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Gilera SATURNO BIALBERO 350 Workshop Manual

Gilera SATURNO BIALBERO 350 Workshop Manual

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WORKSHOP MANUAL

SATURNO BIALBERO
350-500

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Summary of Contents for Gilera SATURNO BIALBERO 350

  • Page 1: Workshop Manual

    WORKSHOP MANUAL SATURNO BIALBERO 350-500...
  • Page 2 NOTES: In addition to this workshop manuals texts and pictures transcribed from original Piaggio/Gilera manuals, there is included a section on the various known faults with which the Saturno is prone to suffer. Whilst these faults were obviously not included in the original official manuals, we believed they should be a part of any publication dealing with Saturno maintenance.
  • Page 3: Table Of Contents

    INDEX Section General information - Known faults Special tools Maintenance ENGINES Working procedures Engine removal/installation Generator - Timing belt - Gearbox selector Cylinder head - Valvetrain components Cylinder - Piston Clutch - Primary drive - Oil pump Crankcase - Gearbox - Crankshaft components FRAMES Working procedures Front Wheel...
  • Page 4 GENERAL INFORMATION SUB INDEX Section - Page Known faults 1 - 1 Safety procedures 1 - 2 Maintenance procedures 1 - 2 Model Identification 1 - 2 Technical data 1 - 3 Torque wrench settings 1 - 4 Engine overhaul data 1 - 5 Cables and wire passage 1 - 6...
  • Page 5: Known Faults

    KNOWN FAULTS 1 - 1 Fan touches Radiator. Remove tank, look down back of radiator & check that fan shroud has about 3mm (1/8”) clearance. The fan mountings are slotted but if there is not enough adjustment, trim the front of the shroud.
  • Page 6: Safety Procedures

    MANTENANCE PROCEDURES 1 - 2 Always use original GILERA spare parts and recommended lubricants. The use of non-original parts or parts not conforming to Gilera specifications may result in damage to the motorcycle.
  • Page 7: Model Identification

    MODEL IDENTIFICATION 1 - 2 1 - 2 ,2...
  • Page 8: Technical Data

    TECHNICAL DATA 1 - 3 DESCRIPTION 350cc - 500cc DIMENSIONS Overall length 2030 mm Overall width 730 mm Overall height 1170 mm Wheelbase 1410 mm Seat height 790 mm Foot pedal height 360 mm Dry weight 145 kg FRAME Triangulated tubular steel space frame Steering column angle 24.3 30’...
  • Page 9 TECHNICAL DATA 1 - 3 350cc - 500cc ENGINE Single cylinder, 4 stroke, vertical cylinder Bore X stroke 80 X 69.4 - 92 X 74 Displacement 348.8 cc - 491.9 cc Compression ratio 9,5:1 - 9,8:1 Cylinder compression (use special tool 19.1.20524) New engine 9 ÷...
  • Page 10: Technical Data

    TECHNICAL DATA 1 - 3 350cc - 500cc CARBURETTOR Dell‘ Orto Throttle valve PHF36PS - PHM40VS Needle jet K54 - K4 3a tacca-3rd notch - 2a tacca-2nd notch Fuel nozzle AB262 - AB265 Max jet - 138 Idle jet Choke jet Pump jet Ø...
  • Page 11: Torque Wrench Settings

    TECHNICAL DATA 1 - 4 TORQUE WRENCH SETTINGS * = Lubricate the thread with oil + = Copper slip on thread 350cc + 500cc Engine (both) Cylinder head, cylinder head cover, cylinder fixing nuts 32-35 Nm Cam pulley bolts 30 Nm Spark plug + 12-15 Nm Crankshaft gearing bolt *...
  • Page 12: Engine Overhaul Data

    ENGINE OVERHAUL DATA 1 - 5 350cc - 500cc Piston/cylinder clearance 0.030 ÷ 0.042 mm Main bearings radial clearance 0.030 ÷ 0.059 mm Connecting rod bearings radial clearance 0.017 ÷ 0.060 mm Crankshaft axial clearance 0.05 ÷ 0.25 mm Big end axial clearance 0.15 ÷...
  • Page 13: Cables And Wire Passage

    CABLES AND WIRE PASSAGE 1 - 6 Point out the passage of each cable and wire (figs. 5-6-7-8-9). 1 - 6...
  • Page 14 SPECIAL TOOLS Sprocket locking wrench Camshaft oil ring installation punch 19.1.20086 19.1.20503 Puller for steering bearing lower race Camshaft pulley blocking tool 19.1.20109 19.1.20504 Flywheel puller Con-rod small end bushing 19.1.20501 installation punch 19.1.20505 Valve guide oil ring Con-rod small end bushing installation punch extraction punch 19.1.20502...
  • Page 15 SPECIAL TOOLS Main journal bearing extraction ring Main journal bushing extraction punch (ignition side) 19.1.20507 19.1.20511 Main journal bearing installation punch Piston support (clutch side) 19.1.20508 19.1.20512 Main journal bearing installation punch Pad for crankshaft and (ignition side) flywheel puller 19.1.20509 19.1.20513 Main journal bearing extraction ring...
  • Page 16 SPECIAL TOOLS Drive gear blocking tool Valve clearance adjustment tool 19.1.20515 19.1.20522 Valve spring compression tool Valve guide extraction/installation punch 19.1.20519 19.1.20523 Oil filter removal spanner Compression check tool 19.1.20520 19.1.20524 Mounted flywheel blocking tool Oil seal installation sleeve 19.1.20521 19.1.20525...
  • Page 17 SPECIAL TOOLS Engine support Pin sliding punch 19.1.20526 19.1.20530 Engine support base Battery charge density meter 19.1.20527 19.1.20564 Complete roller cage extractor Chain slack tool 19.1.20528 19.1.20565 Reamer set for valve seats Punch 19.1.20529 19.1.20566...
  • Page 18 SPECIAL TOOLS Clutch collets tool 19.1.20540 Exhaust manifold spring removal tool 19.1.20551 Complete tool kit 19.1.20563...
  • Page 19 MAINTENANCE SUB INDEX Section - Page Maintenance programme 3 - 1 Instrument panel removal 3 - 2 Fuel passages 3 - 2 Carburettor 3 - 2 Settings 3 - 3 Setting engine speed at idle 3 - 3 Air filter 3 - 3 Valve clearance 3 - 3...
  • Page 20: Maintenance Programme

    MAINTENANCE 3 - 1 MAINTENANCE PROGRAMME (*) check every 500 km 1 th PROGRAMMED OPERATIONS Tightening the engine bolt Tightening the cylinder head bolts Valve clearance control Timing belt tension check Timing belt replacement Decompression check Engine compression check Engine idle speed adjustment Spark plug check Spark plug replacement Engine oil replacement...
  • Page 21 INTENTIONALLY BLANK...
  • Page 22: Instrument Panel Removal

    MAINTENANCE 3 - 2 INSTRUMENT PANEL REMOVAL Remove Fairing. Remove headlamp. Remove speedometer cable. Disconnect tachometer cable. Remove the 3 instrument mounting nuts. Disconnect electrical connectors. Remove instrument assembly (fig. 1). FUEL PASSAGES Check all the fuel lines and replace any component that shows signs of damage, wear or leakage (fig.
  • Page 23 MAINTENANCE 3 - 2 3 - 2,2...
  • Page 24: Air Filter

    MAINTENANCE 3 - 3 ADJUSTMENTS Fuel level Turn over carburettor and let float rest on the needle valve’s damper spring without pressing. Check distance between bowl gasket seat and uppermost edge of the float with proper gauge. Float level = 24 ± 2 mm Adjustment is made by bending slightly the float tongue.
  • Page 25 MAINTENANCE 3 - 3 3 - 3,2...
  • Page 26: Cylinder Compression

    MAINTENANCE 3 - 4 CYLINDER COMPRESSION Warm up engine. Stop engine and remove spark plus (remove tank if necessary). Insert compression gauge (19.1.20524) in spark plug hole. Turn throttle fully open and turn engine over with the electric starter until the gauge measures the highest value.
  • Page 27 MAINTENANCE 3 - 4 3 - 4,2...
  • Page 28: Throttle Control

    MAINTENANCE 3 - 5 THROTTLE CONTROLS Check that the throttle grip turns freely from fully open to fully closed in all steering positions (fig. 12). Lubricate the throttle cable if found to be sticking. Verify that the throttle grip has 2 to 5mm play; replace if found defective. The end of the throttle cable goes in the hole in front of the throttle grip (fig.
  • Page 29 MAINTENANCE 3 - 5 3 - 5,2...
  • Page 30: Chain Replacement

    MAINTENANCE 3 - 6 Chain replacement Remove pinion cover. Remove pinion bolt and remove pinion (fig. 17). Remove gearshift rod. Loosen the bolt on the lower part of the engine and lift it out towards the right (fig. 18). Remove spacer bushing. Remove chain guard cover.
  • Page 31 MAINTENANCE 3 - 6 3 - 6,2...
  • Page 32 MAINTENANCE 3 - 7 ENGINE OIL LEVEL CHECK Stand the motorcycle in a vertical position, on a flat surface. Start up the engine and let it run at idle speed for about a minute. Stop the engine and check the oil level through the transparent oil window on the left side of the engine (fig.
  • Page 33: Clutch Transmission Cylinder On The Engine

    MAINTENANCE 3 - 8 CLUTCH TRANSMISSION CYLINDER ON THE ENGINE Removal Place a clean receptacle under the clutch guard on the right of the engine. Remove the clutch transmission cylinder from the clutch cover (fig. 40). Be careful not to spill any hydraulic liquid on painted surfaces or plastic or rubber parts.
  • Page 34 MAINTENANCE 3 - 8 3 - 8, 2...
  • Page 35 SECTION 4 INTENTIONALLY BLANK...
  • Page 36 ENGINE REMOVAL / INSTALLATION 5 - 1 Section - Page Working procedures 5 - 1 Engine removal / installation 5 - 1 5 - 1...
  • Page 37 ENGINE REMOVAL - INSTALLATION 5 - 1 Working procedures All operations must be carried out in a clean environment. After disassembly of the parts, wash all components in kerosene or other solvent (never use petrol) and blow dry with compressed air. Carbon deposits are removed with a brush having brass bristles or a scraper with chamfered corners.
  • Page 38 ENGINE REMOVAL - INSTALLATION 5 - 1 Remove the engine to frame top mounting bolts; remove the support (figs. 4 - 5). Remove the lower engine bolt (fig. 6). Remove the other engine bolts. Loosen (but don’t remove) the two fork bolts, to allow easier engine removal.
  • Page 39 ENGINE REMOVAL - INSTALLATION 5 - 1 5-1,3...
  • Page 40: Generator - Timing Belt - Gearbox Selector

    GENERATOR - TIMING BELT - GEARBOX SELECTOR INDEX Section - Page Disassembly 6 - 1 Inspection 6 - 1 Reassembly 6 - 2 Valve timing 6 - 2 Torque wrench settings 6 - 3...
  • Page 41 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 1 DISASSEMBLY Remove generator cover mounting bolts together with stator and remove cover (fig. 1). Remove the timing belt cover; loosen idle roller nut and position the idle roller in such a way as to permit the belt to come off the cam pulleys (fig.
  • Page 42 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 1 6 - 1,2...
  • Page 43 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 1 6 - 1,3...
  • Page 44 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 2 REASSEMBLY Reassemble all components in reverse order of disassembly; pay close attention to the following: Replace the block’s left side cover gasket and the O-ring found behind the final drive pinion. Mount the pinion mounting bolt spring washer, of the freewheel starter group and generator rotor, with the convex side facing out.
  • Page 45 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 2 6 - 2,2...
  • Page 46 GENERATOR - TIMING BELT - GEARBOX SELECTOR 6 - 3 TORQUE WRENCH SETTINGS Freewheel fastening bolt * 40 Nm Generator rotor fastening bolt * 40 Nm Chain sprocket fastening bolt ** 40 Nm Selector cam fastening bolt 40 Nm Tensioner pulley fastening nut 40 Nm * = Lubricate threads with oil ** = Use Loctite 270...
  • Page 47 CYLINDER HEAD VALVETRAIN COMPONENTS SUB INDEX Section - Page Diagram 7 - 1 Disassembly 7 - 2 Inspection 7 - 3 Reassembly 7 - 4 Torque wrench settings 7 - 4...
  • Page 48 CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 1 7 - 1...
  • Page 49: Disassembly

    CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 2 DISASSEMBLY Pull off the water passage coupler mounted on the right side of the head and remove the O-ring found under the coupler fitting (fig. 1). Remove timing belt cover; loosen idle roller nut and position the idle roller in such a way as to permit the belt to come off the two cam pulleys (fig.
  • Page 50 CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 2 7 - 2,2...
  • Page 51 CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 2 7 - 2,3...
  • Page 52: Inspection

    CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 3 INSPECTION After a thorough cleaning of all parts, place the components on the bench and inspect them carefully. All those parts that show signs off wear and/or damage must be replaced. Head Scrape the surface and remove traces of head gasket and remove all carbon deposit in the combustion chamber.
  • Page 53 CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 3 7 - 3,2...
  • Page 54: Reassembly

    CYLINDER HEAD VALVETRAIN COMPONENTS 7 - 4 REASSEMBLY Assemble in reverse order of disassembly. Pay close attention to the following points: Every component must be installed in the same position before it was removed. This is most important for rocker arms, valves, spring retainer and collets.
  • Page 55 INTENTIONALLY BLANK...
  • Page 56: Cylinder - Piston

    CYLINDER - PISTON SUB INDEX Section - Page Diagram 8 - 1 Disassembly 8 - 2 Inspection 8 - 2 Reassembly 8 - 2...
  • Page 57 CYLINDER - PISTON 8 - 1 8 - 1...
  • Page 58 CYLINDER - PISTON 8 - 2 DISASSEMBLY Remove the head group, gasket and rubber anti-vibration devises, as described in section 7. Remove the water pump, found on the left of the cylinder (fig. 1). Remove the thermostat’s housing on the front of the cylinder (fig. 2). Lift the cylinder by hand.
  • Page 59 CYLINDER - PISTON 8 - 2 8 - 2,2...
  • Page 60 CYLINDER - PISTON 8 - 2 Piston rings The rings are removed only when necessary. These components are very fragile and must be removed and installed very carefully. To check for ring wear, take each ring and place it “squarely” inside the lower part of the cylinder.
  • Page 61 CYLINDER - PISTON 8 - 2 8 - 2,4...
  • Page 62: Clutch - Primary Drive - Oil Pump

    CLUTCH - PRIMARY DRIVE - OIL PUMP SUB INDEX Section - Page Diagram 9 - 1 Disassembly 9 - 2 Inspection 9 - 2 Reassembly 9 - 3 Torque wrench setting 9 - 3...
  • Page 63 CLUTCH - PRIMARY DRIVE - OIL PUMP 9 - 1 9 - 1...
  • Page 64 CLUTCH - PRIMARY DRIVE - OIL PUMP 9 - 2 DISASSEMBLY Drain the oil. Loosen the kick starter bolt; remove cover plate mounting screws and remove right side cover of the engine block. Remove the seeger ring and the thrust bearing (fig. 1). Block the drive gear of the primary drive with special tool 19.1.20515.
  • Page 65 CLUTCH - PRIMARY DRIVE - OIL PUMP 9 - 2 9 - 2,2...
  • Page 66 CLUTCH - PRIMARY DRIVE - OIL PUMP 9 - 2 9 - 2,3...
  • Page 67 CLUTCH - PRIMARY DRIVE - OIL PUMP 9 - 3 REASSEMBLY Assemble in reverse order of disassembly. Pay close attention to the following points: The crankshaft thrust ring is installed with the grooves facing out and it’s notch in the cover’s seat. When mounting the balance shaft, align it properly.
  • Page 68: Crankcase - Gearbox - Crankshaft Components

    CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS SUB INDEX Section - Page Diagram 10 - 1 Disassembly 10 - 2 Inspection 10 - 3 Reassembly 10 - 3 Torque wrench settings 10 - 3...
  • Page 69 CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS 10 - 1...
  • Page 70 CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS DISASSEMBLY Make sure all necessary components are removed, then remove all bolts that join the two halves of the cases. Open the crankcase and if necessary use a plastic or rubber mallet to loosen it (carefully hit at the joint of the cases and/or at the end of the gearbox shafts).
  • Page 71 CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS 10 - 2,2...
  • Page 72 CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS INSPECTION After a thorough cleaning of all parts, inspect all components carefully. All those parts that show sign of wear and/or damage must be replaced. Crankshaft The crankshaft must be replaced if found damaged or worn. Connecting rod Install the half bearings and mount the connecting rod cap by tightening the nuts to the proper torque setting (28 to 32 Nm).
  • Page 73 CRANKCASE - GEARBOX - CRANKSHAFT COMPONENTS Crankcase Accurately measure the internal diameter of each main journal with a micrometer. Diameter at mounting = 40.030 ÷ 40.046 mm. Once the bearing and main journal internal diameter is known, it is possible to calculate the gap of the two components. Clearance at mounting = 0.030 ÷...
  • Page 74: Front Wheel

    FRAMES INDEX Section Working procedures Front wheel Front suspension - Steering Rear suspension - Rear wheel Brakes...
  • Page 75: Working Procedures

    WORKING PROCEDURES All operations must be carried out in a clean environment. After disassembly of parts, wash all components in kerosene or other solvent (never use petrol) and blow dry with compressed air. All operations must be carried out in a precise order; mark all components to be removed one at a time, or place them in separate containers so as to mount them in the same position as prior to disassembly.
  • Page 76 FRONT WHEEL SUB INDEX Section - Page Diagram 12 - 1 Disassembly 12 - 2 Reassembly 12 - 3 Technical data 12 - 3 Trouble shooting 12 - 4...
  • Page 77 FRONT WHEEL 12 - 1...
  • Page 78: Disassembly

    FRONT WHEEL DISASSEMBLY Disconnect speedometer cable. Loosen the spindle retainer bolts on the right leg. Loosen and slide out wheel spindle with a pin (fig. 1) Remove the wheel. Don’t actuate the front brake lever once the wheel is removed, otherwise it’ll be difficult to insert the brake disc between the brake pads on reassembly.
  • Page 79 FRONT WHEEL 12- 2,2...
  • Page 80: Reassembly

    FRONT WHEEL Bearing disassembly Remove the speedometer drive and drive gear dust cover ring (fig. 6). Remove the wheel bearings and spacer bush from the wheel hub. Do not reinstall the old bearings; once the bearings are removed, they must be replaced with new ones. Bearing reassembly Fill bearing cavity with grease.
  • Page 81 FRONT WHEEL 12 - 2,4...
  • Page 82: Technical Data

    FRONT WHEEL REASSEMBLY Place calliper on brake disc, being careful not to damage the pads. Clean wheel spindle and mount it. There are no spindle thrust or spacer washers. Tighten the spindle to the recommended torque, then connect cable to the speedometer drive.
  • Page 83: Trouble Shooting

    FRONT WHEEL TROUBLE SHOOTING Stiff steering: Steering bearing adjusting ring nut too tight. Faulty steering sleeve bearings. Tyre pressure too low. Tends to steer to one side and has poor handling: Bent front forks. Bent front wheel spindle. Wheel not mounted properly. Different quantity of oil in the two fork legs.
  • Page 84 SUSPENSION - STEERING Section - Page Diagram 13 - 1 Removal 13 - 2 Inspection 13 - 3 Reassembly 13 - 3...
  • Page 85 SUSPENSION - STEERING 13 - 1...
  • Page 86 SUSPENSION - STEERING REMOVAL Remove the fairing’s two side mounting screws; remove the side view mirrors mounting screws and remove the mirrors. Disconnect the front turning signal wires and remove the fairing. Remove the front wheel. Loosen the bolt’s safety screws of the semi-handlebars (fig. 1). Loosen the handlebar’s fastening bolts (fig.
  • Page 87 SUSPENSION - STEERING 13 13 - 2,2...
  • Page 88 SUSPENSION - STEERING Pull out the stanchion and damper piston. Be careful not to confuse the left leg’s piston and other components with those of the right because they’re not interchangeable. Left fork (fig. 6). Right fork (fig. 7). Stanchion inspection Place the stanchion on V-shaped supports and check for straightness error (fig.
  • Page 89 SUSPENSION - STEERING 13 – 3,4...
  • Page 90 SUSPENSION - STEERING - 13 Fill each stanchion with the correct amount of damping oil. Inspect the fork plug’s O-ring and replace if necessary. Install the fork tube spring with the narrow spiral facing up. Right fork component reassembly (figs. 11-12). Left fork component reassembly (figs.
  • Page 91 INTENTIONALLY BLANK...
  • Page 92 REAR SUSPENSION AND WHEEL SUB INDEX Section - Page Diagram 14 - 1 Technical data 14 - 2 Troubleshooting 14 - 2 Wheel 14 - 2 Suspension 14 - 3 Final Drive 14 - 4...
  • Page 93 REAR SUSPENSION AND WHEEL 14 - 1...
  • Page 94: Technical Data

    REAR SUSPENSION AND WHEEL TECHNICAL DATA Wear limit Centering error 2.0 mm Rear wheel spindle runout 0.20 mm TROUBLESHOOTING Motorcycle oscillations and vibrations Deformed rim. Loose wheel bearings. Defective tyre. Wrong tyre pressure. Chain adjustment eccentrics not aligned equally. Suspension too soft Weakened fork springs.
  • Page 95 REAR SUSPENSION AND WHEEL 14 - 2,2...
  • Page 96 REAR SUSPENSION AND WHEEL Chain sprocket inspection Check sprocket teeth; replace if worn or damaged. Check both the chain and driven sprocket. Sprocket in good shape (fig. 4A). Replace sprocket (fig. 4B). Max. allowable wear (fig. 5). NOTE The sprocket retainer hub (flange) is mounted on the rim. The flexible coupling screws are the same ones that hold the chain sprocket to the flange.
  • Page 97 REAR SUSPENSION AND WHEEL 14 - 2,4...
  • Page 98: Suspension

    REAR SUSPENSION AND WHEEL Wheel reassembly Place wheel in swing fork and place the spacers (fig. 12). Place chain on sprocket. Insert the spindle in the chain tension adjuster eccentric and push it into the hub. Mount the spindle nut from the other side. Adjust chain tension and tighten the wheel spindle to the correct torque.
  • Page 99 REAR SUSPENSION AND WHEEL 14 - 3,2...
  • Page 100 REAR SUSPENSION AND WHEEL Remove the uni-ball with the aid of a hydraulic press using special tool 19.1.20566 (fig. 19). Make sure the uni-ball isn’t worn or damaged; replace if necessary (fig. 20). Mount the fork pivot bolt bushing with the aid of a press and the proper mounting tool (fig.
  • Page 101 REAR SUSPENSION AND WHEEL 14 - 3,4...
  • Page 102: Final Drive

    REAR SUSPENSION AND WHEEL FINAL DRIVE Drive chain Chain life depends on lubrication and appropriate tension. Neglecting the above mentioned checks will result in wear and damage of both the drive and driven sprockets thereby compromising motorcycle performance. A chain inspection must be carried out prior to driving off; chain adjustment must be executed every 2,000 km.
  • Page 103 BRAKES Section - Page Brake pad replacement 15 - 1 Servicing information 15 - 2 Technical data 15 - 2 Troubleshooting 15 - 2...
  • Page 104 BRAKES 15 Fluid draining Connect a tube to the bleeder valve. Loosen the bleeder valve and pump with lever. Stop pumping when no more fluid flows out of the bleeder valve. Brake fluid spilled on discs or pads will reduce braking capability. If this should happen, throw away the pads and clean the disc thoroughly with a proper solvent.
  • Page 105 BRAKES 15 – 1,2...
  • Page 106 BRAKES Front brake calliper inspection Remove the calliper from the leg. Remove the calliper assembly bolts. Remove the two pistons (fig. 7). If necessary, use compressed air (with short bursts) in the fluid inlet hole to push out the piston. Check cylinders and pistons for scratches and pitting;...
  • Page 107 BRAKES 15 – 1,4...
  • Page 108 BRAKES SERVICING INFORMATION The brake calliper may be removed without disconnecting it from the hydraulic system. Every time maintenance is performed on the hydraulic system the brakes will feel “spongy,” therefore the system will need to be bled. Avoid foreign matter from getting in the hydraulic system when topping up. Brake fluid will damage painted surfaces.
  • Page 109 BATTERY CHARGING CIRCUIT Section - Page Battery voltage 16 - 1 Battery charging 16 - 1 Battery removal 16 - 1 Battery reinstallation 16 - 1 Charging circuit 16 - 2 Troubleshooting 16 - 2...
  • Page 110 BATTERY CHARGING CIRCUIT BATTERY VOLTAGE Place, with the engine running, the red lead of the voltmeter on the positive (+) terminal of the battery and the black lead on the negative (-). Charge with battery at rest: 12 ÷ 13 V If the meter shows a reading of under 11 V, check the charging circuit connections.
  • Page 111 BATTERY CHARGING CIRCUIT WARNING The electrolyte level must be checked periodically; top up with distilled water if necessary. Remove the battery from the frame when charging. Keep battery away from sparks and flames due to the hydrogen produced by the battery. All charging components may be tested without removal.
  • Page 112 BATTERY CHARGING CIRCUIT Rectifier check It is a three-phase rectifier. Check the diode’s efficiency by disconnecting the connector end (fig. 3): Connect the positive (+) prod of the ohmmeter to the red wire and the negative (-) one to the white wires (one at a time) (fig. 4). With efficient diodes, the pointer should not move.
  • Page 113 BATTERY CHARGING CIRCUIT 16 – 2,3...
  • Page 114: Ignition System

    IGNITION SYSTEM Section - Page Description 17 - 1 Inspection 17 - 2 Spark Plug 17 - 3 Troubleshooting 17 - 3...
  • Page 115 IGNITION SYSTEM DESCRIPTION The ignition system is of the capacitive discharge type. The system is made up of a magneto flywheel, CDI control unit and an HT ignition coil. The voltage generated by the coil is stored in the condenser. The signal generated by the pick-up windings is sent to the control unit that will discharge the current stored in the condenser into the coil’s pri- mary windings;...
  • Page 116 IGNITION SYSTEM INSPECTION The whole ignition system may be tested for malfunctions or weak spark with testers. If the electrodes generated a good spark at the recommended gap then the system is functioning; if there is no spark proceed with testing each component until having found the malfunction. Follow the troubleshooting charts until finding the source of the trouble.
  • Page 117 IGNITION SYSTEM 17 - 2,2...
  • Page 118 IGNITION SYSTEM SPARK PLUG Check spark plug condition; replace if overheated, fouled or worn. Measure electrode gap; clean and adjust if out of specification. The spark plug must be checked every 1,000 km. Electrode gap should be 0.6 ÷ 0.7 mm. Replace plug every 8,000 km. Warning: The use of spark plugs with different heat ranges than recommended or different threads may result in excessive engine damage.
  • Page 119: Electric Starter

    ELECTRIC STARTER Section - Page Starter motor 18 - 1 Casing insulation check 18 - 1 Troubleshooting 18 - 1...
  • Page 120 ELECTRIC STARTER STARTER MOTOR Removal The electric starter may be removed with the engine in the frame. Put ignition switch in the “OFF” position and disconnect the battery’s negative (-) cable prior to starter motor maintenance. Disconnect the starter’s cable. Loosen the starter’s mounting bolts and remove the starter.
  • Page 121 ELECTRIC STARTER 18 - 1,2...
  • Page 122 INTENTIONALLY BLANK...
  • Page 123: Switches - Horn - Lights - Rear Mudguard - Exhaust

    SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE Section - Page Instruments 19 - 1 Head - tail lights - turn indicators 19 - 1 Switches 19 - 2 Horn 19 - 2 Rear mudguard 19 - 2 Exhaust pipe 19 - 2 Troubleshooting...
  • Page 124 SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE In order to isolate an electrical problem, always check the continuity in the current path. A continuity check is usually executed without removing the component from the motorcycle; simply disconnect the wires and connect them to a tester connector or ohmmeter.
  • Page 125 SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE 19 - 1,2...
  • Page 126 SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE NEUTRAL SWITCH Disconnect the neutral switch connector. Check for continuity between the wire and ground for each gear selection. The switch is working properly when there is continuity in the neutral position and no continuity in any other gear.
  • Page 127 SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE If the fan turns, check the thermoswitch in the following manner: Drain the cooling fluid. Remove the thermoswitch from the radiator. Heat the cooling fluid in a container and suspend the thermoswitch in it. Check the temperature where the switch opens and closes.
  • Page 128 SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE 19 - 2,3...
  • Page 129: Trouble Shooting

    SWITCHES - HORN - LIGHTS - REAR MUDGUARD - EXHAUST PIPE TROUBLESHOOTING When ignition switch is in the “ON” position the lights don’t turn on: Faulty or burned bulbs. Defective switch. Open or shorted circuits. Burned fuse. Loose, broken or shorted wires. Battery weak or not connected.
  • Page 130 TROUBLESHOOTING Section - Page Engine doesn’t start or starts with difficulty 20 - 1 Poor performance 20 - 2 Poor road handling 20 - 3...
  • Page 131 TROUBLESHOOTING 20 - 1...
  • Page 132 TROUBLESHOOTING Continued on page 20 - 2,2 20 - 2,1...
  • Page 133 TROUBLESHOOTING Continued from page 20 - 2,1 20 - 2,2...
  • Page 134 TROUBLESHOOTING 20 - 3...
  • Page 135: Circuit Diagram

    CIRCUIT DIAGRAM Section - Page Circuit diagram 21 - 1 WIRING COLOURS LIST OF ELECTRICAL SYSTEM COMPONENTS Lighting group Light Blue Two level bulb 12V - 45/40W Orange Front parking light bulb 12V - 3W Light Blue/Black White Front and rear turn indicators Dark Blue Blinker bulb 12V - 10W Multiple connectors...
  • Page 136 CIRCUIT DIAGRAM 21 - 1 21 - 1...
  • Page 137: Maintenance Tips

    A Gilera tool is available, but you can make do by using a 6mm box spanner for the lock nut, and a screwdriver long enough to work through the middle of the box spanner for the adjuster.
  • Page 138 MAINTENANCE TIPS Cables - oiling Clutch and brake cables used to need oiling regularly with engine oil. Modern cables are nylon lined and will work for ages with no attention. When they start to get stiff, lube them with WD40 or similar. Speedo cables may be nylon lined, if they are you should be able to see a plastic tube around the inner cable if you look at the end that goes into the clock.
  • Page 139 MAINTENANCE TIPS Steering head races You need to get the front wheel off the ground to check the condition of the bearings. Head races are checked by raising the front wheel off the ground and turning the handlebars slowly from side to side. If you notice a slight ‘notchy’...
  • Page 140 MAINTENANCE TIPS Continuation If you have to change the races, the difficult bits are getting the bottom inner race off the stem and getting the outer races out of the steering head. There are tools designed to do the job and a local repair shop MAY lend/hire them to you.

This manual is also suitable for:

Saturno bialbero 500

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