Gilera GP 800 i.e. Service Station Manual Download

Page: 228 / 431

- 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.

CAUTION

PLACE THE CONNECTING RODS PROPERLY.

- Simultaneously hold the crankshaft with one

hand and the tip with the other until the crankshaft

stops on the crankcase half.

- Remove the tip.

Specific tooling

020665Y

Transmission side crankshaft fitting

tip

Engine

GP 800 i.e.

ENG - 78

Summary of Contents for GP 800 i.e.

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: ...to components parts or accessory supplies which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are available in all Countries The availability of individual versions should be confirmed with the official Piaggio sales network Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reprodu...

Page 3: ...e to read the sections of this manual concerning special tools along with the special tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely...

Page 4: ......

Page 5: ...OOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 8: ...compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer Non original or non conforming spares may damage the vehicle Use only the appropriate tools designed for this vehicle Alwa...

Page 9: ...Vehicle identification Chassis prefix A ZAPM55100 Engine prefix B M554M Dimensions and mass GP 800 i e Characteristics CHAR 3 ...

Page 10: ...a dry sump system with double lobe pump one for delivery and one for re turn controlled by a chain and paper filter Lubrication pressure 3 5 4 bar Minimum lubrication pressure 100 C 0 8 bar Fuel supply Multipoint electronic injection with single Ø 38 mm throttle body and electric fuel pump Cooling Forced liquid circulation cooling Fuel Unleaded petrol 95 RON TECHNICAL SPECIFICATIONS OIL PUMP Speci...

Page 11: ... metal reed valve and decantation chamber TECHNICAL SPECIFICATIONS Specification Desc Quantity Cooling system capacity 2 4 l Prescribed fluid AGIP PERMANENT SPEZIAL Sealing pressure Cap calibrated at 0 9 bar THERMOSTAT Specification Desc Quantity Type Wax type with deviator Starts opening 85 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation starts at 105 C ...

Page 12: ...replacement Transmission oil cm Cooling system fluid 2 4 l Fuel tank reserve 14 l 0 5 l 1 8 l Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Start up Electric Ignition High efficiency electronic inductive ignition inte grated with the injection system with variable ad vance and separate HV coil Ignition advance Three dimensional map managed by control unit Spark plug NGK CR7EKB Al...

Page 13: ...eck that given regular conditions there is no continuity between terminals 30 and 87 but that there is continuity between terminals 30 and 87a 2 Apply 12V voltage to power terminals 85 and 86 of the remote control 3 With the remote control powered check that there is continuity between terminals 30 and 87 However there must be no continuity between ter minals 30 and 87a 4 If these conditions are n...

Page 14: ...WINDSHIELD UP BUTTON WINDSHIELD DOWN BUTTON HELMET COMPARTMENT LIGHT BUTTON HORN BUTTON Characteristics GP 800 i e CHAR 8 ...

Page 15: ...STARTER BUTTON LIGHT SWITCH ENGINE STOP SWITCH TURN INDICATOR SWITCH GP 800 i e Characteristics CHAR 9 ...

Page 16: ...een 0 7V and 4V between pins 23 3 on engine side wiring Ground insulation of pins 29 32 3 on engine side wiring STEPPER MOTOR Resistance engine side connector between pins 19 9 51 Ohm Resistance engine side connector between pins 18 17 51 Ohm FUEL INJECTOR Type 4 holes Conicity of the nozzle 24 Resistance at terminals 13 7 15 2 Ohm Characteristics GP 800 i e CHAR 10 ...

Page 17: ...sistance between and 890 Ohm pins 35 25 engine side wiring Insulation between and S and between and S pins 35 34 and 25 34 engine side wiring ENGINE TEMPERATURE SENSOR 0 5900 Ohm 10 3800 Ohm 20 2500 Ohm 30 1700 Ohm 80 300 Ohm H V COIL Primary winding resistance 520 620 mOhm Secondary resistance 6830 7830 Ohm GP 800 i e Characteristics CHAR 11 ...

Page 18: ...single plate ø 41 mm straight stems Front suspension travel 126 mm Oil quantity for stem 295 3 cm Unloaded spring length mm Rear suspension Single shock absorber that acts directly on the fork Rear suspension travel 135 mm Brakes BRAKES Specification Desc Quantity Front brake Ø 300 mm double disc brake with hydraulic control activated by the handlebar right hand lever Two floating callipers ø 28 d...

Page 19: ...mp gear fixing screw 5 6 THERMAL GROUP AND TIMING SYSTEM Name Torque in Nm Spark plug 12 14 Head fixing stud bolts Head fixing nuts 10 12 Exhaust intake head fixing nuts 10 12 Head lubrication control jet 5 7 Tensioner sliding block fixing screw 10 14 injector fixing screw 3 4 inlet manifold fixing screws 11 13 Tappet cover fixing screws 7 9 Throttle body fixing screws 11 13 camshaft retaining bra...

Page 20: ...Screws tightening water pump gear protection plate 3 4 CHASSIS Name Torque in Nm Side stand bolt nut 37 Screws fixing side stand button 6 Screw fixing electric fan radiator 2 3 Screw fixing radiator chassis 5 7 Nut fixing silent block plate chassis 22 25 Nut fixing silent block plate 33 41 Pin fixing nut M14 124 153 Pin fixing nut M10 47 52 Upper nut fixing engine support link rods chassis 33 41 L...

Page 21: ...rear brake calliper coupling 20 25 Brake pipes brake pump coupling 16 20 Screws fixing front brake disc to rim 25 Screws fixing rear brake disc to rim 25 Screws fixing brake pump to handlebar 7 10 Screw fixing three way union to fork head 10 12 Screws fixing front brake calliper to fork 20 25 Screw fixing rear brake calliper to supporting plate 20 25 Screw fixing parking brake calliper to supporti...

Page 22: ...fork 38 46 Screw fixing shock absorber fork 38 46 Screw fixing chain stop slider fork 5 7 Screw fixing centre stand stop buffer fork 5 7 Crown fixing screws 22 5 27 5 Rear wheel pin nut 70 Fork locking ring nut 60 3 Nm Fork pin set screw 0 5 Fork pin nut 90 5 Apply LOCTITE 243 threadlock Overhaul data Assembly clearances Cylinder piston assy Characteristics GP 800 i e CHAR 16 ...

Page 23: ... 87 975 87 982 0 029 0 043 N B THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS Calculate the coupling clearance between pin and connecting rod end Characteristic Standard clearance 0 015 0 029 mm Measure the capacity diameter on the piston Characteristic Standard diameter 22 0 006 0 ...

Page 24: ...ter The coupling is carried out in pairs A A B B C C D D Piston rings Fit rings 2 and 3 with the word TOP facing upwards Position the openings in the rings as shown here Value A of sealing ring inside the cylinder Check the size of the sealing ring opening Compression ring 0 15 0 35 mm Max value 0 5 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm Oil scraper ring 0 25 0 50 mm Max value 0 65 mm ...

Page 25: ...s allowed after use 0 10 mm Intermediate ring Standard coupling clear ance 0 02 0 07 mm Maximum clearances allowed after use 0 10 mm Oil scraper ring Standard coupling clearance 0 01 0 06 mm Maximum clearances allowed after use 0 10 mm Replace the piston if clearances exceed the max imum limits specified in the table Crankcase crankshaft connecting rod Diameter of crankshaft bearings Measure the c...

Page 26: ... 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 A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm Characteristics GP 800 i e CHAR 20 ...

Page 27: ...als Quantity Half shaft trans mission side 23 8 0 1 A D 0 20 0 55 Flywheel side half shaft 23 8 0 1 B D 0 20 0 55 Connecting rod 22 0 10 0 15 C D 0 20 0 55 Complete crank shaft 91 8 0 05 E D 0 20 0 55 Characteristic Crankshaft crankcase axial clearance H GP 800 i e Characteristics CHAR 21 ...

Page 28: ...LL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION Before assembling check that the clearance between the engine crankcase bushing and the crankshaft is within the predetermined limits Characteristic Crankshaft bushing maximum clearance admitted 0 08 mm The standard bushing diameter after driving is variable on the basis of a coupling selection The bushin...

Page 29: ...ng refitting Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted Characteristic Maximum allowable run out 0 1 mm In case of irregularities replace the head Check the sealing surfaces for the intake and exhaust manifold Check that the camshaft and the rocker pin capacities exhibit no wear Check that the head cover surface is not worn Check that the coola...

Page 30: ...e through the valves when these are just pressed with the fingers Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD BEARINGS Specification Desc Quantity Bearing A 42 0 025 Bearing B 19 5 0 2 Bearing C 13 0 018 Measure the unloaded spring length Characteristic Standard length 44 4 mm Admissible limit after use 42 4 mm Characteristics GP 800 i e CHAR 24 ...

Page 31: ... seats with a 45 mill and then grind In case of excessive wear or damages replace the head STANDARD VALVE LENGTH Specification Desc Quantity Inlet 95 0 0 3 mm Outlet 94 2 0 3 mm Measure the diameter of the valve stems in the three positions indicated in the diagram STANDARD DIAMETER Specification Desc Quantity Inlet 4 987 4 972 mm Outlet 4 975 4 960 mm MINIMUM ADMISSIBLE DIAMETER Specification Des...

Page 32: ...he deformation with a comparator Characteristic Limit values admitted 0 1 mm Check the concentricity of the valve head by ar ranging a comparator at right angle relative to the valve head and rotate it on a V shaped abutment Characteristic Admissible limit 0 03 mm Measure the valve guide Characteristic Valve guide 5 0 012 mm Characteristics GP 800 i e CHAR 26 ...

Page 33: ...o failures you can use the same valves To obtain better sealing perform ance grind the valve seats Grind the valves gently with a fine grained lapping compound During the grinding keep the cylinder head with the valve ax es in a horizontal position This will prevent the lapping compound residues from penetrating be tween the valve stem and the guide see figure CAUTION TO AVOID SCORING THE CONTACT ...

Page 34: ...ecification Desc Quantity Bearing A Ø 41 910 mm Bearing B diameter 19 940 mm Using a gauge measure the cam height STANDARD HEIGHT Specification Desc Quantity intake 33 988 mm discharge 33 417 mm ADMISSIBLE LIMITS Specification Desc Quantity intake 33 740 mm discharge 33 170 mm Standard axial clearance 0 0 22 mm Maximum admissible axial clearance 0 3 mm Check that the cam contact sliding block and ...

Page 35: ...EAD IN OR DER TO RESTORE COMPRESSION RATIO BASE GASKET B MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD ON THE OTHER HAND THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE THE SMALLER THE GASKET THICKNESS Characteristic Compression ratio 10 5 0 5 1 BASE GASKET THICKNESS Name Measure A Thickness A MEASURE TAKEN 0 185 0 ...

Page 36: ...ining NLGI 2 ISO L XBCIB2 of the swinging arm AGIP FORK 7 5 W Oil for front fork Hydraulic fluid SAE 7 5 W AGIP ROTRA MP 80W 90 Transmission oil SAE 80W 90 API GL 5 AGIP CHAIN SPRAY Spray lubricating grease Spray lubricating grease for chains and gears UNIT OF MEASUREMENT CONVERSION ENGLISH SYSTEM AND INTERNATIONAL SYSTEM IS Specification Desc Quantity 1 Inch in 25 4 Millimetres mm 1 Foot ft 0 305...

Page 37: ...INDEX OF TOPICS TOOLING TOOL ...

Page 38: ... 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 020382Y012 bush valve removing tool Tooling GP 800 i e TOOL 2 ...

Page 39: ... 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 ing GP 800 i e Tooling TOOL 3 ...

Page 40: ...tion 020565Y Flywheel lock calliper spanner 020659Y Tool to remove clutch and re place belt 020660Y Driving pulley lock 020713Y Flywheel extractor 020527Y Engine support base 020658Y Engine plate Tooling GP 800 i e TOOL 4 ...

Page 41: ...aft fitting tip 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 GP 800 i e Tooling TOOL 5 ...

Page 42: ... 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 Tooling GP 800 i e TOOL 6 ...

Page 43: ...cription 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 GP 800 i e Tooling TOOL 7 ...

Page 44: ...0262Y 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 Tooling GP 800 i e TOOL 8 ...

Page 45: ...tion 020150Y Air heater support 020151Y Air heater 001467Y003 Nut 001467Y004 Lug Taper pin 001467Y005 Screw 001467Y006 Pliers to extract 20 mm bearings 020467Y020 Pliers to extract 30 mm bearings GP 800 i e Tooling TOOL 9 ...

Page 46: ... 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 020360Y Adaptor 52 x 55 mm 020655Y Adaptor 62x68 mm 020670Y Adaptor 34 mm Tooling GP 800 i e TOOL 10 ...

Page 47: ...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 GP 800 i e Tooling TOOL 11 ...

Page 48: ...m 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 Tooling GP 800 i e TOOL 12 ...

Page 49: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 50: ...eplacement Check Nominal 0 15 mm INT and EXH restore only if deviation exceeds 0 05 mm Replace every two years Km x 1000 1 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 6 0 6 5 7 0 7 5 8 0 8 5 9 0 9 5 10 0 Engine Oil Engine Oil level check and top up Oil filter CVT driving belt Slide pads and variator rollers Ignition spark plugs CVT air filter sponge mesh cleaning Air filter Throttle body cleaning EC...

Page 51: ...place the spark plugs into the hole at the due inclination and tighten them by hand Only use the wrench to lock spark plugs in place Place caps C fully over the spark plugs Refit cover B CAUTION SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD SPARK PLUGS MAINTE NANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE USING NON CONFORMING ELECTRONIC CENTRAL UNITS AND ELECTRONIC IGNITIO...

Page 52: ...ly over the spark plugs Refit the lid E CAUTION SPARK PLUGS MUST BE REMOVED WHEN THE ENGINE IS COLD SPARK PLUGS MAINTE NANCE OPERATIONS ARE DESCRIBED IN THE SCHEDULED MAINTENANCE TABLE USING NON CONFORMING ELECTRONIC CENTRAL UNITS AND ELECTRONIC IGNITIONS OR SPARK PLUGS OTHER THAN THOSE PRESCRIBED MAY SERIOUSLY DAMAGE THE ENGINE N B THE USE OF SPARK PLUGS OTHER THAN THE INDICATED TYPE OR OF SHIELD...

Page 53: ...icolo svitare la vite indicata Disimpegnare dalla fascetta di ritegno la tuba zione blow by Operando dal lato sinistro del veicolo svitare le sei viti indicate e rimuovere la fascetta di ritegno del manicotto Rimuovere l elemento filtrante dalla parte interna del depuratore aria Sfilare la tubazione di recupero vapori blow by GP 800 i e Maintenance MAIN 5 ...

Page 54: ...gnare 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 Maintenance GP 800 i e MAIN 6 ...

Page 55: ...ry compartment access cover C by undoing the four screws D Remove the access cover to the cap of expan sion tank E by undoing the four screws F Undo the two screws G Remove the central cover H holding it as shown in the figure and pulling it towards the rear part of the vehicle GP 800 i e Maintenance MAIN 7 ...

Page 56: ...r from the inside to the outside of the filter opposite to the sense the air flow travels under regular operation Clean the external side of the air filter with a clean cloth Remove the cap M regularly drain the content into a container and send it to a recycling bank AIR DEFLECTOR FILTER For filter removal Remove the side fairings Undo the three indicated screws and remove the air deflector Maint...

Page 57: ... is used to lubricate the distribution elements the bench bearings and the thermal group An insufficient quantity of oil can cause serious damage to the engine In all 4T engines the deterioration of the oil characteristics or a certain consumption should be con sidered normal especially if during the run in period Consumption levels in particular can be influenced by the conditions of use e g oil ...

Page 58: ...st be used when checking oil level Then start up the vehicle let it run for a few mi nutes and shut it off After about 5 minutes check the level and if necessary top up but never ex ceeding the MAX level reference mark G sight glass on the right crankcase For top ups and oil changes use new oil of the recommended type Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JAS...

Page 59: ...ENGINE IS WARM DO NOT GO BEYOND THE MAX MARK ON THE CRANKCASE OR BELOW THE MIN LEVEL MARK ON THE DIPSTICK TO AVOID SEVERE ENGINE DAMAGE Check For oil level check Keep the vehicle perfectly upright with both wheels on the ground Remove cover A holding it and pulling it out Unscrew the dipstick cap B and check that the oil level exceeds the MIN mark In order to check oil level properly keep the engi...

Page 60: ...l Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Syn thetic oil Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the ON position However this light should switch off once the engine has been star ted If the light turns on during braking at idling speed or while turning a co...

Page 61: ...tlet 0 15 mm See also Side fairings Air filter Rear head Remove the plastic parts in order to free the head cover access Undo the six fixing screws and remove the tappet cover together with the gasket Check the valve clearance and if necessary re store the correct clearance Characteristic Valve clearance Inlet 0 15 mm Outlet 0 15 mm See also Helmet bay According to the procedure described in the E...

Page 62: ...d CAUTION THE RECOMMENDED COOLANT MUST BE USED FOR TOP UPS TO AVOID DAMAGING THE ENGINE Recommended products AGIP PERMANENT SPEZIAL coolant Monoethylene glycol based antifreeze fluid CU NA NC 956 16 Braking system Level check The front and rear brake fluid reservoirs are both positioned on the handlebars Proceed as follows Rest the vehicle onto the centre stand with the handlebar centred Check the...

Page 63: ...e table Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid Headlight adjustment Proceed as follows Place the vehicle in running order and with the tyres inflated to the prescribed pressure on a flat surface 10 m away from a white screen situated in a shaded area making sure that the longitudinal axis of the vehicle is perpendicular to the screen Turn on the headlight and che...

Page 64: ...e grille Act on the screw L Turn it anticlockwise to raise the light beam and turn it clockwise to lower it Drive chain To check the drive chain clearance Stop the engine Position the scooter on centre stand Maintenance GP 800 i e MAIN 16 ...

Page 65: ...oth sides Insert a pin through the holes on the planetary gears supporting the axle and rotate them to obtain the ideal chain tension There are references on the planetary gears supporting the axle proceed so that the reference indicated is the same on both sides of the fork Drive chain cleaning Do not wash the chain with water jets vapour jets high pressure water jets and highly flammable sol ven...

Page 66: ...he figure Otherwise Undo screw D Restore the level by adding recommended oil with a syringe taking care not to exceed the MAX reference mark indicated in the figure WARNING DO NOT EXCEED THE MAX LEVEL WHEN TOPPING UP Recommended products AGIP ROTRA MP 80W 90 Transmission oil SAE 80W 90 API GL 5 Tighten the drain screw to the prescribed torque Locking torques N m Pinion unit oil filling screw 13 15...

Page 67: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 68: ...or restore the cou pling seal Worn valve oil guard Replace the valve oil guard Worn valve guides Check and replace the head unit if required Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By Pass remains open Check the By Pass and replace if required Care fully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil p...

Page 69: ...d part Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Clogged compensation holes on the pump Clean carefully and blast with compressed air Swollen or glued rubber gaskets Replace gaskets Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardeni...

Page 70: ... the ball bearings and relevant lock nuts the limit switch rubber buffers and the movement bushings In conclusion check the tightening torque of the wheel hub the brake calliper the shock absorber disk in the attachment to the hub and the steering tube Suspension oil leakage OIL LEAKAGE FROM SUSPENSION Possible Cause Operation Seal fault or breakage Replace the shock absorber Check the condition o...

Page 71: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 72: ... Ohm 2W 7 1A diode 8 Stand button 9 1A diode 10 Resistance 120 Ohm 2W 11 Engine stop switch 12 40A fuse 13 Voltage regulator 14 Main fuses 15 Main relay 16 Key switch contacts 17 Start up remote control switch relay 18 Start up maintenance relay 19 1A diode 20 Key switch contacts Electrical system GP 800 i e ELE SYS 2 ...

Page 73: ...ontrol device 38 Light switch 39 Helmet compartment light bulb 40 License plate bulb 41 Rear left turn indicator bulb 42 Rear light A Stop light LEDs B Rear position light LEDs 43 Rear right turn indicator bulb 44 Front left turn indicator bulb 45 Headlight A Front position light bulb B Low beam light bulb C High beam light bulb 46 Front right turn indicator bulb 47 MODE button 48 Instrument panel...

Page 74: ...lay 68 High beam light relay 69 Resistance 120 Ohm 2W 70 Hand brake 71 Fuel level transmitter 72 Windshield motor 73 Windshield relay 74 Windshield relay 75 Injection load relay 76 Fuel pump 77 Engine temperature sensor 78 Lambda probe 79 Throttle valve potentiometer 80 Air temperature sensor 81 Idle speed regulator 82 Revolution sensor 83 Monostable 84 External temperature sensor 85 Oil pressure ...

Page 75: ...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 GP 800 i e Electrical system ELE SYS 5 ...

Page 76: ...ove 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 Electrical system GP 800 i e ELE SYS 6 ...

Page 77: ...h them remove the front shield KEY A Electric fan relay B Start up remote control switch relay C Main relay D Injection load relay E Start up maintenance relay F Low beam light relay G High beam light relay H Start up remote control switch I L Windshield relay M Electric control management device 10 Fuses to reach it remove the battery cover GP 800 i e Electrical system ELE SYS 7 ...

Page 78: ...to reach it remove the left foot rest 13 Rear Cylinder HV coil to reach it remove the right fairing 14 Fuel level transmitter to reach it remove the right fairing Electric characteristic Full tank position 5 Ohm Empty tank position 98 5 Ohm Electrical system GP 800 i e ELE SYS 8 ...

Page 79: ...c characteristic Plug socket 12 V 180 W MAX 16 Immobilizer aerial to reach it remove the shield back plate 17 Immobilizer decoder to reach it remove the front shield 18 GPS wiring to reach it remove the handlebar central cover GP 800 i e Electrical system ELE SYS 9 ...

Page 80: ...e the front shield 21 Voltage regulator to reach it remove the front shield Electric characteristic Control voltage 14 14 7 V at 1000 8000 rpm 22 Horn to reach it remove the front shield Ground points There are three ground points in the electrical system Electrical system GP 800 i e ELE SYS 10 ...

Page 81: ...e the shield back plate B Located on the control unit in the front part of the vehicle To reach it remove the front shield C Located on the engine in the right part of the vehicle To reach it remove the right side fairing GP 800 i e Electrical system ELE SYS 11 ...

Page 82: ...witch F Rpm indicator G Fuel gauge H Warning light for parking brake engaged I Engine control telltale light and injection system failure warning light L Low fuel warning light M Engine stop warning light N Turn indicator warning light O Low oil pressure warning light P High beam warning light Electrical system GP 800 i e ELE SYS 12 ...

Page 83: ... 2 To the left turn indicator 3 To the regulator 4 HV coil 5 To the side stand switch 6 Engine wire unit 7 Ground point 8 To the battery 9 Start up remote control switch 10 Remote control switches electric windshield switches GP 800 i e Electrical system ELE SYS 13 ...

Page 84: ...t turn indicator 5 Snail horn 6 Electric fan connection 7 Starter motor cable 8 Regulator flywheel connector 9 Parking brake switch 10 To the left control unit on the handlebar 11 GPS wiring 12 To the immobilizer aerial 13 Immobilizer ECU 14 Saddle opening receiver Electrical system GP 800 i e ELE SYS 14 ...

Page 85: ...ld switches 7 Electric windshield motor 8 Injection electronic control unit 9 Overturn sensor 10 Connection between main system and the system on the engine 11 GPS wiring 12 Buttons control device on the handlebar 13 Turn indicator control device 14 To the battery negative 15 To the battery positive 16 Diagnostic socket for hand held computer GP 800 i e Electrical system ELE SYS 15 ...

Page 86: ...motor cable 21 Chassis wire unit 22 Voltage regulator cable Back side 1 To the license plate light 2 To the right turn indicator 3 To the fuel level transmitter 4 To the fuel pump 5 Rear cylinder HV coil 6 Ground point 7 Helmet compartment light switch Electrical system GP 800 i e ELE SYS 16 ...

Page 87: ...1 Helmet compartment light switch 2 Rear cylinder coil 3 Plug socket and helmet compartment light GP 800 i e Electrical system ELE SYS 17 ...

Page 88: ...1 Left turn indicator connection 2 To the left turn indicator 3 Fuel level transmitter Electrical system GP 800 i e ELE SYS 18 ...

Page 89: ...1 Plug socket for accessories 2 Helmet compartment light 3 Rear turn indicators 1 Air temperature sensor 2 Throttle valve sensor GP 800 i e Electrical system ELE SYS 19 ...

Page 90: ... To the rear cylinder HV coil 9 Oil pressure sensor 10 To the voltage regulator 11 Starter motor cable 12 Rear cylinder fuel injector 13 To the front cylinder fuel injector 14 Speed sensor connector 15 Lambda probe connector 16 Lambda probe Conceptual diagrams Ignition KEY 1 Immobilizer decoder Electrical system GP 800 i e ELE SYS 20 ...

Page 91: ...nstrument panel 51 Electronic ignition device Engine connector 52 Front cylinder HV coil 53 Rear cylinder HV coil 54 Electronic ignition device Vehicle connector 75 Injection load relay Battery recharge and starting KEY 3 Magneto flywheel 6 Resistance 120 Ohm 2W 7 1A diode 8 Stand button GP 800 i e Electrical system ELE SYS 21 ...

Page 92: ...t up maintenance relay 19 1A diode 21 Auxiliary fuses 22 12V 14Ah battery 23 Starter motor 24 Start up remote control switch 25 Starter button 26 Resistance 120 Ohm 2W 27 1A diode 28 1A diode 35 Stop button on rear brake 36 Stop button on front brake 42 Rear light A Stop light LEDs 48 Instrument panel 54 Electronic ignition device Vehicle connector Electrical system GP 800 i e ELE SYS 22 ...

Page 93: ...4Ah battery 48 Instrument panel 49 Vehicle speed sensor 50 Barometric pressure sensor 51 Electronic ignition device Engine connector 54 Electronic ignition device Vehicle connector 55 Front cylinder fuel injector 56 Rear cylinder fuel injector 71 Fuel level transmitter 75 Injection load relay 77 Engine temperature sensor GP 800 i e Electrical system ELE SYS 23 ...

Page 94: ...pm sensor 83 Monostable 84 External temperature sensor 85 Oil pressure sensor Devices and accessories KEY 4 Roll over sensor 5 Diagnostics socket 14 Main fuses 15 Main relay 16 Key switch contacts 19 1A diode 20 Key switch contacts 21 Auxiliary fuses 22 12V 14Ah battery Electrical system GP 800 i e ELE SYS 24 ...

Page 95: ...turn indicator bulb 47 MODE button 48 Instrument panel 54 Electronic ignition device Vehicle connector 57 Electric fan relay 58 Electric fan 59 Wiring for accessories 60 Horn button 61 Horn 62 Helmet compartment light switch 63 Windshield DOWN button 64 Windshield UP button 65 Windshield limit switch 66 Windshield limit switch 70 Hand brake 72 Windshield motor 73 Windshield relay 74 Windshield rel...

Page 96: ...xiliary fuses 22 12V 14Ah battery 34 Turn indicator switch 37 Turn indicator control device 38 Light switch 40 License plate bulb 41 Rear left turn indicator bulb 42 Rear light B Rear position light LEDs 43 Rear right turn indicator bulb 44 Front left turn indicator bulb 45 Headlight Electrical system GP 800 i e ELE SYS 26 ...

Page 97: ...9 Resistance 120 Ohm 2W Checks and inspections This section is devoted to the checks on the electrical system components Immobiliser The EMS system is independent from the immo bilizer antitheft device Its functions are Start up enabled by key recognition Deterrent flashing The system consists of EMS system control unit Decoder Aerial master key service key Deterrent and diagnosis LED GP 800 i e E...

Page 98: ...witches on as shown in the figure The LED is turned on by the decoder Specific tooling 020460Y Scooter diagnosis and tester To connect the diagnostic tester open the battery inspection port and pull out the EMS diagnosis socket Remove the protection cap and connect the tester terminal Power the diagnostic tester by connecting the ter minals to the battery poles or the specific connec tor to the so...

Page 99: ... to program the system again Programming is indispensable for the engine start up see injection chapter 3 Control unit replacement Programming is indispensable when the control unit is replaced to enable the engine start up In this case it is sufficient to switch to ON using the master key N B THE SERVICE KEY IS NOT USED FOR PROGRAMMING WHEN NOT PROGRAMMED THE CONTROL UNIT ALLOWS NO FUNCTIONAL DIA...

Page 100: ...n Diagnostic codes The LED indication is divided into 3 steps 1st step A flash ON switching recognition 2nd step Series of flashes diagnosis code indication 3rd step Steady light on or off on start up disabled off start up enabled Diagnostic code 1 flash Code 1 indicates a non programmed system If the code is still displayed after having carried out the programming procedure repeat the procedure c...

Page 101: ...nit connect the battery Repeat the programming 7 The system is OK Diagnostic code 2 flashes Code no 2 denotes a system where the decoder does not perceive the transponder signal Start up disabled Injection telltale light on steady In this case proceed as follows 1 Check whether the code is repeated using the second key YES go to 3 NO go to 2 2 Failure detected with the service key Replace and prog...

Page 102: ...decoder perceives a transponder not provided for by pro gramming Start up disabled Injection telltale light on steady 1 Check whether the code is still displayed using the master key YES go to 3 NO go to 2 2 Program again using all service keys 3 Check that all components keys decoder control unit are properly matched YES go to 5 NO go to 4 4 Restore 5 Replace decoders and control unit Program the...

Page 103: ...d remote control base Restore connections if necessary Electric characteristic High voltage coil primary resistance value 0 7 0 9 Ohm HV coil secondary check Disconnect the spark plug caps and measure the resistance between both Electric characteristic Resistance value of high voltage coil secon dary with spark plug caps 17000 Ohm If values are incorrect disconnect the caps and measure the resista...

Page 104: ...connector between stator and regulator with the three yellow cables as shown in the photograph 3 Working on the stator connector pin measure the resistance between each of the yellow termi nals and the other two Electric characteristic Resistance 0 2 1 Ω 4 Check that there is insulation between the each yellow cable and the ground 5 If values are incorrect replace the stator Voltage regulator chec...

Page 105: ...tand 2 With the battery correctly connected to the circuit place the tester terminals between the battery terminals 3 Turn on the engine increase the engine rpm and at the same time measure the voltage Electric characteristic Control voltage 14 14 7 V at 1000 8000 rpm Maximum current output check Connect a 12V 55W twin filament bulb to the battery poles as shown in the figure Connect the diagnosti...

Page 106: ...itch 12 40A fuse 14 Main fuses 15 Main relay 16 Key switch contacts 17 Start up remote control switch relay 18 Start up maintenance relay 19 1A diode 21 Auxiliary fuses 22 12V 14Ah battery 23 Starter motor 24 Start up remote control switch 25 Starter button 26 Resistance 120 Ohm 2W Electrical system GP 800 i e ELE SYS 36 ...

Page 107: ...the continuity of the following cables restore them if necessary between the starter button Grey Black cable negative multimeter probe and the start up maintenance relay Grey White cable positive probe Also check continuity between the latter and pin 28 of the control unit vehicle side connector between the stand button White Green cable negative multimeter probe and pin 38 of the control unit veh...

Page 108: ...it vehicle side connector negative probe Green cable 13 Check the contacts of the starter button stop buttons stand button and engine stop switch Horn control KEY 14 Main fuses 15 Main relay 16 Key switch contacts 19 1A diode 21 Auxiliary fuses 22 12V 14Ah battery 60 Horn button 61 Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED Electrical syste...

Page 109: ...inuity of the cable harness with the fuse box 7 Check the working order of fuse No 8 8 Check the horn button contacts 9 Check if there is voltage between the Yellow Pink cable of the horn button with the latter press ed and the ground connection If there is no voltage check the continuity of the cable harness between the main relay fuse box and button 10 Check the continuity of the Yellow Pink cab...

Page 110: ...icator switch 37 Turn indicator control device 41 Rear left turn indicator bulb 43 Rear right turn indicator bulb 44 Front left turn indicator bulb 46 Front right turn indicator bulb WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED Electrical system GP 800 i e ELE SYS 40 ...

Page 111: ...r control device connec tor If there is no voltage check the continuity of the cable harness 7 Check the turn indicator switch contacts 8 With the turn indicator switch pressed check if there is voltage between pins 2 and 9 switch to the left and pins 3 and 9 switch to the right of the turn indicator control device 9 If there is no voltage check the continuity of the cable harness between the fuse...

Page 112: ...ce values between the White Green cable and the Black ca ble of the fuel level transmitter by moving the arm with the float 2 If the transmitter works but the indication on the multimeter is not exact check the continuity of the cable harness between transmitter and multime ter Electric characteristic Full tank position 5 Ohm Empty tank position 98 5 Ohm Lights list Electrical system GP 800 i e EL...

Page 113: ...INUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED TAIL LIGHT CHECK 1 Check the bulbs and replace them as indicated in the bulb table 2 Check fuse No 4 and contacts G and H of the key switch 3 Check the continuity of the cable harness between the battery fuse box fuse No 4 and contacts of the key switch 4 Check fuse No 10 5 Check the continuity of the cable harness bet...

Page 114: ...harness between the light switch and the low beam light relay Brown White cable 3 Check the light switch contacts 4 Check the continuity of the cable harness between the light switch and the high beam light relay Purple cable 5 Check the high beam light relay 6 Check the continuity of the cable harness between the high beam light relay and fuse No 7 Red Green cable 7 Check that the Black cable of ...

Page 115: ...buttons and the rear light Grey Green cable 12 Check that the Black cable of the rear light is earthed LIGHT BULBS TABLE Specification Desc Quantity 1 Low beam bulb Type HALOGEN H7 Power 12V 55W Quantity 1 2 High beam light bulb Type HALOGEN H1 Power 12V 55W Quantity 1 3 Front tail light bulb Type ALL GLASS Power 12V 5W Quantity 1 4 Front turn indicator bulb Type WITH BULB Power 12V 10W Quantity 1...

Page 116: ...SE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL E G A PIECE OF ELECTRIC WIRE FUSES Specification Desc Quantity 1 Fuse No 1 Capacity 15A Protected circuits Live Main relay fuses No 8 9 via relay 2 Fuse No 2 Capacity 15A Protected circuits Helmet compartment lightning plug socket Pre installation for an titheft device saddle opening receiver...

Page 117: ...ield relay engine for windshield via relay Sealed battery Sealed battery start up operations If the vehicle is provided with a sealed battery the only maintenance required is the check of its charge and recharging if necessary These operations should be carried out before delivering the vehicle and on a six month basis while the vehicle is stored in open circuit Besides upon pre delivery it is the...

Page 118: ...battery in the vehicle be careful not to reverse the connections remembering that the ground wire black marked must be connected to the negative clamp while the other two red wires marked must be con nected to the clamp marked with the positive sign If the vehicle is provided with a sealed battery the only maintenance required is the check of its charge and recharging if necessary These operations...

Page 119: ...ere is no continuity between terminals 30 and 87 2 Apply 12V voltage to power terminals 85 and 86 of the remote control 3 With the remote control powered check that there is continuity between terminals 30 and 87 4 If these conditions are not fulfilled the remote control is damaged and must be replaced CHECKING REMOTE CONTROLS B OPER ATING AS SWITCHES 1 Check that given regular conditions there is...

Page 120: ...hes 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 KEY Ar Orange Az Sky Blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple TURN INDICATOR SWITCH ENGINE STOP SWITCH LIGHT SWITCH Electrical system GP 800 i e ELE SYS 50 ...

Page 121: ...STARTER BUTTON HORN BUTTON HELMET COMPARTMENT LIGHT BUTTON WINDSHIELD DOWN BUTTON GP 800 i e Electrical system ELE SYS 51 ...

Page 122: ...WINDSHIELD UP BUTTON MODE BUTTON Electrical windshield check KEY 14 Main fuses 20 Key switch contacts Electrical system GP 800 i e ELE SYS 52 ...

Page 123: ...With the specific switches pressed and the windshield not at the end of its travel check wheth er there is voltage between the Blue and the Black cables for one remote control and between the Yellow and Black cables for the other remote con trol 6 If there is no voltage check the continuity of the cable harness and check the contacts of switches and limit switches 7 Check that the remote controls ...

Page 124: ...eter Grey Black 32 Throttle valve potentiometer Brown Yellow 34 Engine rpm sensor shield Black 35 Engine rpm sensor Red 37 Cylinder 2 injector Blue 38 Cylinder 1 HV coil Pink Black 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 i...

Page 125: ...tor warning light Pink 8 Right turn indicator warning light White Blue 9 High beam warning light Purple 10 Parking brake warning light Sky Blue Black 11 Engine rpm signal Brown 12 Ambient temperature sensor Yellow Blue 13 Ambient temperature sensor ground White Yellow 14 Engine disabled warning light Sky Blue Yel low 15 Immobilizer warning light Red Green 16 Engine check warning light Brown White ...

Page 126: ...e 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 Injection load relay Black Green 2 Control unit Sky Blue REAR CYLINDER INJECTOR CONNECTOR 1 Control unit Red Yellow 2 Injection load relay Black Green Electrical system GP 800 i e ELE SYS 56 ...

Page 127: ... Blue SADDLE OPENING RECEIVER CONNECTOR 1 Aerial Purple 2 Saddle opening actuator Yellow Grey 3 Reset White 4 Battery positive Blue 6 Live positive Yellow Black 7 Ground Black 11 Pre installation for antitheft device Green 12 Pre installation for antitheft device Green TURN INDICATOR CONTROL DEVICE CON NECTOR 2 Left turn indicator switch White Pink 3 Right turn indicator switch Blue Black 4 Left t...

Page 128: ...ES 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 Ground Black DIAGNOSTICS SOCKET CONNECTOR 2 Ground Black 3 Control unit Purple White Electrical system GP 800 i e ELE SYS 58 ...

Page 129: ...t 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 Ground Black 3 Instrument panel White Green STAND SWITCH CONNECTOR 1 Ground Black 2 Control unit White Green GP 800 i e Electrical system ELE SYS 59 ...

Page 130: ...e Grey 2 Control unit negative Sky Blue Green WATER TEMPERATURE SENSOR CONNEC TOR 1 Control unit Grey Green 2 Instrument panel Green Yellow 3 Control unit negative Sky Blue Green 4 Instrument panel Brown Black VEHICLE SPEED SENSOR CONNECTOR 1 Control unit negative Sky Blue Green 2 Vehicle speed signal Brown Red 3 Control unit positive Red Blue Electrical system GP 800 i e ELE SYS 60 ...

Page 131: ...Control unit Brown Yellow 3 Control unit Orange Sky Blue EXTERNAL TEMPERATURE SENSOR CON NECTOR 1 Control unit White Yellow 2 Control unit negative Yellow Blue BAROMETRIC PRESSURE SENSOR CONNEC TOR 1 Control unit positive Red Blue 2 Control unit negative Sky Blue Green 3 Barometric pressure signal Orange GP 800 i e Electrical system ELE SYS 61 ...

Page 132: ...ting the ECU memory and following the same steps as per programming the immobilizer system in the keys Battery replacement The remote control in the black ignition key is pow ered by inner batteries that get discharged after extended used You may need to replace the batteries if the re mote control fails or if its range of operation is reduced To replace the batteries separate the two halves of th...

Page 133: ...mming has been successfully executed by opening the saddle WARNING TO STORE THE OTHER REMOTE CONTROLS TO MEMORY MAXIMUM 8 YOU NEED TO RE PEAT THE WHOLE PROCEDURE AGAIN FAILURE TO CARRY OUT THESE OPERATIONS WITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THE PROCESS FOR PROGRAMMING THE REMOTE CONTROLLED KEYS WARNING AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHE...

Page 134: ...Electrical system GP 800 i e ELE SYS 64 ...

Page 135: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 136: ...e 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 Undo the three screws indicated and collect the washers Engine from vehicle GP 800 i e ENG VE 2 ...

Page 137: ...ners 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 GP 800 i e Engine from vehicle ENG VE 3 ...

Page 138: ...r 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 For size reasons it can only be removed after being released from the catalytic converter retain ers Engine from vehicle GP 800 i e ENG VE 4 ...

Page 139: ...ffler supporting arm is now free Release the muffler supporting arm from the cat alytic converter Unscrew the two nuts fixing the front exhaust manifold Unscrew the nut indicated loosen the clamp and remove the front exhaust manifold together with the gasket and the graphite bushing GP 800 i e Engine from vehicle ENG VE 5 ...

Page 140: ...cated 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 Engine from vehicle GP 800 i e ENG VE 6 ...

Page 141: ...se the attachment plate of the centre stand Remove the catalytic converter Remove rear exhaust manifold together with the gasket and the graphite bushing Unscrew the two retainers fixing the catalytic converter support to the engine Check the silent block for wear replace it if nec essary GP 800 i e Engine from vehicle ENG VE 7 ...

Page 142: ...r fixing screw Follow the removal steps but in reverse order be careful to tighten to the prescribed torques MUFFLER TIGHTENING TORQUES Name Torque in Nm Nut fixing head exhaust manifold 16 18 Centre stand front bolt nut 34 39 Centre stand rear bolt nut 74 81 Screw fixing silencer muffler support arm 11 Silencer fixing screw 22 Screw fixing catalytic converter catalytic convert er support 22 24 Sc...

Page 143: ...urised Disconnect the delivery and reverse fuel pipes from the pump From both cylinders disconnect the injector con nector undo the screw and release it from the retainer clamp remove the pipes connecting both injectors N B BE VERY CAREFUL WHEN PULLING OUT THE CARBURETTOR PIPING SINCE AN EXCES SIVE FORCE MAY DAMAGE THE PLASTIC IN SERTS ON THE PUMP BODY UPON REAS SEMBLY IT IS THEREFORE NECESSARY TO...

Page 144: ...e 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 Remove the two retainer clamps Engine from vehicle GP 800 i e ENG VE 10 ...

Page 145: ...e 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 GP 800 i e Engine from vehicle ENG VE 11 ...

Page 146: ...REAR RETAINERS Release the engine from the front retainers un screwing from both sides the nuts indicated re move the two screws from the internal part CAUTION THE ENGINE IS NOW FREE FROM ITS RETAIN ERS AND DISCONNECTED FROM THE CHAS SIS Partially lift the rear section of the chassis so as to free it from the engine N B GUIDE THE CHASSIS SO AS TO RELEASE IT FROM THE RIGHT SIDE FRONT HEAD COVER Dis...

Page 147: ...ng 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 Undo the three screws fixing the throttle body to the inlet manifold The engine is now free GP 800 i e Engine from vehicle ENG VE 13 ...

Page 148: ...he 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 Check the silent block for wear replace the com ponents if necessary See also Exhaust assy Removal Helmet bay Air filter Fuel tank Fork Engine from vehicle GP 800 i e ENG VE 14 ...

Page 149: ...End gear shaft FITTING KEY A Nut fixing silent block plate chassis B Nut fixing silent block plate GP 800 i e Engine from vehicle ENG VE 15 ...

Page 150: ...k plate 33 41 Pin fixing nut M14 124 153 Pin fixing nut M10 47 52 Upper nut fixing engine support link rods chassis 33 41 Lower nut fixing engine support link rods chassis 33 41 Restore all the retainers check the engine oil level and top up with the recommended oil type if nec essary Fit the complete muffler unit Fit the pinion unit the rear fork together with the wheel and check if the chain ten...

Page 151: ...INDEX OF TOPICS ENGINE ENG ...

Page 152: ...erations 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 Engine GP 800 i e ENG 2 ...

Page 153: ...spanner Remove the nut and collect the washer Remove the transmission cover with a mallet to help extracting both shafts from their bearings Check that both bearings rotate freely otherwise replace them N B EACH TIME THE TRANSMISSION COVER IS REMOVED REPLACE THE CRANKSHAFT AD JUSTING RING GP 800 i e Engine ENG 3 ...

Page 154: ... 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 Engine GP 800 i e ENG 4 ...

Page 155: ...OVER STRUC TURE WOULD BEND NOT ONLY IN THE AREA OF MAXIMUM STURDINESS Specific tooling 001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020357Y 32 x 35 mm adaptor 020363Y 20 mm guide Refitting the driven pulley shaft bearing Heat the transmission cover interior using the heat gun Specific tooling 020151Y Air heater Place the bearing onto the special tool with a little grease to preven...

Page 156: ...ger 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 Specific tooling 020151Y Air heater Engine GP 800 i e ENG 6 ...

Page 157: ...lley Inspecting the clutch drum Check that the clutch bell is not worn or damaged Measure the clutch bell inside diameter N B CHECK THE ECCENTRICITY MEASURED 0 2 MM MAX Characteristic Max value 175 5 mm Standard value 175 0 0 2 mm Removing the clutch Remove the clutch together with the driven pulley using the specific tool CAUTION WHILE PERFORMING THESE OPERATIONS AVOID CONTACT WITH OIL OR GREASE ...

Page 158: ...the clutch is completely disassem bled Inspecting the clutch Check the thickness of the clutch mass friction material Characteristic Minimum thickness permitted 1 mm The masses must not show traces of lubricants Otherwise check the driven pulley unit seals N B UPON RUNNING IN THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER VARIOUS CONDITIONS CAN CAUSE T...

Page 159: ...llar 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 otherwise replace the fixed driven half pulley Remove the lock ring using pliers GP 800 i e Engine ENG 9 ...

Page 160: ... BY THE BELL Specific tooling 001467Y002 Driver for OD 73 mm bearing Remove the roller bearing using the special tool supporting the fixed half pulley with the bell Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020183Y 30 mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half pulley Check that the belt contact surface is free from wear Measure the out...

Page 161: ...ameter 55 00 0 035 0 00 mm Refitting the driven half pulley bearing Install a new roller bearing using the special tool N B PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS Properly support the half pulley to prevent damaging the threading If you are working on the driven pulley unit fully assembled use the special tool Specific tooling 020478Y Punch for driven pulley...

Page 162: ...e the top sealing ring during the in troduction Make sure the pins and collar are not worn re assemble the pins and collar Using a bent beak greaser lubricate the driven pulley unit with about 10 gr of grease this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole This operation is necessary to avoid the presence of...

Page 163: ...en pulley unit Insert the driven pulley unit the spring with sheath and clutch into the tool CAUTION WHILE PERFORMING THESE OPERATIONS AVOID CONTACT WITH OIL OR GREASE WHICH COULD MAKE THE FAYING SURFA CES BETWEEN THE BELT AND THE HALF PULLEYS SLIPPERY Specific tooling 020659Y Tool to remove clutch and replace belt Compress the spring and insert the clutch on the driven pulley bushing N B BE CAREF...

Page 164: ... 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 HALF PULLEY Screw the tool so as to separate the two half pulleys Engine GP 800 i e ENG 14 ...

Page 165: ... 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 Make sure the driving belt is not damaged and does not show abnormal wear Replace as indicated in the scheduled maintenance table GP 800 i e Engine ENG 15 ...

Page 166: ...ph 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 Remove the driven pulley together with the belt Engine GP 800 i e ENG 16 ...

Page 167: ... 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 GP 800 i e Engine ENG 17 ...

Page 168: ...eristic Maximum admissible diameter 40 045 mm Standard diameter 40 00 0 009 0 034 mm Measure the pulley sliding bushing outside di ameter shown in the figure Characteristic Minimum admissible diameter 39 05 mm Standard diameter 40 00 0 015 0 040 mm Check that the rollers are not damaged or worn Characteristic Minimum admissible diameter Ø 24 5 mm Standard diameter 25 0 0 1 mm Engine GP 800 i e ENG...

Page 169: ...660Y Driving pulley lock Locking torques N m Drive pulley nut 252 278 Air switch screw 3 4 End gear shaft A CHAIN Lubricate check and restore chain tension as in dicated in the scheduled maintenance table see the Maintenance Chapter To replace follow the instructions in the following pages B CROWN The crown is fastened to an anti vibration buffer flange to the rear wheel To replace follow the inst...

Page 170: ...CO PRE STARE ATTENZIONE DURANTE LO SMON TAGGIO E LA REVISIONE A NON DISPER DERE L OLIO CONTENUTO ALL INTERNO Tirare la catena fino a quando la vite di serraggio della cuffia di tenuta olio solidale con l asse grup po pignone sia in una posizione che permetta l accesso di un cacciavite Allentare la vite di serraggio Svitare le tre viti di collegamento al telaio Rimuovere il gruppo pignone completo ...

Page 171: ... 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 MARK THEM SO AS TO RESPECT THE FITTING CLEARANCE CRE ATED DURING THE MOVEMENT PHASE Loosen the eight screws fixing the pinion to the driving bushing from the safety plate Undo the eight screws GP 800 i e Engine ENG 21 ...

Page 172: ... 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 Check that the shaft and the four driving sliders exhibit no signs of abnormal wear Engine GP 800 i e ENG 22 ...

Page 173: ...the plate N B THE PLATE FORMS AN INTEGRAL UNIT WITH THE PINION DRIVING BUSHING AND THE SUPPORT ONCE THE PLATE IS UN SCREWED REMOVE THE PINION Remove the pinion driving bushing plus the pin ion bearings and spacer from the support Slide off the components from the driving bush ing GP 800 i e Engine ENG 23 ...

Page 174: ...0376Y Adaptor handle Drive a new bearing with the specific tool working from outside the pinion unit Specific tooling 020655Y Adaptor 62x68 mm 020662Y Guide 50 mm 020376Y Adaptor handle Fit the specific tool and drive a new oil seal work ing from inside the pinion unit Specific tooling 020655Y Adaptor 62x68 mm 020662Y Guide 50 mm 020376Y Adaptor handle Engine GP 800 i e ENG 24 ...

Page 175: ... recommended product from the opposite side Loctite 243 medium strength Locking torques N m Screw for plate locking pinion driving bush ing 4 6 Grease the driving sliders with the recommended product Fit the shaft together with the seeger ring and the support side driving sliders Recommended products AGIP GREASE PV2 Grease for steering bear ings bolt seatings for swinging arms and fay ing surface ...

Page 176: ...ith the recommended product Fit both engine side driving sliders Recommended products AGIP GREASE PV2 Grease for steering bear ings bolt seatings for swinging arms and fay ing surface of driven pulley spring only pulley side Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Fit the cover and tighten the six fixing screws to the prescribed torque using the recommended product...

Page 177: ...ribed torque Locking torques N m Screws fixing pinion unit chassis 50 Tighten the oil drain screw B to the prescribed torque Locking torques N m Pinion unit oil drain screw 13 15 Undo the oil filling screw D Fill up to the oil level with the recommended product following the indications described in the figure WARNING DO NOT EXCEED THE MAX LEVEL WHEN TOPPING UP Recommended products AGIP ROTRA MP 8...

Page 178: ...lease the chain from the rear wheel Remove the complete pinion unit so as to release the chain Replace the chain with a new one and following the indications described in the specific sections fit the pinion unit and the wheel Restore the correct chain clearance following the indications in the Maintenance Chapter Refitting the transmission cover Follow the removal steps but in reverse order being...

Page 179: ...both crankcase halves To replace proceed as follows Transmission side crankcase half Remove the driven pulley shaft axle and the toothed wheel Acting on the specific tool take out the bearing Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Belle for OD 47 mm bearings GP 800 i e Engine ENG 29 ...

Page 180: ...on both crankcase halves To fit proceed as follows Transmission side crankcase half Heat the crankcase using the heat gun Specific tooling 020151Y Air heater Insert the pinion unit shaft bearing until it stops against the bottom of the seat using the specific tool Specific tooling 020376Y Adaptor handle 020363Y 20 mm guide 020359Y 42x47 mm adaptor Flywheel side crankcase half Heat the crankcase us...

Page 181: ...c 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 Specific tooling 020376Y Adaptor handle 020655Y Adaptor 62x68 mm 020662Y 50 mm guide GP 800 i e Engine ENG 31 ...

Page 182: ...lley 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 Engine GP 800 i e ENG 32 ...

Page 183: ...Check the two shafts exhibit no wear or distortion of the toothed surfaces the bearing housings and the oil seal housings In case of faults replace the damaged parts Characteristic Bearing diameter for driven pulley shaft A Ø30 0 01 0 02 mm B Ø20 0 01 0 02 mm Diameter for pinion unit shaft C Ø20 0 01 0 02 mm D Ø50 0 01 0 023 mm GP 800 i e Engine ENG 33 ...

Page 184: ...eater 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 020655Y Adaptor 62x68 mm Fit the seeger ring Fit the oil seal from outside the transmission side crankcase half Engine GP 800 i e ENG 34 ...

Page 185: ...Refitting the hub bearings Place the two shafts as shown in the figure Flywheel cover GP 800 i e Engine ENG 35 ...

Page 186: ...ywheel 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 Inspecting the cover components Check the condition of the stator and of the re spective cable harness Engine GP 800 i e ENG 36 ...

Page 187: ...ck of the cable harness that contains two types of cable Rigid cables close to the stator and flexible cables close to the connector Check that the winding is positioned so as not to interfere with the heads of the retaining screws Refitting the stator Install the stator assembly together with the wir ing harness tightening the 3 screws to the pre scribed torque N B INSERT THE RUBBER WIRING SEALIN...

Page 188: ...attery Connect the diagnostic tester see the injection chapter Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor Remove the 7 5A fuse No 10 see the fuses chapter Switch in position ON with interrupt switch in position RUN and side stand raised Select the PARAMETERS function Start the engine so that it cannot move long enough to measure the rpm and st...

Page 189: ...tarter control circuit is not controlled by the immobilizer system therefore before insisting on the starter system check the consensus of the immobilizer In order to check the enabling switches circuit see the Electrical system chapter whereas to check the engine shaft control transmission follow what is described in the Flywheel and starter system chapter Removing the starter motor Disconnect th...

Page 190: ...k 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 Engine GP 800 i e ENG 40 ...

Page 191: ...rity of the magnets Check that the magnet support cage is free from deformation or cracks Starter gear rim Check that there is no wear or abnormal impres sions on the rollers of the freewheel and on the surface of the starter ring gear hub Check the hub outside diameter Characteristic Hub outside diameter Diameter 45 665 0 008 0 005 mm GP 800 i e Engine ENG 41 ...

Page 192: ...E TO REPLACE ONLY THE COMPLETE START UP RIM IN THAT CASE CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNEC TION ON THE CRANKSHAFT IN CASE OR IRREGULARITIES REPLACE THE CRANKSHAFT Intermediate gear Check that the toothing is not worn Check the diameter of the two bearings Characteristic Gear bearing diameter 12 0 0 011 mm Also check the shaft diameter on the flywheel cov er and on the engine cr...

Page 193: ...nversion of rotation direction of the crankshaft which would impair the engine structure The limiter assembly cannot be overhauled In case of irregularities on the toothed discs replace the assembly Refitting the free wheel Make sure the free wheel contact surfaces are in good condition Thoroughly clean the free wheel to remove LOCTITE residue Degrease the threading of the holes in the free wheel ...

Page 194: ...r ring visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the intermediate gear Lubricate the gear housing on the engine crank case Insert the intermediate gear with torque limiter Engine GP 800 i e ENG 44 ...

Page 195: ...wheel 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 Insert the starter motor Tighten the 2 fastening screws to the prescribed torque Locking torques N m starter motor retainers 11 13 GP 800 i e Engine ENG 45 ...

Page 196: ...Cylinder assy and timing system Removing the intake manifold Remove the coolant pipes Undo the six fixing screws Engine GP 800 i e ENG 46 ...

Page 197: ...photograph align the refer ences on the timing system gear of the rear cylin der with the reference on the cam cap valves N B PLACING THE ENGINE AS INDICATED IT IS IN THE COMBUSTION PHASE AND ALL THE VALVES ARE CLOSED THIS HELPS FITTING REMOVAL OPERATIONS Loosen the central screw on the tensioner Unscrew the two retainers indicated in the pho tograph and remove the tensioner with the rele vant gas...

Page 198: ...E TONE WHEEL IS ONLY ON THE REAR CYLINDER IN THE FRONT CYLINDER IT IS RE PLACED BY A SPACER Specific tooling 020565Y Flywheel lock calliper spanner Repeat the operations for the front cylinder timing system gear Removing the cam shaft Unscrew the 3 fastening screws and remove camshaft retaining bracket N B REMOVING THE FASTENING SCREWS MAY BE DIFFICULT BE CAREFUL NOT TO DAM AGE THE INSIDE HEXAGON ...

Page 199: ...E FITTING PHASE THE HEADS MUST BE CORRECTLY REMOVED WITH THE PISTONS AT TDC AND THE VALVES CLOSED Remove the rear cylinder head following the indicated operations CAUTION REMOVE THE HEADS AFTER PERFORMING THE TIMING OPERATION Perform timing of the front cylinder rotate the crankshaft by 270 towards the engine direction of rotation then remove the head following the indicated operations Remove the ...

Page 200: ...e 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 N B THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKING LEVER PINS AND FIT TING BRACKET IF NECESSARY Engine GP 800 i e ENG 50 ...

Page 201: ... slider Removing the valves Using the appropriate tool fitted with an adaptor remove the cotters caps springs and valves Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush valve removing tool CAUTION ARRANGE THE VALVES SO AS TO RECOG NISE THE ORIGINAL POSITION ON THE HEAD FLYWHEEL SIDE AND TRANSMISSION SIDE GP 800 i e Engine ENG 51 ...

Page 202: ...il 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 Engine GP 800 i e ENG 52 ...

Page 203: ...locking rings by the spe cific housings Extract the pin and remove the piston N B USE PAPER OR A CLOTH TO CLOSE THE CYL INDER HOUSING MOUTH ON THE CRANK CASE TO PREVENT SLIPPAGE OF ONE OF THE PIN LOCKING RINGS INTO THE CASE Remove the piston sealing rings and the oil scra per CAUTION NOTE THE ASSEMBLY POSITIONS OF THE LININGS TO PREVENT INVERTING THE POSI TION IN CASE OF REUSE N B BE CAREFUL NOT T...

Page 204: ... N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the piston rings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Piston rings Removing the piston Fit the piston and pin onto the connecting rod aligning the piston arrow towards the engine di rection of rotation Engine GP 800 i e ...

Page 205: ...Specific tooling 020470Y Pin retainers installation tool N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Install a comparator on the special tool using the short union as shown in the figure Specific tooling 020475Y Piston position checki...

Page 206: ...ness to keep the correct compres sion ratio Remove the special tool and the cylinder N B IF DEVIATIONS OR RECESSES OR PROJECTIONS CLOSE TO THE CHANGE OF CATEGORY ARE MEASURED REPEAT THE MEASUREMENT AT THE OPPOSED SIDE TO DO SO REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION See also Slot packing system Refitting the piston rings Place the scraper ring spring on the piston Install the scrape...

Page 207: ...ricate the components with engine oil The engine uses the first compression lining with an L section Refitting the cylinder Insert the cylinder base gasket with the thickness determined above Using the fork and the ring clamp fit the cylinder as shown in the figure N B BEFORE FITTING THE CYLINDER CAREFUL LY BLOW THE LUBRICATION DUCT AND LU BRICATE THE CYLINDER LINER CHECK THE PRESENCE OF THE TWO R...

Page 208: ...ng 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 Engine GP 800 i e ENG 58 ...

Page 209: ... the entire unit N B IF THE CHAIN HAS DAMAGED THE PINION REPLACE THE CRANKSHAFT AS DESCRIBED IN CHAPTER CRANKCASE AND CRANKSHAFT Chain tensioner Remove the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole assembly Inspecting the valve sealings N B TO MEASURE...

Page 210: ... CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Inspecting the springs and half cones Check that the upper and lower supporting spring washers the cotters and the oil seal show exhibit no signs of abnormal wear Replace a component when worn Measure the unloaded spring length N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head...

Page 211: ...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 GP 800 i e Engine ENG 61 ...

Page 212: ...HE VALVE SPRINGS WITH THE REF ERENCE COLOUR ON COTTER SIDE TURNS WITH GREATER PITCH Inspecting the cam shaft N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Refitting the head and timing system components Heads are fitted in two separate stages Fit the rear cylinder head and then the front cylinder head following the indications described I...

Page 213: ...lubrication channel is per fectly clean Clean with compressed air jets if required Insert the head Lubricate the stud bolts and the 4 fixing stud bolts Tighten the 4 fixing stud bolts crosswise to the prescribed torque as shown in the figure Locking torques N m Head fixing stud bolts Apply a preliminary torque of 10 Nm in a crossed sequence tighten with a torque of 13 N m 90 in a crossed sequence ...

Page 214: ...ntake 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 Locking torques N m Exhaust intake head fixing nuts 10 12 Engine GP 800 i e ENG 64 ...

Page 215: ...ing torques N m Rpm timing sensor screw 7 5 8 5 Nm Insert the timing control belt on the crankshaft according to the initial direction of rotation Install the tensioner shoe with its spacer tight ening the bolt to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Locking torques N m Tensioner slidi...

Page 216: ...ighten to the prescribed torque Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threadlock Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque being careful not to damage the inside hexagon Locking torques N m Camshaft retaining bracket screws 4 6 Finish closing the flywheel side crankcase ...

Page 217: ...one wheel the timing system gear with the chain and align the reference marks Once the reference marks are aligned as indica ted with the reference marks on the valve cam cap tighten the screw with the washer to the prescribed torque Locking torques N m Timing system gear on camshaft screw 12 14 Place the tightener cursor in the rest position keeping the retain tab pressed GP 800 i e Engine ENG 67...

Page 218: ...perations of the rear cylinder for the front cylinder timing head and components Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit For this reason it is not possible to declare the reference values based on the engine rpm The ignition timing value is detectable any time using the diagnostic tester It is possible to che...

Page 219: ...ne position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diagnostic tester Replace the inspection cap on the flywheel side Specific tooling 020460Y Scooter diagnosis and tester If the values do not match check distribution timing revolution timing sensor Injection control unit Refitting the rocker arms cover Check that the gasket is in good w...

Page 220: ...ining 4 screws in a crossed se quence 3 4 5 6 N B CHECK THE PROPER POSITION OF THE GAS KET Locking torques N m Tappet cover fixing screws 7 9 Refitting the intake manifold Fit the intake manifold on the engine Fit the six fixing screws and tighten to the pre scribed torque Locking torques N m inlet manifold fixing screws 11 13 Engine GP 800 i e ENG 70 ...

Page 221: ... heads pistons as described in the Thermal group and Timing system chapter Before opening the crankcase check the crankshaft axial clearance Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Standard clearance 0 10 0 50 mm Admissible increase limit after use 0 60 mm Upper clearances are an indication of wear on the surfaces of the crankshaft ...

Page 222: ...bush ings Undo the seven screws B and collect the cop per washers Undo the twelve screws C and collect the washers 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 ...

Page 223: ... Detach the crankcase halves while keeping the crankshaft inserted on the transmission side crankcase half Remove the coupling gasket GP 800 i e Engine ENG 73 ...

Page 224: ...ol matches the shaft perfectly CAUTION DUE TO THE TIP WEIGHT BE CAREFUL THAT THE TOOL FIT ADEQUATELY AND DOES NOT FALL ALWAYS HOLD IT WITH BOTH HANDS CAUTION FAILURE TO OBSERVE THIS RULE CAN DAMAGE THE MAIN BUSHINGS Specific tooling 020665Y Transmission side crankshaft fitting tip Lubricate the external surface of the tip with petroleum jelly grease Engine GP 800 i e ENG 74 ...

Page 225: ...ossible to remove the transmission side timing chain Inspecting the crankshaft components N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Inspecting the crankshaft alignment N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod GP 800 i e Engine ...

Page 226: ...on to the crankcase coupling and the crankcase cylinder surfaces Defects in the crankcase coupling surface gasket can cause a drop in the oil pressure thus affecting the lubricating pressure Check the main bearing seats that limit axial clearance in the crankshaft exhibit no wear For the dimensional check refer to the instructions about checking the axial clearance and the dimensions on the cranks...

Page 227: ...IFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Refitting the crankcase halves Fit the driven pulley shaft and the pinion unit axis Fit the specific tool on the transmission side crankshaft being particularly careful that the tool matches the shaft perfectly CAUTION FAILURE TO OBSERVE THIS RULE CAN DAM AGE THE MAIN BUSHINGS CAUTION DUE TO THE TIP WEIGHT BE CAREFUL THAT THE TOOL FI...

Page 228: ...DRIVE CHAIN BEFORE THE CRANKSHAFT Fit the crankshaft with the driving pulley shaft in side the transmission side crankcase half CAUTION PLACE THE CONNECTING RODS PROPERLY Simultaneously hold the crankshaft with one hand and the tip with the other until the crankshaft stops on the crankcase half Remove the tip Specific tooling 020665Y Transmission side crankshaft fitting tip Engine GP 800 i e ENG 7...

Page 229: ...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 N B LUBRICATE THE BUSHINGS WITH ENGINE OIL BEFORE FITTING THE CRANKSHAFT GP 800 i e Engine ENG 79 ...

Page 230: ... Be careful and fit the flywheel side crankcase half until there is a complete coupling Engine GP 800 i e ENG 80 ...

Page 231: ...ws M8 25 28 Fit the centring bushings the washers and screw the fixing nuts to the support Turn the support so as to operate on the trans mission side Screw the six screws A with the washers and tighten to the prescribed torque Locking torques N m Engine crankcase coupling screws M6 11 13 Fit a new oil seal in the transmission side crank case half on the driving pulley shaft Fit the oil seal manua...

Page 232: ...llowing the indications described in the fig ure Lubrication N B REFER TO THE SPECIFICATIONS CHAPTER FOR THE LUBRICATION SYSTEM SPECIFICA TIONS See also Engine Conceptual diagrams LUBRICATION CIRCUIT Specification Desc Quantity 1 FRONT HEAD CAMSHAFTS 2 REAR HEAD CAMSHAFTS 3 CONNECTING ROD BUSHINGS 4 FRONT PISTON LUBRICATION JET Engine GP 800 i e ENG 82 ...

Page 233: ...re filter is fitted Pump delivery is controlled by means of a piston type by pass calibrated to 4 5 bar This valve is located upline the cartridge filter The by pass located before the cartridge filter improves the operating conditions for the filter particularly with cold oil The filter is equipped with an anti drain back valve and a pressure relief valve the latter intervenes when the filtering ...

Page 234: ...ilure in these components implies oil getting into the line supplying air to the engine Excessive oil vapours may result in clogged ducts on the throttle body In order to signal low oil pressure in the system a pressure switch is used located immediately after the oil filter outlet The lubrication circuit does not include the piston or the pin also in this case the cooling nozzle is particularly i...

Page 235: ...inimum pressure switch 8 If pressure lower than 1 3 1 5 bar is measured AHEAD go to 9 9 Replace the oil filter and repeat the pressure check with oil at 80 C YES go to 10 NO go to 13 10 The failure was fixed It is recommended to respect the suggested number of kilometres covered 11 Check and restore the electrical system 12 If pressure lower than 4 bar is measured AHEAD go to 9 13 Open the engine ...

Page 236: ...CASE CARRY OUT A VISUAL AND DI MENSIONAL INSPECTION OF THE TIMING SYSTEM COMPONENTS SEE THERMAL GROUP AND TIMING SYSTEM CHAPTER Oil pressure check 1 In case of oil or oil filter leaks check the lubrication pressure AHEAD go to 2 2 Install the special tool Specific tooling 020193Y Oil pressure gauge 020434Y Oil pressure control fitting AHEAD go to 3 3 Check the system pressure with cold engine and ...

Page 237: ...e hole efficiency Oil pump Removal KEY A Pressure pump B Scavenge oil pump C By pass The lubrication system includes the pressure and scavenge oil pumps To act on the pressure pump remove the casing of the oil anti backflow plate under the flywheel To act on the scavenge oil pump open the crankcase and operate inside the flywheel side crankcase half GP 800 i e Engine ENG 87 ...

Page 238: ...collect the washer Remove the oil pump control crown N B IT IS ADVISABLE TO MARK THE CHAIN IN OR DER TO ENSURE THAT THE INITIAL DIREC TION OF ROTATION IS MAINTAINED Specific tooling 020565Y Flywheel lock calliper spanner Undo the two fixing screws and remove the oil pump cover casing Remove the pressure oil pump together with the gasket Engine GP 800 i e ENG 88 ...

Page 239: ...ft 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 GP 800 i e Engine ENG 89 ...

Page 240: ... 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 Engine GP 800 i e ENG 90 ...

Page 241: ... 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 ly GP 800 i e Engine ENG 91 ...

Page 242: ...OF WEAR Once you check that the components are in good conditions fit the pump and check size Fit the two rotors and align them following the reference marks Fit the assembled rotors inside the pump body with the reference marks facing the inside CAUTION ONCE THE ROTORS ARE FITTED IN THE PUMP BODY THE REFERENCE MARKS ON THEM MUST NOT BE VISIBLE Engine GP 800 i e ENG 92 ...

Page 243: ... rotor surfaces and the pump body with a trued bar as a contrasting plane as indicated in the figure CAUTION FAILURE TO OBSERVE THESE RULES CAN SERIOUSLY DAMAGE THE ENGINE IF THE VALUES ARE NOT WITHIN THE PRESCRIBED LIMITS REPLACE THE COMPONENTS Characteristic Limit values admitted 0 1 mm Check all the conditions indicated above after wards fit the plug and tighten the fixing screws to the prescri...

Page 244: ...s in the correct position N B THE TOOTH OF THE GASKET MUST BE IN ITS SEAT Fit the scavenge oil pump and the casing of the oil anti backflow plate Tighten the two screws indicated to the prescri bed torque Locking torques N m Screws fixing oil pump to the crankcase 5 6 Fit the water pump control gear on the oil pump shaft Tighten the locking screw with the washer to the prescribed torque Locking to...

Page 245: ...screw 10 14 Fit the pressure oil pump Fit the oil pump cover casing and tighten the two screws to the prescribed torque Locking torques N m Screws fixing oil pump to the crankcase 5 6 Fit the oil pump control crown and the driving chain Using the specific tool tighten the fixing screw with the belleville washer to the prescribed torque CAUTION PLACE THE BELLEVILLE WASHER WITH THE CONVEX PART FACIN...

Page 246: ...king 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 Specific tooling 020661Y Water pump overall seal replacement kit Engine GP 800 i e ENG 96 ...

Page 247: ...T ROTATE IN REVERSE SENSE Place two flat blade screwdrivers as shown in the figure so as to lever on the marked crankcase edge and disassemble the overall seal pressure fitted on the rotor shaft CAUTION USE TEFLON AS SHOWN IN THE FIGURE SO AS NOT TO DAMAGE THE WATER PUMP COVER SEALING SURFACE Small scratches on the seat edge do not pose functional problems Change the position of the screwdrivers i...

Page 248: ...tor 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 N B MAKE THE HOLES WITH A STRONG HIT MULTIPLE LIGHT BLOWS COULD DEFORM THE PART WITHOUT PASSING THROUGH Engine GP 800 i e ENG 98 ...

Page 249: ...ON FIX IT PROPERLY WITHOUT TEARING THE PLATE Complete the tool by fitting the bracket the screw and the nut Hold the screw in position and operate the nut until the fixed part of the sealing is completely re moved Remove the extractor with the fixed part of the overall seal GP 800 i e Engine ENG 99 ...

Page 250: ...smission side crankcase half Slide off the idle gear Slide off the water pump control gear together with the shaft Undo the two screws indicated and remove the gear protection plate Insert a punch on the water pump shaft seat and remove the oil seal See also Splitting the crankcase halves Engine GP 800 i e ENG 100 ...

Page 251: ...ump shaft oil seal punch Fit and lock the plate in its position by tightening the two screws indicated to the prescribed torque Locking torques N m Screws tightening water pump gear protection plate 3 4 Fit the water pump shaft together with the control gear Fit the idle gear Overall seal fitting CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY CAUTION GP 800 i e Engine ENG 101 ...

Page 252: ...e 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 Fit the nut to the tie rod Engine GP 800 i e ENG 102 ...

Page 253: ...mic seal preloading Screw the rotor anticlockwise thread Locking torques N m Water pump impeller 4 5 Fit the pump cover with a new gasket lubricate the gasket previously with petroleum jelly grease Tighten the six cover screws to the prescribed torque N B TO AVOID DEFORMATION DO NOT LUBRI CATE THE O RING WITH PETROLEUM GREASE Locking torques N m Water pump rotor cover 3 4 GP 800 i e Engine ENG 103...

Page 254: ...Engine GP 800 i e ENG 104 ...

Page 255: ...INDEX OF TOPICS INJECTION INJEC ...

Page 256: ...he ai valori rilevati dalla sonda lambda la carburazione viene gestita modificando il tempo di apertura dell iniettore La pressione di alimentazione della benzina viene mantenuta costante in funzione della pressione am biente Il circuito di alimentazione di tipo multipoint è costituito da Pompa benzina Filtro benzina Iniettori Regolatore di pressione La pompa il filtro ed il regolatore sono inseri...

Page 257: ... strument panel Failures are detected and restored by the diag nostic tester In any case when the fault is no longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture Specific tooling 020460Y Scooter diagnosis and tester The EMS injection ignition system ha...

Page 258: ...ill the tank up to a little over half the level This will ensure the pump will be covered by fuel 7 When washing the vehicle be careful with the electric components and wiring 8 When an ignition problem is detected start the checks from the battery and the injection system connections 9 Before disconnecting the EMS control unit connector perform the following operations in the order shown Set the ...

Page 259: ...or 2 EMS faults may be caused by loose connectors Make sure that all connections have been correctly made Check the connections as follows A check that the terminals are not bent B check that the connectors have been properly connected C check whether the malfunction can be fixed by shaking the connector slightly 3 Check the entire system before replacing the EMS control unit If the fault is fixed...

Page 260: ... 16 Diagnostics socket Purple White 17 Live positive White Black 18 Engine disabled warning light Sky Blue Yel low 22 Lambda probe White Green 23 Stop lights Grey Green 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 ENGINE CONTROL UNIT CONNECTOR 3 Throttle valve potentiometer ...

Page 261: ...r negative Sky Blue Green 22 Sensor positive Red Blue 25 Engine rpm sensor White 28 Cylinder 1 injector Red Yellow 29 Throttle valve potentiometer Grey Black 32 Throttle valve potentiometer Brown Yellow 34 Engine rpm sensor shield Black 35 Engine rpm sensor Red 37 Cylinder 2 injector Blue 38 Cylinder 1 HV coil Pink Black EMS circuit diagram Troubleshooting procedure GP 800 i e Injection INJEC 7 ...

Page 262: ...mpression pressure End of compression pressure Starting difficulties ENGINE START UP PROBLEMS Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Start up speed Starter motor and remote control Battery Ground connections End of compression pressure End of compression pressure Power to th...

Page 263: ... head Throttle body manifold Intake sleeve Filter box Fuel feed low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Ignition e...

Page 264: ...lter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold muffler Muffler welding Engine revs irregularly ENGINE IRREGULAR PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system seal Intake sleeve Filter box Ignition system Spark plug wear check Parameter reliabi...

Page 265: ...Fuel supply Fuel level in the tank Fuel pressure Fuel filter Injector capacity Engine knocking PRESENCE OF KNOCKING HEAD KNOCKING 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 Ignition efficiency Spark plug Parameter reliability Throttle valve position signal Coolant ...

Page 266: ...ted to the injectors by 3 semi flexible pipes 6 fast release couplings N B BEFORE WORKING ON THE FUEL SUPPLY SYSTEM CAREFULLY CLEAN THE PARTS TO PREVENT DAMAGING THE FAST RELEASE COUPLING SEAL OR TO PREVENT DIRT GETTING INTO THE DUCTS CAUTION THE SYSTEM IS UNDER PRESSURE DO NOT SMOKE DURING ANY OPERATION PREVENT ANY FUEL SPRAYING WARNING BEFORE STARTING THE ENGINE CHECK WHETHER THERE IS FUEL IN TH...

Page 267: ...Pump supply circuit GP 800 i e Injection INJEC 13 ...

Page 268: ...connettore pompa e massa Circuit leak test Install the specific tool for checking the fuel pressure with the pipe fitted with the gauge Check during regular operation by placing the ap propriate tool between the pump and the injector With battery voltage 12 V check that the fuel pressure is 3 BAR and that the input current is 2 8 A With the battery voltage 12 V check the pump flow rate by disconne...

Page 269: ...e decreases Check that within 15 seconds the pump has a flow rate of approx 300 cm Specific tooling 020480Y Petrol pressure check set Inspecting the injector circuit REAR CYLINDER INJECTOR CONNECTOR 1 Control unit Red Yellow 2 Injection load relay Black Green GP 800 i e Injection INJEC 15 ...

Page 270: ...ioni In caso contrario verificare la linea di massa tra pin 37 connettore centralina motore e il pin 1 del con nettore iniettore cilindro anteriore e tra pin 28 connettore centralina e il pin 1 del connettore iniettore cilindro posteriore Verificare la linea 12V tra teleruttore carichi iniezione e pin 2 connettore iniettore Immobiliser circuit The EMS system is independent from the immo bilizer an...

Page 271: ...e key switch is set to ON the LED switches on as shown in the figure The LED is turned on by the decoder Specific tooling 020460Y Scooter diagnosis and tester To connect the diagnostic tester open the battery inspection port and pull out the EMS diagnosis socket Remove the protection cap and connect the tester terminal Power the diagnostic tester by connecting the ter minals to the battery poles o...

Page 272: ...ssary to program the system again Programming is indispensable for the engine start up see injection chapter 3 Control unit replacement Programming is indispensable when the control unit is replaced to enable the engine start up In this case it is sufficient to switch to ON using the master key N B THE SERVICE KEY IS NOT USED FOR PROGRAMMING WHEN NOT PROGRAMMED THE CONTROL UNIT ALLOWS NO FUNCTIONA...

Page 273: ...N and OFF again Diagnostic codes The LED indication is divided into 3 steps 1st step A flash ON switching recognition 2nd step Series of flashes diagnosis code indication 3rd step Steady light on or off on start up disabled off start up enabled Code 1 Code 1 indicates a non programmed system If the code is still displayed after having carried out the programming procedure repeat the procedure care...

Page 274: ... the control unit connect the battery Repeat the programming 7 The system is OK Code 2 Code no 2 denotes a system where the decoder does not perceive the transponder signal Start up disabled Injection telltale light on steady In this case proceed as follows 1 Check whether the code is repeated using the second key YES go to 3 NO go to 2 2 Failure detected with the service key Replace and program a...

Page 275: ...resence of the code Code 3 Code no 3 denotes a system where the decoder perceives a transponder not provided for by pro gramming Start up disabled Injection telltale light on steady 1 Check whether the code is still displayed using the master key YES go to 3 NO go to 2 2 Program again using all service keys 3 Check that all components keys decoder control unit are properly matched YES go to 5 NO g...

Page 276: ...he continuity between pin 1 of the revolution timing sensor connector and pin 25 of the engine connector control unit Check the continuity between pin 2 of the revolution timing sensor connector and pin 35 of the engine connector control unit Check insulation between them and the ground lead of pin 1 and 2 of the connector and shielding Check the continuity between pin 3 of the connector and pin 3...

Page 277: ...HT coil REAR CYLINDER HV COIL CONNECTOR 1 Injection load relay Black Green 2 Control unit Pink Black GP 800 i e Injection INJEC 23 ...

Page 278: ...e engine connector control unit Inspecting the spark plug shielded cap Measure the shielded cap resistance Electric characteristic Resistance 5 KΩ If different values are measured 1 20KΩ replace the shielded cap N B A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM FOR INFORMATION ON THE SPARK PLUG SEE THE SPECIFICATIONS AND MAINTE NANCE CHAPTERS Spark advance The ignition a...

Page 279: ...ht 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 Replace the inspection cap on the flywheel side Specific tooling 020460Y Scooter diagnosis and tester I...

Page 280: ...V voltage between pin 1 and 3 of the sensor connector Check the continuity between pin 1 of the sensor connector and pin 5 of the engine connector control unit Check the continuity between pin 3 of the sensor connector and pin 20 of the engine connector control unit Check the ground insulation of the lines Repeat checks between pin 2 of the connector and pins 3 20 of the instrument panel also betw...

Page 281: ...n INTAKE AIR TEMPERATURE SENSOR 10 9600 Ohm 0 5900 Ohm 10 3800 Ohm 20 2500 Ohm 30 1700 Ohm With the switch set to ON check if there is 5V voltage between pins 1 and 2 of the sensor connector Check the continuity between pin 1 of the sensor connector and pin 14 of the engine connector control unit GP 800 i e Injection INJEC 27 ...

Page 282: ...ween pin 2 of the sensor connector and pin 20 of the engine connector control unit With the palm top computer compare the value shown with the ambient temperature value Throttle valve opening sensor THROTTLE SENSOR CONNECTOR 1 Control unit Grey Black 2 Control unit Brown Yellow 3 Control unit Orange Sky Blue Injection GP 800 i e INJEC 28 ...

Page 283: ...ing the minimum opening of the throttle valve to obtain a certain flow of air under pre set reference conditions Pre calibration ensures optimal air flow to control idling This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition advance The throttle body after the pre ...

Page 284: ...tic 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 Injection GP 800 i e INJEC 30 ...

Page 285: ...ction 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 Step motor GP 800 i e Injection INJEC 31 ...

Page 286: ...tween 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 perform the Stepper motor active diagnosis Slight rpm variations must be detected Check the continuity of the 4 Stepper motor control lines Check the ground insulation of the 4 lines Injection GP 800 i e INJEC 32 ...

Page 287: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 288: ...ion 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 Loosen the two screws indicated on the right fork leg Suspensions GP 800 i e SUSP 2 ...

Page 289: ...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 Agendo sull attrezzatura specifica estrarre un cuscinetto Specific tooling 001467Y001 Pliers to extract 25 mm Ø bearings 001467Y007 Driver for OD 54 mm bearing GP 800 i e Suspensions SUSP 3 ...

Page 290: ...distanziale interno e nelle sedi dei cuscinetti non siano presenti usure anomale Utilizzando l attrezzatura specifica riscaldare la sede di un cuscinetto Specific tooling 020151Y Air heater Inserire un nuovo cuscinetto portandolo fino a battuta utilizzando l attrezzatura specifica Specific tooling 020376Y Adaptor handle 020364Y 25 mm guide Suspensions GP 800 i e SUSP 4 ...

Page 291: ...indicato e portare a battuta Refitting the front wheel To refit carry out the removal operations but in reverse order and tighten to the prescribed torques Locking torques N m 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 cove...

Page 292: ...o 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 Suspensions GP 800 i e SUSP 6 ...

Page 293: ...e 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 GP 800 i e Suspensions SUSP 7 ...

Page 294: ...orting 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 Fit the four fixing screws and tighten to the pre scribed torque Locking torques N m Screws fixing frame supporting plate 4 5 7 Suspensions GP 800 i e SUSP 8 ...

Page 295: ...ebar inserts on the half handlebars and tighten the screw indicated to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium strength threadlock Locking torques N m 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 Giler...

Page 296: ...AIN SPRING PRELOADED KEEP THE CAP PROP ERLY FITTED DURING THE REMOVAL FINAL STAGE TO AVOID ACCIDENTS Support the fork leg properly remove the main spring and drain off the fork leg oil Remove the screw fixing the hydraulic rod with the specific sealing gasket Lock hydraulic rod rotation using the specific tool Undo the fixing screw and collect the copper washers Specific tooling 020632Y 22 mm Hexa...

Page 297: ...eal 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 WHEN THE STEM IS BEING REMOVED THE LOWER BUSHING WORKS AS AN EXTRACTOR AGAINST THE UPPER BUSHING THE WASHER AND THE OIL SEAL ON THE FORK LEG GP 800 i e Suspensions SUSP 11 ...

Page 298: ...atching the couplings Visually inspect that the upper sliding bushing exhibits no signs of abnormal wear on the internal surface Check that the stem exhibits no scores dents or distortions Check that the stop bushing for the hydraulic rod is properly fixed through caulking Visually inspect that the lower sliding bushing ex hibits no signs of abnormal wear on the external surface Suspensions GP 800...

Page 299: ...ons Check that the main spring exhibits no signs of yielding or abnormal wear Check that the closing cap O ring of the stem is in good conditions Refitting Preassemble the stem with the lower sliding bushing the hydraulic rod with the spring and the stop bushing Fit the pre assembled components inside the fork leg GP 800 i e Suspensions SUSP 13 ...

Page 300: ... screw 25 35 Apply LOCTITE 243 threadlock Lock hydraulic rod rotation using the specific tool Specific tooling 020632Y 22 mm Hexagonal spanner Fit the upper sliding bushing and the bushing stop washer inside the fork leg First grease the splitting chamber of the two seal ing lips of the new oil seal Fit the sealing ring on the stem and keep the identification words facing upwards Suspensions GP 80...

Page 301: ...Y 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 Drive the sealing ring to the end of stroke acting on the fork leg with a mallet Fit the oil seal retaining circlip GP 800 i e Suspensions SUSP 15 ...

Page 302: ...he photograph Locking torques N m Stem support clamp tightening screws 20 25 Refill the fork leg with the recommended product to the prescribed amount Recommended products AGIP FORK 7 5 W Oil for front fork Hydraulic fluid SAE 7 5 W Characteristic Oil quantity for stem 295 3 cm Bleed the hydraulic rod by actuating the stem re peatedly Fit the spring into the stem Suspensions GP 800 i e SUSP 16 ...

Page 303: ...ing screws cap 35 55 Repeat the procedure for the other fork leg N B IF BOTH FORK LEGS ARE SERVICED AT THE SAME TIME BE CAREFUL NOT TO INVERT THE RIGHT FORK LEG WITH THE LEFT ONE Steering column Removal Remove the front wheel Undo the screw indicated and remove the brake force distribution mechanism from the fork GP 800 i e Suspensions SUSP 17 ...

Page 304: ...per steering fifth wheel and rele vant components the fork is now free CAUTION HOLD IT SO THAT IT DOES NOT COME OFF SUDDENLY Slide off the complete front fork remove the lower steering fifth wheel Overhaul Clean thoroughly and visually inspect if the com ponents are in good conditions Check the upper steering fifth wheel for wear Suspensions GP 800 i e SUSP 18 ...

Page 305: ...headstock until it makes contact with the upper track Hit with force the specific tool placing it at differ ent points diametrically opposed so as to remove the upper track Specific tooling 020004Y Punch for removing fifth wheels from headstock From the upper part fit the specific tool in the two millings on the headstock indicated in the figure so as to make contact with the lower track Hit with ...

Page 306: ...he nut until the tracks are fully inserted N B LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BEFORE USE Specific tooling 001330Y Tool for fitting steering seats 001330Y014 Tool for fitting steering seats 001330Y015 Tool for fitting steering seats Recommended products AGIP GREASE PV2 Grease for steering bearings bolt seatings for swinging arms and faying surface of driven pulley...

Page 307: ...ey side Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Refitting Fit the lower steering fifth wheel on the steering tube Fit the fork together with the lower steering fifth wheel on the headstock and hold it so that it does not fall N B LUBRICATE THE STEERING FIFTH WHEEL TRACKS WITH RECOMMENDED GREASE BE FORE USE Recommended products AGIP GREASE PV2 Grease for steering be...

Page 308: ...ate 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 Specific tooling 020668Y Steering ring nut wrench Locking torques N m Steering tube lower ring nut 20 22 Suspensions GP 800 i e SUSP 22 ...

Page 309: ...d 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 Specific tooling 020668Y Steering ring nut wrench Locking torques N m Steering tube upper ring nut 48 54 GP 800 i e Suspensions SUSP 23 ...

Page 310: ...ead Locking torques N m Screw fixing three way union to fork head 10 12 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 Suspensions GP 800 i e SUSP 24 ...

Page 311: ...ERVICE Remove the protection sleeve and the spacer from both sides using a flat blade screwdriver as a lever Visually inspect if the components are in good conditions and that they exhibit no signs of abnor mal wear Acting on the specific tool pull out one bearing Specific tooling 020467Y020 Pliers to extract 30 mm bearings 001467Y002 Driver for OD 73 mm bearing GP 800 i e Suspensions SUSP 25 ...

Page 312: ...signs of abnormal wear Heat the seat of one bearing with the specific tool Specific tooling 020151Y Air heater Insert a new bearing until it stops with the specific tool Specific tooling 020376Y Adaptor handle 020483Y 30 mm guide 020655Y Adaptor 62x68 mm Fit the internal spacer from the opposite side Repeat the previously described procedure to fit the other bearing Suspensions GP 800 i e SUSP 26 ...

Page 313: ...ghten to the prescribed torque Locking torques N m Rear wheel pin nut 70 Shock absorbers Removal Remove the fork Unscrew the nut indicated to remove the pin See also Removal Refitting Fix the fork to the shock absorber with a pin Tighten the nut indicated to the prescribed tor que Locking torques N m Nut fixing shock absorber fork 38 46 GP 800 i e Suspensions SUSP 27 ...

Page 314: ...rk 38 46 Removal See also Exhaust assy Removal Refitting See also Exhaust assy Removal Fork Removal Remove the left side fairing Remove the rear wheel Undo the two screws indicated and collect the washers thus releasing the rear brake pipe retain er Release the rear shock absorber front retainer Undo the screw indicated and collect the washer N B THE NOW FREE FORK ROTATES DOWN WARDS Suspensions GP...

Page 315: ...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 GP 800 i e Suspensions SUSP 29 ...

Page 316: ...k 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 Specific tooling 001467Y035 Bell Ø 42 001467Y001 Pliers to extract 25 mm Ø bearings Suspensions GP 800 i e SUSP 30 ...

Page 317: ...l wear Specific tooling 020376Y Adaptor handle 020670Y Adaptor 34 mm 020483Y 30 mm guide Fit the adaptor handle from the right side then prepare the adaptor and the guide Pull out the ball bearing cage with the specific tool Visually inspect if the surfaces are in good con ditions and that they exhibit no signs of scratches or abnormal wear Specific tooling 020376Y Adaptor handle 020670Y Adaptor 3...

Page 318: ...products AGIP GREASE PV2 Grease for steering bear ings and spindle seats Soap based lithium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 of the swinging arm Drive a new bearing with the specific tool and a hydraulic press Specific tooling 020376Y Adaptor handle 020359Y 42 x 47 mm Adaptor For main bear ings and wheel axle 020364Y 25 mm guide Suspensions GP 800 i e SUSP 32 ...

Page 319: ...ations 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 Upon fitting tighten the three screws to the pre scribed torque Locking torques N m Screw fixing chain stop slider fork 5 7 GP 800 i e Suspensions SUSP 33 ...

Page 320: ...e stand stop buffer fork 5 7 Fit the pin and the stop bushing Fitting N B CLEAN ALL THE SURFACES AND THREADS THOROUGHLY BEFORE FITTING LUBRICATE ALL THE FRICTION AREAS THOROUGHLY Fit the fork together with the rear shock absorber Tighten the screw fixing it to the chassis to the prescribed torque Locking torques N m Screw fixing shock absorber fork 38 46 Suspensions GP 800 i e SUSP 34 ...

Page 321: ...pare the specific tool and the torque wrench for tightening N B PLACE THE WRENCH AT 90 REGARDING THE SPECIFIC TOOL FAILURE TO OBSERVE THIS POSITIONING MAY ALTER THE PROPER LOCKING TORQUE Using the specific tool tighten the set screw lock ing ring nut to the prescribed torque while keeping the set screw locked Specific tooling 020667Y Wrench for fork pin adjustment ring nut Locking torques N m Fork...

Page 322: ...orque Locking torques N m Fork pin nut 90 5 Tighten the two screws together with the wash ers thus fixing the rear brake pipes CAUTION UPON FITTING BE PARTICULARLY CAREFUL WHEN INSERTING THE BREATHER PIPE IN THE FORK SLOT Centre stand See also Exhaust assy Removal Suspensions GP 800 i e SUSP 36 ...

Page 323: ...he connector remove the two clamps undo the two connecting screws to the chassis and remove the button FITTING Follow the removal steps but in reverse order and tighten to the prescribed torques Locking torques N m Screws fixing side stand button 6 Side stand bolt nut 37 Grease with the recommended product Recommended products AGIP GP 330 Grease brake lever throttle grip Calcium complex soap based...

Page 324: ...Suspensions GP 800 i e SUSP 38 ...

Page 325: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 326: ... operations are completed purge the braking system Locking torques N m Screws fixing the calliper to the supporting plate 20 25 Front brake calliper Removal Remove the two retainers fixing the brake calliper to the fork N B SHOULD THE BRAKE CALLIPER BE RE PLACED BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORTING BRACKET FIRST LOOSEN THE OIL HOSE FIT TING AFTER HAVING EMPTIED THE SY...

Page 327: ...xing front brake calliper to fork 20 25 Fix the brake pipe coupling to the calliper Locking torques N m Brake pipes front brake calliper coupling 16 20 Purge the system Rear brake disc Removal Remove the rear wheel Undo the five screws fixing the disc to the rim GP 800 i e Braking system BRAK SYS 3 ...

Page 328: ...rtant 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 New rear disc thickness 5 mm Disc thickness at wear limit rear 4 5 mm Remove the wheel and check using the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test ...

Page 329: ... 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 Locking torques N m Screws fixing front brake disc to rim 25 GP 800 i e Braking system BRAK SYS 5 ...

Page 330: ...disc 5 mm Disc thickness at wear limit front 4 5 mm Remove the wheel and check using the appro priate tools that the axial run out of the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axial run out 0 1 mm Front brake pads Braking system GP 800 i e BRAK S...

Page 331: ...eck the thickness of the friction material Re place the pads if the thickness is below the mini mum value Characteristic Minimum friction material thickness 1 5 mm In case of uneven wear replace the pads when the thickness difference in the friction material is 0 5 mm GP 800 i e Braking system BRAK SYS 7 ...

Page 332: ...o 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 25 Rear brake pads Braking system GP 800 i e BRAK SYS 8 ...

Page 333: ...ess difference in the residual friction material is permitted Characteristic Minimum value 1 5 mm Refitting To fit proceed as follows Insert the two pads in the callipers Screw the two pad lock pins to the correct torque and apply the recommended product Fit the calliper on its support tightening the two screws to the prescribed torque N B IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER O...

Page 334: ...uid recovery pipe and refit the rub ber cap over the bleed screw Top up the brake fluid to the right level in the res ervoir If necessary bleeding can be done using a special vacuum pump N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DUR ING THE BLEEDING OPERATIONS REGARD ING THE BRAKE CALLIPERS MAKE SURE...

Page 335: ...ove the fluid recovery pipe and refit the rub ber cap over the bleed screw Top up the brake fluid to the right level in the res ervoir If necessary bleeding can be done using a special vacuum pump N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT FURTHERMORE DUR ING THE BLEEDING OPERATIONS REGARD ING THE BRAKE CALLIPERS...

Page 336: ...through the specific sight glass Top up whenever the level is below the MIN ref erence A for the left reservoir and reference B for the right reservoir Removal Remove the two contacts from the stop light switch Drain off the braking system corresponding to the circuit being tested Remove the oil pipe coupling Braking system GP 800 i e BRAK SYS 12 ...

Page 337: ...NCE REFITTING IS FINISHED BLEED THE SYSTEM Locking torques N m Screws fixing brake pump to handlebar 7 10 Brake pipes brake pump coupling 16 20 Removal Remove the two contacts from the stop light switch Drain off the braking system corresponding to the circuit being tested Remove the oil pipe coupling GP 800 i e Braking system BRAK SYS 13 ...

Page 338: ...g brake pump to handlebar 7 10 Brake pipes brake pump coupling 16 20 Brake pipes FRONT BRAKE PIPE FITTING Fix the three way union to the fork head Locking torques N m Screw fixing three way union to fork head 10 12 Fit the front brake pipes to the right and the left Locking torques N m Brake pipes three way union coupling 18 23 Brake pipes front brake calliper coupling 16 20 Braking system GP 800 ...

Page 339: ... N m Brake pipes three way union coupling 18 23 Brake pipes brake pump coupling 16 20 REAR BRAKE PIPE FITTING To reach the rear brake pipes thread the pipes through the left half handlebar and afterwards fix the coupling to the brake pump Thread the pipes through the left half handlebar and afterwards fix the coupling to the brake pump Fasten the pipe to the clip GP 800 i e Braking system BRAK SYS...

Page 340: ... 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 Braking system GP 800 i e BRAK SYS 16 ...

Page 341: ... clip 11 13 Fix the brake pipe coupling to the brake calliper Locking torques N m Brake pipe rear brake calliper coupling 20 25 PARKING BRAKE TRANSMISSION FITTING Fit the transmission cable of the control lever and thread the transmission sheath to the other side of the vehicle as shown in the figure GP 800 i e Braking system BRAK SYS 17 ...

Page 342: ... 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 13 Braking system GP 800 i e BRAK SYS 18 ...

Page 343: ...s 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 Locking torques N m Screw fixing parking brake calliper to supporting plate 24 27 Parking brake adjusting nut 10 GP 800 i e Braking system BRAK SYS 19 ...

Page 344: ...d remove the transmission cable BRAKE PAD REPLACEMENT Remove the brake calliper Unscrew the two retaining pins and slide off the pads To refit carry out the previous operations but in reverse order Locking torques N m Pin fixing parking brake pads 15 20 Braking system GP 800 i e BRAK SYS 20 ...

Page 345: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 346: ...Circuit diagram KEY 1 Rear head outlet 2 To radiator Cooling system GP 800 i e COOL SYS 2 ...

Page 347: ...the thermostat output to the radiator is closed even though there is still a little flow for de aeration obtained by a hole into the closing plate In this case the circulation into the thermal units is active to ensure an even heating Once the working temperature has been reached the main circulation on radiator and expansion tank starts With the small openings in the thermostat there is a flow ov...

Page 348: ...ic fan control circuit for failures Specific tooling 020460Y Scooter diagnosis and tester Select the ACTIVE DIAGNOSIS function in this menu and run a simulation of the electric fan op eration If the electric fan is certainly efficient check the ventilation start and stop temperatures Select the PARAMETERS function in this menu to display the coolant temperature Electric fan starts 105 C Electric f...

Page 349: ...s provided with a drainage hole in case of leaks from the cooling system mechan ical seal or from the shaft sealing oil guard If coolant leaks are detected replace the pump see Engine Chapter Coolant replacement Restore all the cooling system connections re move the compartment cover giving access to the expansion tank and unscrew the cap Remove the front section of the helmet compart ment remove ...

Page 350: ...peed again and keep it running until the electric ventilation temperature is obtained Shut off the engine and wait until it cools down CAUTION GIVEN REGULAR CONDITIONS OF USE WITH ENGINE AT IDLE SPEED THE TIME REQUIRED TO TAKE THE TEMPERATURE BELOW THE ELECTRIC FAN ACTIVATION LEVEL IS 35 SEC CHECK THAT THE ACTIVATION TIME AFTER BLEEDING THE SYSTEM DOES NOT DEVIATE MUCH FROM THE TIME SPECIFIED OTHE...

Page 351: ...ving the water pump cover Loosen the six fixing screws and remove the wa ter pump cover Check that the water pump cover is not deformed or dented Check that the sealing O ring is in good working order Otherwise replace the component Adequately fit a new O ring be careful to lubricate it with petroleum jelly grease N B TO AVOID DEFORMATION DO NOT LUBRICATE THE O RING WITH PETROLEUM GREASE CAUTION F...

Page 352: ...p and timing system chapter 3 Replace the cap Cooling fluid consumption 1 Check the system outside seals as described above YES go to 2 NO go to 3 2 Check the head gasket seal see Thermal unit and timing system chapter If water leaks are detected in the engine oil inspect the pad on the head cooling circuit 3 Fix any damaged seals Oil in the fluid 1 Oil into the coolant YES go to 2 2 Check the hea...

Page 353: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 354: ...er section C Battery compartment cover Expansion tank inspection compartment cover D Front headlight assembly Front shield E Front central cover F Handlebar G Shield back plate Central rear part H Helmet compartment front part I Chassis side cover rear part L Grab handles and upper side fairings Rear light unit M Spoiler N Side fairings Footrests O Helmet compartment P Fuel tank Chassis GP 800 i e...

Page 355: ...xing 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 GP 800 i e Chassis CHAS 3 ...

Page 356: ... 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 Chassis GP 800 i e CHAS 4 ...

Page 357: ...T FRAME Undo the two screws indicated and take out the front headlight assembly from its seat Remove it once the connector has been discon nected Legshield Remove the windshield together with the brack ets Remove the rear view mirrors Remove the headlight assembly Undo the two screws indicated and remove the front shield upper part GP 800 i e Chassis CHAS 5 ...

Page 358: ... 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 Undo the two screws indicated on both sides and remove side fairings Chassis GP 800 i e CHAS 6 ...

Page 359: ...ake pumps U bolts release them from the half handlebars CAUTION BE CAREFUL WITH THE SWITCH STOP CON NECTORS Remove the handlebar together with the sup porting plate Remove the GP800 clip on badge and undo the screw underneath that fixes the badge to the chas sis Remove the key switch frame Unscrew the expansion tank cap Undo the screw fixing the expansion tank to the shield back plate GP 800 i e C...

Page 360: ...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 Chassis GP 800 i e CHAS 8 ...

Page 361: ...r 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 Removal GP 800 i e Chassis CHAS 9 ...

Page 362: ...ient 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 Remove the front wheel housing together with the radiator cover Taillight assy Undo the two screws indicated Chassis GP 800 i e CHAS 10 ...

Page 363: ...h the rear light unit from the license plate support Footrest These operations are described once but apply to both footrests Remove the chassis side cover Undo the two external screws Undo the three screws from the internal side and collect the washers See also Side fairings GP 800 i e Chassis CHAS 11 ...

Page 364: ...trale anteriore Rimuovere la parte anteriore del vano portacas co Rimuovere lo spoiler Svitare le tre viti indicate Rimuovere il tappetino in gomma della pedana poggiapiedi Svitare le due viti indicate Svitare le due viti di collegamento al vano ruota anteriore Rimuovere la copertura centrale telaio completa di pedana poggiapiedi Chassis GP 800 i e CHAS 12 ...

Page 365: ...ng 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 license plate support together with the rear light unit GP 800 i e Chassis CHAS 13 ...

Page 366: ...ue viti indicate Svitare le tre viti indicate Rimuovere la parte anteriore del vano portacas co Rimuovere il gruppo ottico posteriore Svitare il tappo serbatoio carburante e le quattro viti indicate Chassis GP 800 i e CHAS 14 ...

Page 367: ... e rimuovere il va no portacasco spoiler These operations are described once but apply to both spoilers Remove the rubber mat Undo the four screws indicated Undo the lower connecting screw to the wheel housing and the connecting screw to the chassis side cover rear part Remove the spoiler GP 800 i e Chassis CHAS 15 ...

Page 368: ...rte superiore La rimozione dei semiser batoi deve avvenire separatamente seguendo le indicazioni riportate Rimuovere il carburante contenuto all interno del serbatoio Rimuovere il vano portacasco Svitare le tre viti indicate e rimuovere la staffa Disimpegnare dalle fascette la tubazione di sfia to Svitare le sei viti indicate e rimuovere la prote zione in plastica del tubo di compensazione Chassis...

Page 369: ...REAS SEMBLY IT IS THEREFORE NECESSARY TO SLIGHTLY PRESS THE PIPES AND THE RE TAINING RING TOWARDS THE PUMP THEN KEEP THE RING PRESSED AND PULL THE COUPLING UPWARDS Scollegare dal semiserbatoio destro la fascetta del tubo di compensazione Scollegare dal semiserbatoio destro la fascetta del manicotto di giunzione e scollegare il tubo di sfiato Svitare da entrambi i lati le tre viti indicate per rimu...

Page 370: ...ULARLY 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 Chassis GP 800 i e CHAS 18 ...

Page 371: ...dicated on both sides Radiator fan Get a container of suitable capacity disconnect the pipes indicated and let the fluid drain off the cooling system Disconnect the pipes indicated Disconnect the connector of the electric fan Undo the two screws indicated and collect the washers GP 800 i e Chassis CHAS 19 ...

Page 372: ... the four fixing screws of the cover and release it from the two leverages Handles and top side fairings These operations are described once but apply to both vehicle fairings Remove the rear central cover Undo the three screws indicated to remove the passenger grab handles Undo the screws indicated and remove the li cense plate holder cover Chassis GP 800 i e CHAS 20 ...

Page 373: ...ards 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 Undo the two screws indicated Unscrew the two screws indicated from the hel met compartment GP 800 i e Chassis CHAS 21 ...

Page 374: ...ase the tongue Flyscreen Undo the fours screws indicated and remove the windshield Undo the four nuts indicated and collect the washers Remove the screws and the internal spacers in order to remove the connecting brack ets to the windshield adjustment motor Radiator cover See also Front wheel housing Chassis GP 800 i e CHAS 22 ...

Page 375: ...attery negative and positive wires WARNING IN ORDER TO AVOID DAMAGING THE ELEC TRICAL SYSTEM NEVER DISCONNECT THE WIRING WHILE THE ENGINE IS RUNNING To remove the battery from its housing remove the shield back plate Disconnect the cable harnesses at the back of the battery compartment Undo the three screws indicated GP 800 i e Chassis CHAS 23 ...

Page 376: ...Chassis GP 800 i e CHAS 24 ...

Page 377: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 378: ... pipes brake pump couplings Brake pipes front brake pump couplings FRONT SUSPENSION Front wheel pin nut Screw fixing wheel pin on right fork leg FRONT BRAKE Screws fixing front brake calliper to forks Brake pipes front brake calliper couplings REAR SUSPENSION Rear wheel pin nut Screws tightening the fork pin cam REAR BRAKE Screws fixing parking brake calliper to supporting plate Parking brake adju...

Page 379: ...N WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE LEAD WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS IT CONTAINS SUL PHURIC ACID AVOID CONTACT WITH EYES SKIN AND CLOTHING IN CASE OF CONTACT WITH EYES OR SKIN RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES ...

Page 380: ...ring rotation Possible losses electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Hydraulic braking system lever travel Clutch proper functioning check Engine proper general functioning and no abnormal noise check Other paper che...

Page 381: ...INDEX OF TOPICS TIME TIME ...

Page 382: ...voted to the time necessary to carry out repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine to chassis Replace ment Time GP 800 i e TIME 2 ...

Page 383: ...Replace ment 4 007007 Water pump rotor cover 5 001187 Overall sealing Replac 6 005134 Speed sensor Replacement 7 001160 Minimum oil pressure sensor Replacement 8 110301 Blow by valve and or blow by pipe Replac 9 003064 Engine oil change 10 001100 Oil seal clutch side Re placement 11 001188 Water pump shaft sealing ring Replac GP 800 i e Time TIME 3 ...

Page 384: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Time GP 800 i e TIME 4 ...

Page 385: ...Cylinder assy CYLINDER GROUP Code Action Duration 1 001002 Cylinder piston Replace ment 2 001154 Pin ring piston unit Service GP 800 i e Time TIME 5 ...

Page 386: ...nt 2 001049 Valves Adjustments 3 001056 Head gasket Replacement 4 001126 Head Replacement 5 000235 Coolant temperature sensor Replac 6 007012 Coolant bleed valve Re placement 7 005089 Tone wheel Replacement 8 005116 revolution timing sensor Re placement Time GP 800 i e TIME 6 ...

Page 387: ...ion 1 001044 Camshaft Replacement 2 001148 Rocking lever valve Re placement 3 001129 Chain tightener Replace ment 4 001051 Belt Timing chain Replace ment 5 001125 Chain guide pads Replace ment 6 140021 Camshaft timing system pul ley Replac GP 800 i e Time TIME 7 ...

Page 388: ...Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replace ment Time GP 800 i e TIME 8 ...

Page 389: ...Flywheel cover FLYWHEEL COVER Code Action Duration 1 001087 Flywheel cover replace 2 001150 Flywheel cover gasket Re placement 3 001123 Oil filter Replacement GP 800 i e Time TIME 9 ...

Page 390: ...en pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley Overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell housing Re placement Time GP 800 i e TIME 10 ...

Page 391: ... control gear Re plac 2 001122 Oil pump chain Replace ment 3 001042 Oil pump Service 4 001184 Oil delivery pump Replac 5 001124 Lubrication by pass Re placement 6 001189 Water pump control gear Replac 7 001185 Oil scavenge pump Replac GP 800 i e Time TIME 11 ...

Page 392: ...Final gear assy FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 1 001195 Toothed wheel Replac 2 001196 Driven pulley shaft Replac 3 001190 Oil sealing casing Replac Time GP 800 i e TIME 12 ...

Page 393: ...tion 1 001086 Driving half pulley Replace ment 2 001011 Driving belt Replacement 3 001006 driving pulley Service 4 001066 driving pulley Replacement 5 001177 Variator rollers shoes Re placement 6 001181 Adjusting ring Replac GP 800 i e Time TIME 13 ...

Page 394: ...Replac 6 000605 Final drive pinion chain crown Replacement 7 002077 Final drive chain Replace ment 8 410371 Pinion bearings Replac 9 410271 Flange oil seal Replac 10 001192 Pinion unit support Replac 11 001193 Pinion unit cover O ring Re plac 12 001194 Pinion unit cover Replac 13 000604 Rear hub anti vibration buffer Replac 14 000122 Final drive chain Adjustment and lubrication Time GP 800 i e TIM...

Page 395: ...ona ruota posteriore Sost Transmission cover TRANSMISSION COVER Code Action Duration 1 001096 External transmission cover Replacement 2 001131 Transmission air intake Re placement 3 001170 Air manifold replacement 4 001135 Transmission cover bearing Replacement GP 800 i e Time TIME 15 ...

Page 396: ...t 2 161011 Water pump and or gasket Replacement 3 001111 Water pump gear Replace ment 4 007008 Cylinder head outlet rubber coupling Replacement 5 007022 Head outlet T joint Replac 6 001182 Head intake rubber sleeve Replac 7 001183 Head intake T joint Replac Time GP 800 i e TIME 16 ...

Page 397: ...neto MAGNETO FLYWHEEL Code Action Duration 1 001173 Rotor Replacement 2 001067 Stator Removal and Refit ting 3 001058 Complete flywheel Replace ment 4 001104 Start up freewheel Replace ment GP 800 i e Time TIME 17 ...

Page 398: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold change 2 001047 Injector Replacement 3 001166 Throttle body Replacement Time GP 800 i e TIME 18 ...

Page 399: ...ent 3 170101 Exhaust pipe gasket Re placement 4 005138 Lambda probe Replace ment 5 170071 Catalytic converter and or gasket Replacement 6 003077 Muffler supporting arm rear shock absorber Replace ment 7 170171 Muffler duct No 1 Replace ment 8 170211 Muffler duct No 2 Replace ment GP 800 i e Time TIME 19 ...

Page 400: ...ER Code Action Duration 1 110301 Blow by valve and or blow by pipe Replac 2 001015 Air filter box Replacement 3 001014 Air filter Replacement cleaning 4 004122 Cleaner Throttle body union Replacement Time GP 800 i e TIME 20 ...

Page 401: ...Frame CHASSIS Code Action Duration 1 004001 Chassis Replacement 2 004147 Footrest support bracket one side Replacement 3 004116 Rear frame Replacement GP 800 i e Time TIME 21 ...

Page 402: ...Centre stand STAND Code Action Duration 1 004004 Stand Replacement 2 004179 Stand buffer Replacement 3 001053 Stand bolt Replacement 4 004102 Side stand Replacement Time GP 800 i e TIME 22 ...

Page 403: ...spoiler FRONT SHIELD Code Action Duration 1 004021 Shield upper section Re placement 2 004064 Front shield Replacement 3 004020 Headlight frame Replace ment 4 004085 Fairing 1 Replacement GP 800 i e Time TIME 23 ...

Page 404: ...e fairings SIDE COVERS Code Action Duration 1 004036 Frame cover Replacement 2 004129 Rear fairing Replacement 3 004068 Passenger handgrip Re placement 4 004053 Spoiler Replacement Time GP 800 i e TIME 24 ...

Page 405: ...EAR SHIELD Code Action Duration 1 004065 Front shield rear part Re moval and refitting 2 004023 Shield rim Replacement 3 004132 Half panel replac 1 4 004071 Battery compartment Re placement GP 800 i e Time TIME 25 ...

Page 406: ...flap Replacement 2 004011 Central chassis cover Re placement 3 004012 Rear fairings Removal and refitting 4 004015 Footrest Removal and Re fitting 5 004075 Front mat Replacement 6 004186 Passenger footrest support Replac 7 004187 Passenger footrests Re plac Time GP 800 i e TIME 26 ...

Page 407: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard Replace ment 2 003087 Wheel housing Replace ment GP 800 i e Time TIME 27 ...

Page 408: ...010 Tank float Replacement 3 004109 Fuel tank breather Replace ment 4 004168 Fuel tank cap Replacement 5 004005 Fuel tank Replacement 6 004073 Fuel pump Replacement 7 004188 Connecting sleeve Replac 8 004189 Whole compensation pipe Replac 9 004190 Pipe guard Replac Time GP 800 i e TIME 28 ...

Page 409: ... Duration 1 003007 Rear shock absorber Re moval and Refitting 2 003078 Rear fork Replac 3 000601 Fork removal and fitting Bushings and spacer remov al 4 003125 Fork bolt Replac 5 003126 Fork guards Replac 6 003127 Eccentric Replac GP 800 i e Time TIME 29 ...

Page 410: ...Left knob Replacement 6 003059 Counterweight Replace ment 7 002037 Brake lever Replacement 8 002067 Rear brake pump Replace ment 9 002080 Rear brake oil bleeding sys tem Replacement 10 002024 Front brake pump replace 11 002047 Front brake fluid and air bleeding system Replace ment 12 005017 Stop switch Replacement 13 004026 Handlebar cover Replace ment 14 003128 Handlebar frame Replac 15 003129 Su...

Page 411: ...ode Action Duration 1 003015 Traversa anteriore sostegno motore Sost 2 003016 Tamponi anteriori sostegno motore Sost 3 003017 Tampone posteriore suppor to motore Sost 4 001032 Engine support pin Replace ment GP 800 i e Time TIME 31 ...

Page 412: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Time GP 800 i e TIME 32 ...

Page 413: ...Instrument panel INSTRUMENT PANEL Code Action Duration 1 005014 Odometer Replacement 2 004099 Odometer housing Replace ment GP 800 i e Time TIME 33 ...

Page 414: ...S Code Action Duration 1 005146 Electric saddle opening acti vator Replacement 2 004054 Saddle lock catch Replace ment 3 004010 Anti theft lock Replacement Turn signal lights Front lights Time GP 800 i e TIME 34 ...

Page 415: ...R LIGHTS Code Action Duration 1 005067 Front direction indicator bulb Replacement 2 005012 Front direction indicators Replacement 3 005002 Front light Replacement 4 005008 Light bulbs Replacement Rear lights GP 800 i e Time TIME 35 ...

Page 416: ... Duration 1 005005 Taillight Replacement 2 005022 Rear turn indicators Re placement 3 005031 Licence plate light bulb Re placement 4 005131 Licence plate light support Replacement 5 005068 Rear turn indicator bulb Re placement Time GP 800 i e TIME 36 ...

Page 417: ...003047 Front tyre Replacement 2 003037 Front wheel rim Replace ment 3 002041 Front brake disc Replace ment 4 004123 Front wheel Replacement 5 003040 Front wheel bearings Re placement 6 003038 Front wheel axle Removal and Refit GP 800 i e Time TIME 37 ...

Page 418: ... Rear brake disc Replace ment 2 001016 Rear wheel Replacement 3 001071 Front wheel rim Removal and refitting 4 004126 Rear wheel tyre Replace ment 5 002031 Rear wheel hub bearings Replacement 6 004125 Rear wheel axle Replace ment Time GP 800 i e TIME 38 ...

Page 419: ...AL START UP Code Action Duration 1 001020 Starter motor Replacement 2 005045 Starter motor cable harness Replacement 3 001017 Start up pinion Replace ment 4 001151 Start up driven gearing Re placement GP 800 i e Time TIME 39 ...

Page 420: ...park plug cap Replace ment 3 832311 Turn indicator flash Re placement 4 001023 Control unit Replacement 5 005009 Voltage regulator Replace ment 6 005099 Electric saddle opening de vice Replacement 7 005081 Temperature sensor Re placement 8 005127 Roll over sensor Replace ment Time GP 800 i e TIME 40 ...

Page 421: ...zer aerial Replace ment 2 005073 Immobilizer decoder Re placement 3 005003 Horn Replacement 4 005011 Start up remote control switch Replacement 5 005007 Battery Replacement 6 000319 Remote control Replac 7 005052 Fuse 1 Replacement GP 800 i e Time TIME 41 ...

Page 422: ...WIRE UNIT Code Action Duration 1 005001 Electrical system Replace ment 2 005114 Electrical system Service 3 820021 Engine cable harness Re plac Time GP 800 i e TIME 42 ...

Page 423: ...controls HANDLEBAR CONTROLS Code Action Duration 1 000307 RIGHT OR LEFT CONTROL ASSEMBLY REPLACE MENT 2 888126 Helmet compartment light switch replacement 3 005079 Stand switch Replacement GP 800 i e Time TIME 43 ...

Page 424: ...Transmissions TRANSMISSIONS Code Action Duration 1 002063 Complete throttle control Replacement 2 003061 Accelerator transmission Adjustment Time GP 800 i e TIME 44 ...

Page 425: ...ARTMENT Code Action Duration 1 004016 Helmet compartment Re placement 2 005026 Helmet compartment bulb Replacement 3 005027 Helmet compartment bulb support Replacement 4 004142 Plug socket Replacement GP 800 i e Time TIME 45 ...

Page 426: ...Rear side fairings REAR COVERS Code Action Duration 1 005048 Licence plate holder Re placement 2 004136 License plate support Re placement Time GP 800 i e TIME 46 ...

Page 427: ...ENSION Code Action Duration 1 003010 Front suspension Service 2 003112 Central steering tube re placement 3 003107 Sliding stems replacement 4 003002 Steering fifth wheel Re placement 5 331352 Fork service GP 800 i e Time TIME 47 ...

Page 428: ...ent 2 001052 Coolant and air bleed Re placement 3 007001 Expansion tank Replace ment 4 007024 Expansion tank cap Re placement 5 007003 Coolant delivery and return pipe Replacement 6 007016 Fan with support Replace ment 7 007002 Water radiator replacement 8 001057 Thermostat Replacement Time GP 800 i e TIME 48 ...

Page 429: ...8 Parking brake flexible trans mission replacement 5 002002 Shoes Rear brake pads Replacement 6 002007 Front brake pads Replace ment 7 002039 Front brake calliper Re placement 8 003121 Parking brake control lever replacement 9 003122 Parking brake control lever micro switch replacement 10 002048 Rear brake calliper Re placement 11 002112 Parking brake calliper pads Replac GP 800 i e Time TIME 49 ...

Page 430: ...ndshield support Replac 5 004192 Windshield support tube Re plac 6 004193 Windshield motor unit Re plac 7 004194 Sliding plate Replac 8 004195 Windshield electric motor Replac 9 005123 End of stroke enabling switches Adjustment re placement 10 004197 Sliding carriage Replac 11 004196 Guide profile Replac 12 004146 Front frame Replacement Time GP 800 i e TIME 50 ...

Page 431: ...Stickers TRANSFERS Code Action Duration 1 004066 Driving mirror Replacement 2 004159 Plates Stickers Replace ment GP 800 i e Time TIME 51 ...

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Gilera GP 800 i.e., Service Station Manual

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