Saturno Owners in Australia

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garagien
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Re: Saturno Owners in Australia

Postby garagien » Mon Jun 12, 2017 9:14 am

please give us some time for help
HP

garagien
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Re: Saturno Owners in Australia

Postby garagien » Mon Jun 12, 2017 6:37 pm

Dear Leo,
honestly I am not too happy about the desription of the French. Important things like to desribe the mechancal seal and how to replace are missing. Merde.
You can copy the pics and the pics are numbered. The try of my translation is referred to the pics. I think a smart mechanic will handle the repair.
Maybe the wording sounds a bit strage, so it´s the translation from French to German and back to English.

PIC3
Fasten the pump in a vice or similar with material to protect the surface so that you can press the pump shaft from beltside in direction to impeller.

For disassemble / reassemble heating up the belt wheel may help.

PIC4
At this moment you must have 2 pieces in your hands:
the pulley with the pump body in aluminum with inside the ball bearings and the axle attached to the impeller

PIC5/6
Secure the pump body in a vise without tightening and press the shaft out in direction of impeller

PIC7
Remove the circlip and the metal washer

PIC8/9
Turn the pump body in a vice always without tightening it and with a 16mm diameter shaft, press to remove the 2 bearings and the washer out

PIC10
Here the desription of the machanical seal is missing

Check if the shaft is not damaged

Clean all parts carefully (to clean the fan part with demineralised water and the rest with motor cleaning products)

PIC11/12
With a tube or shaft of outside diameter of the bearing, press the 1st bearing into the aluminum pump body (warming up the aluminium may help)

PIC13
Locate the washer between the 2 bearings

PIC14
Repeat the same with the 2nd bearing

PIC15/16/17
Add the steel washer and the circlips

PIC18/19
position the rubber seal and the mechanical seal

PIC20
Press the impeller with its shaft in the pump body

PIC21
tighten the belt wheel

PIC22
press only on the shaft of the impeller (check to leave ½ mm between the impeller and the pump body)

Good luck
HP

garagien
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Re: Saturno Owners in Australia

Postby garagien » Mon Jun 12, 2017 6:47 pm

WP05.jpg
WP02.jpg
WP01.jpg
Pumpenschnitt2.jpg
P6130075.JPG


Some more pics for better understanding.
HP
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Leow
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Re: Saturno Owners in Australia

Postby Leow » Sun Jun 18, 2017 11:14 pm

Dear HP, thank you very much for the translation and photographs. I took the whole lot to the company that supply the bearings and seals and they said that it would be no problem to do the job. I can only hope that it turns out well. I wonder, if you are familiar with or know anything about the decompressor on the engine. Is it only involved with the kickstart, or also the electric start.? Is it something that requires attention/maintenance, or if I'm not using the kickstart do you just ignore it. But, I do have periods when the engine doesn't want to start on the electric starter motor. And, I was reading one of the other posts where someone was having starting problems and they were enquiring about the decompressor working or not working. But, I couldn't find any follow-up answers to this post. It's not an emergency but if you have a moment (or anyone else) could you please give me some background information on the decompressor. Thank you Leo

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Re: Saturno Owners in Australia

Postby garagien » Mon Jun 19, 2017 7:10 am

Dear Leo,

since 1989 I´m doing with the Saturnos and other Gileras. Honestly I just once tried the kickstart in the early beginning but I think that from engineering point of view the kickstart design is a disaster. So I dismanteled all kickstart stuff out of my engines. A modern engine design needs no kickstart. I know that a lot of guys loving to trample around the kickstart, because it´s cool and devides boys from men. Let them believe in.
So only for kickstart purpose you need the decompression lever. If you need some extra information about to adjust the cable, ask me, it´s easy.
The starter motor is strong enough to start the engine even when slightly tuned. Some problems occurred with corroded connections preventing sufficient revs of the starter. Especially the bigger sized electric cables Plus and Minus from battery to magnetic switch and back to starter motor needs good contact. Clean carefully with sand paper or file even all the Minus connections to frame. Use new screws or nuts to connect. Next to the ignition coil is a frame connection with lots of (black) cables which you should check too. Any informations you need, please ask.
Regards
HP

Leow
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Re: Saturno Owners in Australia

Postby Leow » Wed Jul 26, 2017 8:43 am

dear HP, well long story short. The people who supply the bearings etc messed around for so long that I got the water pump back from them. I took it to the Ducati specialist Byron Bay and he said he could fix it, and he did. Replace the bearings, seals were still good. God willing, job done. Thanks for all your advice and help, just got to put all the parts back together. Will let you know final result. Leo

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Re: Saturno Owners in Australia

Postby Joachim » Wed Jul 26, 2017 9:31 am

rulez

ciao Joachim
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Leow
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Re: Saturno Owners in Australia

Postby Leow » Mon Sep 25, 2017 3:28 am

Dear HP, I finally got the water pump fixed by the local Ducati dealer. I haven't really had a chance to test it out because when I put everything back together again I find that the starter motor sometimes doesn't engage the engine to turn it over and fire it up. I don't know if it's coincidental or I have done something wrong but I suspect the Spragg clutch inside has failed. I looked at the NORWEST.RAPIDMOUSE.COM , website, mechanic, and what appears to be a Spragg starter clutch replacement. Is the engine in the Nord West 600 the same as the Saturno 500? Or do they just share various parts? Could you please give me some guidance as to how I can fix this problem. Thank you Leo

Leow
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Re: Saturno Owners in Australia

Postby Leow » Sun Oct 01, 2017 10:34 am

Dear HP, followed the instructions in Nordwest.rapidmouse.com mechenic free wheel with its various pictures and translated French explanation. Unable to remove the clutch but the gear is jammed in it. How do you separate them? Regards Leo

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Re: Saturno Owners in Australia

Postby Leow » Sun Oct 01, 2017 10:36 am

dear HP, correction to last post. Change unable' to able. Regards Leo

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Joachim
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Re: Saturno Owners in Australia

Postby Joachim » Sun Oct 01, 2017 11:13 am

*thumb*

ciao Joachim
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Leow
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Re: Saturno Owners in Australia

Postby Leow » Sun Oct 01, 2017 9:07 pm

Dear Joachim, thank you for your reply. Do I just separate the gear from the clutch carefully with a screwdriver? Is there any reason to check on the kickstart while I have the bike in this situation? And also the decompression mechanism? There is a fairly good YouTube video on the kickstart which I have seen in my travels, but I cannot remember one that explains the decompression system. Maybe you could direct me in that department. I will obtain a complete clutch from Bob Wright as I don't think I have the ability or the tools to do a rebuild job with the KTM bearing part, as in the video. Thanks once going for all help, Leo

Leow
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Re: Saturno Owners in Australia

Postby Leow » Wed Oct 04, 2017 11:35 am

Dear HP, Joachim, and anyone else. I am planning on taking the kick starter out of the Gilera Saturno 500. I can't remember where but I saw someone in a video giving the name of a screw to blank the exit off. Does anyone know? Or does anyone have the necessary for sale? Thank you leo

Leow
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Re: Saturno Owners in Australia

Postby Leow » Fri Oct 06, 2017 9:07 am

Dear HP, I see on a lot of photos of Gilera Saturno bikes , none of them have Ciriani front forks. My bike has, were they a later add-on or what? They have the quick release mechanisms to drop the front wheel with the axle out in one piece. Love to know the story regards Leo PS also have adjustment top and bottom.

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Re: Saturno Owners in Australia

Postby Joachim » Fri Oct 06, 2017 9:33 am

the Ceriani fork was not on the european Saturnos.
As far as i know, it was only mounted on the japanese TT Version.
Together with a different fairing, seat and exhaust.

Next time i will read with more care.
I thought you are through and your Sat is back on the road ;)

Replacing the sprag clutch is not that hard.
You should use some kind of a big hose clamp to fix the cover before bending up the edge with a big screw driver.
Same when you put back the cover and bending down the edge with a hammer.
I think that is what is shown at the rapidmouse pages.
The clutch is also available from China.
Have a look at the ebay shop of tongtong-motor

Due to my lousy english i am not shure about the kickstarter question.
There is a trick for remounting the kickstarter and the case.
There is a big allen key bolt on the left side of the motor.
The procedure is described in the workshop manual.
If you are not shure about that, just ask again. I will try to translate HPs guide i have here.

ciao Joachim
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