Gilera SATURNO BIALBERO 350 Instruction manual

WORKSHOPMANUAL
SATURNOBIALBERO
350-500

Reproduced by
OWNERSCLUB
OFBRITAIN
frominformation obtainedfromoriginalorcopied
manualsoriginallyissued by
Piaggio/Gilera
Whilsteverycarehasbeen taken toensure
accuracyofthe contents,IGottaGileradoesnot
acceptanyliabilityof anytype duetoanyerrorsor
omissions,and useofthismanualwilldenote
acceptanceofthiscondition.
NOTES:
Inaddition tothisworkshop manualstextsand picturestranscribed fromoriginal
Piaggio/Gileramanuals,thereisincluded asection on thevariousknownfaultswith
whichthe Saturno isprone tosuffer. Whilst thesefaultswereobviouslynot included
inthe originalofficialmanuals,webelieved theyshouldbe apartofanypublication
dealing withSaturno maintenance.
Therehavealsobeen acoupleof“obvious”errorswithinthe originalmanualsand
thesehavebeencopied “asis”intothismanual,butanotehasbeen added with
what webelievetobe the correct details.
You will alsofind attheveryrearofthismanual,afewgeneralmaintenancetips,
whichyou mayfind useful.
If you find anyothererrors,pleaseemail [e-mail] sothatthismanual
can be updated tobe asaccurateasispossible.

INDEX
Generalinformation -Knownfaults
Specialtools
Maintenance
ENGINES
Workingprocedures
Engine removal/installation
Generator-Timing belt -Gearboxselector
Cylinderhead-Valvetraincomponents
Cylinder-Piston
Clutch-Primarydrive-Oilpump
Crankcase-Gearbox-Crankshaft components
FRAMES
Workingprocedures
FrontWheel
Front suspension-Steering
RearSuspension-Rearwheel
Brakes
ELECTRICALSYSTEM
Battery-Charging circuit
Ignition system
Electricstarter
Switches-Horn-Lights-Rearmudguard-Exhaust
Troubleshooting
Circuitdiagram
Section
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

GENERALINFORMATION1
SUB INDEX
Knownfaults
Safetyprocedures
Maintenanceprocedures
ModelIdentification
Technicaldata
Torquewrenchsettings
Engine overhauldata
Cablesand wirepassage
Section-Page
1-1
1-2
1-2
1-2
1-3
1-4
1-5
1-6
1

KNOWNFAULTS1-1
Fantouches Radiator.Removetank,lookdownback ofradiator&
check thatfan shroudhasabout3mm(1/8”)clearance.Thefan
mountingsareslottedbutifthereisnotenough adjustment, trimthe front
of the shroud.
Sidestandboltscomeloose/fall out.Removestand andcheck
mounting surfacesareclean&flat. Refitstandwith‘Loctite’on mounting
boltthreads. Checkstand regularly.
Fueltanktouches frame. Tankisrubbermounted andcanmove,
touchthe frametubes(alongthe bottomnearthe front)and alsothe rear
mounting rubberscanbeaproblem,bothofwhichcanresultinleaks
occurring.Removethemetaltubespacersfromthe rearrubbersand
check theirlengths.Ifone islonger,fileitdowntothe lengthofthe
shorterone.Placing awasherunderthe frontmountingswillmakeabig
difference.
Starterboltsworkloose. ’Loctite’on the boltthreadsand check
occasionally.
Rearsuspensionlinkagegetsall thebadweather. Putaxlestands
underfootreststosupportbikewithrearwheelofftheground.Take
weightofwheel/swingingarmand removeboltsfromrisingratelink(3
pointbracketattached tobottomofrearsuspension unit)Grease
thoroughlyand replace.Thisshouldbedoneevery6months.
Risingratebottomlinkboltcanseize. Removerising ratelink(see
above),twoofthe bearingsareselfaligningballjoints,thesejustneed
somegreaseeitherside tokeepthe wetout. The lowerlong bearing
needstobe cleaned and greased aswellaspossibleasitisvulnerable
and can easilyrust.
Longrearengineboltscanseize. Removethe boltsone atatime,
clean off anycorrosion and coatthemin‘CopperSlip’orgreasebefore
refitting. Torque 30Nm.
Seatretaininglugssnapoff.Noeasy solutionbutmetalreinforcing
bracketscanbe made.
1-1

SAFETYPROCEDURES 1-2
Wheneverworkingwiththe engine running,neverworkinclosedareas;always
havethe areawell ventilated due tothetoxicgases(carbon monoxide)contained in
the exhaust.
The battery’selectrolytecontainssulphuricacid.Always protectthe eyes,clothes
and skin.If electrolytegetsintothe eyes,flushthoroughlyand seekmedical
assistancepromptly.
Petrolishighlyflammableandincertainconditionsevenexplosive.Neversmokein
workareas; avoidsparks orflames.
The batteryproduceshydrogen whichishighlyexplosive.Neversmokearound a
batteryand avoidsparks and flames, especiallywhilecharging.
MANTENANCEPROCEDURES 1-2
Always useoriginalGILERAsparepartsand recommended lubricants.Theuseof
non-originalpartsorpartsnotconforming toGileraspecificationsmayresultin
damage tothe motorcycle.
Always usethe specialtoolsdesigned specificallyforthismotorcycle.
Always usenewgaskets, O-rings, split pinsand safetyplateswhen reassembling.
Always tighten nutsorboltsstartingwiththoseofgreaterdiameterorfound
internally;tighteninadiagonalsequencein2or3passesand totherecommended
torque unless otherwisenoted.
Cleancomponentswithnon-flammablesolventsoratleastsolventshavingahigh
flashpoint. Lubricateworkingsurfacespriortoreassembly.
Afterreassembly, makesurethatallcomponentsareinstalled andoperateproperly.
Always usemetrictoolswhen working on thismotorcycle;metricnutsand boltsare
notinterchangeablewiththeBritishsizes.Theuseofeithernon-metrictoolsand/or
nutsand boltsmaycausedamage tothe motorcycle.
Arrange allelectricalwiresasindicated inthe “Cablesand wirepassage”
paragraph.
MODELINDENTIFICATION1-2
Frameand enginenumbersarestamped on the Manufacturer’splate(fig.1).The
framenumberisalsostamped on the frame(fig.2),andthe engine numberand
sizearestamped on aplatefound at the rearof the engine (fig. 3).
The carburettorpartnumberisfound on the side of thecarburettor(fig. 4).
1-2,1

MODELIDENTIFICATION1-2
1 -2,2

TECHNICALDATA1-3
DESCRIPTION
DIMENSIONS
Overalllength
Overallwidth
Overallheight
Wheelbase
Seat height
Foot pedalheight
Dryweight
FRAME
Triangulated tubularsteelspaceframe
Steering columnangle
Forestroke
Front suspension
-Marzocchitelescopichydraulicfork
-Stroke
-Stanchion diameter
-Oilcapacity(eachside)
Rearsuspension
-Marzocchimonodamperpowerdriveprogressive
-Stroke
Wheels
-Front:
-Tyresize
-Pressure
Abovebelieved tobe incorrect, werecommend
-Rear:
-Tyresize
-Pressure
Abovebelieved tobe incorrect, werecommend
Brakes
-Front, floating disc withhydraulicdoublepiston
-Disc diameter
-Rear, floating disc withhydraulicsinglepiston
-Disc diameter
Fueltankcapacity
Fueltankreserve
350cc -500cc
2030 mm
730 mm
1170 mm
1410 mm
790 mm
360 mm
145 kg
24.30 30’
89.7mm
120 mm
40 mm
310 cc
130 mm
3.00 X17”
110/70-17
1.7bar
2.1bar30 psi
4.00 X17”
140/70-17
1.7bar
2.3bar33 psi
300 mm
240 mm
20ltrs4.4galls
1.5ltrs.33galls
1-3,1

TECHNICALDATA1-3
ENGINE
Singlecylinder, 4stroke, verticalcylinder
BoreXstroke
Displacement
Compressionratio
Cylindercompression (usespecialtool19.1.20524)
Newengine
Over5,000km
BHP
Torqueat 5,500 rpm
Valvetrain-2belt driven overheadcamshaft
Lubricatingsystem-forced,innergeardriven pump
Oilcapacity(10w40 semisynthetic)
Coolingsystem-permanent coolant withrecirculating
pumpand by-pass thermostat
Coolant capacity(Silkolene Pro-cooletc)
Airfilter-sponge type
Intakevalvediameter
Exhaust valvediameter
Valveclearance(cold): clearancebetween camshaft
and rockerarm
Intake(cold)
Exhaust (cold)
TRANSMISSION
Clutch-wet, multiplate
Primarydrive
Gearboxwithstraight-toothgearsandclawcouplings
Gearratio
1st gear
2nd gear
3rdgear
4thgear
5thgear
Finaldrive
350cc -500cc
80 X69.4-92 X74
348.8cc -491.9cc
9,5:1-9,8:1
9÷11
8÷10
24kW(33 hp)-32kW(44 hp)
a/at 7500-a/at 7000
g/1’-rpm
33Nm(3.3kgm)-47Nm(4.7kgm)
a/at 6250-a/at 6000
g/1’-rpm
2.2ltrs
1.3ltrs
28.4mm-31 mm
25.5mm-28mm
0.05mm
0.10mm
33/77
13/31
18/28
21/24
23/21
25/19
15/48 -15/43
1-3,2

TECHNICALDATA1-3
CARBURETTOR
Throttlevalve
Needlejet
Fuelnozzle
Maxjet
Idlejet
Chokejet
Pumpjet
Needlenotch
Fuelnozzle
Throttlevalve
Float
Weight
Airmixturescrew
RPMsat idle
ELECTRICALSYSTEM
Ignition -electroniccapacitivedischarge
Ignition timing Fixed
Variable
Alternator-three phaseACalternator
Batterycapacity
Kick starting
Electricalstarting
Standardsparkplug(Champion)
Electrode gap
Fuses
Startermotor
Headlamp
Drivinglamp
Tail/stop lamp
Turnsignallamp
Instrument lamp
Warning indicatorlamp
350cc -500cc
Dell‘Orto
PHF36PS -PHM40VS
K54 -K4
3a tacca-3rdnotch-2a tacca-2ndnotch
AB262 -AB265
128 -138
58 -53
40 -40
Ø 1.1
5C55-3/5
AB262 -AB265
5.5
14g -10g
1giro-rev1300÷1400-1.5giro-rev1300÷1400
1300÷1400 (both)
7°
30°at 4,500 g/1’-rpm
180w
14 Ah
3Ah
14 Ah
A5YC
0.6÷0.7(both)
15 Amp
0.65 kW-0.80 kW
40/45 Watt
5watt
5/21 watt
10 watt
2watt
1.2watt
1-3,3

TECHNICALDATA1-4
TORQUEWRENCH SETTINGS
*=Lubricate thethreadwithoil
+=Coppersliponthread
Engine
Cylinderhead, cylinderhead cover, cylinderfixing nuts
Campulleybolts
Sparkplug +
Crankshaft gearingbolt *
Countershaft gearing bolt *
Free wheelbolt *
Clutchbolt *
Flywheelmagnetobolt *
Chaindrivesprocketbolt
Startermotormounting bolts
Kick starterclampbolt
Bigendbolts
Crankcasemountingbolts
Belt tightening pulleynut
Draining oilplug
Coolingfan thermostaticswitch
Thermistor
Oilpressureindicator
Frame
Frontengine support
Reartop engine support
Rearlowerengine support
Engine support on head
Lowerplatemounting bolts
Top platemounting bolts
Dampermount
Rearforkmount
Suspension connecting rod support toframe
Suspension connecting rod / levermount
Suspension / damperlevermount
Suspension / rearforklevermount
Front calliper
Frontbrakedisk
Rearcalliper
Rearbrakedisc onflange
Rearwheelflange
Rearsprocket mounting bolts
Front wheelspindle
Spindlefasteningboltsonfork
Rearwheelspindle
Eccentriclocking nuts
350cc +500cc
(both)
32-35 Nm
30 Nm
12-15 Nm
40 Nm
40 Nm
40 Nm
40 Nm
40 Nm
60 Nm
7-9Nm
18-20 Nm
28-32 Nm
7-9Nm
28-30 Nm
12-15 Nm
20-22 Nm
8-10 Nm
15-17 Nm
25-30 Nm
25-30 Nm
30-35 Nm
25-30 Nm
25-30 Nm
25-30 Nm
40-45 Nm
55-60 Nm
50-55 Nm
50-55 Nm
50-55 Nm
50-55 Nm
44-48 Nm
18-20 Nm
16-18 Nm
9-11 Nm
18-20 Nm
48-52 Nm
50-60 Nm
9-11 Nm
50-60 Nm
20-22 Nm
1-4

ENGINEOVERHAULDATA1-5
Piston/cylinderclearance
Mainbearingsradialclearance
Connecting rod bearingsradialclearance
Crankshaft axialclearance
Bigendaxialclearance
Gudgeon pin/pistonclearance
Gudgeon pin/small end clearance
Bushings/smallendclearance
Mainbearingstoseat clearance
Valveguide/cylinderheadclearance
Valvestem/guideclearance
Intake
Exhaust
Gudgeon pindiameter
Mainjournaldiameter
Cylinderbore
Piston diameter
Camheight(theoretical)
Oilpumprotorsaxialclearance
Selectordrumaxialclearance
Innervalvespringfree length
Outervalvespring free length
Clutchspringsfree length
Clutchplatethickness
Camshaft boltsradialclearance
Axle/rockerarmradialclearance
Piston ring gap
1st and2nd ring
scraperring
Ringsaxialclearance
1st and2nd ring
scraperring
Oilpressure
Waterthermostat opensat
Waterthermostat fullyopensat
Coolingfan enabletemperature
Valveclearance(betweencamshaft androckerarm)?
Intake(cold)
Exhaust (cold)
350cc -500cc
0.030 ÷0.042mm
0.030 ÷0.059mm
0.017 ÷0.060mm
0.05 ÷0.25 mm
0.15 ÷0.25 mm
0.000 ÷0.008mm
0.015 ÷0.030mm
0.049 ÷0.087mm
0.084 ÷0.140mm
0.030 ÷0.066mm
0.012 ÷0.042mm
0.025 ÷0.055mm
40.018÷40.030 mm
39.987÷40.000 mm
see tablebelow
see tablebelow
36.18 mm
0.025 ÷0.060mm
0.07 ÷0.42 mm
37.6÷38.6mm
38.7÷39.7mm
38.5mm
2.9÷3.0mm
0.035 ÷0.070mm
0.016 ÷0.052mm
0.30÷0.50 -0.40÷0.65mm
0.25÷0.50 -0.30÷0.60mm
0.035 ÷0.072mm
0.025 ÷0.062mm
4barat5,500g/1’rpm
750C
850C
92 ±30C
0.05 mm
0.10 mm
350 Cylinder500
80.000÷80.006 -92.000÷92.006
80.006÷80.012 -92.006÷92.012
80.012÷80.018 -92.012÷92.018
1-5
350 Piston 500
79.964÷79.970 -91.964÷91.970
79.970÷79.976 -91.970÷91.976
79.976÷79.982 -91.976÷91.982
Class
A
B
C
PISTON/CYLINDERMATCHING CHART (value inmm)

CABLES AND WIREPASSAGE1-6
Point out the passage of eachcableand wire(figs. 5-6-7-8-9).
1-6

SPECIALTOOLS2
Valveguide oilring
installation punch
19.1.20502
Con-rod small endbushing
extraction punch
19.1.20506
2.1
Flywheelpuller
19.1.20501 Con-rod small endbushing
installation punch
19.1.20505
Pullerforsteering bearinglowerrace
19.1.20109 Camshaft pulleyblocking tool
19.1.20504
Sprocketlocking wrench
19.1.20086 Camshaft oilring installation punch
19.1.20503

SPECIALTOOLS2
Mainjournalbearing extractionring
(clutchside)
19.1.20510
Timing drivegearpuller
19.1.20514
2.2
Pad forcrankshaft and
flywheelpuller
19.1.20513
Piston support
19.1.20512
Mainjournalbushingextraction punch
19.1.20507
Mainjournalbearing extractionring
(ignition side)
19.1.20511
Mainjournalbearing installation punch
(clutchside)
19.1.20508
Mainjournalbearing installation punch
(ignition side)
19.1.20509

SPECIALTOOLS2
Mounted flywheelblockingtool
19.1.20521 Oilsealinstallation sleeve
19.1.20525
2.3
Oilfilterremovalspanner
19.1.20520 Compressioncheck tool
19.1.20524
Valvespring compressiontool
19.1.20519 Valveguide extraction/installation punch
19.1.20523
Drivegearblocking tool
19.1.20515 Valveclearanceadjustment tool
19.1.20522

SPECIALTOOLS2
Reamerset forvalveseats
19.1.20529 Punch
19.1.20566
2.4
Completerollercage extractor
19.1.20528 Chainslack tool
19.1.20565
Engine support base
19.1.20527 Batterycharge densitymeter
19.1.20564
Engine support
19.1.20526 Pinsliding punch
19.1.20530

SPECIALTOOLS2
2.5
Exhaustmanifoldspringremovaltool
19.1.20551
Clutchcolletstool
19.1.20540
Completetoolkit
19.1.20563

MAINTENANCE3
SUB INDEX
Maintenanceprogramme
Instrument panelremoval
Fuelpassages
Carburettor
Settings
Setting engine speed atidle
Airfilter
Valveclearance
Cylindercompression
Engine oiland filterreplacement
Sparkplug
Throttlecontrol
Clutch
Drivechain
Chainreplacement
Rearbrakepedalheightadjustment
Gearshift leverheight adjustment
Foot pedalsdamperbushingsreplacement
Troubleshooting
Engine oilreplacement
Clutchtransmission cylinderon the engine
Section-Page
3-1
3-2
3-2
3-2
3-3
3-3
3-3
3-3
3-4
3-4
3-4
3-5
3-5
3-5
3-6
3-6
3-6
3-6
3-6
3-7
3-8

MAINTENANCE3-1
MAINTENANCEPROGRAMME(*)check every500 km
3-1
Tighteningthe engine bolt
Tighteningthe cylinderhead bolts
Valveclearancecontrol
Timing belt tensioncheck
Timing belt replacement
Decompression check
Engine compression check
Engine idlespeedadjustment
Sparkplug check
Sparkplug replacement
Engine oilreplacement
Oilfilterreplacement
Airfiltercheck and cleaning
Airfilterreplacement
Liquidcheck and fillup
Rearwheelflexiblecouplingcheck
Brakeand clutchcheck and adjustment
Sprocket, brakecalliperand disc, wheel
spindle, chainpinion mountingbolts(*)
Chaincheck, adjustment, lubrication (if
necessary,replacethe wholedrive)(*)
Brakepadsand blocks check, replaceifreq’d
Forkoilreplacement
Forkpivot joint tightening check
Steering bearing playcheck and lubrication
Batterycharge/electricalsystemefficiency
Tyrepressurecheck
X
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X
-
X
X
X
X
-
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km
24
th
20
th
16
th
12
th
8
th
4
th
500
to
1th
PROGRAMMEDOPERATIONS