TOPIC:

I'm up to the point of removing the cam belt on my Saturno to get the water pump out and was wondering if anyone had any tips on the process.

I've aligned the timing marks and slackened off the belt tension pulley as per the manual but there is still a fair bit of friction between the belt and the pulleys. This is not a real problem getting the belt off so much as fitting a new one.

Finally, is there an alternative way of removing the flywheel without a factory puller?

Mike

Hi Mike,
To remove and refit I take off the tension pulley, when refitting I lever the pulley into position with a screwdriver, DO NOT use a screw driver or any leaver on the belt,
To remove the flywheel buy or make a puller
John

i think it is not possible to remove the fly wheel without a puller.
In most cases it is hard work to remove it even with the puller.
Of course you did not need the (expensive) original Gilera one.
The 600ccm engines have a M38x1,5mm thread.
You can use the Suzuki Burgman puller available from Buzzetti

The smaller engines (350 and 500ccm) have a smaller thread
Buzzetti M35X1,5 ROTAX
Artikel Nr.: BZ5340

ciao Joachim

You can remove and repace the pump without removing the flywheel

Yes I know but I need to replace the belt anyway. It was slipping over the seized water pump for some miles before I noticed that the bike was overheating. The friction wouldn't have done it any good so it's prudent to replace it.

Mike

Picked up a 35 x 1.5mm female puller off ebay for $26 so that problem's solved.

I will need to order a cam belt soon.
I've noticed Dayco belts advertised on ebay from Germany for the Saturno.
They don't list part numbers though which makes finding a local alternative difficult.

Mike