Gilera SATURNO BIALBERO 350 Workshop Manual 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.
Brake fluid filling
Do not mix different types of brake fluids; they're not compatible.
Close the bleeder valve; fill main cylinder with DOT 4 brake fluid up to the
maximum level. Pump the hydraulic system with either the brake lever or
pedal until there aren't any bubbles visible in the reservoirs small hole, and
there is sufficient resistance coming from the lever or pedal.
Use this procedure for both the front and rear brakes.
During the bleeding phase, always check fluid level to avoid getting air into
the master cylinder in the event of fluid depletion.
BRAKE PAD REPLACEMENT
Front brake
Always replace brake pads in pairs; this will allow a uniform pressure on
the disc.
Loosen the front pad's bolt lock nut (fig. 1).
Remove the pads bolt and remove the pads (fig. 2).
Install new pads and mount the pads bolt; mount the lock nut and tighten
to the correct torque.
Rear brake
Remove the calliper mounting bolts (fig. 3).
Remove the pads bolt snap ring (found internally); remove the pads pin
and protection cover and pull out the pads (fig. 4).
Install two new pads and mount the pads retainer pin; mount the bolt snap
ring.
Install the calliper and secure it to it's support with the two mounting bolts
and tighten to the correct torque.
Front master cylinder inspection
Drain the brake fluid.
Remove the master cylinder from the handlebars.
Remove the main piston, seal caps and spring (fig. 5).
Measure the piston outer diameter (fig. 6).
Wear limit: 12.94 mm
Make sure the piston seals aren't damaged.
Lubricate all components with brake fluid prior to assembly.
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