Gilera SATURNO BIALBERO 350, Workshop Manual

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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’ feel especially as you pass the straight ahead position,
the bearings are damaged. Next, stand in front of the bike and grip the
bottom of the fork legs. Pull and push, there should be no free play at the
head stock. If there is movement, you need to tighten the races. You
may not be able to feel any free play but as a double check, get
someone else to pull and push whilst you put your finger half on the
bottom yoke and half on the head stock. You will be able to feel the
smallest movement.
Adjusting the head races.
Loosen the pinch bolts on the bottom yoke. Loosen the top nut in the
middle of the top yoke. Under the top yoke there is a castellated ring.
Turn it clockwise to tighten using a C spanner or tap it round with a
hammer and punch. It will not need to be moved much. Do not turn it till
it is tight. The taper roller races are correctly adjusted when there is no
free play. It is very easy to over tighten them and then they will fail quite
quickly.
Tighten them until the forks will not fall from side under their own weight
when you turn them. Now slacken off slightly until they will fall freely.
Now tighten the top nut. You may find that now the races are too tight. If
they are, slacken the top nut, loosen the adjuster a bit and retighten the
top nut. If it feels OK, tap under the bottom yoke (both sides) just to
make sure that the fork legs have moved in the clamps and then tighten
the clamp bolts.
Greasing the bearings.
Support front of bike and remove front wheel. Take of the callipers and
tie them up to the bike somewhere. Disconnect the speedo. Take the
top yoke off. (Be careful as when you do this, the forks will fall out and
they are quite heavy). The forks will come out complete with the bottom
yoke and one half of the bottom bearing and the rollers. The top race will
be left complete at the top.
Clean roller cages and races in petrol or something similar. Inspect the
races for any signs of dents or damage including rust. If all is well, then
thoroughly grease the rollers, re-assemble and adjust as above.
Because you have not loosened the bottom yoke clamps, the forks will go
back together easily and straight.
continued