Chain Replacement; Rear Brake Pedal Height Adjustment; Gearshift Lever Height Adjustment; Foot Pedals Damper Bushings Replacement - Gilera SATURNO BIALBERO 350 Workshop Manual

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.
Remove chain.
Install new chain and assemble components in reverse of disassembly.

REAR BRAKE PEDAL HEIGHT ADJUSTMENT

Adjust rear brake height by turning the adjusting screw (fig. 19).
Every time the pedal is adjusted, the play in the rear brake master cylinder
must be adjusted too.
Play in the master cylinder is adjusted by loosening the master cylinder's
push rod lock nut, then rotate the rod in the desired position (fig. 20).

GEARSHIFT LEVER HEIGHT ADJUSTMENT

Loosen the gearshift rod.
Remove the joint and rotate it to the desired position (fig. 21).

FOOT PEDALS DAMPER BUSHINGS REPLACEMENT

Remove the socket head screw at the end of the pedal; remove the
bushing and aluminium coupler; replace bushings if worn (fig. 22).
Remove the pedal bolt.
Check bolt diameter, should be 16 mm (fig. 23).
Service limit: 0.05 mm.
Grease contact surfaces well before mounting the spindle (fig. 24).
Put a securing device at the end of the threaded spindle.
Mount spindle, bushings and aluminium coupler in reverse of disassembly.

TROUBLE SHOOTING

Oil level too low: External oil leak and/or worn piston rings and/or worn
valve guides.
Dirty oil: Oil and filter not replaced regularly and/or faulty head gasket
and/or worn piston rings.
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