Gilera Dakota / Saturno / XRT / RC 600 / Nordwest Workshop Manual 1987–1993 (P/N 405753)

Gilera workshop manual P/N 405753, published by Piaggio V.E. S.p.A., covers the Dakota/Dakota ER, Saturno Bialbero, XRT, RC 600, and Nordwest families. Coverage gaps: Printed general-information pages 1-3 through 1-22 and the indexed wiring diagrams for Saturno, Dakota/Dakota ER, and XRT are missing.

PDF Reading and Diagram Limitations

Search and wiring detail: PDF text search and embedded bookmarks are not available. Small wiring labels require zooming; some diagrams have faint or broken lines and cropped component legends.

One printable English/Italian PDF contains 258 pages, including the original cover, three section-divider pages, and 15 notes pages.

Engine Overhaul, Chassis Service and Electrical Tests

These selected workshop topics outline part of the manual’s contents. Additional sections cover bodywork removal and instrument-light replacement.

• Engine repair: Step-by-step engine removal and installation, cylinder-head and valvetrain disassembly, piston inspection, crankcase separation, and internal gearbox work.

• Timing and starter drive: Generator removal, timing-belt replacement, valve timing, gear-selector adjustment, and electric-starter freewheel inspection.

• Clutch and lubrication: Clutch-pack, primary-drive, and oil-pump disassembly, plus Dakota/Dakota ER hydraulic-clutch master-cylinder and slave-cylinder service.

• Fuel and cooling: Carburetor removal, jet and float inspection, fuel-level adjustment, thermostat checks, and water-pump replacement.

• Chassis and brakes: Fork and steering service, suspension-linkage and wheel bearings, disc and drum brake repair, and hydraulic-system bleeding.

• Electrical diagnosis: Charging-system checks, capacitive- and inductive-discharge ignition tests, starter-motor inspection, and wiring diagrams for RC 600 and Nordwest configurations.

This manual suits professional mechanics and experienced DIY owners who already use precision measuring tools, electrical test equipment, and model-specific service tools.

Engine Inspection and Assembly References

The engine chapters go beyond external maintenance. Inspection instructions cover cylinder taper and ovality, piston-ring wear, connecting-rod bearings, and gearbox shaft clearance, including adjustment-washer selection.

Photographic references, exploded views, RC 600 piston/cylinder matching charts, and component-specific torque tables provide a bench reference for assessing wear and checking component orientation during a rebuild.

Valve-timing illustrations show the relationship between the crankshaft and camshaft reference marks. The special-tool section identifies equipment such as flywheel puller 19.1.20501 and valve-clearance adjustment tool 19.1.20522.

The cylinder-head chapter warns that machining the head’s upper surface can lock the camshafts.

Carburetor Work and Cooling-System Limits

Teikei primary and vacuum-secondary carburetor specifications include separate jetting data. The 500 cc fuel-system instructions warn that crushing the black air-feed tube can obstruct the main jet’s air supply.

The cooling instructions cover thermostat inspection and water-pump removal. The water pump is replaced as a complete unit rather than internally rebuilt.

Fork Variants, Suspension and Brakes

Fork information includes Marzocchi specifications, separate Kayaba procedures for the RC 600 '91 and RC 600 R, and the Nordwest’s Paioli upside-down fork. Internal assembly views accompany the seal-replacement instructions.

Rear-suspension coverage includes Power-Drive layout information, swingarm and linkage bearings, and shock inspection. Shock content addresses replacement and applicable preload or damping adjustments rather than internal shock rebuilding.

Brake sections distinguish Dakota/Dakota ER rear drums from XRT and RC/Nordwest disc systems. Master-cylinder and caliper inspection, wear specifications, and model-specific pad-replacement procedures are included.

Charging, Ignition and Fault Tracing

Electrical sections explain regulator/rectifier diode checks, stator continuity and insulation tests, ignition-coil and pickup checks, and starter-armature inspection.

No-start and poor-performance charts help separate fuel-flow, spark, compression, and valve-timing causes. Ignition advance is electronically controlled; the ignition chapters describe checks rather than a mechanical advance-adjustment procedure.

Fuel-system and ignition work requires appropriate test equipment and a work area free of flames or sparks.

Examples from the Engine Torque and Fluid Tables

The RC 600 torque table lists 7–9 Nm for crankcase joining and cover screws, and 32–35 Nm for the cylinder-head, head-cover, and cylinder fixing nuts.

For the RC 600, coolant capacity is listed as 1.3 L. The 350/500 oil-service instructions specify 2.2 L when the filter cartridge is also replaced, with SAE 15W/40 among the recommended oils.