Gilera Saturno 500 Anniversary edition.

[MidnightMike]

This bike has been my Grandfathers since I was about 5 (19 now), and the only place I had seen it up untill now was sitting in his garage or shed under a cover as he slowly brought it up to the standard it is today.

He suggested starting it up to hear it go and one thing led to another and I ended up taking it for a ride with him following in the passenger seat of the Holden (He is unfortunately unable to ride it anymore due to a shoulder injury - but that didn't stop him from getting all his old leathers etc on for a photo)

Most likely there will be a video put up on youtube of it in the next week or so.

It has some top shelf components on it too, Marzocchi Suspension, Brembo brakes etc. And its just BEAUTIFUL. A true little italian thoroughbred.

I would appreciate it if anyone had some more information on this bike (Especially on the Anniversary Model) as I'm having trouble finding some good info; eg. Full specifications list, Number produced, etc etc because he loves reading/ talking about it.

Thanks.
Mike.

[Blackbird]

I've always loved that bike and wanted one before I got my GB400 in the late 80's. I might still have some info somewhere and will post it if I can find anything. There used to be some good info on the 'net.

Still reckon it's one of the best looking bikes around - elegantly simple design.

[The Baron]

That is a stuning bike. I had to keep looking at the photos again and again.

He has done one hell of a job in the restoring of it too.

[MidnightMike]

I've always loved that bike and wanted one before I got my GB400 in the late 80's. I might still have some info somewhere and will post it if I can find anything. There used to be some good info on the 'net.

Still reckon it's one of the best looking bikes around - elegantly simple design.

Thanks Blackbird.

[vifferman]

That is a stuning bike. I had to keep looking at the photos again and again.

He has done one hell of a job in the restoring of it too.
Indeed! :niceone:
Thanks for posting the photos, Mike!

[Blackbird]

Thanks Blackbird.

Sorry, can't find the old magazine article I had but there is an international Gilera website forum with an English language option: http://www.gileraclub.de/. you should be able to find out everything you need to know from it.

BTW, Top speed is 177 km/hr and it weighs 162 kg.

[pete376403]

If I havent binned it, I have a "Streetbike" test of the Saturno. Will get up in the roof and see if it's there

[Paul in NZ]

Cool bikes. I've seen the black (the best) and a red version. There was a 350 as well. They were sold new here and a few jap imports.

Some had some valve / rocker / cam issues and some didn't. keep the oil fresh as it's a wee gem. Back in the day a mate had one - nothing could touch it over the Akaroa Hill, different story on the flat (cough)

[Kickaha]

There is a Black 500 racing down here in BEARs and at Ruapuna the other weekend there was a 350 for sale

[merv]

It never quite looked like this but when I think of Gilera I think of Simon Turner racing one about 15 or more years ago, and I couldn't believe how quick he made it go and when I first had a close look I was surprised to find it was only a single cylinder engine.

[Motu]

only a single cylinder engine.

ONLY!!! I agree - now I own a twin cylinder motorcycle I can now see I wasted too many years on motorcycles with ONLY one cylinder.I'll never make that mistake again!

[MidnightMike]

There is a Black 500 racing down here in BEARs and at Ruapuna the other weekend there was a 350 for sale

I think I found it on the photographers site, is it #67? (Pics attached)

How does it go in its class?

[MidnightMike]

I've done a bit more in depth searching on the net and found some PDF mailers from a Gilera forum.... HUGE amount of info in terms of specs.

Still haven't found the number of anniversary models produced though.

Heres a fact sheet on it:

SATURNO 500 FACT SHEET

The new Saturno was created using Japanese money after a request from the C.Itoh corporation.
The engine was basically the 350cc & 500cc unit used in the Dakota trail bike.

Colours

Red with white graphics
Black with gold graphics, special anniversary edition.
White is listed but I have never seen one.
Multi coloured for the Japanese market

Frame no. 212 * 00001> stamped into left side of frame head stock.
Engine no. 213 * 00001> plate on top of gear box, behind cylinder.
Dimensions
Length - 2030mm
Width - 730mm
Height - 1170mm
Wheel base - 1410mm
Seat Height - 790mm
Pedal Height - 360mm
Dry Weight - 145kg (claimed)
Chassis
Steering head angle - 24.5deg.
Trail - 89.7mm
Front fork - Workshop manual. page 13-2 to 13-5.
Marzocchi
Stroke - 120mm
Stanchion Dia. - 40mm
Oil - 310cc in each leg. Or better 150mm air gap.
measure distance from oil to top of fork leg with
the spring removed and the leg fully compresed.
GeN 10p5
- 7.5sae fork oil. mix equal parts
of 5 & 10 weight oil
Fork seal - size********part no. 341239

Spring free length - 420mm + 2.5mm part no. 318949 x 2
Min. length -.415mm
WP dual rate springs are available. p/n:9932.100.D. phone. 01280-705888
Info on forks - GeN 5p20. 6p13. 10p5
Rear Suspension - Workshop manual. page no.14-6 to 14-9.
Marzocchi mono shock
Stroke - 130mm
Only spring pre load adjustment.
Not rebuildable
Wheel Front - Workshop manual. page 12-2 to 12-6.
Marvic Aero light weight three spoke cast alloy - 3.00x17”
Bearing size - *******part no. 328972 x 2
Rim. Radial variation - 2.00mm (limit)
Rim. Axial variation - 2.00mm (limit)
Spindle bend - 0.20mm (limit)
Workshop manual - page 12.1 - 12.5
Tyre - 110/70-17 Pirelli MP7 (Original)
110/70 ZR17 from Bridgestone, Metzler, Pirelli etc.
Pressure - 2.1 bar (30psi) solo
Wheel Rear -.Workshop manual. page 14-2
Marvic Aero light weight three spoke cast alloy - 4.00x17”
Bearing size - **********part no. 328972 x 2
Rim. Radial variation - 2.00mm (limit)
Rim. Axial variation - 2.00mm (limit)
Spindle bend - 0.20mm(limit)
Tyre - 140/70-17 Pirelli MP7 ( Original)

Several tyre manufactures recommend 160/60 but 160 is too wide for the rim. I think
they recommend it because they believe the Saturno has a 4.5” rim. None of them
recommend fitting a 160 on a 4 inch rim so beware. 150/60 seems a good fitment.
Bridgestone, Metzler, Pirelli etc. all produce 150/60 ZR17 rear tyres.

Pressure - 2.3 bar (33psi)
Brake Front Disc - Workshop manual. page 15-2 to 15-6
Brembo Gold Line fully floating
Disc - 300mm dia. part no.939102
Thickness (new) - 5.00mm.
Wear limit - 4.5mm minimum.
Caliper - Brembo four piston caliper
Fluid - Dot 4. change every two years
Piston dia. - 32mm. Wear limit: 31.94mm minimum.
Piston seal kit - part no. 318897
Pad Original - part no. 318895
Ferodo - part no. FRP 408
Brake Rear Disc - Workshop manual. page 15-2 to 15-6
Non floating disc - 240mm dia. part no. 343413
Thickness (new) - 6.00mm.
Wear limit - 5.5mm minimum.
Caliper - Grimeca single piston
Piston dia. - 32mm. Wear limit: 31.94mm minimum.
Piston seal kit - part no. 305840
Pad Original - part no. 323626
Ferodo - part no. FDB 207R
Fuel Tank
capacity - 20 ltr.
reserve - 2 ltr.
Check that tank can not touch frame tubes especially near front.

ENGINE

Bore & Stroke - 92x74mm
Capacity - 491.9cc
Compression ration - 9.8:1
Compression test - 9 to 11 bar (new)
- 8 to 10 bar (over 5000km)
BHP - 44 bhp at 7000 rpm. (claimed)
Torque - 47 Nm at 6000 rpm. (claimed)
Oil - 10w40 semi synthetic
Oil capacity - 2.2ltr.
Oil filter - Technocar R15 part no. 321205
Change oil every 4000km and change filter every other oil change.
Coolant - permanent. un-diluted. Silkolene Pro-cool etc.
capacity - 1.3ltr. Change coolant every two years.
Air filter - Oiled sponge. part no. 939055.
Workshop manual page 3-5
Oil - Foam filter oil or SAE 90 gear oil.

Valves
Inlet diameter - 31mm (x2)
Exhaust diameter - 28mm (x2)
Clearance Inlet - 0.05mm (cold). w/s manual page 3-5.
Exhaust - 0.10mm (cold)
Details on checking clearances are available from GeN, send SAE.
Cam belt - 321406/2 Isoran. part no. 321406.
Workshop manual page 6-2>

To change belt you need tool part no.19.1.20501 available from tool hire scheme
Bob Wright can supply a cheap pattern tool. Phone:01934-413847
Full details on doing the job are available from GeN, send SAE.

Clutch - Wet, multi plate
Friction plates - 8 x part no. 324851
Thickness - 2.9 to 3.0mm (new). wear limit 2.7mm
Steel plates - 7 x part no. 328546
Warp limit - 0.10mm max.
Final drive
Gear box sprocket - 15 tooth. part no. 321586
Sprocket oil seal - size: 35 x 47 x 7. part no.328232
Rear sprocket - 5 x (8mm) bolt fixing ******mm radius.
- *****dia centre hole. Sprocket is flat
- 43 tooth. part no. 939211

Chain - 520 x 104 links
Slack - 35 - 40 mm of vertical movement.
Wear limit - 20 links = 319.4mm (12.57in) max.
With chain tight measure from centre of pin 1 to centre of pin 21
Carburettor
Dell’ Orto PHM 40 VS
40mm conventional slide carb with accelerator pump
Air screw - 1.5 turns open
Float level - 23 - 25mm

Full carb spec available from GeN, send SAE
ELECTRICAL SYSTEM - Workshop manual. page 16-2 to 16-6.
- Three phase AC alternator. 180w
Regulated & rectified - 13.5 - 14 volts DC.
Battery - 14 Ah. Yuasa YB14-LA2
Bulbs (all 12 volt) - Workshop manual. page 19-2 to 19-8.
Head Light - 40/45w tungsten. Bosch bayonet fitting
Tail / stop - 5/21w
Indicator - 10w bayonet
Driving (side) light - 5w
Instrument illumination - 2w mini cap less
Warning lights - 1.2w mini cap less
Fuses - 2 x 15w blade type (common on cars)
Ignition - Workshop manual. page 17-2 to 17-5
Timing - 7deg (static). 30deg at 4500rpm. not adjustable.
Charger coil - part of stator. part no. 328239
Resistance test - 150 ohm + 10% (pink to green)
H.T. Coil - part no.321825
Primary res. - 0.2 - 0.3 ohm + 10% (white-lt.blue to black)
Secondary res. - 4.5 K ohms + 10% (white-lt.blue to H.T.)
Pick up coil - part no.328240
Resistance - 110 ohm + 10% (white-green to white-red)
Spark plug - Champion RA4HC (original)
- NGK DPR9EA9 or DPR9EV9 is a good alternative.
- Nippon Denso X27 EPRU-9 or X27 EPRZU-9
Plug gap - 0.6 to 0.7mm
Torque - 12 to 15 Nm. put “Copper Slip” on threads
Plug cap - 1 K ohm resistance

POSSIBLE FAULTS TO LOOK FOR

Fan touches radiator
Remove tank. Look down back of radiator. Check that fan shroud has about 3mm (1/8”)
clearance all round. The fan mountings are slotted but if there is not enough adjustment, trim the
front of the shroud.
Rising rate bottom link bolt can seize
It is well worth dismantling the rear suspension linkage every year . Support rear of bike,
then remove the rising rate link. Two of the bearings are self aligning ball joints, these just
need some grease either side to keep the wet out. The lower long bearing needs to be cleaned
and greased as well as possible. It is vulnerable and can easily get full of water and go rusty.
Long rear engine bolts can seize
This may be a problem in the future if you need to remove the engine. Remove the bolts
one at a time clean off any corrosion and coat them in “Copper Slip” or grease before
refitting. Torque 30Nm. GeN 1p9
Starter clutch failure
Some last for ever but others fail in a few thousand kilometres. Similar units are used on some other
makes and they give trouble as well. Piaggio tell us that quality has been improved now so let’s
hope it will cease to be a problem in time. Job can be done with engine in frame, remove left side engine
cover. Starter clutch is p/n: 328652. Replace gasket p/n: 321942 & gear shaft oil seal p/n:
321275.
Details of possible repair in GeN 8p16. Also see GeN 6p5.
Tank touches frame tubes
Because the tank is rubber mounted it can move and touch the frame tubes where they are

[jimbo]

Cool bike Mike I remember them

[Kickaha]

I think I found it on the photographers site, is it #67? (Pics attached)

How does it go in it's class

Yeah thats Tony Mac and he goes ok

They also did a race kit for them at the time

[nsrpaul]

tony mac, bucket racing legend

[oyster]

No 67 is in in a million bits, under my bench awaiting repair.
What happened is the water pump bearings crapped out and since the pump is driven by a flat pulley off the outside of the timing belt, the bearing failure took out the near new belt. In turn it then bent all the valves. What a mess, and the parts are VERY expensive. So I've made a new waterpump housing from scratch, and machining up new valves from aftermarket racing quality blanks. The reason being the waterpump is around $800, the valves about $200 each and the exhausts "on order forever"
SO CHECK THE WATERPUMP. The 350 seen for sale at Ruapuna has had the waterpump pressed apart and new bearings put in. The original ones were right on the edge of failing.

[NordieBoy]

No 67 is in in a million bits, under my bench awaiting repair.
What happened is the water pump bearings crapped out and since the pump is driven by a flat pulley off the outside of the timing belt, the bearing failure took out the near new belt. In turn it then bent all the valves. What a mess, and the parts are VERY expensive. So I've made a new waterpump housing from scratch, and machining up new valves from aftermarket racing quality blanks. The reason being the waterpump is around $800, the valves about $200 each and the exhausts "on order forever"
SO CHECK THE WATERPUMP. The 350 seen for sale at Ruapuna has had the waterpump pressed apart and new bearings put in. The original ones were right on the edge of failing.

The waterpump should only be a couple of hundred $?

I would love a Saturno. Especially one with a blown motor :whistle:

Big bore Saturno :woohoo:

[gavinnz]

All good into chaps!

I can add a couple of things...
They came in three colour variations, all three could be 350 or 500cc.
All red.
Black with white wheels.
Black with gold wheels (Anniversary edition).

I have owned and black and white 350 in the past and currently own a red 350 that I am repowering with a 558 Nordwest engine. I am also modifying the bike to even lighter than the 145kg mine was when I started.

I will have a 350 engine spare soon if anyone needs one.. 6500km only and runs great.... and a few other original parts I have replaced with lighter ones.

Regards
Gavin

[NordieBoy]

I have owned and black and white 350 in the past and currently own a red 350 that I am repowering with a 558 Nordwest engine. I am also modifying the bike to even lighter than the 145kg mine was when I started.

Café racer style like Pete Fisher's one or with the fairings?

[Eurodave]

Just out of interest, I make fibreglass/carbon replica Saturno fairings & seats & tinted windscreens.........:msn-wink:

[grotto]

One of the guys at Red Baron in Auckland had one (may still). best sounding bike I've heard for a long time. I talked to him about it, but he said parts were a hassle to get and his spent quite a bit of time off the road.
Beautiful bikes

[gavinnz]

Café racer style like Pete Fisher's one or with the fairings?
With fairing...
I have set myself some rules to making the bike light...
aim...
Make the lightest roading Gilera Saturno.
Must be ridable and road legal with lights.
Must be recognisable as a Saturno. (so yes I aim keeping the fairings shape)
Weight to be taken with the bike ready to go if only petrol was added.
Modifications must not make the bike less of a weapon on a tight road.

I have do quite a lot already and lost almost 10kg without doing some big ticket items yet. I am trying to think outside the box a little.
I run this thought process on every single part however small....

1. Focus on one part.
2. What is it for? What does it need to do?
3. Can it be done without?
4. Can it be replaced with a lighter component?
5. Can it be made smaller?
6. Can it be made from a different material?
7. Can it be incorperated into another part to do two jobs?

It's amazing what you can do when you think along those lines.

Some of the things I have done so far....
Cut and redon the rear sub frame shorter.... in the process of making a one piece carbon/kevlar gas tank and self suporting seat.
Under engine carbon muffler.
Carbon front guard and faring.
Cut down screen in thinner material without a trim.
Trail tech dash... gets rid of speedo and drive, tacho and drive and water temp guage and does it all in one.
Higher pressure coolent tank cap without catch tank... no fans... I will not be city riding on it... it's weekend tight road fun bike.
Led bar end indicators that work both ways....
LED tail light.
Aluminum rear sprocket that saved 700 grams!
Hollowed axles... smaller wheel bearings with aluminum spacers.
It all adds up!

before anyone tells me it's a waste of time....
I know it is... I am doing it for a fun intellectual and practical creative
exercise.

Gavin