engine - Make sure that the centring dowel is properly fit- ted and insert the cylinder until it stops. Inspecting the cylinder head N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head ENG - 58...
Page 209 GP 800 i.e. Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Check that the crankshaft pinion and the camshaft timing gear and crankshaft pinion exhibit no wear. In case of wear of the sliding blocks, replace them.
Page 210 GP 800 i.e. Engine Cylinder Head Inspecting the valves N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Inspecting the valve stem guide clearance N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 211 GP 800 i.e. Engine Refitting the valves - Place the valve spring support washers on the head. - Fit the four oil seals alternately with the specific tool. Specific tooling 020306Y Punch for assembling valve seal rings - Lubricate the oil guards and the valve guides. ENG - 61...
Page 212 GP 800 i.e. Engine - Fit the valves, the springs and the caps. - With the specific tool equipped with the appro- priate adaptor, compress the springs and fit the cotters in their seats. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool) N.B.
Page 213 GP 800 i.e. Engine THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER. THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS. - Fit the head gasket. - The head gasket is made of steel and has a standard thickness.
Page 214 GP 800 i.e. Engine - Tighten the fastening nuts on the exhaust and on the intake side to the prescribed torque. Locking torques (N*m) Exhaust / intake head fixing nuts: 10 - 12 Undo the two screws inside the timing system side head to the prescribed torque.
Page 215 GP 800 i.e. Engine - Install the coolant temperature sensor with the washer and tighten to the prescribed torque. CAUTION FAILURE TO OBSERVE THE TIGHTENING TORQUE CAN DAMAGE THE SENSOR. Locking torques (N*m) Coolant temperature sensor 21 ÷ 23 - Fit the spark plugs and tighten them to the prescribed torque. Locking torques (N*m) Spark plug 12 ÷...
Page 216 GP 800 i.e. Engine - Clean the camshaft by blowing with little com- pressed air jets, especially the retaining plate housing. - Lubricate the 2 shafts. - Insert the camshaft into the head with the cams opposite the rocking levers. - Remove any LOCTITE residues from the screws fixing the camshaft retaining bracket using a brush.
Page 217 GP 800 i.e. Engine - With the references aligned, operate on the driv- ing pulley to turn the crankshaft until, the rear cylinder timing reference mark «1» on the flywheel is aligned to the crankcase reference mark. - Fit the tone wheel, the timing system gear with the chain and align the reference marks.
Page 218 GP 800 i.e. Engine - Insert the chain tensioner in the cylinder together with the gasket and tighten the screws to the pre- scribed torque. Locking torques (N*m) timing chain tensioner screws 11 ÷ 13 - Check and restore the correct clearance of the valves if necessary.
Page 219 GP 800 i.e. Engine - Unscrew the TDC reference inspection cap. - Connect the stroboscopic light. - Connect the diagnostic tester. - Start the engine. - Select the «parameter» function in this menu. - Select the stroboscopic light command in the traditional four-stroke engine position (1 spark 2 revs). - Check that the real values of rpm and ignition advance match those measured using the diagnostic tester.
Page 220 GP 800 i.e. Engine - Tighten the two screws indicated in the figure with "1" and "2" to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a crossed se- quence (3, 4, 5, 6).
Page 221 GP 800 i.e. Engine Crankcase - crankshaft - Remove the transmission cover, the driving and the driven pulleys, as described in the «Automatic transmission» chapter. - Remove the flywheel cover as described in the «Flywheel cover» chapter. - Remove the flywheel with the starting system following the instruction given in "Flywheel and Starting system".
Page 222 GP 800 i.e. Engine Splitting the crankcase halves - Working from the transmission side, undo the six screws «A» and collect the washers. - Turn the support so as to operate on the flywheel side. - Undo the three nuts fixing it to the support, collect the washers and remove the three centring bush- ings.
Page 223 GP 800 i.e. Engine - Detach the crankcase halves while keeping the crankshaft inserted on the transmission-side crankcase half. - Remove the coupling gasket. ENG - 73...
Page 224 GP 800 i.e. Engine - Remove the tip. Specific tooling 020664Y Flywheel side crankshaft fitting tip - Fit the specific tool on the transmission-side crankshaft, being particularly careful that the tool matches the shaft perfectly. CAUTION DUE TO THE TIP WEIGHT, BE CAREFUL THAT THE TOOL FIT ADEQUATELY AND DOES NOT FALL;...
Page 225 GP 800 i.e. Engine - Hold the tip with one hand and the crankshaft with the other, pull the crankshaft upwards. - Remove the crankshaft once the tip has been re- moved from the bushings. - Once the crankshaft has been removed it is possible to remove the transmission-side timing chain. Inspecting the crankshaft components N.B.
Page 226 GP 800 i.e. Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - Clean the jets and contacts carefully. N.B. THE JET IS FED THROUGH THE MAIN BUSHINGS. PROPER OPERATION OF THIS COMPONENT IMPROVES PISTON CROWN COOLING.
Page 227 GP 800 i.e. Engine N.B. TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION, DRIVING IS FORCED ON CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES. N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 228 GP 800 i.e. Engine - Lubricate the external surface of the tip with petroleum jelly grease. N.B. LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT. CAUTION FIT THE TRANSMISSION-SIDE TIMING CHAIN. FIT THE DRIVE CHAIN BEFORE THE CRANKSHAFT. - Fit the crankshaft with the driving pulley shaft in- side the transmission-side crankcase half.
Page 229 GP 800 i.e. Engine - Place the coupling gasket. - Fit the specific tool on the flywheel-side crank- shaft, being particularly careful that the tool match- es the shaft perfectly. CAUTION FAILURE TO OBSERVE THIS RULE CAN DAM- AGE THE MAIN BUSHINGS. Specific tooling 020664Y Flywheel side crankshaft fitting tip - Lubricate the external surface of the tip with petroleum jelly grease.
Page 230 GP 800 i.e. Engine - Be careful and fit the flywheel-side crankcase half until there is a complete coupling. ENG - 80...
Page 231: Engine Crankcase Coupling Screws (M6)
GP 800 i.e. Engine - Remove the tip. Specific tooling 020664Y Flywheel side crankshaft fitting tip - Tighten the seven screws «B» with the copper washers as far as they will go. - Tighten the twelve screws «C» with the washers as far as they will go.
Page 232 GP 800 i.e. Engine - With a pipe of the indicated size (inside Ø: 36.5 mm - outside Ø: 49.5 mm) set the oil seal at the indicated distance; with a gauge check the driving depth following the indications described in the fig- ure.
Page 233 GP 800 i.e. Engine Specification Desc./Quantity REAR PISTON LUBRICATION JET STARTING RING GEAR BUSHING LUBRICA- TION CRANKSHAFT BUSHINGS WATER PUMP CONTROL DRIVING GEAR SHAFT LUBRICATION WATER PUMP SHAFT LUBRICATION MINIMUM OIL PRESSURE SENSOR NON-RETURN VALVE OIL CARTRIDGE FILTER POMPA MANDATA OLIO BY-PASS VALVE POZZETTO OLIO SCAVENGE OIL PUMP:...
Page 234 GP 800 i.e. Engine The components of the timing system function with low-pressure oil lubrication. The camshaft bearings are installed directly on the aluminium of the head; the camshaft axial clearance is partially compensated by the oil supplied to the smaller diameter bearing. The camshaft supplies the lubricant to the rocking levers via the holes provided;...
Page 235 GP 800 i.e. Engine AHEAD - go to 5 5 - Measure the pressure with cold and idling engine. STANDARD VALUES Specification Desc./Quantity 20°C Temperature 1200 rpm approx. 4.5 bar Specific tooling 020460Y Scooter diagnosis and tester YES go to 6 NO go to 12 6 - Let the engine warm up and repeat the check with hot oil.
Page 236: Oil Pressure Check
GP 800 i.e. Engine - radial clearance, especially in the direction of the cylinder axis - clearance according to the direction of rotation with the connecting rod in quadrature YES go to 16 NO go to 17 15 - Replace damaged components. 16- Proceed with engine service operations.
Page 237: Oil Pump
GP 800 i.e. Engine YES go to 5 NO go to 4 4 - Check the thermal group seals (piston rings, valve guides and oil guards), see "Thermal group and Timing system" chapter. 5 - Restore the valve or the drainage hole efficiency. Oil pump Removal KEY:...
Page 238 GP 800 i.e. Engine - Operating from the outside undo the chain ten- sioner pad fixing screws. - Remove the chain tensioner pad. - With the specific tool, lock and undo the fixing screw and collect the washer. - Remove the oil pump control crown. N.B.
Page 239 GP 800 i.e. Engine - Operating from inside: - Lock the scavenge oil pump shaft, undo the fixing screw and collect the washer. - Remove the water pump control gear, undo the two screws indicated and collect the washers. - Remove the casing of the oil anti-backflow plate. - Remove the oil pump and the relevant gasket.
Page 240 GP 800 i.e. Engine - Undo the four screws indicated. - Remove the by-pass scavenge duct together with its gasket. Inspection - The procedure is described once but applies to both pumps. ENG - 90...
Page 241 GP 800 i.e. Engine - Undo the two screws and remove the oil pump cover. - Slide off the shaft together with the driving pins of the rotors. - Remove the two rotors and wash them thorough- ENG - 91...
Page 242 GP 800 i.e. Engine N.B. VISUALLY INSPECT THAT ALL THE COMPO- NENTS ARE IN GOOD CONDITIONS. MAKE SURE THERE ARE NO SIGNS OF WEAR OR SCRATCHES. REPLACE THE COMPONENTS IF THERE ARE EVIDENT SIGNS OF WEAR. - Once you check that the components are in good conditions, fit the pump and check size.
Page 243 GP 800 i.e. Engine - Measure the distance between rotors with a thick- ness gauge at the position indicated. Characteristic Standard clearance: 0.04 - 0.1 mm - Check the distance between external rotor and pump body; see figure. Characteristic Standard clearance: 0.05 - 0.12 mm - Check the levelness of the two rotor surfaces and the pump body with a trued bar as a contrasting...
Page 244 GP 800 i.e. Engine Refitting - Operating from inside the flywheel-side crank- case half: - Fit the by-pass scavenge duct together with the gasket and tighten the four fixing screws to the prescribed torque. Locking torques (N*m) By-pass scavenge duct fixing screws 11 ÷ 13 - Make sure the gasket is in the correct position.
Page 245 GP 800 i.e. Engine - Once the scavenge oil pump fitting is finished, operate from outside the flywheel-side crankcase half. - Make sure the gasket is in the correct position. N.B. THE TOOTH OF THE GASKET MUST BE IN ITS SEAT.
Page 246: Water Pump
GP 800 i.e. Engine - Fit the tensioner pad and tighten the two screws to the prescribed torque. Locking torques (N*m) Oil pump chain tensioner pad 2 ÷ 3 Water pump Removal N.B. REPLACEMENT OF THE OVERALL SEALING CAN BE CARRIED OUT WITH ENGINE INSTALLED ON THE VEHICLE, SEE «HIGHLIGHTED PROCEDURES».
Page 247 GP 800 i.e. Engine - Remove the six screws, the water pump cover and the gasket with a screwdriver. - Unscrew the water pump rotor with a 10-mm wrench. CAUTION THE ROTOR THREAD IS ANTICLOCKWISE. THE PUMP SHAFT HELPS REMOVING THE ROTOR AS THE GEARED CONTROL CANNOT ROTATE IN REVERSE SENSE.
Page 248 GP 800 i.e. Engine During seal disassembly, the ceramic may split. - Clean all the parts thoroughly before removing them. - Place the extractor together with the pin on the fixed part of the ceramic seal. - Without modifying the extractor position, make three holes on the fixed part of the seal using the pin supplied and a hammer.
Page 249 GP 800 i.e. Engine - Fix the extractor to the fixed part of the sealing using the screws supplied with the tool. CAUTION FIX IT PROPERLY WITHOUT "TEARING" THE PLATE - Complete the tool by fitting the bracket, the screw and the nut.
Page 250 GP 800 i.e. Engine - To work on the water pump shaft and the relevant oil seal, open the engine crankcase and work from inside the transmission-side crankcase half. - Slide off the idle gear. - Slide off the water pump control gear together with the shaft.
Page 251 GP 800 i.e. Engine Fitting - Fit the oil seal from the outside being careful not to grease the contact surfaces. - With the specific tool fit the seal until it stops. Specific tooling 020663Y Water pump shaft oil seal punch - Fit and lock the plate in its position by tightening the two screws indicated to the prescribed torque.
Page 252 GP 800 i.e. Engine LUBRICATE THE ROTOR SHAFT WITH ENGINE OIL. - Place the overall seal on the shaft. - Fit the tie rod by screwing it to the rotor shaft. CAUTION THE SHAFT THREAD IS ANTICLOCKWISE. SCREW IT MANUALLY UNTIL IT STOPS. - Place the calibrated punch (at preloading value).
Page 253: Water Pump Impeller
GP 800 i.e. Engine Keep the tie rod in position and screw the nut up to the end of stroke. The tool will drive the fixed part seat on the crank- case and the movable part seat on the shaft, thus obtaining the correct ceramic seal preloading.
Page 254 GP 800 i.e. Engine ENG - 104...
Page 255 INDEX OF TOPICS INJEC NJECTION...
Page 256 GP 800 i.e. Injection Sistema di iniezione EMS Il sistema di iniezione è del tipo sequenziale fasata con iniezione e accensione integrate. L'iniezione è del tipo indiretta nel collettore mediante elettroiniettori. L'iniezione e l'accensione sono fasate sul ciclo 4T mediante una ruota fonica calettata sul comando dell'albero a camme del cilindro posteriore ed un sensore a variazione di riluttanza.
Page 257 GP 800 i.e. Injection Nel caso in cui venissero a mancare alcuni segnali in entrata, viene comunque garantito un funziona- mento accettabile del motore, per permettere all'utente di raggiungere l'officina di riparazione. Naturalmente ciò non può accadere quando viene a mancare il segnale di giri-fase oppure quando l'anomalia interessa i circuiti di comando: - Pompa benzina - Bobine A.T.
Page 258 GP 800 i.e. Injection The EMS control unit power supply is further con- trolled by the emergency switch, side stand switch and the stop buttons; that is to provide further safety for the scooter. Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults.
Page 259 GP 800 i.e. Injection Troubleshooting hints 1An EMS failure is more likely to be due to the connections than to the components. Before troubleshooting the EMS, carry out the following checks: A: Electrical power supply a. Battery voltage b. Blown fuse c.
Page 260 GP 800 i.e. Injection Terminals setup VEHICLE CONTROL UNIT CONNECTOR 1. Start-up remote control switch relay (Orange- White) 4.Battery positive (White-Red) 6. Injection load relay (Black-Purple) 7. Immobilizer decoder (Orange) 8. Low-beam light relay (Yellow-Grey) 9. Rpm indicator (Brown) 11. Lambda probe (Purple) 13.
Page 261 GP 800 i.e. Injection 13. Barometric pressure signal (Orange) 14. Air temperature sensor (White-Grey) 17. Idle adjustment motor (Sky Blue-Red) 18. Idle adjustment motor (Sky Blue-Black) 19. Idle adjustment motor (Orange-Red) 20. Sensor negative (Sky Blue-Green) 22. Sensor positive (Red-Blue) 25.
Page 262 GP 800 i.e. Injection Engine does not start ENGINE DOES NOT START IF ONLY PULLED Possible Cause Operation Immobiliser enabling signal System not encoded System not efficient, repair according to the indi- cations of the self-diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector...
Page 263 GP 800 i.e. Injection Engine stops at idle ENGINE DOES NOT HOLD IDLING/ IDLING IS UNSTABLE/ IDLING TOO LOW Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Ignition efficiency Spark plug...
Page 264 GP 800 i.e. Injection Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor...
Page 265 GP 800 i.e. Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Spark plug power supply...
Page 266 GP 800 i.e. Injection Fuel supply system Fuel is fed to the injectors by a pump, a filter and a pressure regulator. The fuel supply circuit includes the electric pump, the filter, the pressure regulator, injectors and the fuel delivery and reverse pipes. The electric pump is located in the tank from which the fuel is pumped and sent to the injectors through the filter.
Page 267 GP 800 i.e. Injection Pump supply circuit INJEC - 13...
Page 268 GP 800 i.e. Injection FUEL PUMP CONNECTOR 2. Ground (Black) 5. Injection load relay (Black-Green) FUEL PUMP UNIT Mechanical type pressure regulator operating at a pressure of 3 BAR Pump winding resistance: ~ 1,5 Ohm Verificare, commutando in «ON», la presenza di tensione batteria, per circa 2 secondi, tra il pin 5 del connettore pompa e massa con connettore pompa staccato.
Page 269 GP 800 i.e. Injection Be careful not to further choke pipes if pressure remains evenly at 3 BAR while flow rate decreases. Check that within 15 seconds the pump has a flow rate of approx. 300 cm³. Specific tooling 020480Y Petrol pressure check set Inspecting the injector circuit REAR CYLINDER INJECTOR CONNECTOR 1.
Page 270 GP 800 i.e. Injection FRONT CYLINDER INJECTOR CONNECTOR 1. Control unit (Blue) 2. Injection load relay (Black-Green) FUEL INJECTOR Type: 4 holes Conicity of the nozzle: 24° Resistance at terminals: 13.7 ÷ 15.2 Ohm Scollegare il connettore dell'iniettore. Commutare in "ON". Eseguire la diagnosi attiva iniettore tramite palmare.
Page 271 GP 800 i.e. Injection - Aerial - master key - service key - Deterrent and diagnosis LED Virgin circuit When control unit (ECU) and decoder are not pro- grammed, 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.
Page 272 GP 800 i.e. Injection 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.
Page 273 GP 800 i.e. Injection 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.
Page 274 GP 800 i.e. Injection TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER. 1- With a multimeter, check the continuity between pin 7 of the vehicle side connector control unit and pin 6 of the decoder connector. YES go to 3 NO go to 2 2 - Repair or replace the wiring.
Page 275 GP 800 i.e. Injection YES go to 5 NO go to 4 4 - Restore the connection and check the presence of the code 5 - Disconnect the aerial connector and check con- tinuity (8 ± 2 W). YES go to 7 NO go to 6 6 - Replace the aerial.
Page 276 GP 800 i.e. Injection ENGINE RPM SENSOR CONNECTOR 1. Control unit (White) 2. Control unit (Red) 3. Sensor shield (Black) 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) Check the continuity between pin 1 of the revolution timing sensor connector and pin 25 of the engine connector control unit.
Page 277 GP 800 i.e. Injection HT coil REAR CYLINDER HV COIL CONNECTOR 1. Injection load relay (Black-Green) 2. Control unit (Pink-Black) INJEC - 23...
Page 278 GP 800 i.e. Injection FRONT CYLINDER HV COIL CONNECTOR 1. Injection load relay (Black-Green) 2. Control unit (Sky Blue) H.V. COIL Primary winding resistance: 520 ÷ 620 mOhm Secondary resistance: 6830 ÷ 7830 Ohm Check if there is voltage for 2 seconds, switching to "ON" between pin 1 of the coil connectors and ground lead.
Page 279 GP 800 i.e. Injection It is possible to check whether the ignition advance determined by the system does in fact correspond with the value actually activated on the engine, by means of the stroboscopic light. Specific tooling 020460Y Scooter diagnosis and tester 020330Y Stroboscopic light for timing control - Unscrew the TDC reference inspection cap.
Page 280 GP 800 i.e. Injection WATER TEMPERATURE SENSOR CONNEC- 1. Control unit (Grey-Green) 2. Instrument panel (Green-Yellow) 3. Control unit negative (Sky Blue-Green) 4. Instrument panel (Brown-Black) ENGINE TEMPERATURE SENSOR 0° = 5900 Ohm +10° = 3800 Ohm +20° = 2500 Ohm +30°...
Page 281 GP 800 i.e. Injection Intake air temperature sensor AIR TEMPERATURE SENSOR CONNECTOR 1. Control unit (White-Grey) 2. Control unit negative (Sky Blue-Green) INTAKE AIR TEMPERATURE SENSOR -10° = 9600 Ohm 0° = 5900 Ohm +10° = 3800 Ohm +20° = 2500 Ohm -30°...
Page 282 GP 800 i.e. Injection With the sensor connector disconnected, check that pin 2 of the sensor connector is earthed with the key set to "ON". Check the continuity between pin 2 of the sensor connector and pin 20 of the engine connector control unit.
Page 283 GP 800 i.e. Injection 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 Pins 1(A) - 3(C): Throttle valve closed: approximately 2.5 kOhm;...
Page 284 GP 800 i.e. Injection Connect the diagnostic tester. Switch to «ON». Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020460Y Scooter diagnosis and tester Make sure that the throttle valve with the control is supporting the stop screw. Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure.
Page 285 GP 800 i.e. Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Page 286 GP 800 i.e. Injection IDLE ADJUSTMENT MOTOR CONNECTOR 1. Control unit (Sky Blue-Red) 2. Control unit (Orange-Red) 3. Control unit (Sky Blue-Yellow) 4. Control unit (Sky Blue-Black) STEPPER MOTOR Resistance engine-side connector between pins 19 - 9 ~ 51 Ohm Resistance engine-side connector between pins 18 - 17 ~ 51 Ohm With the palm top computer, while the engine is running and with at least one electric ventilation trip,...
Page 287 INDEX OF TOPICS SUSP USPENSIONS...
Page 288: Removing The Front Wheel
GP 800 i.e. Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Support the scooter adequately. - Undo the screws indicated from both sides and release the front brake callipers from the discs. - Unscrew the wheel pin fixing nut.
Page 289 GP 800 i.e. Suspensions - Slide off the front wheel pin and remove the wheel. Front wheel hub overhaul - Rimuovere da entrambi i lati lo scodellino di pro- tezione e il distanziale, colpendo con un mazzuolo in più punti. - Verificare visivamente il buono stato dei compo- nenti, e che non siano presenti usure anomale.
Page 290 GP 800 i.e. Suspensions - Rimuovere il distanziale interno. - Dal lato opposto in modo analogo a quanto de- scritto sopra, ripetere l'estrazione dell'altro cusci- netto. - Verificare visivamente che sul distanziale interno e nelle sedi dei cuscinetti non siano presenti usure anomale.
Page 291: Front Wheel Pin Nut
Screw fixing wheel pin on right fork leg 6 ÷ 7 Front wheel pin nut 60 ÷ 70 Screws fixing front brake calliper to fork 20 ÷ 25 Handlebar Removal - Remove the Gilera clip-on badge, undo the screw indicated and remove the handlebar cover. SUSP - 5...
Page 292 GP 800 i.e. Suspensions - The half-handlebar comprises two parts: undo the indicated screw to remove the handlebar in- sert. - Undo the five screws indicated to remove both half-handlebars. - Undo the four screws indicated, remove the frame by passing the inserts through to the inside. CAUTION BE CAREFUL WITH THE SWITCH STOP CON- NECTORS.
Page 293 GP 800 i.e. Suspensions - Undo the two screws indicated. - Remove the supporting plate. Refitting - Fit the supporting plate on the steering tube. - Align the plate following the indicated reference so as to allow the upper fixing screw to fit into the hole on the steering tube.
Page 294 GP 800 i.e. Suspensions - Tighten the two screws indicated to the prescri- bed torque. Locking torques (N*m) Screws fixing handlebar supporting plate - steering tube 50 ÷ 55 - Fit both handlebar inserts inside the frame as in- dicated in the photograph. - Assemble the frame on the supporting plate .
Page 295: Handlebar Cover Fixing Screw 2
Screw fixing half-handlebar insert - half-han- dlebar 20 ÷ 25* - Fit the handlebar cover, tighten the screw indi- cated to the prescribed torque and fit the Gilera clip-on badge. Locking torques (N*m) Handlebar cover fixing screw 2.5 ÷ 4...
Page 296 GP 800 i.e. Suspensions Overhaul - Support the fork in a vice. - Loosen the three screws tightening the stem sup- porting clamp. - Unscrew the stem closing cap and slide off the fork leg together with the stem from the relevant support.
Page 297 GP 800 i.e. Suspensions - Remove the stem dust guard with a screwdriver. - Remove the circlip retaining the oil seal. - Pull out the stem with force to the end of stroke. N.B. THE STEM HAS A SLIDING BUSHING LOCA- TED IN THE UPPER PART.
Page 298 GP 800 i.e. Suspensions - Remove the hydraulic rod with the corresponding sealing gasket, the spring and the stop bushing. COMPONENT CHECK CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY. - Check that the fork leg exhibits no dents or dam- age matching the couplings. - Visually inspect that the upper sliding bushing exhibits no signs of abnormal wear on the internal surface.
Page 299 GP 800 i.e. Suspensions - Check that hydraulic rod caulkings, the contrast spring to the unloaded the end of stroke and the hydraulic rod sealing ring are in good conditions. - Check that the main spring exhibits no signs of yielding or abnormal wear.
Page 300: Hydraulic Rod Fixing Screw
GP 800 i.e. Suspensions - Fit the hydraulic rod fixing screw with the copper sealing washer and tighten to the prescribed tor- que using the recommended product. CAUTION ALWAYS USE NEW COPPER WASHER. Locking torques (N*m) Hydraulic rod fixing screw 25 ÷ 35* (°) Apply LOCTITE 243 threadlock - Lock hydraulic rod rotation using the specific tool.
Page 301 GP 800 i.e. Suspensions - Fit the specific tool in the sealing ring in the initial driving position. Specific tooling 020633Y Clamp for sealing ring driving of Kayaba 41-mm and Marzocchi 40-mm forks - Fix the specific tool in a vice with the stem placed at approximately halfway.
Page 302 GP 800 i.e. Suspensions - Grease and fit a new dust guard. - Fit the fork leg together with the stem on the fork support clamp until it stops. - Tighten the three screws to the prescribed torque in the sequence indicated in the photograph. Locking torques (N*m) Stem support clamp tightening screws 20 ÷...
Page 303: Fork Locking Screws Cap
GP 800 i.e. Suspensions - Lubricate the stem closing cap O-ring. - Preload the spring; fit the closing cap and tighten to the prescribed torque. Locking torques (N*m) Fork locking screws cap 35 - 55 - Repeat the procedure for the other fork leg. N.B.
Page 304 GP 800 i.e. Suspensions - Remove the half-handlebar supporting plate. - Unscrew the steering ring nuts with the specific tool. Specific tooling 020668Y Steering ring nut wrench - Remove the upper steering fifth wheel and rele- vant components; the fork is now free. CAUTION HOLD IT SO THAT IT DOES NOT COME OFF SUDDENLY.
Page 305 GP 800 i.e. Suspensions - Check the lower steering fifth wheel for wear. - Visually inspect that the steering fifth wheel tracks, the headstock and the steering tube exhibit no scores or abnormal wear. Otherwise, replace them. STEERING FIFTH WHEEL TRACK REMOVAL - Remove the steering fifth wheel tracks on the chassis with the specific tool, following the indica- ted procedure.
Page 306 GP 800 i.e. Suspensions - Remove the lower fifth wheel seat on the steering tube using the specific tool. Specific tooling 020004Y Punch for removing fifth wheels from headstock STEERING FIFTH WHEEL TRACK FITTING - Thoroughly clean the track seats on the headstock and the steering tube. - Fit the new tracks of the headstock with the specific tool.
Page 307 GP 800 i.e. Suspensions - Fit the lower fifth wheel seat on the steering tube. - With a tube of the indicated sizes, fit the lower seat until it stops. Inside Ø: 40.5 mm; Outside Ø: 48 mm; Length: 350 mm. N.B.
Page 308 GP 800 i.e. Suspensions - Fit the upper steering fifth wheel. - Fit the steering fifth wheel upper seat. - Fit the cover plate. - Fit the lower tightening ring nut with the cham- fered side facing down, screw it until it stops and with the specific tool, tighten to the indicated tor- que.
Page 309 GP 800 i.e. Suspensions - Fit the spacer between the two ring nuts on the steering tube in the position indicated. - Fit the upper tightening ring nut with the cham- fered side facing up, screw it until it stops and with the specific tool, tighten to the indicated torque.
Page 310: Screw Fixing Three-Way Union To Fork Head
GP 800 i.e. Suspensions - Fix the three-way union to the fork head. Locking torques (N*m) Screw fixing three-way union to fork head 10 ÷ - Fit the front wheel. Rear Removing the rear wheel - Unscrew the wheel pin fixing nut. - Remove the wheel pin and collect the spacer in- dicated.
Page 311 GP 800 i.e. Suspensions - Move the wheel to the front part of the vehicle so as to obtain chain clearance to remove it from the sprocket. - Release the calliper holding plate from the disc. - Remove the wheel. REAR WHEEL HUB SERVICE - Remove the protection sleeve and the spacer from both sides using a flat blade screwdriver as a...
Page 312 GP 800 i.e. Suspensions - Remove the internal spacer. - Repeat the previously described procedure to pull out the other bearing from the opposite side. - Visually inspect that the internal spacer and the bearing seats exhibit no signs of abnormal wear. - Heat the seat of one bearing with the specific tool.
Page 313: Shock Absorbers
GP 800 i.e. Suspensions - Insert the assembled protection cap and spacer until they stop on both sides as described. Refitting the rear wheel - Follow the removal steps but in reverse order and tighten to the prescribed torque. Locking torques (N*m) Rear wheel pin nut 70 Shock absorbers Removal...
Page 314 GP 800 i.e. Suspensions - Following the operations indicated in the relevant section, fit the rear fork on the vehicle thus fixing the shock absorber to the chassis to the prescribed torque. Locking torques (N*m) Screw fixing shock absorber - fork 38 - 46 Removal See also Exhaust assy.
Page 315 GP 800 i.e. Suspensions - Undo the fork pin tightening nut and collect the washer. - Slide off the fork pin. - Remove the fork paying attention to the shock absorber. Service - Slide off the internal spacer from the right side and remove the stop bushing from the left side.
Page 316 GP 800 i.e. Suspensions - Thoroughly wipe off any lubricating grease on the spacer. - Check that the roller casing work surfaces exhibit no signs of scratches or abnormal wear. Characteristic Standard diameter 30.0 mm -0.02 -0.041 - Remove the seeger ring. - Take out the bearing using the specific tool.
Page 317 GP 800 i.e. Suspensions - Fit the adaptor handle from the left side, then prepare the adaptor and the guide. - Pull out the two ball bearing cages with the spe- cific tool. - Visually inspect if the surfaces are in good con- ditions and that they exhibit no signs of scratches or abnormal wear.
Page 318 GP 800 i.e. Suspensions - Drive the new ball bearing cages with the specific tool and a hydraulic press. - Grease with the recommended product. Specific tooling 020669Y roller casing fitting punch Recommended products AGIP GREASE PV2 Grease for steering bear- ings and spindle seats Soap-based lithium and zinc oxide grease con- taining NLGI 2;...
Page 319 GP 800 i.e. Suspensions - Fit the seeger ring. - Pull out the rear shock absorber silent-block with a hydraulic press - Similarly to the removal operations, drive a new silent-block after heating with the specific tool. Specific tooling 020151Y Air heater - Undo the three fixing screws to replace the chain stop slider.
Page 320 GP 800 i.e. Suspensions - Undo the two fixing screws and collect the wash- ers to replace the stand stop buffer. - Upon fitting, tighten the two screws to the pre- scribed torque. Locking torques (N*m) Screw fixing centre stand stop buffer - fork 5 ÷ - Fit the pin and the stop bushing.
Page 321 GP 800 i.e. Suspensions - Fit the fork pin. - Tighten the set screw to the prescribed torque. Locking torques (N*m) Fork pin set screw 0.5 CAUTION MAKE THE FORK SWING SLIGHTLY UPON TIGHTENING SO AS TO OBTAIN THE PROPER COUPLING ON THE FORK SHAFT.
Page 322 GP 800 i.e. Suspensions - Lock the pin from the vehicle right side, tighten the fork pin locking nut to the prescribed torque. Locking torques (N*m) Fork pin nut 90 ± 5 - Tighten the two screws together with the wash- ers, thus fixing the rear brake pipes.
Page 323: Side Stand
GP 800 i.e. Suspensions Side stand REMOVAL - Remove the left footrest. - Remove the two return screws and unscrew the nut indicated. - Slide off the pin and remove the side stand. - Should the side stand button be replaced, undo the two screws indicated and remove the footrest support.
Page 324 GP 800 i.e. Suspensions SUSP - 38...
Page 325 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 326: Rear Brake Calliper
GP 800 i.e. Braking system This section è is devoted to the description of the braking system components. Rear brake calliper Removal - Remove the two retainers fixing the brake calliper to the bracket. - Remove the pads. Refitting To refit, carry out the removal operations but in reverse order. Once these operations are completed, purge the braking system.
Page 327 GP 800 i.e. Braking system Refitting - Fasten the brake calliper to the fork with the two screws. Locking torques (N*m) Screws fixing front brake calliper to fork 20 ÷ - Fix the brake pipe coupling to the calliper. Locking torques (N*m) Brake pipes / front brake calliper coupling 16 ÷...
Page 328: Front Brake Disc
GP 800 i.e. Braking system Refitting - Place the disc on the rim so that the words face the vehicle external side. - Fasten the disc with the five screws and apply specific product on them. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock Locking torques (N*m) Screws fixing rear brake disc to rim 25...
Page 329 GP 800 i.e. Braking system Removal - Remove the front wheel. - Undo the five screws fixing the disc. Refitting - Place the disc on the rim so that the words face the vehicle external side. - Fasten the disc with the five screws. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock...
Page 330: Front Brake Pads
GP 800 i.e. Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic Thickness of a new front disc 5 mm Disc thickness at wear limit (front) 4.5 mm...
Page 331 GP 800 i.e. Braking system Removal - Remove the brake calliper. - Remove the two stop clips and slide off the pin. - Remove the two pads. - Check the thickness of the friction material. Re- place the pads if the thickness is below the mini- mum value.
Page 332 GP 800 i.e. Braking system Refitting - Insert the two pads in the callipers. - Lock the pads using the pin and fit the clips. - Fit the calliper on the fork stem. Locking torques (N*m) Screws fixing front brake calliper to fork 20 ÷ Rear brake pads BRAK SYS - 8...
Page 333 GP 800 i.e. Braking system Removal Proceed as follows: - Remove the rear brake calliper - Loosen the two pins shown in the figure that lock the two pads. - Remove the pads, being careful with the pad spring clamp. - Check the thickness of the friction material of the pads.
Page 334: Bleed Screw
GP 800 i.e. Braking system Parking brake adjusting nut 10 Rear brake pad fixing pins 15 ÷ 20 Fill Rear - combined - Remove the rubber cap from the bleed screw and insert a rubber pipe to collect the brake fluid. - With the left-hand brake lever, load the system and bring it up to the required pressure.
Page 335 GP 800 i.e. Braking system Locking torques (N*m) Brake calliper bleed screws. 12 ÷ 16 Front - Remove the rubber cap from the bleed screw and insert a rubber pipe to collect the brake fluid. CAUTION CARRY OUT THE FOLLOWING OPERATIONS ON BOTH CALLIPERS - With the right-hand brake lever, load the system and bring it up to the required pressure.
Page 336 GP 800 i.e. Braking system Brake calliper bleed screws. 12 ÷ 16 Brake fluid level check - Rest the vehicle onto the centre stand, with the handlebar centred. - Check the fluid level through the specific sight glass. - Top-up whenever the level is below the MIN ref- erence «A»...
Page 337 GP 800 i.e. Braking system - Remove the two screws fixing the pump to the handlebar. Refitting - To refit, carry out the removal operations but in reverse order. CAUTION ONCE REFITTING IS FINISHED, BLEED THE SYSTEM. Locking torques (N*m) Screws fixing brake pump to handlebar 7 ÷...
Page 338: Brake Pipes / Brake Pump Coupling
GP 800 i.e. Braking system - Remove the two screws fixing the pump to the handlebar. Refitting - To refit, carry out the removal operations but in reverse order. CAUTION ONCE REFITTING IS FINISHED, BLEED THE SYSTEM. Locking torques (N*m) Screws fixing brake pump to handlebar 7 ÷...
Page 339 GP 800 i.e. Braking system - Remove the front shield. - Thread the pipes through the right half-handlebar and lay it to the vehicle left side. - Fix the coupling to the brake pump. - Fix the coupling to the three-way union. Locking torques (N*m) Brake pipes / three-way union coupling 18 ÷...
Page 340 GP 800 i.e. Braking system - Fasten the pipe to the clamp. - Fasten the pipe to the clip. - Fasten the pipes to the chassis with a strap. - Fasten the pipes to the chassis with a strap. BRAK SYS - 16...
Page 341 GP 800 i.e. Braking system - Fasten the pipe to the clip. - Fasten the pipe to the rear fork with the two clips. Locking torques (N*m) Nut fixing rear brake pipe retaining clip 11 ÷ 13 - Fix the brake pipe coupling to the brake calliper. Locking torques (N*m) Brake pipe / rear brake calliper coupling 20 ÷...
Page 342 GP 800 i.e. Braking system - Fasten the sheath to the chassis with a strap. - Fasten the pipes to the chassis with a strap. - Fasten the pipe to the clip. - Fasten the pipe to the rear fork with the two clips. Locking torques (N*m) Nut fixing rear brake pipe retaining clip 11 ÷...
Page 343: Screw Fixing Parking Brake Calliper To Supporting
GP 800 i.e. Braking system Parking brake PARKING BRAKE CALLIPER REMOVAL - Undo the two screws and remove the protection. - Loosen the nut indicated and remove the trans- mission. - Undo the two screws and remove the calliper. - To refit, carry out the previous operations but in reverse order. After adjustment, tighten the nut indi- cated to the prescribed torque.
Page 344: Pin Fixing Parking Brake Pads
GP 800 i.e. Braking system PARKING BRAKE CONTROL REMOVAL - Remove the shield back plate. - Undo the four fixing screws and remove the transmission cable. BRAKE PAD REPLACEMENT - Remove the brake calliper. - Unscrew the two retaining pins and slide off the pads.
Page 345 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 346 GP 800 i.e. Cooling system Circuit diagram KEY: 1. Rear head outlet 2.To radiator COOL SYS - 2...
Page 347 GP 800 i.e. Cooling system 3.Expansion tank 4.Radiator breather pipe 5. Circuit filling pipe 6. Thermostat 7. By-pass pipe 8. Intake from radiator 9. Coupling (T-joint) 10.Front head outlet 11. Delivery to the cylinders 12. Pump 13. Intake from radiator The cooling system is a forced circulation type system, with continuous venting and air pressurisation.
Page 348 GP 800 i.e. Cooling system Specification Desc./Quantity 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...
Page 349: Coolant Replacement
GP 800 i.e. Cooling system AVOID STARTING THE ENGINE WITHOUT PRESSURISATION SINCE IT MAY REACH THE BOIL- ING TEMPERATURE BEFORE THE ELECTRIC FAN STARTS WORKING. IN CASE THE ELECTRIC VENTILATION TIME INCREASES, CHECK THE THERMOSTAT OPEN- ING TEMPERATURE. Recommended products AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze fluid, CUNA NC 956-16 (*) System sealing check...
Page 350 GP 800 i.e. Cooling system - Connect the bleed screw to the expansion tank, using a transparent hose to be able to visually check that air is escaping. - Start the vehicle. - Keep it running at idle speed up to 30 sec max., causing the air to escape.
Page 351 GP 800 i.e. Cooling system In case of noise or fluid leaks from the water pump drainage hole, inspect the water pump as descri- bed in the Engine Chapter. Proceed to carry out a few preliminary operations as described below: - Place the vehicle on its centre stand and on flat ground.
Page 352 GP 800 i.e. Cooling system diagnosis Excessive system pressure 1 - Check the expansion tank cap efficiency. N.B. THE CAP IS EQUIPPED WITH A PRESSURE RELIEF VALVE CALIBRATED AT 0.9 BAR. There is also a valve that must allow air inlet during the cooling step. YES go to 2 NO go to 3 2 - Check the head gasket seal (see «Thermal group and timing system»...
Page 353 INDEX OF TOPICS CHAS HASSIS...
Page 354 GP 800 i.e. Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. To remove the bodywork, follow this order: Front part: «A» Rear-view mirrors - Adjustable windshield «B» Front shield upper section «C»...
Page 355 GP 800 i.e. Chassis Seat - Undo the four fixing screws and remove the sad- dle. Driving mirrors - Undo the two fixing screws on both sides and re- move the rear-view mirrors. Instrument panel - Remove the front shield. - Disconnect the two connectors.
Page 356 GP 800 i.e. Chassis - Undo the six screws fixing it to the shield back plate. - Remove the instrument panel. Headlight assy. - Undo the screw indicated and remove the grille. - Undo the two screws indicated. CHAS - 4...
Page 357 GP 800 i.e. Chassis - Undo the five fixing screws and remove the head- light frame plus the gasket. CAUTION UPON REFITTING, CHECK THE CORRECT PO- SITION OF THE GASKET OF THE HEADLIGHT FRAME. - Undo the two screws indicated and take out the front headlight assembly from its seat.
Page 358 - Undo the seven screws indicated. - Undo the two screws indicated on both sides of the wheel housing. - Working on both sides, remove the Gilera clip-on badge and undo the screw underneath. - Remove the battery compartment cover and the cover of the expansion tank cap.
Page 359 GP 800 i.e. Chassis - Detach the front shield from the vehicle, discon- nect the turn indicator connectors and remove the front shield. Knee-guard - Remove the front shield. - Disconnect the stop switches and unscrew the retainers of the brake pumps U-bolts; release them from the half-handlebars.
Page 360 GP 800 i.e. Chassis - Undo the two fixing screws to the front central cover. - Remove both fuse terminal blocks. - Disconnect the instrument panel connectors. - Pull the shield back plate upwards to detach it from the vehicle. CHAS - 8...
Page 361 GP 800 i.e. Chassis - Disconnect, one at a time, the brake pumps plus the pipes and the half-handlebar plus the controls, pass them through the central opening in the shield back plate. - Remove the shield back plate. - Once the shield back plate has been removed, remove the central frame by undoing the five screws indicated from the rear part: See also...
Page 362 GP 800 i.e. Chassis Front wheel housing - Remove the fork - Undo the two screws indicated. - Undo the two screws indicated. - Disconnect the ambient temperature sensor. - Release the throttle control transmissions and the oil bleed pipe of the air filter from the clamps. - Undo the screw fixing the electrical cable harness clamp.
Page 363 GP 800 i.e. Chassis - Remove the license plate support together with the rear light unit. - Undo the screw indicated and detach the rear light unit from the license plate support Footrest - These operations are described once but apply to both footrests.
Page 364 GP 800 i.e. Chassis Side fairings COPERTURA LATERALE TELAIO - Le operazioni sono descritte una volta solo ma sono valide per entrambi i lati del veicolo. - Rimuovere la copertura centrale anteriore. - Rimuovere la parte anteriore del vano portacas- - Rimuovere lo spoiler.
Page 365 GP 800 i.e. Chassis License plate holder - Remove the side fairings. - Undo the two screws indicated from both fairings. - Undo the two connecting screws to the support bracket. - Disconnect the connector of the left turn indicator. - Detach the license plate support, disconnect the connectors of the right turn indicator, the license plate light and the rear light unit, and remove the...
Page 366 GP 800 i.e. Chassis Helmet bay - Svitare le due viti indicate. - Svitare le tre viti indicate. - Rimuovere la parte anteriore del vano portacas- - Rimuovere il gruppo ottico posteriore. - Svitare il tappo serbatoio carburante e le quattro viti indicate.
Page 367 GP 800 i.e. Chassis - Svitare le due viti indicate. - Sollevare dalla parte anteriore il vano portacasco e scollegare i connettori indicati e rimuovere il va- no portacasco. spoiler - These operations are described once but apply to both spoilers. - Remove the rubber mat.
Page 368: Fuel Tank
GP 800 i.e. Chassis Fuel tank Il serbatoio carburante è composta da due semi- serbatoi situati sotto le fiancate destra e sinistra del veicolo, collegati da un tubo di compensazione nella parte inferiore e un manicotto di giunzione nella parte superiore. La rimozione dei semiser- batoi deve avvenire separatamente seguendo le indicazioni riportate: - Rimuovere il carburante contenuto all'interno del...
Page 369 GP 800 i.e. Chassis - Operando sul lato destro scollegare i connettori del sensore di livello e le tubazioni della pompa carburante. N.B. PAY ATTENTION WHEN DISCONNECTING THE FUEL PIPES AS EXERTING EXCESSIVE FORCE COULD DAMAGE THE PLASTIC IN- SERTS ON THE PUMP BODY. UPON REAS- SEMBLY, IT IS THEREFORE NECESSARY TO SLIGHTLY PRESS THE PIPES AND THE RE- TAINING RING TOWARDS THE PUMP;...
Page 370: Front Mudguard
GP 800 i.e. Chassis CAUTION UPON FITTING, BE PARTICULARLY CAREFUL WHEN INSERTING THE BREATHER PIPE IN THE FORK SLOT. Rear central cover - Act on the two tongues indicated to detach the rear central cover. Front mudguard - Undo the two fixing screws on both sides. CHAS - 18...
Page 371 GP 800 i.e. Chassis - Once the mudguard has been removed, detach the front part from the rear part by undoing the two screws indicated on both sides. Radiator fan - Get a container of suitable capacity, disconnect the pipes indicated and let the fluid drain off the cooling system.
Page 372 GP 800 i.e. Chassis - Remove the radiator by releasing it from its fit- tings. - To remove the electric fan, first remove the radi- ator and afterwards undo the three screws indica- ted. Rear Remove the four fixing screws of the cover and release it from the two leverages.
Page 373 GP 800 i.e. Chassis - Undo the five screws indicated. - Remove the side fairing by pulling it outwards and towards the rear part of the vehicle at the same time to release the tongues. Front central cover - Remove the battery compartment cover and ex- pansion tank compartment cover.
Page 374 GP 800 i.e. Chassis - Hold the front central cover as shown in the fig- ure. - Push the shield back plate and pull towards the vehicle rear part to release the tongue. Flyscreen - Undo the fours screws indicated and remove the windshield.
Page 375 GP 800 i.e. Chassis Battery - Undo the four screws indicated and remove the battery compartment cover. - Undo the screw and remove the battery fixing bracket. - Undo the battery negative and positive wires. WARNING IN ORDER TO AVOID DAMAGING THE ELEC- TRICAL SYSTEM, NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING.
Page 376 GP 800 i.e. Chassis CHAS - 24...
Page 377 INDEX OF TOPICS PRE DE DELIVERY...
Page 378: Screws Fixing Half-Handlebars - Supporting Plate
GP 800 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection - Visually check that there is a yellow mark on the following clamps: HANDLEBAR •...
Page 379 GP 800 i.e. Pre-delivery • Centre stand bolt nuts • Muffler support flange screw Electrical system • Battery • Main switch • Lights: high beams, low beams, side/taillights (front and rear) and relevant warning lights - Regulating the headlights according to the regulations currently in force •...
Page 380 GP 800 i.e. Pre-delivery - Engine coolant level - Engine oil level Road test Test ride - Cold start - Instrument operations - Response to the gas command - Stability on acceleration and braking - Rear and front brake efficiency - Parking brake efficiency - Rear and front suspension efficiency - Abnormal noise...
Page 381 INDEX OF TOPICS TIME...
Page 382 GP 800 i.e. Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine to chassis - Replace- ment TIME - 2...
Page 383 GP 800 i.e. Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase- Replace- ment 001153 Crankcase half gasket - Re- placement 001111 Water pump gear - Replace- ment 007007 Water pump rotor cover 001187 Overall sealing - Replac. 005134 Speed sensor - Replacement 001160 Minimum oil pressure sensor - Replacement...
Page 384 GP 800 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 4...
Page 385 GP 800 i.e. Time Cylinder assy. CYLINDER GROUP Code Action Duration 001002 Cylinder piston - Replace- ment 001154 Pin ring piston unit - Service TIME - 5...
Page 386 GP 800 i.e. Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - Adjustments 001056 Head gasket - Replacement 001126 Head - Replacement 000235 Coolant temperature sensor - Replac. 007012 Coolant bleed valve - Re- placement 005089 Tone wheel - Replacement...
Page 387 GP 800 i.e. Time Rocker arms support assy. OCKING LEVER UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Rocking lever valve - Re- placement 001129 Chain tightener - Replace- ment 001051 Belt/ Timing chain - Replace- ment 001125 Chain guide pads - Replace- ment 140021 Camshaft timing system pul-...
Page 388 GP 800 i.e. Time Cylinder head cover HEAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replace- ment TIME - 8...
Page 389 GP 800 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - replace 001150 Flywheel cover gasket - Re- placement 001123 Oil filter -Replacement TIME - 9...
Page 390: Driven Pulley
GP 800 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Re- placement TIME - 10...
Page 391 GP 800 i.e. Time Oil pump OIL PUMP Code Action Duration 001186 Oil pump control gear - Re- plac. 001122 Oil pump chain - Replace- ment 001042 Oil pump - Service 001184 Oil delivery pump - Replac. 001124 Lubrication by-pass - Re- placement 001189 Water pump control gear -...
Page 392 GP 800 i.e. Time Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001195 Toothed wheel - Replac. 001196 Driven pulley shaft - Replac. 001190 Oil sealing casing - Replac. TIME - 12...
Page 393 GP 800 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001006 driving pulley - Service 001066 driving pulley - Replacement 001177 Variator rollers / shoes - Re- placement 001181 Adjusting ring - Replac.
Page 394 GP 800 i.e. Time Final drive FINAL DRIVE Code Action Duration 001190 Oil sealing casing - Replac. 001191 Driving sliders - Replac. 370011 Propeller shaft - Replac. 410301 Pinion flange - Replac. 001103 Final drive pinion - Replac. 000605 Final drive (pinion, chain, crown) - Replacement 002077 Final drive chain - Replace-...
Page 395: Transmission Cover
GP 800 i.e. Time Code Action Duration 001141 Belt anti-flapping roller - Re- placement 004128 Corona ruota posteriore - Sost Transmission cover TRANSMISSION COVER Code Action Duration 001096 External transmission cover - Replacement 001131 Transmission air intake - Re- placement 001170 Air manifold - replacement 001135...
Page 396 GP 800 i.e. Time Water pump WATER PUMP Code Action Duration 007017 Water pump cover - Replace- ment 161011 Water pump and/or gasket - Replacement 001111 Water pump gear - Replace- ment 007008 Cylinder head outlet rubber coupling - Replacement 007022 Head outlet T-joint - Replac.
Page 397: Flywheel Magneto
GP 800 i.e. Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001173 Rotor - Replacement 001067 Stator - Removal and Refit- ting 001058 Complete flywheel - Replace- ment 001104 Start-up freewheel - Replace- ment TIME - 17...
Page 398 GP 800 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - change 001047 Injector - Replacement 001166 Throttle body - Replacement TIME - 18...
Page 399 GP 800 i.e. Time Exhaust pipe MUFFLER Code Action Duration 001105 Silencer - Replacement 001095 Muffler guard - Replacement 170101 Exhaust pipe gasket - Re- placement 005138 Lambda probe - Replace- ment 170071 Catalytic converter and/ or gasket - Replacement 003077 Muffler supporting arm/ rear shock absorber - Replace-...
Page 400: Air Cleaner
GP 800 i.e. Time Air cleaner AIR CLEANER Code Action Duration 110301 Blow-by valve and/or blow-by pipe- Replac. 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Cleaner / Throttle body union - Replacement TIME - 20...
Page 401 GP 800 i.e. Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004147 Footrest support bracket, one side - Replacement 004116 Rear frame - Replacement TIME - 21...
Page 402 GP 800 i.e. Time Centre-stand STAND Code Action Duration 004004 Stand - Replacement 004179 Stand buffer - Replacement 001053 Stand bolt - Replacement 004102 Side stand - Replacement TIME - 22...
Page 403 GP 800 i.e. Time Legshield spoiler FRONT SHIELD Code Action Duration 004021 Shield upper section - Re- placement 004064 Front shield - Replacement 004020 Headlight frame - Replace- ment 004085 Fairing (1) - Replacement TIME - 23...
Page 404 GP 800 i.e. Time Side fairings SIDE COVERS Code Action Duration 004036 Frame cover - Replacement 004129 Rear fairing - Replacement 004068 Passenger handgrip - Re- placement 004053 Spoiler - Replacement TIME - 24...
Page 405 GP 800 i.e. Time Rear cover REAR SHIELD Code Action Duration 004065 Front shield, rear part - Re- moval and refitting 004023 Shield rim - Replacement 004132 Half-panel - replac. (1) 004071 Battery compartment - Re- placement TIME - 25...
Page 406 GP 800 i.e. Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replacement 004011 Central chassis cover - Re- placement 004012 Rear fairings - Removal and refitting 004015 Footrest - Removal and Re- fitting 004075 Front mat - Replacement 004186 Passenger footrest support -...
Page 407 GP 800 i.e. Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replace- ment 003087 Wheel housing - Replace- ment TIME - 27...
Page 408 GP 800 i.e. Time Fuel tank UEL TANK Code Action Duration 004137 Injector pump pipe - Replace- ment 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004168 Fuel tank cap - Replacement 004005 Fuel tank - Replacement 004073 Fuel pump - Replacement 004188...
Page 409 GP 800 i.e. Time Rear shock-absorber REAR SHOCK ABSORBERS Code Action Duration 003007 Rear shock absorber - Re- moval and Refitting 003078 Rear fork - Replac. 000601 Fork removal and fitting / Bushings and spacer remov- 003125 Fork bolt - Replac. 003126 Fork guards - Replac.
Page 410 GP 800 i.e. Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002059 Right-hand knob - change 002060 Complete throttle control - Replacement 004154 Left/ right half-handlebar - Replac. 004155 Left/ right half-handlebar sup- port - Replac. 002071 Left knob - Replacement 003059 Counterweight - Replace- ment...
Page 411 GP 800 i.e. Time Swing-arm RACCIO OSCILLANTE Code Action Duration 003015 Traversa anteriore sostegno motore - Sost 003016 Tamponi anteriori sostegno motore - Sost 003017 Tampone posteriore suppor- to motore - Sost 001032 Engine support pin - Replace- ment TIME - 31...
Page 412 GP 800 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 32...
Page 413 GP 800 i.e. Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement 004099 Odometer housing - Replace- ment TIME - 33...
Page 414 GP 800 i.e. Time Locks LOCKS Code Action Duration 005146 Electric saddle opening acti- vator - Replacement 004054 Saddle lock catch - Replace- ment 004010 Anti-theft lock - Replacement Turn signal lights Front lights TIME - 34...
Page 415 GP 800 i.e. Time RONT TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005067 Front direction indicator bulb - Replacement 005012 Front direction indicators - Replacement 005002 Front light - Replacement 005008 Light bulbs - Replacement Rear lights TIME - 35...
Page 416 GP 800 i.e. Time EAR TURN INDICATORS INDICATOR LIGHTS Code Action Duration 005005 Taillight - Replacement 005022 Rear turn indicators - Re- placement 005031 Licence plate light bulb - Re- placement 005131 Licence plate light support - Replacement 005068 Rear turn indicator bulb - Re- placement TIME - 36...
Page 417: Front Wheel
GP 800 i.e. Time Front wheel RONT WHEELS Code Action Duration 003047 Front tyre - Replacement 003037 Front wheel rim- Replace- ment 002041 Front brake disc - Replace- ment 004123 Front wheel - Replacement 003040 Front wheel bearings - Re- placement 003038 Front wheel axle - Removal...
Page 418: Rear Wheel
GP 800 i.e. Time Rear wheel REAR WHEEL Code Action Duration 002070 Rear brake disc - Replace- ment 001016 Rear wheel - Replacement 001071 Front wheel rim - Removal and refitting 004126 Rear wheel tyre - Replace- ment 002031 Rear wheel hub bearings - Replacement 004125 Rear wheel axle - Replace-...
Page 419: Electric Start
GP 800 i.e. Time Electric start ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 005045 Starter motor cable harness - Replacement 001017 Start-up pinion - Replace- ment 001151 Start-up driven gearing - Re- placement TIME - 39...
Page 420 GP 800 i.e. Time Electric devices ΗΛΕΚΤΡΙΚΑ ΕΞΑΡΤΗΜΑΤΑ Code Action Duration 001069 HV coil - Replacement 001094 Spark plug cap - Replace- ment 832311 Turn indicator flash - Re- placement 001023 Control unit - Replacement 005009 Voltage regulator - Replace- ment 005099 Electric saddle opening de-...
Page 421 GP 800 i.e. Time REMOTE CONTROLS Code Action Duration 005072 Immobilizer aerial - Replace- ment 005073 Immobilizer decoder - Re- placement 005003 Horn - Replacement 005011 Start-up remote control switch - Replacement 005007 Battery - Replacement 000319 Remote control - Replac. 005052 Fuse (1) - Replacement TIME - 41...
Page 422 GP 800 i.e. Time WIRE UNIT Code Action Duration 005001 Electrical system - Replace- ment 005114 Electrical system - Service 820021 Engine cable harness - Re- plac. TIME - 42...
Page 423 GP 800 i.e. Time Electronic controls HANDLEBAR CONTROLS Code Action Duration 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE- MENT 888126 Helmet compartment light switch - replacement 005079 Stand switch - Replacement TIME - 43...
Page 424 GP 800 i.e. Time Transmissions TRANSMISSIONS Code Action Duration 002063 Complete throttle control - Replacement 003061 Accelerator transmission - Adjustment TIME - 44...
Page 425 GP 800 i.e. Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Re- placement 005026 Helmet compartment bulb - Replacement 005027 Helmet compartment bulb support - Replacement 004142 Plug socket - Replacement TIME - 45...
Page 426 GP 800 i.e. Time Rear side fairings REAR COVERS Code Action Duration 005048 Licence plate holder - Re- placement 004136 License plate support - Re- placement TIME - 46...
Page 427: Front Suspension
GP 800 i.e. Time Front suspension FRONT SUSPENSION Code Action Duration 003010 Front suspension - Service 003112 Central steering tube - re- placement 003107 Sliding stems - replacement 003002 Steering fifth wheel - Re- placement 331352 Fork service TIME - 47...
Page 428 GP 800 i.e. Time Cooling system COOLING SYSTEM Code Action Duration 007013 Radiator expansion tank con- nection pipe - Replacement 001052 Coolant and air bleed - Re- placement 007001 Expansion tank - Replace- ment 007024 Expansion tank cap - Re- placement 007003 Coolant delivery and return...
Page 429 GP 800 i.e. Time Braking system RAKE SYSTEM Code Action Duration 002021 Front brake piping - Replace- ment 002081 Rear brake disc piping - Re- placement 003109 Parking brake mechanical calliper - replacement 003108 Parking brake flexible trans- mission - replacement 002002 Shoes - Rear brake pads - Replacement...
Page 430 GP 800 i.e. Time Windscreen WINDSHIELD Code Action Duration 442601 Right side protection replac. 442611 Left side protection replac. 004101 Windshield - Replacement 004191 Windshield support - Replac. 004192 Windshield support tube - Re- plac. 004193 Windshield motor unit - Re- plac.
Page 431 GP 800 i.e. Time Stickers RANSFERS Code Action Duration 004066 Driving mirror - Replacement 004159 Plates / Stickers - Replace- ment TIME - 51...

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