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PIAGGIO Beverly 300 i.e. Service Station Manual Download Page 2

SERVICE STATION

MANUAL

Beverly Tourer 300 i.e.

The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all countries. The availability of each

model should be checked at the official Piaggio sales network.

"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

Summary of Contents for Beverly 300 i.e.

Page 1: ...SERVICE STATION MANUAL xxxxxx IT xxxxxx EN xxxxxx FR xxxxxx DE xxxxxx ES xxxxxx PT xxxxxx NL xxxxxx EL Beverly Tourer 300 i e...

Page 2: ...e any changes to components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions models shown in th...

Page 3: ...isable to read the sections of this manual concerning special tools along with the special tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION...

Page 4: ......

Page 5: ...OLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHAS...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 7: ...n such a way that you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGG...

Page 8: ...t the saddle and re move the lid A The engine prefix B is stamped near the rear left shock absorber lower support VEHICLE IDENTIFICATION Specification Desc Quantity Chassis prefix M28A00 Engine prefix...

Page 9: ...y 278 cm Bore x Stroke 75x63 mm Compression ratio 11 0 5 1 Engine idle speed 1 700 100 rpm Timing system 4 valves single overhead camshaft chain driven Valve clearance Intake 0 10 mm Exhaust 0 15 mm M...

Page 10: ...cation Desc Quantity Engine oil 1 3 l Transmission oil 250 cm Cooling system fluid 1 75 l Fuel tank reserve 10 l 0 5 Fork oil quantity per stem 133 cm Electrical system ELECTRICAL SYSTEM Specification...

Page 11: ...Nm Handlebar fixing screw 45 to 50 Fixing screws for the handlebar control unit U bolts 7 to 10 Steering tube upper ring nut 40 45 Steering tube lower ring nut 14 17 CHASSIS Name Torque in Nm Centre...

Page 12: ...il drainage plug 15 to 17 Oil filter on crankcase fitting 27 to 33 Engine oil drainage plug mesh filter 24 to 30 Oil filter 4 to 6 Oil pump cover screws 7 9 Screws fixing oil pump to the crankcase 5 t...

Page 13: ...SE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead transmission side half shaft screws 4 to 6 Engine crankcase coupling screws 11 to 13 Starter screws 11 to 13 Crankcase timing cov...

Page 14: ...HE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARK FACING UPWARDS Measure the outer diameter of the gud...

Page 15: ...clearance 0 015 0 06 mm Middle piston ring maximum clearance al lowed after use 0 07 mm oil scraper ring stand ard coupling clearance 0 015 0 06 mm oil scraper ring maximum clearance allowed after use...

Page 16: ...missionside half shaft 16 6 0 0 05 A D 0 20 to 0 50 Flywheel side halfshaft 16 6 0 0 05 B D 0 20 to 0 50 Connecting rod 18 0 10 0 15 C D 0 20 to 0 50 Spacer tool 51 4 0 05 E D 0 20 to 0 50 Diameter of...

Page 17: ...KSHAFT Specification Desc Quantity Crankshaft bearings Standard diameter Cat 1 28 998 29 004 mm Crankshaft bearings Standard diameter Cat 2 29 004 29 010 mm Beverly Tourer 300 i e Characteristics CHAR...

Page 18: ...MAX ADMISSIBLE DISPLACEMENT Specification Desc Quantity A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm Characteristics Beverly Tourer 300 i e CHAR 18...

Page 19: ...e matching surface of the two half bearings must be perfectly orthogonal to the cylinder axis as shown in the figure The oil feeding channel section is also affected by the bushings driving depth comp...

Page 20: ...THE ENDS ARE RE LIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION N B CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY C BUSHINGS YE...

Page 21: ...ead surface is not worn or distorted Characteristic Maximum allowable run out 0 1 mm In case of faults replace the head Check the sealing surfaces for the intake and exhaust manifold Check that the ca...

Page 22: ...alve seats of any carbon residues Using the Prussian blue check the width of the impression on the valve seat V Characteristic Standard value 1 1 3 mm Admissible limit 1 6 mm If the impression width o...

Page 23: ...0 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc Quantity Intake 4 96 mm Exhaust 4 945 mm Calculate the clearance between valve and valve guide Check the deviation of the valve stem by resting it o...

Page 24: ...After measuring the valve guide diameter and the valve stem diameter check clearance between guide and stem INTAKE Specification Desc Quantity Standard clearance 0 013 0 04 mm Admissible limit 0 08 m...

Page 25: ...EFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES RIGHT LEFT Check that the ca...

Page 26: ...tion Desc Quantity Camshaft check Standard axial clearance 0 11 0 41 mm Camshaft check Maximum admissible axial clearance 0 42 mm Measure the outside diameter of the rocking lever pins Check the rocki...

Page 27: ...king system Characteristic Compression ratio 10 5 11 5 1 Measurement A to be taken is a value of piston re entry it indicates by how much the plane formed by the piston crown falls below the plane for...

Page 28: ...or in creased adhesiveness AGIP GP 330 Grease for brake lever gas White calcium complex soap based spray grease with NLGI 2 ISO L XBCIB2 AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA...

Page 29: ...INDEX OF TOPICS TOOLING TOOL...

Page 30: ...lliper to extract 15 mm bearings 005095Y Engine support 002465Y Calliper for circlips 006029Y Punch for fitting fifth steering bearing on steering tube 020004Y Punch for removing steering bearings fro...

Page 31: ...port base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020262Y Crankcase splitting plate 020263Y Driven pulley assembly sheath Beve...

Page 32: ...020306Y Punch for assembling valve seal rings 020329Y Mity Vac vacuum operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator Tooling Beverly...

Page 33: ...cription 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32x35 mm Adaptor 020359Y 42x47 mm Adaptor 020360Y 52x55 mm Adaptor 020363Y 20 mm guide Beverly Tourer 300 i e T...

Page 34: ...28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band 020412Y 15 mm guide Tooling...

Page 35: ...wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure check fitting 020444Y Tool for fitting removing the driven pu...

Page 36: ...scription 020456Y 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30 mm guide 020489Y Hub cover support stud bolt kit 020428Y Piston position check mounting 020680Y Diagnosis Tool Tooling Beverly Tourer 3...

Page 37: ...raction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing outside 47 mm 020626Y Driving pulley lock wrench 001467Y013 Calliper to extract 15 mm bearings 020627Y Flywheel lock wr...

Page 38: ...Y Flywheel extractor 020454Y Tool for fitting piston pin stops 200 250 020622Y Transmission side oil seal punch 020480Y Petrol pressure check kit 020244Y 15 mm diameter punch 020115Y 18 punch Tooling...

Page 39: ...removing fitting silent bloc 020638Y 250 l ENGINE SOFTWARE E ABS 020469Y Reprogramming kit for vehicle diagnostic tester 020487Y Fork oil seal extractor 020458Y Puller for lower bearing on steering tu...

Page 40: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 41: ...R R R R R R Tyre pressure and wear I I I I I I I I I Vehicle road test I I I I I I I I I Suspension I I I I I I I I I Steering I I I I I I I I I Time 60 10 10 0 45 15 0 10 14 0 10 15 0 45 10 0 10 19 0...

Page 42: ...plug and spark plug cap Connect the induction clamp on the spark gap cable respecting the proper polarity the arrow on the clamp must be pointing at the spark plug Connect the diagnostic tester Start...

Page 43: ...y adjust the gap by carefully bend ing the outer electrode forward or away Make sure the sealing washer is in good condi tions Fit the spark plug screw it manually and lock it to the prescribed torque...

Page 44: ...lower end if the level is under the MAX mark it needs to be filled with the right amount of hub oil Screw up the oil dipstick again and make sure it is locked properly into place Replacement Remove th...

Page 45: ...k it in a mixture of 50 petrol and 50 speci fied oil Gently squeeze the filtering element with your hands but do not wring it allow it to drip dry and then refit CAUTION IF THE VEHICLE IS USED ON DUST...

Page 46: ...tions Lubricate them and refit the mesh filter and the oil drainage plug screwing them up to the prescribed torque Refit the new cartridge filter being careful to lubri cate the O ring before fitting...

Page 47: ...l line will be lower in order to carry out a cor rect check wait at least 10 minutes after the en gine has been stopped so as to get the correct level Oil top up The oil should be topped up after havi...

Page 48: ...cking the ignition timing Remove the plastic cap on the flywheel cover Turn the flywheel until the reference mark T on the rotor matches the reference mark on the fly wheel cover as shown in the figur...

Page 49: ...orrect proceed to top up when the engine is cold If it is necessary to top up the coolant frequently or if the expansion tank is com pletely dry you should look for the cause in the cooling system WAR...

Page 50: ...ioned on the handlebar Proceed as follows Rest the vehicle onto the centre stand with the handlebar centred Check the fluid level through the sight glass A A certain lowering of the level is caused by...

Page 51: ...OFF WITH WATER WARNING THE BRAKING CIRCUIT LIQUID IS HYGROSCOPIC AND ABSORBS THE HUMIDITY OF SURROUNDING AIR IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE IT WILL LEAD TO INEFFICIENT B...

Page 52: ...TH THE EURO PEAN STANDARDS REGARDING MAXIMUM AND MINI MUM HEIGHT OF LIGHT BEAMS REFER TO THE STATU TORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED To adjust light beams Undo the f...

Page 53: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 54: ...alve seat distorted Replace the head unit Starting difficulties DIFFICULT STARTING Possible Cause Operation Rpm too low at start up or engine and start up system dam aged Check the starter motor the s...

Page 55: ...that the clutch mass faying surface with the bell is mainly in the centre with equivalent characteristics on the three masses Check that the clutch casing is not scored or worn in an anomalous way Ins...

Page 56: ...que not conforming Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustments check the rotation seats and the ste...

Page 57: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 58: ...LED 7 fuel gauge 8 engine temperature gauge 9 injection telltale light 10 low fuel warning light 11 fuel level transmitter 12 oil pressure warning light 13 oil pressure sensor 14 immobilizer aerial 15...

Page 59: ...electric fan 37 electric fan remote control 38 starter button 39 starter motor 40 start up remote control switch 41 saddle opening button 42 engine stop switch 43 side stand switch 44 light switch 45...

Page 60: ...ery remove the battery cover located in the helmet compartment to reach it Characteristic Battery 12V 12Ah 3 Start up remote control switch remove the right side fairing to reach it 4 Primary fuses re...

Page 61: ...3 4 k 6 Voltage regulator remove the right side fairing to reach it Electric characteristic Control voltage 14 15 V to 1500 12000 rpm 7 Oil pressure sensor placed at the bottom at the back of the veh...

Page 62: ...0 Horn remove the shield back plate to reach it 11 Immobilizer Aerial remove the legshield to reach it 12 Key switch remove the legshield to reach it Electrical system Beverly Tourer 300 i e ELE SYS 6...

Page 63: ...l B Electric fan remote control C Injection load remote control 15 Auxiliary fuses located in the front glove box 16 Fuel level transmitter remove the central cover to reach it Electric characteristic...

Page 64: ...Saddle opening actuator remove the left side panel to reach it 19 Injection ECU remove the inspection cover lo cated in the helmet compartment to reach it 20 Plug socket located in the helmet compart...

Page 65: ...Beverly Tourer 300 i e Electrical system ELE SYS 65...

Page 66: ...he battery cover located in the helmet compartment to reach it Characteristic Battery 12V 12Ah 3 Start up remote control switch remove the right side fairing to reach it 4 Primary fuses remove the rig...

Page 67: ...3 4 k 6 Voltage regulator remove the right side fairing to reach it Electric characteristic Control voltage 14 15 V to 1500 12000 rpm 7 Oil pressure sensor placed at the bottom at the back of the veh...

Page 68: ...e vehicle right side to reach it 10 Horn remove the shield back plate to reach it 11 Immobilizer Aerial remove the legshield to reach it 12 Key switch remove the legshield to reach it Electrical syste...

Page 69: ...l B Electric fan remote control C Injection load remote control 15 Auxiliary fuses located in the front glove box 16 Fuel level transmitter remove the central cover to reach it Electric characteristic...

Page 70: ...Saddle opening actuator remove the left side panel to reach it 19 Injection ECU remove the inspection cover lo cated in the helmet compartment to reach it 20 Plug socket located in the helmet compart...

Page 71: ...il pressure warning light H Digital clock I Low fuel warning light L Right turn indicator warning light M Clock controls N Fuel gauge O Water temperature gauge P Headlight warning light Q Trip odomete...

Page 72: ...nti theft ECU 3 Saddle opening switch 4 To fuel gauge 5 To fuel pump 6 Towards right fairing 7 To helmet compartment light switch 8 Engine ground lead 9 Ground lead clamping to chassis 10 To stand swi...

Page 73: ...n remote control 15 Injection load remote control 1 Immobilizer aerial 2 Turn indicator control device 3 Injection load remote control 4 On the left side 5 Light remote control 6 Electric fan remote c...

Page 74: ...rn indicator 5 To front brake stop button 6 To engine stop switch 7 To light switch 8 To starter button 9 To turn indicator switch 10 To horn button 11 To light switch 12 To left turn indicator 13 To...

Page 75: ...Back side 1 Saddle opening actuator 2 To internal light 3 Battery positive Beverly Tourer 300 i e Electrical system ELE SYS 75...

Page 76: ...heel regulator connection 4 Regulator system connection 5 Spark plug cap 6 Main wire unit 7 Diagnostics socket 8 Voltage regulator 9 HV coil 10 Rear fuse box 11 Plug socket for accessories 12 Battery...

Page 77: ...internal light 2 To actuator 3 To battery positive 4 To battery negative 5 To plug socket for accessories 6 To rear light 7 To the license plate light Beverly Tourer 300 i e Electrical system ELE SYS...

Page 78: ...bda sensor 5 Oil pressure sensor 6 Lambda probe connector 7 Injection ECU 8 Injector 9 To lambda probe 10 Engine temperature sensor 11 Starter motor positive 12 Starter motor ground lead clamping Conc...

Page 79: ...erial 15 injection ECU 20 HV coil 21 engine revolution sensor 25 injection load remote control 29 battery 30 main fuses unit fuses 1 2 4 49 key switch contacts 54 auxiliary fuses unit Fuses 9 Beverly...

Page 80: ...eto flywheel 38 starter button 39 starter motor 40 start up remote control switch 42 engine stop switch 43 side stand switch 49 key switch contacts 54 auxiliary fuses unit Fuses 7 55 stop buttons Leve...

Page 81: ...it fuses 9 10 Devices and accessories 1 bulbs for turn indicator warning lights 2 turn indicator bulbs 3 turn indicator switch 4 turn indicator control device 5 clock 15 injection ECU 16 diagnostics s...

Page 82: ...rn indicator control device 26 stop light bulb 27 helmet compartment light bulb 28 helmet compartment light control switch 29 battery 30 main fuses unit fuses 1 3 5 44 light switch 45 instrument panel...

Page 83: ...ilizer system consists of the following components an electronic control unit immobilizer aerial master key with built in transponder service key with built in transponder diagnosis LED The diagnosis...

Page 84: ...n if there is battery voltage between terminals 5 26 and terminals 5 chassis ground fixed power sup ply If there is no voltage check the key switch contacts and that fuses No 1 and 9 and their ca ble...

Page 85: ...isation of the service keys The Master and service keys must be used to code the system as follows Insert the Master key turn it to ON and keep this position for two seconds limit values 1 to 3 second...

Page 86: ...on imposed on the number of revs 2 Previously unused control unit transpond er absent or cannot be used The LED is per manently ON in this condition no operations are possible including starting of th...

Page 87: ...iliser aerial or the transponder Turn the switch to ON using several keys if the code is repeated even with the Master key check the aerial wiring and change it if necessary If this is not the case re...

Page 88: ...plug cap from the HV cable and measure the resistance between the HV cable end and the HV coil negative terminal see figure 3 Measure the resistance between the 2 ends of the spark plug cap Character...

Page 89: ...of the solenoid 3 With the solenoid fed check that there is con tinuity between terminals 87 and 30 4 If these conditions are not met the solenoid is surely damaged and therefore it should be re plac...

Page 90: ...STARTER BUTTON LIGHT SWITCH TURN INDICATOR SWITCH HORN BUTTON Electrical system Beverly Tourer 300 i e ELE SYS 90...

Page 91: ...right side panel 2 Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture 3 Measure the resistance between each of the yellow terminals and the oth...

Page 92: ...e battery negative pole 4 With the ignition key always OFF the reading indicated by the ammeter must be must be 0 5 mA Charging current check WARNING BEFORE CARRYING OUT THE CHECK MAKE SURE THAT THE B...

Page 93: ...7 7 Stop buttons 8 Starter button 9 Injection ECU WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check if there is continuity of the Red cable connec...

Page 94: ...ey switch contacts 4 Fuse No 8 5 Horn button 6 Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED 1 Check fuses No 1 and 8 key switch contacts and the...

Page 95: ...he working order of bulbs 2 Check fuses No 1 and 10 and the key switch contacts 3 Check if there is intermittent voltage between the Blue Black cable of the turn indicator control device and the groun...

Page 96: ...check that the cable harnesses between them are not interrupted Electric characteristic Resistance value when the tank is full 7 Resistance value when the tank is empty 90 13 3 Lights list LIST OF BU...

Page 97: ...tem is equipped with 1 Six protective fuses A located inside the side panel on the right hand side 2 Four protective fuses B located inside the compartment on the upper left hand side The chart shows...

Page 98: ...15A Protected circuits Light switch via remote control 6 Fuse No 6 Capacity 7 5 A Protected circuits Injection ECU 7 Fuse No 7 Capacity 7 5 A Protected circuits Headlight remote control stop lights st...

Page 99: ...delivery it is therefore necessary to check the battery charge and recharge it if re quired before storing the vehicle and afterwards every six months INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN...

Page 100: ...N BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEE...

Page 101: ...mpty and proceed immediately to the next point 6 Battery closing Insert the airtight cover strips into the filling holes Press horizontally with both hands and make sure that the strip is levelled wit...

Page 102: ...w timer c connect the clamps of the battery charger to the battery poles black clamp to negative pole and red clamp to positive pole d Press the red button as shown in figure e Press the MF black butt...

Page 103: ...t i i The battery is now completely activated disconnect the battery charger from the fuel supply grid disconnect the clamps from the battery and proceed to fitting the battery on the vehicle Connecto...

Page 104: ...ument panel lighting Yellow Black IMMOBILIZER AERIAL CONNECTOR 1 Live power supply Red White 2 Ground lead Black 3 Injection ECU Orange White FUEL PUMP CONNECTOR 1 Not connected 2 Ground lead Black 3...

Page 105: ...t light Red Yellow 7 Not connected 8 Not connected 2 PIN CONNECTOR ONLY 1 Sky blue black positive from control unit 2 White Green negative from control unit VOLTAGE REGULATOR CONNECTOR 1 Battery posit...

Page 106: ...ics socket Purple White 17 Immobilizer LED Red Green 18 Side stand Sky blue 19 Not connected 20 Injection load remote control Black Purple 21 Not connected 22 HV coil negative Pink Black 23 Not connec...

Page 107: ...y Black 2 Ground lead Black 3 Fuel level indicator White Green COOLANT TEMPERATURE SENSOR CON NECTOR 1 Ground lead Grey Green 2 Instrument panel Green Yellow 3 Injection ECU Sky blue Green 4 Ground le...

Page 108: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 109: ...obe ca ble Undo the two exhaust manifold fixings on the head To unscrew the nuts that fix the silencer flange to the head properly use a jointed wrench that allows according to the travel direction to...

Page 110: ...ion cover in helmet compart ment Remove the full silencer unit Remove the air filter Release the blow by return pipe from the clamp and disconnect it from the head CAUTION THIS OPERATION MUST BE CARRI...

Page 111: ...mpty the sys tem Remove the engine coolant outlet pipe as indi cated Disconnect fuel piping and retainer clamp injector connector control unit connector Remove the coolant outlet pipe from the engine...

Page 112: ...ated in the picture Remove the positive and negative wiring from the starter motor as shown in the picture Disconnect the connectors from the flywheel wir ing harness Disconnect the relevant cable fro...

Page 113: ...y out the removal operations but in reverse order and respect the tightening torques shown in the Specifications Chapter Check the engine oil level and if necessary top it up with the recommended type...

Page 114: ...crew Check the engine oil level and if necessary top it up with the recommended type Fill and bleed the cooling circuit Check accelerator and electric devices for correct functioning Pay particular at...

Page 115: ...INDEX OF TOPICS ENGINE ENG...

Page 116: ...ing a screwdriver in the slotted holes Using the clutch bell lock wrench shown in the figure remove the driven pulley shaft locking nut and washer Specific tooling 020423Y Driven pulley lock wrench Re...

Page 117: ...aptor 020412Y 15 mm guide Refitting the driven pulley shaft bearing Slightly heat the crankcase from the inside so as not to damage the painted surface Insert the bearing in its seat Refit the Seeger...

Page 118: ...that could jeopardise belt functioning For refitting place the roller with the belt contain ment edge on the engine crankcase side Tighten the wrench to the prescribed torque Locking torques N m Anti...

Page 119: ...15 and 17 mm Lock with the original spacer and nut Place the bell shaft unit on the support to check the crankshaft alignment Using a feeler dial gauge and the magnetic base measure the bell eccentric...

Page 120: ...lutch and spring with its plastic holder CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CON TACT WITH THE TOOL EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TO...

Page 121: ...OMISE THE O RING SEAL Remove the 4 torque server pins and pull the pulley halves apart Removing the driven half pulley bearing Check there are no signs of wear and or noisi ness Replace with a new one...

Page 122: ...m guide Inspecting the driven fixed half pulley Measure the outside diameter of the pulley bush ing Check the faying surface with the belt to make sure there are no flaws Check the riveted joints are...

Page 123: ...3 mm standard diameter 41 000 41 035 mm maximum allowable diameter 41 08 mm Refitting the driven half pulley bearing Support the pulley bushing adequately from the threaded side using a wooden surface...

Page 124: ...ly grease through one of the holes in the bushing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B THE TORQUE...

Page 125: ...against the torque server closing collar Insert the spring with its plastic holder in contact with the clutch Insert the drive belt into the pulley unit according to their direction of rotation Insert...

Page 126: ...BE CARE FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING N B FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYM METRIC THE FLATTEST SURFACE SHOULD BE MOUN TED IN CONTACT WITH THE CLUTCH S...

Page 127: ...ogram you are advised to check that the rim bottom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does re...

Page 128: ...meter B of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the guide shoes for the variator back plate are not worn Check the wear of the roller hou...

Page 129: ...fitting the driving pulley Preassemble the movable half pulley with the roller contrast plate by putting the rollers in their housings with the larger support surface touching the pulley according to...

Page 130: ...alignment dowels and that the sealing gasket for the oil sump on the trans mission cover is adequately fitted Replace the cover and tighten the 10 screws to the specified torque Refit the oil loading...

Page 131: ...through the oil drainage plug Remove the 7 flanged screws indicated in the figure Remove the hub cover and its gasket Removing the wheel axle Remove the wheel axis complete with gear Remove the inter...

Page 132: ...r Specific tooling 001467Y013 Calliper to extract 15 mm bear ings Removing the wheel axle bearings Take out the clip on the outside of the gearbox cover Support the hub cover and expel the bearing By...

Page 133: ...ve the Seeger ring shown in the figure Remove the driven pulley shaft bearing using the modular punch Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20 mm guide Inspecting...

Page 134: ...n the figure Fit the Seeger ring Fit the oil seal with seal lip towards the inside of the hub and place it flush with the internal surface by means of the appropriate tool used from the 52 mm side The...

Page 135: ...ADEQUATELY SUPPORT THE COVER WITH THE STUD BOLT KIT Refit the driven pulley shaft bearing with a mod ular punch as shown in the figure N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN ER PLACE IT SO...

Page 136: ...ipe using black silicone sealant Fit the gearbox cover making sure the breather pipe is in the correct position Position the shorter screw that can also be rec ognised from the different colour as sho...

Page 137: ...er Remove the 10 clamps Remove the flywheel cover Removing the stator Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure Rem...

Page 138: ...ent the end as shown in the figure Orient the water pump shaft with reference to the transmission gear seat as shown in the picture Refit the cover over the engine and tighten the screws to the prescr...

Page 139: ...s seat Removing the flywheel magneto Remove the water pump shaft and crankshaft spline clip Line up the two holes in the flywheel as shown in the picture Screw in the guide bushing that is part of the...

Page 140: ...picture Specific tooling 020467Y Flywheel extractor Inspecting the flywheel components Check the integrity of the internal plastic parts of the flywheel and the Pickup control plate Refitting the free...

Page 141: ...prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the flywheel magneto Remove the freewheel retaining plate indicated in the picture...

Page 142: ...Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque Locking torques N m Starter scr...

Page 143: ...ing and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifte...

Page 144: ...Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioner slider must be removed from the transmissi...

Page 145: ...ING THE CHAIN AND THE CRANKSHAFT CHAIN TENSIONER Removing the cylinder head Remove the spark plug Remove the 2 side fixings shown in the figure Loosen the 4 head cylinder fastening nuts in two or thre...

Page 146: ...al tool 020382Y Valve cotters equipped with part 012 removal tool 020431Y Valve oil seal extractor Removing the cylinder piston assy Removing cylinder and piston Remove the chain guide slider Remove t...

Page 147: ...so Cylinder piston assy Inspecting the piston N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder piston assy Inspecting the cylinder N B TO MEASURE WE...

Page 148: ...HE STOPS HOUS ING Specific tooling 020454Y Pin lock fitting tool Choosing the gasket Provisionally fit the piston into the cylinder without any base gasket Assemble a dial gauge on the specific tool S...

Page 149: ...op posed to the spring junction and with the writing top facing the piston crown The chamfered side of the oil scraper ring should always be facing the piston crown Fit the second lining with the iden...

Page 150: ...PLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Cylinder Head Inspecting the timing system components Check that the guide slider and the tensioner slider are not worn out Ensure that the ca...

Page 151: ...he oil seal show exhibit no signs of abnormal wear Replace a component when worn Measure the unloaded spring length N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER S...

Page 152: ...lower timing chain sprocket wheel on the crankshaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on the crankshaft Fit the chain tensioner slider from the cylin...

Page 153: ...ish using the counterweight screw fastener as a reference Tighten the clamping screw to the prescribed tor que Set the tensioner cursor in the rest position Fit the chain tensioner on the cylinder usi...

Page 154: ...asket and the cylinder head Lubricate the stud bolt threading Tighten up the nuts to an initial pre torque of 7 1 N m Tighten up the nuts to a second pre torque of 10 1 N m Rotate by an angle of 270 T...

Page 155: ...Timing chain tensioner support screw 11 to 13 Refitting the rocker arms cover Refit the cylinder head cover and tighten the 5 clamping screws to the prescribed torque Make sure the gasket is positione...

Page 156: ...shown in the diagram Check the axial clearance on the connecting rod Check the radial clearance on the connecting rod Check the surfaces that limit the axial free play are not scored and measure the...

Page 157: ...IMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER See also Crankcase crankshaft connecting rod Inspecting the crankcase halves Before proceeding to check the crankcase halves thoroughly cl...

Page 158: ...ARE DIFFICULT TO DETECT PISTON TEMPERATURE IN CREASE FAILURE OR LEAKS CAN CAUSE A CONSID ERABLE DROP IN THE LUBRICATION PRESSURE FOR MAIN BUSHINGS AND CONNECTING ROD N B THE HEAD LUBRICATION CHANNEL...

Page 159: ...e prescribed torque Fit the oil filter fitting and tighten it to the prescri bed torque Position the oil pre filter element as shown in the picture Place a new gasket on one of the crankcase halves pr...

Page 160: ...r seat in the crankcase Check the depth of stud bolt driving with a gauge as indicated in the picture If it varies significantly from the driving depth indicated it means that the stud bolt has yielde...

Page 161: ...e carter thoroughly Refit a new stud bolt and apply the special product on the threading crankcase side Tighten up to the depth of the driving indicated Recommended products Loctite Quick Set Loctite...

Page 162: ...Engine Beverly Tourer 300 i e ENG 162...

Page 163: ...ove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the fan cover If the oil pressure is not within the s...

Page 164: ...seal Specific tooling 020622Y Transmission side oil seal punch Refitting Always use a new oil seal upon refitting Prepare the new oil seal by lubricating the sealing lip Preassemble the oil seal with...

Page 165: ...NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OIL SEA...

Page 166: ...t wheel with relative O ring Remove the oil pump by undoing the two screws in the figure Remove the oil pump seal N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION O...

Page 167: ...0 mm Distance between the rotors Admissible limit clearance 0 12 mm Refitting Check there are no signs of wear on the oil pump shaft or body Check there are no signs of scoring or wear on the oil pump...

Page 168: ...xing oil pump to the crankcase 5 to 6 Oil pump command sprocket screw 10 to 14 Oil pump cover screws 0 7 0 9 Removing the oil sump Remove the oil filler plug the transmission cover the complete drivin...

Page 169: ...e two centring dowels Refit the sump taking care to locate the spring in the appropriate recess machined into the inside of the sump Refit the rear brake cable brackets and the screws in the reverse o...

Page 170: ...INDEX OF TOPICS INJECTION INJEC...

Page 171: ...vehicle is fitted with an integrated injection and ignition system Injection is indirect in the manifold through an electro injector The injection and ignition are timed on the four stroke cycle by me...

Page 172: ...ngs This allows obtaining a continuous circulation thereby avoiding the risk of fuel boiling The pressure regulator is situated at the end of the circuit The fuel pump is controlled by the MIU control...

Page 173: ...n the rpm indicator and the electric fan for radiator cooling The MIU control unit has a decoder for the anti theft immobilizer system The MIU control unit is connected to a diagnostic LED on the inst...

Page 174: ...fault occurs again 4 For troubleshooting use a multimeter with an internal resistance of more than 10 K W V Instruments that are not suitable might damage the MIU control unit Instruments must be use...

Page 175: ...e control unit 10 Do not invert the poles when fitting the battery 11 To avoid causing any damage disconnect and reconnect the MIU system connectors only if re quired Before reconnecting check that th...

Page 176: ...r 10 11 Lambda probe positive 12 Engine stop switch 13 Engine speed sensor 14 Fuel injector 15 Engine speed sensor 16 Diagnostics socket output 17 Immobilizer LED 18 Side stand 19 20 Injection load so...

Page 177: ...ystem not encoded System not efficient repair according to the indications of the self diagnosis Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor...

Page 178: ...iming Correctness of the parameters Throttle valve position sensor Stepper Coolant temperature sensor Intake air temperature sensor Intake system cleaning Air filter Diffuser and throttle valve Additi...

Page 179: ...low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold silencer silencer welding Engine revs irregularly ENGINE IRREGULAR P...

Page 180: ...e self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe Ignition efficiency Spark plug Parameter reliability Throttle valve position sign...

Page 181: ...Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure Beverly Tourer 300 i e Injection INJEC 181...

Page 182: ...ittings from the injector support Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold Injection Beverly...

Page 183: ...mand fitting as indicated in the picture Refitting the butterfly valve To refit perform the operations in the reverse or der from the removal operations being careful to position the clip fixing the t...

Page 184: ...S Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load solenoid 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda probe Injection...

Page 185: ...sed hydraulic circuit 2 A to be checked with specific tool for fuel pressure control choking the circuit on the return pipe Check the efficiency of 10 A fuse N 4 injection load Check the efficiency of...

Page 186: ...ack Pur ple cable of the solenoid base If there is not check the continuity of the Red White cable between the fuse box and the solenoid base and of the Black Purple cable between the pin 20 of the co...

Page 187: ...ted Otherwise check the continuity of the Black Green cable between the pump connector and the solenoid base Check the efficiency of the ground line of the fuel pump by measuring the continuity betwe...

Page 188: ...auge of the appropriate tool Get a graded burette with a flow rate of approximately 1 L Rotate the pump using the active diagnoses of the palm top computer Using a pair of long flat needle nose pliers...

Page 189: ...clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture Remove the filter from the pump mounting Beverly Tourer 300 i e Injection...

Page 190: ...N LOADS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load solenoid 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda probe Inj...

Page 191: ...he efficiency of 7 5 A fuse No 9 key con trolled control unit power supply Check the efficiency of the injection load solenoid Check the resistance of the energising coil be tween pins 86 and 85 40 to...

Page 192: ...cable between the pin 20 of the control unit and the solenoid base N B CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED SOLENOIDS CON TROL UNIT FUSES ETC Check the presence of fi...

Page 193: ...lack Green cable of the injector con nector and the ground lead With injector disconnected and the injector load solenoid disconnected check the continuity of the Black Green cable between the injecto...

Page 194: ...mp with the active diagnosis Check that within fifteen seconds approximately 40 cm of fuel is dis pensed with an adjustment pressure of approxi mately 2 5 BAR Specific tooling 020480Y Petrol pressure...

Page 195: ...electronic injection control unit MIU 2 Battery 12V 12 Ah 3 Water temperature sensor 4 HV coil 5 Engine Speed sensor 6 Lambda probe 7 Diagnostics socket connector 8 Fuel pump 9 Electric fan solenoid 1...

Page 196: ...e engine and wait for it to stop With the wiring connected to the control unit and system try to start up the engine and check that the voltage between pins 13 and 15 is around 2 8 V With the interfac...

Page 197: ...ected from the control unit check that the Red and Brown cables pin 13 15 are isola ted from each other and insulated from the ground Specific tooling 020481Y Control unit interface wiring 020331Y Dig...

Page 198: ...ification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load solenoid 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda probe Injection Bever...

Page 199: ...ed by the control unit The ignition power is increased during the engine start up phase The injection system recognises the 4 stroke cycle and therefore ignition is only controlled during compression...

Page 200: ...ack Pur ple cable of the solenoid base If there is not check the continuity of the Red White cable between the fuse box and the solenoid base and of the Black Purple cable between the pin 20 of the co...

Page 201: ...TH THE COMPONENTS DISCONNECTED SOLENOIDS CON TROL UNIT FUSES ETC Check there is voltage between pins 22 and 26 of the interface wiring for around two seconds when switching to ON Check the resistance...

Page 202: ...ide discon nected and the coolant temperature sensor con nector connected check that the resistance val ues between pin 9 and the ground lead correspond with the engine temperature 20 2500 100 80 308...

Page 203: ...he management of the idling through the Stepper motor and the variation of the ignition advance The throttle body after the pre calibration has an opened valve with an angle that can vary depending on...

Page 204: ...procedure Reset should be performed in the following cases on first fitting if the injection control unit is replaced N B THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECA...

Page 205: ...the TPS resetting is also done when the control unit is replaced place the control unit filter box bellows at 45 during the refitting operation as shown in the picture Beverly Tourer 300 i e Injection...

Page 206: ...pecification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 10 A 3 Fuse 30 A 4 Ignition key contacts 5 Fuse 7 5 A 6 Injection load solenoid 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda probe Injection Be...

Page 207: ...rated passes from a high value to a low value with a mixture with lambda 1 Since the sensor only works at high temperatures it has an electric preheating element inside it controlled by the control un...

Page 208: ...ack Pur ple cable of the solenoid base If there is not check the continuity of the Red White cable between the fuse box and the solenoid base and of the Black Purple cable between the pin 20 of the co...

Page 209: ...GNAL CONTROL Install the electronic control unit interface wiring Start the engine and warm up until the electric fan switches on Use an analogue multimeter with a direct voltage scale measuring down...

Page 210: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 211: ...oval Front wheel hub overhaul Check that the wheel bearings do not show signs of wear If you have to replace the wheel bearings proceed as follows Remove the plastic cover on the tone wheel side to av...

Page 212: ...om the odometer drive side to permit the removal of the brake disc side bearing and the spacer bushing Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15 mm guide Heat the bearin...

Page 213: ...t the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side installed previously Heat the bearing seat on the odometer drive side with the heat gun Insert...

Page 214: ...en the wheel axle nut to the prescribed tor que N B TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE FOR THE SAKE OF SAFETY OFFSET THE INTERNAL STOP FROM THE STOP OF THE TONE WHEEL BY 90 Tighten the two saf...

Page 215: ...en the handlebar fixing screw on the steer ing tube to the prescribed torque Locking torques N m Handlebar fixing screw 45 to 50 Lubricate the nuts with engine oil before installation Front fork Remov...

Page 216: ...oil Remove the hydraulic rod fixing screw with the corresponding sealing gasket With a 19 mm hexagonal spanner lock hydraulic rod rotation Undo the fixing screw and collect the copper washer Remove th...

Page 217: ...rwise replace the damaged parts Characteristic Maximum fork leg diameter 35 10 mm Minimum stem diameter 34 90 mm Take out the oil seal using the appropriate tools Fit the tie rod into the oil seal Ins...

Page 218: ...g 020487Y Fork oil seal extractor Remove the hydraulic rod with the corresponding sealing gasket the spring and the stop bushing COMPONENT CHECK CAUTION CLEAN ALL THE COMPONENTS THOROUGHLY Check that...

Page 219: ...ded the end of stroke and the hydraulic rod sealing ring are in good conditions Check that the main spring exhibits no signs of yielding or abnormal wear Check that the closing cap O ring of the stem...

Page 220: ...m Adaptor Pre fit the stem with the hydraulic rod the spring and the stop bushing Fit the pre assembled components inside the fork leg Fit the hydraulic rod fixing screw with the copper sealing washer...

Page 221: ...o the prescribed torque in the sequence indicated in the picture Locking torques N m Stem support clamp tightening screws 20 to 25 Refill the fork leg with the recommended product to the prescribed am...

Page 222: ...ad the spring fit the closing cap and tighten to the prescribed torque Locking torques N m Fork locking screws cap 15 30 Repeat the procedure for the other fork leg N B IF BOTH FORK LEGS ARE SERVICED...

Page 223: ...er washer and the counter ring nut Extract the fork N B TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT IT FROM COMING OFF ABRUPTLY Specific tooling 020055Y Wrench for steering tube ring nut Refitting...

Page 224: ...thium and zinc oxide grease con taining NLGI 2 ISO L XBCIB2 Fit the upper steering fifth wheel CAUTION INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FAC ING UPWARDS Fit the steering fifth wheel upper sea...

Page 225: ...Steering tube lower ring nut 14 17 Fit the spacer between the two ring nuts on the steering tube in the position indicated Insert the upper tightening ring nut screw until it stops and with the specif...

Page 226: ...cable passage as shown in the figure Fit the front wheel Steering bearing Removal Clean thoroughly and visually inspect if the com ponents are in good conditions Check the upper steering fifth wheel...

Page 227: ...teering fifth wheel tracks on the chassis with the specific tool following the indica ted procedure Fit the specific tool from the lower part of the headstock until it makes contact with the upper tra...

Page 228: ...ower steering fifth wheel track Remove the lower fifth wheel seat on the steering tube using the specific tool Specific tooling 020004Y Punch for removing steering bearings from headstock Suspensions...

Page 229: ...ducts AGIP GREASE PV2 Grease for steering bear ings bolt seatings for swinging arms and fay ing surface of driven pulley spring only pulley side Soap based lithium and zinc oxide grease con taining NL...

Page 230: ...ng the rear wheel Carry out the removal operations but in reverse order observing the prescribed tightening torques Locking torques N m Fixing screw for wheel rim to hub 33 37 Swing arm Removal Place...

Page 231: ...winging arm Overhaul Check that the silent bloc is not damaged If there is replace it Remove the Seeger ring shown in the picture Remove the full silent bloc bracket Hold the full silent bloc bracket...

Page 232: ...lent bloc as shown in the picture Specific tooling 020271Y Tool for removing fitting silent bloc Check there is no sticking in the movement of the connection of the swinging arm on the engine side to...

Page 233: ...ial tool 020229Y Alternatively use two washers with inside diame ter of 12 mm for pins outside diameter min 30 mm and thickness min 4 mm Separate the swinging arm on the engine side from the vehicle s...

Page 234: ...the roller bearing housings with grease Insert the spacers Assemble the two arms with the relative bolt in the position shown in the picture Adjust the bolt as shown in the picture Position the frame...

Page 235: ...winging arm inserting part 2 Tighten part 3 to the prescribed torque Screw and tighten part 4 to the prescribed tor que Screw and tighten part 5 to the prescribed tor que Beverly Tourer 300 i e Suspen...

Page 236: ...llows place the vehicle on its centre stand lift the engine a little with a jack so as to free the two shock absorbers remove the silencer undo the shock absorber spring assembly clamp ing screw from...

Page 237: ...haust bracket Removal Loosen and remove the lower retaining bolt of the right hand shock absorber at the mounting arm Loosen the 2 retaining screws between arm and engine Remove the split pin and safe...

Page 238: ...unch install a new bearing in the seat as shown in the picture Specific tooling 020376Y Adaptor handle 020151Y Air heater Refitting To refit carry out the removal operations in reverse order observing...

Page 239: ...stand On refitting tighten the nut to the specified torque Locking torques N m Centre stand bolt 40 45 Side stand Removal of the side stand Unhook the springs Loosen the nut Pull out the screw Fittin...

Page 240: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 241: ...H WITH DENATURED ALCOHOL N B FOR TOPPING UP AND CHANGE USE ONLY BRAKE FLUID DOT4 NHTSA 116 OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS HYDRAULIC FLUID IS EXTREMELY CORROSIVE FOR PAINTED SURFACES BRAKE F...

Page 242: ...g Follow the removal procedures but in reverse order and tighten to the prescribed torques with the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 t...

Page 243: ...ut in reverse order Locking torques N m Screw tightening calliper to support 24 27 If the calliper is replaced CAUTION ALWAYS USE NEW COPPER WASHERS CAUTION ONCE REFITTING IS FINISHED BLEED THE SYSTEM...

Page 244: ...stallation position the disc correctly us ing the arrow stamped on it as reference Tighten the screws to the prescribed torque and apply the recommended product N B THE SURFACE OF THE DISC WITH THE ST...

Page 245: ...isc screws 8 to 10 Disc Inspection Checking the disc is important it must be perfectly clean with no sign of rust oil or grease or any oth er dirt and must show no signs of deep scoring Characteristic...

Page 246: ...ct N B THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 t...

Page 247: ...follows Remove the front brake calliper Loosen the two pins shown in the figure that lock the two pads Remove the pads being careful with the pad spring clamp Check the thickness of the friction mate...

Page 248: ...G GENTLY EXPAND THE PADS Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques N m Pad fixing pin 19 6 24 5 Rear brake pads Removal Remove the rear...

Page 249: ...to the correct torque and apply the recommended product Fit the calliper on its support tightening the two screws to the prescribed torque N B IF IT IS NOT POSSIBLE TO CORRECTLY POSITION THE CALLIPER...

Page 250: ...HE BRAKE CALLIPERS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS FAILURE TO OBSERVE THIS PRECAUTION WILL ENDANGER THE PROPER WORKING AND EFFICIENCY...

Page 251: ...s Rest the vehicle onto the centre stand with the handlebar centred Check the fluid level through the sight glass A A certain lowering of the level is caused by wear on the brake pads Front brake pump...

Page 252: ...ar cover Drain the braking system Disconnect the brake fluid line from the pump paying attention to a possible escape of remaining brake fluid Remove the brake stop button from the lever Undo the two...

Page 253: ...ALLIPER CAREFULLY DRY THE CALLIPER AND DE GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT Locking torques N m Oil bleed screw 12 16 Hydraulic line fixing screw 16 20 Fixing screws for the handlebar...

Page 254: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 255: ...diagram KEY A Expansion tank B Radiator C Radiator intake pipe D Water pump E Delivery pipe to cylinder F By Pass pipe G Thermostat H Radiator delivery pipe Beverly Tourer 300 i e Cooling system COOL...

Page 256: ...tarts at 100 C Electric ventilation stops at 90 C WATER PUMP Specification Desc Quantity Type Centrifugal Control Coaxial to crankshaft RADIATOR Specification Desc Quantity Type Aluminium with horizon...

Page 257: ...e bleed valve Obtain a rubber tube that is of the right length to connect the valve to the expansion tank Place one end of the pipe on the bleed valve and the other in the expansion tank Loosen the sc...

Page 258: ...thermostat and keep it in the centre of the container Immerse the multimeter temperature probe and keep it close to the thermostat Heat up the container using the thermal gun Check the temperature at...

Page 259: ...ollow the removal steps but in reverse order be careful to tighten screws to the prescribed torque Locking torques N m Thermostat cover screws 3 to 4 Once the cooling circuit is restored refill using...

Page 260: ...INDEX OF TOPICS CHASSIS CHAS...

Page 261: ...three re taining screws indicated in the figure Side fairings Remove the side bumper loosening the retaining screw shown in the figure Rear rack Remove snapped in plastic cover from the rear luggage...

Page 262: ...nd remove the brake pump compart ment inspection cover Undo the screw indicated From below undo the screw fixing it to the front handlebar cover Undo the two screws fixing it to the frame Remove the r...

Page 263: ...dlebar cover Remove the rear handlebar cover Disconnect the electrical connectors of the head lamp and turn indicators Undo the five screws indicated and remove the headlight assembly and the front ha...

Page 264: ...it from the rear section of the scooter then separat ing it from the transmission for the opening of the access cover Legshield Remove the headlight assembly Remove the fixing screw of the expansion t...

Page 265: ...tion to the correct seating of the shield on the shield back plate See also Headlight assy Frame central cover Knee guard Remove the legshield Remove the 2 fixing screws of the fuse box in the front g...

Page 266: ...tach the electrical wiring Remove the ignition key switch by removing the spring retainer shown in the figure Lightly push the master cylinder and extract the lock from the notch shown in the figure H...

Page 267: ...RIBED IN THE PREVIOUS PARAGRAPH See also Removing the ignition key switch when on off Front wheel housing Remove the shield back plate Remove the footrests Remove the front suspension Loosen the remai...

Page 268: ...also Rear rack Side fairings Footrest Remove the central cover Remove the mat of the footrest Loosen the eight footrest mounting screws Remove the footrest See also Chassis Beverly Tourer 300 i e CHAS...

Page 269: ...ear light assembly Remove the cover under the saddle by loosening the retaining screw located under the saddle mounting plate Loosen the 6 side fairing fixing screws indicated in the 3 pictures Remove...

Page 270: ...Disconnect the two manifold clamps Disconnect the three clamps connecting the Blow By pipe Rear mudguard Loosen the 4 fixing screws 2 of which are indi cated in the figure and the other 2 located on...

Page 271: ...connect the battery and the electrical cable harness Disconnect the cable from the electric saddle opening device Remove the 10 screws indicated in the figure Remove the helmet compartment in advance...

Page 272: ...ws Remove the support bracket by loosening the 2 retaining screws of the bracket at the frame Remove the three tank retaining screws at the frame Remove the tank by tilting it downwards and pull ing o...

Page 273: ...ndi cated in the figure and remove the mudguard Radiator fan Remove the front wheel housing Prepare a container for the coolant Remove the expansion tank outlet and return pipes Remove the coolant sup...

Page 274: ...Flyscreen Undo the screw indicated Undo the four screws indicated and remove the windshield Chassis Beverly Tourer 300 i e CHAS 274...

Page 275: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 276: ...screws Lower shock absorber retainer Nuts fixing muffler supporting arm engine Screws fixing muffler to supporting arm Rear wheel pin nut REAR BRAKE Screws fixing rear brake calliper to supporting pla...

Page 277: ...ENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES...

Page 278: ...CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional Checks Hydraulic braking system lever travel Clutch proper functioning check Engine proper...

Page 279: ...INDEX OF TOPICS TIME TIME...

Page 280: ...repairs For each operation the description code and time envisages are specified Engine ENGINE Code Action Duration 1 001001 Engine from chassis Removal and refit 2 003064 Engine oil change 3 001127...

Page 281: ...rankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replace ment 2 001133 Engine crankcase Replacement 3 001124 Lubrication by pass Replacement Beverly Tourer 300 i e Time TIME 28...

Page 282: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement Time Beverly Tourer 300 i e TIME 282...

Page 283: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001176 Rings Pin Replacement Beverly Tourer 300 i e Time TIME 283...

Page 284: ...001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves adjust 4 001056 Head gasket change 5 000235 Coolant temperature sensor Repl 6 001057 Thermostat Replacement 7 007012 Coolant bleed v...

Page 285: ...Rocker arms support assy CAMSHAFT Code Action Duration 1 001148 Rockers valves Replacement 2 001044 Camshaft Replacement 3 001169 Pressure reducer Replacement Beverly Tourer 300 i e Time TIME 285...

Page 286: ...HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001089 Head cover Replacement 3 001088 Head cover gasket Replacement 4 001074 Oil vapour recovery pipe Replace ment Time Beverly Tour...

Page 287: ...Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor change 3 001102 Net oil filter change Cleaning Beverly Tourer 300 i e Time TIME 287...

Page 288: ...ration 1 001087 Flywheel cover Replacement 2 001150 Flywheel cover gasket change 3 007007 Water pump rotor Replacement 4 001113 Water pump Pump rotor Replace ment 5 001099 Flywheel side oil seal Repla...

Page 289: ...pulley DRIVEN PULLEY Code Action Duration 1 001022 Clutch Replacement 2 001012 Driven pulley overhaul 3 001110 Driven pulley Replacement 4 001155 Clutch bell Replacement Beverly Tourer 300 i e Time TI...

Page 290: ...elt chain Replace ment 3 001042 Oil pump overhaul 4 001112 Oil pump change 5 001122 Oil pump chain Replacement 6 001172 Chain cover flap change 7 001130 Oil sump change 8 001129 Chain tensioner Servic...

Page 291: ...e Action Duration 1 001010 Reduction gear Replacement 2 003065 Gear box oil Replacement 3 001156 Reduction gear cover Replacement 4 004125 Rear wheel axle Replacement 5 004180 Reduction gear pipe repl...

Page 292: ...cement 2 001011 Drive belt Replacement 3 001066 Driving pulley Removal and refitting 4 001177 CVT rollers sliders Replacement 5 001141 Belt anti flapping roller Replace ment 6 001006 Driving pulley Se...

Page 293: ...ver TRANSMISSION COVER Code Action Duration 1 001096 Transmission crankcase cover Re placement 2 001135 Transmission cover bearing Re placement 3 001170 Air deflector Replacement Beverly Tourer 300 i...

Page 294: ...Water pump WATER PUMP Code Action Duration 1 007017 Water pump cover Replacement 2 007009 Head pump by pass rubber sleeve Replacement Time Beverly Tourer 300 i e TIME 294...

Page 295: ...ter motor ELECTRICAL START UP Code Action Duration 1 001020 Starter motor Replacement 2 001151 Starter driven gearing Replacement 3 001017 Start up pinion Replacement Beverly Tourer 300 i e Time TIME...

Page 296: ...o MAGNETO FLYWHEEL Code Action Duration 1 001067 Stator Removal and Refitting 2 001173 Rotor Replacement 3 001058 Complete flywheel change 4 001104 Start up freewheel Replacement Time Beverly Tourer 3...

Page 297: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001166 Throttle body Replacement 2 001047 Injector Replacement 3 001013 Intake manifold change Beverly Tourer 300 i e Time TIME 297...

Page 298: ...e MUFFLER Code Action Duration 1 005138 Lambda probe Replacement 2 001092 Exhaust manifold Replacement 3 001095 Silencer heatshield Replacement 4 001009 Silencer Replacement Time Beverly Tourer 300 i...

Page 299: ...leaner AIR CLEANER Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Air cleaner carburettor union Re placement Beverly Tourer 300 i e Time TIM...

Page 300: ...n Duration 1 004001 Chassis Replacement 2 004147 footboard support bracket one side Replacement 3 004148 Footrest support bracket both sides Replacement 4 004146 Front chassis Replacement Time Beverly...

Page 301: ...D Code Action Duration 1 001053 Stand pin Replacement 2 004004 Stand Replacement 3 004179 Stand bumper Replacement 4 004102 Side stand Replacement 5 005079 Stand switch Replacement Beverly Tourer 300...

Page 302: ...ld spoiler LEGSHIELD SPOILER Code Action Duration 1 004064 Legshield front section Replace ment 2 004023 Shield rim Replacement 3 004149 shield central cover Replacement Time Beverly Tourer 300 i e TI...

Page 303: ...Side fairings SIDE COVERS Code Action Duration 1 004012 Rear side panels Replacement 2 004129 Rear fairing Replacement Beverly Tourer 300 i e Time TIME 303...

Page 304: ...Rear cover REAR SHIELD Code Action Duration 1 004065 Shield back plate Replacement 2 004081 Top box lid Replacement Time Beverly Tourer 300 i e TIME 304...

Page 305: ...COVER Code Action Duration 1 004135 Fuel tank port Replacement 2 004011 Central chassis cover Replacement 3 004059 Spark plug inspection flap Replace ment 4 004015 Footrest Replacement Beverly Tourer...

Page 306: ...et compartment band Re placement 2 005033 Glove box light switch Replace ment 3 004016 Helmet compartment Replacement 4 004112 Cock carburettor hose Replace ment 5 005046 Battery cover change 6 005026...

Page 307: ...Plate holder LICENSE PLATE HOLDER Code Action Duration 1 004136 License plate holder support Re placement 2 005048 number plate holder Replacement Beverly Tourer 300 i e Time TIME 307...

Page 308: ...Mudguard MUDGUARDS Code Action Duration 1 004002 Front mudguard change 2 004053 Spoiler Replacement 3 004009 Rear mudguard Replacement Time Beverly Tourer 300 i e TIME 308...

Page 309: ...Fuel tank FUEL TANK Code Action Duration 1 004109 Fuel tank breather change 2 004005 Fuel tank Replacement 3 005010 Tank float Replacement Beverly Tourer 300 i e Time TIME 309...

Page 310: ...ear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003077 Muffler supporting arm rear shock absorber Replacement 2 003007 Rear shock absorber Replacement Time Beverly Tourer 300 i e TIME 31...

Page 311: ...Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004018 Front handlebar covers Replace ment 2 004019 Rear handlebar covers Replace ment Beverly Tourer 300 i e Time TIME 311...

Page 312: ...Handlebar components HANDLEBAR COMPONENTS Code Action Duration 1 002060 Complete throttle control Replace ment 2 002059 Right hand knob Replacement Time Beverly Tourer 300 i e TIME 312...

Page 313: ...mp Replacement 9 002024 Front brake pump Replacement 10 004162 Mirror mounting and or brake pump fitting U bolt Replacement 11 004066 Driving mirror Replacement Swing arm SWINGING ARM Code Action Dura...

Page 314: ...brake calliper Replacement 5 002047 Front brake fluid and air bleed sys tem Replacement 6 002020 Rear brake disc piping Replace ment 7 002081 Rear brake rigid pipes Replacement 8 003071 Rear brake pa...

Page 315: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Beverly Tourer 300 i e Time TIME 315...

Page 316: ...UMENT PANEL Code Action Duration 1 005014 Odometer Replacement 2 005078 Odometer glass Replacement 3 005038 Dashboard warning telltale lights Replacement 4 005076 Clock Cell Replacement Time Beverly T...

Page 317: ...Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement 2 004062 Luggage rack cover Replacement Beverly Tourer 300 i e Time TIME 317...

Page 318: ...ti theft lock Replacement 2 004054 Saddle lock catch Replacement 3 005099 Electric saddle opening device Re placement 4 002083 Saddle opening transmission Re placement 5 005072 Immobilizer aerial Repl...

Page 319: ...Turn signal lights INDICATOR LIGHTS Code Action Duration 1 005002 Front light replacement 2 005008 Headlight bulbs Replacement Beverly Tourer 300 i e Time TIME 319...

Page 320: ...005031 number plate light bulb Replace ment 9 005068 Rear turning indicator bulb Re placement Front wheel FRONT WHEEL Code Action Duration 1 003038 Front wheel axle Replacement 2 002011 Odometer drive...

Page 321: ...REAR WHEEL Code Action Duration 1 001016 Rear wheel Replacement 2 004126 Rear wheel tyre Replacement 3 001071 Rear wheel rim Replacement 4 002070 Rear brake disc Replacement Beverly Tourer 300 i e Tim...

Page 322: ...Fuel pump FUEL PUMP Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Injector pump pipe Replacement Time Beverly Tourer 300 i e TIME 322...

Page 323: ...Electric devices VOLTAGE REGULATOR Code Action Duration 1 005009 Voltage regulator Replacement 2 001069 HV coil Replacement 3 001094 Spark plug cap Replacement Beverly Tourer 300 i e Time TIME 323...

Page 324: ...light solenoid Replacement 2 005096 Injection Component contactor Re placement 3 005117 Electric fan contactor Replacement 4 005003 Horn Replacement 5 005011 Starter relay Replacement 6 005007 Battery...

Page 325: ...WIRE UNIT Code Action Duration 1 005054 Fuse holder Replacement 2 005052 Fuse Replacement 3 005001 Electrical system Replacement Beverly Tourer 300 i e Time TIME 325...

Page 326: ...ement 2 005006 Light or turning indicator switch Re placement 3 005040 Horn button Replacement 4 005121 Saddle opening button Replace ment 5 005041 Starter button Replacement 6 005077 Emergency stop s...

Page 327: ...s TRANSMISSIONS Code Action Duration 1 002051 Odometer transmission assembly Replacement 2 002049 Odometer cable Replacement 3 002082 Fuel tank door opening drive Re placement Beverly Tourer 300 i e T...

Page 328: ...e fork Replacement 2 003010 Front suspension Service 3 003076 Fork sheath Replacement 4 003079 Fork stem Replacement 5 003048 Fork oil seal Replacement 6 003002 Steering fifth wheels Replacement 7 003...

Page 329: ...lacement 2 007024 Expansion tank cap Replacement 3 007013 Radiator expansion tank connection pipe change 4 007016 Fan with support Replacement 5 001052 Coolant and air bleed Replacement 6 007003 Coola...

Page 330: ...Windscreen WINDSCREEN Code Action Duration 1 004028 Windshield glass Replacement Time Beverly Tourer 300 i e TIME 330...

Page 331: ...Stickers TRANSFERS Code Action Duration 1 004159 Plates Stickers Replacement Beverly Tourer 300 i e Time TIME 331...

Page 332: ...Bulbs C Checks 83 Coolant 202 E Electric 256 323 Engine oil 46 F Fuel 180 188 272 309 322 Fuses 97 H Headlight 51 263 265 Horn 94 Hub oil 44 I Identification 8 Instrument panel 71 263 316 L Luggage ra...

Page 333: ...Spark plug 43 88 Stand 239 Start up Suspension 56 328 T Tank 272 309 Transmission 10 55 116 130 293 Turn indicators 82 Tyres 11 V Vehicle 8 109 110...

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