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Gilera SATURNO BIALBERO 500 User Manual

Gilera SATURNO BIALBERO 500
140 pages
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WORKSHOP MANUAL
SATURNO BIALBERO
350-500
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Gilera SATURNO BIALBERO 500 Specifications

General IconGeneral
Displacement499 cc
Compression Ratio10.5:1
Transmission5-speed
FrameSteel Trellis
Front SuspensionTelescopic fork
Front BrakeSingle disc
Seat Height800 mm
Fuel Capacity14 liters
Bore x Stroke92 mm x 75 mm
Cooling SystemLiquid-cooled
Rear BrakeSingle disc

Summary

General Information

Known Faults

Details common issues and potential solutions for the motorcycle.

Safety Procedures

Guidelines for safe operation and maintenance of the motorcycle.

Technical Data

Specifications and measurements for various motorcycle components.

Torque Wrench Settings

Specific torque values for engine and frame fasteners.

Engine Overhaul Data

Detailed specifications for engine component clearances and measurements.

Special Tools

Compression Check Tool

Tool used to measure engine compression.

Maintenance

Maintenance Programme

Scheduled maintenance tasks and intervals.

Carburettor

Details on carburettor removal, overhaul, and adjustment.

Valve Clearance

Procedure for checking and adjusting valve clearances.

Cylinder Compression

How to measure cylinder compression and common causes of low/high compression.

Engine Oil and Filter Replacement

Steps for changing engine oil and replacing the oil filter.

Engine Oil Replacement

Detailed steps for checking and topping up engine oil.

Engine Removal / Installation

Working Procedures

General guidelines for engine removal and installation.

Engine Removal - Installation

Detailed steps for removing the engine from the motorcycle.

Engine Installation

Procedure for reinstalling the engine back into the motorcycle.

Generator, Timing Belt, Gearbox Selector

Valve Timing

Procedure for setting the valve timing correctly.

Cylinder Head and Valvetrain Components

Cylinder and Piston

Clutch, Primary Drive, Oil Pump

Crankcase, Gearbox, Crankshaft Components

Disassembly

Steps for disassembling crankcase, gearbox, and crankshaft.

Reassembly

Steps for reassembling crankcase, gearbox, and crankshaft components.

Torque Wrench Settings

Specific torque values for connecting rod and crankcase fasteners.

Frames

Brakes

Information on brake system maintenance, replacement, and troubleshooting.

Battery Charging Circuit

Ignition System

Inspection

Procedures for testing ignition system components.

Spark Plug

Inspection, gap measurement, and replacement of spark plugs.

Troubleshooting

Common ignition system issues and their solutions.

Electric Starter

Troubleshooting

Engine Doesn't Start or Starts with Difficulty

Diagnostic flowchart for starting problems.

Poor Performance

Diagnostic flowchart for engine performance issues.

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