PIAGGIO Beverly 400 E5 Service Manual Download Page 108

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Inspecting the rollers case

- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner

diameter A.

- Measure outer diameter B of the pulley sliding

bushing shown in the figure.

- Check that the rollers are not damaged or worn.

- Check the sliding shoes for the variator back-

plate are not worn.

- Check the wear of the roller housings and of the

belt facing surfaces on both pulley halves.

- Check that stationary driving pulley does not

show signs of abnormal wear on the grooved edge

and on the surface in contact with the belt.

CAUTION

DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS

Characteristic

movable driving half-pulley bushing: Standard
Diameter

30 mm (+0 +0.021)

movable driving half-pulley bushing: Maxi-
mum allowable diameter

Ø 26.12 mm

Sliding bushing: Standard Diameter

Ø 30 mm (-0.02 +0.041)

Sliding bushing: Minimum diameter permitted

Ø 25.95 mm

Roller: Standard diameter

Ø 25 mm±0.1

Engine

Beverly 400 E5

ENG - 108

Summary of Contents for Beverly 400 E5

Page 1: ...MANUALE STAZIONE DI SERVIZIO 1Q000884 Beverly 400 E5...

Page 2: ...any changes to components parts or accessory supplies which it deems necessary to improve the product or which are required for manufacturing or commercial reasons Not all the versions shown in this p...

Page 3: ...degli impianti e delle attrezzature necessarie ed per questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l attrezzatura specifica e il catalogo degli attrezzi specifici N B P...

Page 4: ......

Page 5: ...INDEX OF TOPICS GENERAL MANDATORY REQUIREMENTS NORM PRE DELIVERY PRE DE TECHNICAL DATA DT TOOLING TOOL MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE ENG BRAKING SYSTEM BRAK SYS...

Page 6: ...INDEX OF TOPICS GENERAL MANDATORY REQUIREMENTS NORM...

Page 7: ...ety of the PROFESSIONAL CUSTOMER as required by EC Regulation 1907 2006 REACH EC Directive 2000 53 EC END of LIFE VEHICLES SCIP Database Directive Article 9 paragraph 1 letter i of the Waste Framework...

Page 8: ...radiator exhaust manifold exhaust pipe catalytic converter and muffler 8 Do not smoke during maintenance operations 9 To avoid possible injury do not wear rings watches jewellery or loose clothing bef...

Page 9: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 10: ...OTHING IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE Q...

Page 11: ...unit will automatically change when Km or mi is selected N B THE MEASUREMENT UNIT CONVERSION CAN TAKE PLACE ONLY WITH THE VEHICLE AT A STANDSTILL CLOCK SETTING To set or adjust the time with the engin...

Page 12: ...ES WILL RESULT IN A RESET OF THE CLOCK ASR SYSTEM The ASR system is a driving aid that assists the driver in acceleration manoeuvres particularly on low grip surfaces or under conditions that can caus...

Page 13: ...started ASR system not working or not calibrated or vol untarily deactivated ASR ASR OFF ICON OPERATION MODE ASR System status ICON with engine off or key ON ICON with engine on ASR working ACTIVE an...

Page 14: ...will be come steady on initially it was off as the ASR system had already been calibrated in the past 4 Drive at a low speed for a few meters until the ABS indicator light stops flashing 5 To start th...

Page 15: ...Y THE USER THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF THE VEHICLE IS OFF BY USING THE ENGINE STOP SWITCH THE NEXT TIME THE STARTER SWITCH IS TURNED THE ASR SYSTEM IS AUTOMATICALLY ENABLED CA...

Page 16: ...O INSIST WITH THE THROTTLE GRIP IN THIS PARTICULAR CONDITION N B IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR SYSTEM SUCH EVENT APPEARS UNDER NORMAL OPERATION CONDITIONS...

Page 17: ...INDEX OF TOPICS TECHNICAL DATA DT...

Page 18: ...ssed air carefully to avoid the risk of inhaling dust produced by worn friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spa...

Page 19: ...mber stamped on the vehicle corresponds with that on the vehicle documentation CAUTION PLEASE REMIND THAT ALTERING IDENTIFICATION REG ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS IMPOUNDING O...

Page 20: ...er trapezoid belt automatic clutch oil bath centrifuge Final drive reduction gear Gear reduction unit in oil bath Lubrication Engine lubrication with trochoidal pump inside the crankcase oil filter an...

Page 21: ...ed rear disc brake controlled from LH handlebar lever braking assisted by ABS system Wheel rims type Light alloy Front wheel 3 00 x 16 Rear wheel 4 00 x 14 Front tire 120 70 16 M C 57S Rear tire 150 7...

Page 22: ...IN CHAP SPECIFICATIONS FRONT SUSPENSION FRONT SUSPENSION Name Torque in Nm Front mudguard Steering tube 10 0 1 0 Nm Lower steering bearing lock nut Steering tube 15 0 2 0 Nm Upper steering bearing loc...

Page 23: ...Beverly 400 E5 Technical Data DT 23...

Page 24: ...Technical Data Beverly 400 E5 DT 24...

Page 25: ...pport bracket 9 0 1 0 Nm Ground cable ABS control unit 9 0 1 0 Nm Brake pipes ABS control unit 18 5 1 5 Nm ABS control unit support bracket Frame 10 5 0 5 Nm Ground cable ABS control unit support brac...

Page 26: ...Technical Data Beverly 400 E5 DT 26...

Page 27: ...0 5 0 Nm Mudguard frame Engine 22 5 2 5 Nm Swingarm bushing Frame 6 0 1 0 Nm Swingarm Silent block bracket 98 0 10 0 Nm Swingarm Frame 52 5 2 5 Nm Engine side swinging arm Chassis side swinging arm 42...

Page 28: ...Technical Data Beverly 400 E5 DT 28...

Page 29: ...UG4 control unit connection retainer clamp Throttle body 7 0 1 0 Nm Earth braid Engine 8 5 1 0 Nm Starter motor ground Starter motor 12 0 1 0 Nm Positive cable connection Starter motor 7 0 1 0 Nm ENGI...

Page 30: ...Technical Data Beverly 400 E5 DT 30...

Page 31: ...r head to crankcase 20 24 Impeller on the pump shaft 4 6 Bearing lock screw 9 11 Oil relief screw 15 17 Reduction unit oil drainage screw 15 17 Driven pulley nut 50 60 Nut M14x1 5 securing the driving...

Page 32: ...le opening actuator support bracket Frame 6 0 1 0 Nm Saddle lock Helmet compartment 6 0 1 0 Nm Glove box opening rocker Frame 6 0 1 0 Nm Overhaul data Assembly clearances Cylinder piston assy Technica...

Page 33: ...Characteristic Maximum allowable run out 0 001 in 0 05 mm Piston rings Carefully clean the seal housings Measure the coupling clearance between the sealing rings and the piston grooves using suitable...

Page 34: ...onside half shaft A 0 72 0 0 002 in 18 4 0 0 05 mm D 0 007 0 01 in 0 20 0 50 mm Flywheel side halfshaft B 0 72 0 0 002 in 18 4 0 0 05 mm D 0 008 0 019 in 0 20 0 50 mm Connecting rod C 0 7 0 003 0 005...

Page 35: ...crankcase halves combining the two components Shaft and Crankcase featuring the same category Cylinder Head Before performing head service operations thoroughly clean all coupling surfaces Note the po...

Page 36: ...e head does not ooze through the valves when these are just pressed with the fingers Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD BEARINGS Specification Des...

Page 37: ...valve seat is larger than the prescribed limits true the seats with a 45 mill and then grind In case of excessive wear or damage replace the head Measure the diameter of the valve stems in the three...

Page 38: ...tate it on a V shaped abutment Characteristic Limit allowed 0 007 in 0 2 mm Measure the valve guide Characteristic Valve guide 0 196 0 0 0004 in 5 0 0 012 mm After measuring the valve guide diameter a...

Page 39: ...NOT ROTATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED CAUTION DO NOT REVERSE THE FI...

Page 40: ...1 008 0 03 mm Camshaft check Standard height Exhaust 1 181 0 001 in 30 005 0 03 mm Check the axial clearance of the camshaft CAMSHAFT AXIAL CLEARANCE Specification Desc Quantity Camshaft check Standar...

Page 41: ...CKING LEVERS Specification Desc Quantity Rocking lever inside diameter Standard diameter C 0 512 0 513 in 13 015 13 035 mm Rocking lever pin diameter Standard diameter D 0 510 0 511 in 12 977 12 985 m...

Page 42: ...falls inside the cylinder the less the base gasket to be applied to recover the compression ratio and vice versa N B MEASUREMENT A MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK CASE AND C...

Page 43: ...INDEX OF TOPICS TOOLING TOOL...

Page 44: ...g seats 001467Y014 Calliper to extract 15 mm bearings 006029Y Punch for fitting steering bearing on the steering tube 020004Y Punch for removing steering bearings from headstock 020055Y Wrench for ste...

Page 45: ...de Description 020115Y punch 18 020151Y Air heater 020193Y Oil pressure gauge 020244Y punch 15 020271Y Tool for removing fitting silent bloc 020263Y Driven pulley assembly sheath Beverly 400 E5 Toolin...

Page 46: ...e Description 020306Y Punch valve seal rings fitting 020329Y Mity Vac vacuum pump 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge Tooling Beverly 400...

Page 47: ...42 x 47 mm Adaptor 020358Y 37 x 40 mm Adaptor 020360S 52 x 55 mm adaptor 020363Y 20 mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re moval too...

Page 48: ...adapter for valve removal tool 020412Y 15 mm guide 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020428Y Piston position check mounti...

Page 49: ...al extractor 020434Y Union for oil pressure measurement 020439Y 17 mm guide 020442Y Pulley lock wrench 020444Y Tool for installing removing clutch on from driven pulley 020454Y Tool for fitting the pi...

Page 50: ...ode Description 020456Y 24 mm adaptor 020467Y Flywheel extractor 020477Y Adapter 37 mm 020480Y Fuel pressure measurement kit 020483Y 30 mm guide 020487Y Fork oil seal extractor Tooling Beverly 400 E5...

Page 51: ...0489Y Hub cover support stud bolt kit 020627Y Flywheel lock tool 020648Y Single battery charger 020917Y Driven pulley stop 020922Y Diagnosis Tool 020924Y Bluetooth per Strumento di Diagnosi PADS Bever...

Page 52: ...Stores code Description 021017Y EOBD E5 diagnostics cable Tooling Beverly 400 E5 TOOL 52...

Page 53: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 54: ...ext 5 sec onds the maintenance icon will flash with a fre quency of 1 Hz If the SET key is released before the 5 seconds the scheduled service is not reset CAUTION THE MAINTENANCE ICON RESET PROCEDURE...

Page 55: ...THE VEHICLE STARTING FROM THE SERVICE OF 5 000 Km 3 106 mi OR 5 MONTHS Recommended products Piaggio Group recommends the use of prod ucts from its Castrol official partner for the scheduled maintenan...

Page 56: ...engine ensure that the temperature of the coolant is maintained at about 90 C When all the bars and the icon on the coolant level indicator start flashing stop the engine immedi ately let it cool down...

Page 57: ...OID THE RISK OF SCALDING DO NOT UNSCREW THE EXPANSION TANK COVER WHILE THE ENGINE IS STILL HOT WARNING YOU MUST MAKE SURE THE FLUID NEVER EXCEEDS THE MAXIMUM LEVEL INDICATED SO AS TO AVOID IT OVERFLOW...

Page 58: ...nscrew the fixing screw of the rear handlebar cover located on the left side of the vehicle Unscrew the fixing screw of the rear handlebar cover located on the right side of the vehicle Gently press t...

Page 59: ...both sides of the vehicle Unscrew the lower fixing screws of the rear han dlebar cover one from the right side and one from the left side of the vehicle Unscrew the upper fixing screws of the rear han...

Page 60: ...he rear han dlebar cover Slightly move the rear handlebar cover and re lease the instrument panel connector Remove the rear handlebar cover Unscrew the two fixing screws of the brake pump right or lef...

Page 61: ...DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS CAUTION AVOID CONTACT OF BRAKE FLUID WITH EYES SKIN AND CLOTHING IN CASE OF ACCIDENTAL CONTACT RINSE WITH WATER N B SEE THE BRAKING SYSTEM CHAPTER W...

Page 62: ...The evaporative emissions control system is located on the rear side of the vehicle Key 1 Canister Maintenance Beverly 400 E5 MAIN 62...

Page 63: ...anister valve 5 Pipe for connecting the fuel tank to the canister 6 Breather valve Removing system components Remove the helmet compartment and the side fairings to gain access to the components of th...

Page 64: ...ame making sure to position the purge pipe fitting down ward Upon reassembling the components use caution when connecting the pipes to the canister 1 canister insertion coupling connection pipe 2 tank...

Page 65: ...DIRECTION OF THE COMPONENTS INSTALLATION IF INSTALLED IN REVERSE THEY COULD COMPROMISE THE FUNCTIONALITY OF THE ENTIRE EVAPORATING SYSTEM After having installed the components secure the pipes with n...

Page 66: ...k is small enough to avoid the satura tion of the canister it is necessary to regenerate the activated carbon by means of a reversed flow of ambient air sucked by the engine These vacuums of pollution...

Page 67: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 68: ...bilizer LED C Engine management system warning lamp MIL D High beam lights on indicator lamp E Low engine oil pressure warning lamp F ABS warning lamp G Right turn indicator warning light H Digital di...

Page 69: ...D Multifunctional panel E Ice hazard icon F Ambient temperature indicator G ASR system activation icon H ASR system deactivation icon I Side stand icon L Tachometer M Smartphone multimedia profiles co...

Page 70: ...Z MODE button for display on the multifunctional panel and measurement unit conversion on the digital display X Speedometer Y Engine start inhibited icon DIGITAL DISPLAY BACK LIGHT COLOUR CHANGE To c...

Page 71: ...the key is turned to ON the digital dis play will show the ambient temperature in C or in F If the ambient temperature is less than 3 C 37 4 F the digital display indicates with the spe cific symbol t...

Page 72: ...RY CONTROL UNIT OPTIONAL THE MODE BUTTON ON THE HANDLEBAR MANAGES THE HEATING LEVELS AND NO LONGER ACTS AS THE MODE BUTTON ON THE IN STRUMENT PANEL SHORT PRESS PROLONGED PRESS Specification Desc Quant...

Page 73: ...L DISPLAY MEASUREMENT UNIT CON VERSION Km mi l gal C F With the ignition switch turned to OFF press and hold the MODE but ton on the instrument cluster and si multaneously turn the ignition switch to...

Page 74: ...the set value or cur rent value if no changes were made the minutes value mm now starts flashing press the SET button briefly and re peatedly to set the correct minutes val ue press and hold the SET b...

Page 75: ...application that can be installed on the smart phone it is possible to exchange data with the vehicle and manage multimedia content Once the connection is established correctly be tween the control u...

Page 76: ...E HEADPHONE OR HEADSET ASSOCIATED ICON MUST BE SELECTED For specific information about the pairing of the Piaggio MIA system and for any differen ces in the procedure depending on the type of smartpho...

Page 77: ...the low beam light on for a predefined time after the engine is switched off For more details about the operation read the instructions described directly in the APP Lights list This section lists the...

Page 78: ...AN CAUSE MALFUNCTIONING AND RISK OF FIRE MAIN FUSES The location and characteristics of the nine main fuses on the vehicle situated in the specific fuse holder are indicated in the table MAIN FUSES Sp...

Page 79: ...under starter switch Headlight switch passing USB port diagnostic socket electric top box provision accessory provision Piaggio MIA PMP3 device 8 Fuse 8 Capacity 15A Protected circuits battery powere...

Page 80: ...cs cable 2 Start duplication procedure before entering Keyless Self diagnosis using PADS 2 1 Ignition key on OFF 2 2 Press the ignition key and at the same time approach the master key mechanical key...

Page 81: ...section and start Adjustment Remote Control Programming fol lowing the guided procedure proposed by PADS 3 5 At the end of each remote control program ming PADS shows a message Programming successful...

Page 82: ...INDEX OF TOPICS ENGINE ENG...

Page 83: ...This section describes the operations to be carried out on the engine and the tools to be used N B Beverly 400 E5 Engine ENG 83...

Page 84: ...ENT UNITS REFER TO THE CONVERSION TABLE IN CHAP SPECIFICATIONS Automatic transmission Transmission cover Insert the special tool Rotate the engine until the driven pulley stops Specific tooling 020917...

Page 85: ...and remove the central screw from the transmission cover Remove the transmission cover Air duct Unscrew and remove the cooling cover fastening screws Remove the cooling cover Beverly 400 E5 Engine EN...

Page 86: ...le 020358Y 37 x 40 mm Adaptor 020439Y 17 mm guide 001467Y002 Driver for OD 73 mm bearing Refitting the driven pulley shaft bearing Use the heat gun to heat the inner part of the lid CAUTION DO NOT HEA...

Page 87: ...ulley together with the belt WARNING AS A RESULT OF THE OPERATION THERE MAY BE A LIGHT HAMMERING BETWEEN THE KNURLING OF THE PULLEY AXLE THIS CAN MAKE REMOVAL BY HAND DIF FICULT IN CASE OF NEED USE AN...

Page 88: ...two screwdrivers work on the appendi ces and remove the cover taking care not to drop the clutch assembly Remove the clutch assembly Inspecting the clutch COVER REVISION Adequately support the cover...

Page 89: ...and guide in order to main tain the position of the bearing during operation on the vertical axis Specific tooling 020151Y Air heater 020376Y Adaptor handle 020360S 52 x 55 mm adaptor 020364Y 25 mm gu...

Page 90: ...ten the three wing nuts until you hear the end of stroke Prepare two aluminium protections in the vice and tighten the shaft of the driven pulley Specific tooling 020919Y Clutch discs disassembly tool...

Page 91: ...the Belleville spring Remove the spring door upper disc Remove the discs separation spring Remove the semi trimmed duct disc trimmed on one side Remove a conductor disc Remove the discs clearance rec...

Page 92: ...Engine Beverly 400 E5 ENG 92...

Page 93: ...recovery spring Remove a non trimmed duct metallic disc Remove a conductor disc trimmed on both sides Remove the discs clearance recovery spring Remove the semi trimmed duct disc trimmed on one side B...

Page 94: ...ANCE RECOVERY SPRING DISCS ARE FIT TED INDIVIDUALLY THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI TIONED TOWARDS THE INSIDE OF THE HOUSING AS SHOWN IN FIGURE Remove the hub Remove the shaft Engine Beve...

Page 95: ...e lower spring holder disc complete with the six springs Remove the rollers Check that there is no abnormal wear on the roll ers the support channels for rollers and those for discs Beverly 400 E5 Eng...

Page 96: ...s 3 2 0 1 mm Clearance recovery spring wear limit 2 8 mm CLUTCH DISCS REVISION Check the clutch discs for damage or signs of wear In this case replace them all Measure the thickness of the discs in fo...

Page 97: ...mm Trimmed duct wear limit C 1 7 mm CLUTCH DISCS REVISION MAXIMUM DEFOR MATION Measure the maximum deformation of the discs by positioning them on a reference plane and check ing with a feeler gauge I...

Page 98: ...ir has its opposite for proper balance Lubricate the parts of the clutch pack with the recommended product Recommended products Transmission oil 80W 90 Lubricant for gear boxes and transmissions SAE 8...

Page 99: ...overy spring CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT TED INDIVIDUALLY THE LAST IN THE ASSEMBLY PHASE MUST BE POSI TIONED TOWARDS THE INSIDE OF THE HOUSING AS SHOWN IN FIGURE Insert the sem...

Page 100: ...retaining ring at the specified loca tion Specific tooling 020919Y Clutch discs disassembly tool FINAL CHECK Once the clutch is assembled turn by hand the exit axis to the final reduction The rotatio...

Page 101: ...fic tools remove the roller casing Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings Insert a new roller casing and set it with specific tools Specif...

Page 102: ...g the support of an appendix against a pin Ensure the centring of the driven pulley by means of the key inserted on the nut Specific tooling 020444Y Tool for installing removing clutch on from driven...

Page 103: ...e the following components in this order upper cap spring lower spring support synthetic ring Using two screwdrivers lift the locking sheath of the torque server and remove it Beverly 400 E5 Engine EN...

Page 104: ...rectly into the holes in the bushing CAUTION THE TORQUE SERVER PINS ARE SET ON THE BUSHING WITH INTERFERENCE AND ARE THEREFORE NOT RE MOVABLE WHEN IT IS NECESSARY TO REPLACE THE INTERNAL SEAL RINGS OR...

Page 105: ...er taking care to respect the positioning of the ap pendices in their corresponding seats Refitting the driven pulley Insert the synthetic ring Insert the lower spring support Insert the spring lubric...

Page 106: ...driven pulley Turn the control screw of the specific tool and spring preloading Insert the fixing nut and using the specific wrench tighten to torque Specific tooling 020444Y009 wrench 46 x 55 Lockin...

Page 107: ...riving pulley and loosen the flanged nut Specific tooling 020442Y Pulley lock wrench remove the flat washer and the cup washer remove the stationary half pulley and the washer disengage the belt remov...

Page 108: ...f the belt facing surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt CAUTION DO NO...

Page 109: ...e the specific tool to lock the pulley tightening to the prescribed torque Specific tooling 020442Y Pulley lock wrench Locking torques N m Nut M14x1 5 securing the driving pulley 120 130 CAUTION DURIN...

Page 110: ...nsmission cover to the crankcase to the pre scribed torque Locking torques N m Transmission cover screws 11 13 Insert the nut Insert the special tool Rotate the pulley axle until the pulley stops Spec...

Page 111: ...iner large enough to recover the final reduction oil Unscrew the indicated screw and re cover the aluminium seal Unscrew the oil filler screw in order to facilitate bleeding Unscrew the seven hub cap...

Page 112: ...eduction cap complete with the wheel axle being careful not to drop the inter mediate gear Remove the final reduction cap Turn the shaft of the driven pulley until aligning a slot with the axis of the...

Page 113: ...inion and the specific tool CAUTION CLEAN THE THREAD FROM ANY RESIDUAL THREAD LOCK Removing the hub bearings REMOVAL Removing the clutch shaft bearing Remove the screw and countersunk washer Using the...

Page 114: ...adaptor 020412Y 15 mm guide FITTING Heat the crankcase by means of the specific tool and then insert the bearings Specific tooling 020151Y Air heater Fitting the Wheel axle bearing Using the equipmen...

Page 115: ...g the direction of the washer and apply the recommen ded product Recommended products Loctite 242 Medium strength thread locking sealant Blue Locking torques N m Bearing lock screw 9 11 Refitting the...

Page 116: ...unit in the re duction cover and tighten the screws to the speci fied torque tightening in crossed sequence Check the correct the tightening drainage screw Locking torques N m Final reduction cover sc...

Page 117: ...the screw indicated and remove the plate Install the support plate Specific tooling 020916Y Magneto flywheel blocking tool Install the specific tool and unscrew the retainer nut of the flywheel recov...

Page 118: ...O TECT THE THREAD AGAINST THE STRAIN EXERTED BY THE EXTRACTOR AND ALSO PREVENTS DROPPING THE FLYWHEEL ACCIDENTALLY UPON EXTRACTING IT PO TENTIAL DROPS MAY DAMAGE THE CERAMIC INSERTS Specific tooling 0...

Page 119: ...te gear Lubricate the sliding surfaces and insert the in termediate gear in its seat Refitting the flywheel magneto Place the tab Insert the magneto flywheel on the crankshaft Insert the washer Beverl...

Page 120: ...t the specific tool Tighten the flywheel fixing nut to the specified torque Specific tooling 020627Y Flywheel lock tool Locking torques N m Flywheel fixing nut 100 to 110 Removing the intake manifold...

Page 121: ...nd cover Unscrew and remove the special cover fastening screws Remove the big end cover Removing the timing system drive Before working on the timing system it is recom mended to place the engine at T...

Page 122: ...First loosen the tensioner and unscrew the fixing screws Remove the tensioner complete with gasket Undo the fixing screw and remove the washer Engine Beverly 400 E5 ENG 122...

Page 123: ...Remove the complete mass of the return spring Loosen the screw Remove the counterweight fixing screw Remove the counterweight Beverly 400 E5 Engine ENG 123...

Page 124: ...the sprocket and re move the camshaft control sprocket Removing the cam shaft Remove the big end cover Remove the timing system control Unscrew the two screws of the camshaft lock Remove the plate Eng...

Page 125: ...ESERVE THE COUPLINGS CAUTION IF NECESSARY USE A TELESCOPIC MAGNET TO RE MOVE THE PADS PAY PARTICULAR ATTENTION THAT THEY DO NOT FALL IN THE TRANSMISSION HOUSING Remove the pins and the rockers N B IF...

Page 126: ...the washers Remove the cylinder head N B IF NEEDED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS AND ROCKING LEVERS WITHOUT RE MOVING THE DRIVING PULLEY UNIT REMEMBER TO HOLD THE TIMING CHAIN WITH A...

Page 127: ...ol to remove the cotters cap and spring CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS Specific tooling 020382Y Tool to extract valve cotters 020382Y012 bush valve remov...

Page 128: ...the valve oil seal Specific tooling 020431Y Valve oil seal extractor Slide off the valve and remove the lower support Removing the cylinder piston assy Unscrew and remove the fastening screws of the c...

Page 129: ...B IN ORDER NOT TO DAMAGE THE BASE GASKET WITH THE PISTON LOCK FORK 020512Y DURING THE MOUNT ING PHASE IT IS RECOMMENDED TO INSERT THE ALIGNMENT DOWELS OF THE CYLINDER CRANKCASE UNDER THE CYLINDER DURI...

Page 130: ...he piston N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP TER Inspecting the piston rings N B TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES SEE THE SPECIFICATIONS CHAP...

Page 131: ...base gasket Fit the specific tool Specific tooling 020426Y Piston fitting fork Place the seal rings as indicated in the figure Place the cylinder and the specific tool Specific tooling 020128Y Piston...

Page 132: ...amshaft control pulley chain as sembly and the sprocket wheel are not worn If you detect wear replace the parts or if the chain sprocket wheel and pulley are worn replace the whole unit Remove the cen...

Page 133: ...RALLY IN LINE WITH THE VALVES IN ORDER TO PREVENT ACCIDENTAL BENDING OF THE BLADE THAT MAY AFFECT THE MEAS UREMENTS Characteristic Valve clearance cold engine Intake 0 10 mm Exhaust 0 15 mm Detecting...

Page 134: ...ORDER TO PRESERVE THE INDICATION OF THICKNESS OVER TIME THE OUTLET ROCKER SLIDES ON THE AXIS ONLY AF TER THE INTAKE ROCKER HAS BEEN MOVED MAKE SURE THAT THE PADS DO NOT FALL INSIDE THE ENGINE COMPART...

Page 135: ...al punch fit the four valve seal rings Fit the valves the springs and the caps Using the appropriate tool with adapter compress the springs and insert the cotters in their seats N B DO NOT CHANGE THE...

Page 136: ...D BOLTS FOR FITTING QUOTA SEE THE SECTION MOTOR STUD BOLT SHAFT CRANKCASE Position the crankshaft to the TDC in compres sion Insert the head gasket and check the correct op eration of the alignment do...

Page 137: ...to 9 11 Nm then proceed for 270 0 5 0 of rotation Fit the pins and rocking levers Lubricate the two rockers through the upper holes Lubricate the two housings and insert the cam shaft in the cylinder...

Page 138: ...st position Fit the chain tensioner on the cylinder using a new gasket and tight the two screws to the specified torque Insert the chain tensioning screw together with the spring and washer tightening...

Page 139: ...ody clamp screws 1 3 1 7 Splitting the crankcase halves Undo the twelve crankcase coupling screws Separate the crankcase halves while keeping the crankshaft in one of these two halves Only after the h...

Page 140: ...MIGHT ACCIDENTALLY FALL Remove the gasket and be careful with the align ment dowels Remove the by pass and the oil bulkhead After removing the oil bulkhead blow and clean thoroughly before fitting Co...

Page 141: ...Refitting the crankcase halves Insert the crankshaft on one of the two crankcase halves insert the oil shield Insert the by pass valve Place a new crankcase gasket Beverly 400 E5 Engine ENG 141...

Page 142: ...cific tools to support the dial gauge verify that the fitting clearance is within the limits Higher clearances are signs of wear of the crank shaft crankcase supporting surfaces Specific tooling 02016...

Page 143: ...e lubricated and the big end with high pressure the piston pin and connecting rod small end via spray H Afterwards the oil through a nozzle M whose function is to reduce the flow rate reaches the timi...

Page 144: ...appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the flywheel cover If the oil pressure is not within the spe...

Page 145: ...er pump command screw and collect the washer CAUTION THE THREAD IS ANTICLOCKWISE Unscrew the two screws and remove the ten sioner pad Remove the oil pump command sprocket com plete with chain Undo the...

Page 146: ...auge check the distance be tween the rotors in the position shown in the figure Check the distance between the outer rotor and pump body see figure Check the axial clearance of the rotors using a true...

Page 147: ...seat Insert and tighten the oil pump fastening screws to the crankcase to the specified torque Recommended products Loctite 243 Medium strength thread locking sealant Blue Locking torques N m Screws...

Page 148: ...T THE PUMP TURNS FREELY Locking torques N m Oil pump command sprocket screw 9 11 Removal Before removing the flywheel cover loosen the impeller CAUTION THE THREAD IS ANTICLOCKWISE CAUTION IF THE LOCKI...

Page 149: ...er underneath CAUTION THE THREAD IS ANTICLOCKWISE Using the special tool and appropriate supports ensure a proper support surface Using a hammer and a plug of diameter less than 8 mm and being careful...

Page 150: ...seal Using a screwdriver remove the seal ring from the flywheel cover Check that the shaft housing hole on the crank case does not show abnormal wear Make sure the ceramic seal seat does not show sig...

Page 151: ...h grease and insert it in the flywheel cover Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor Grease the shaft and insert it in the seat Insert the shim washer and manually start up...

Page 152: ...5 Insert the new ceramic seal using the specific tool Start the tool Insert the new ceramic seal Insert the housing of the tool and tighten the nut with a wrench while holding the central pin locked S...

Page 153: ...Insert and screw the impeller to the specified tor que Locking torques N m Impeller on the pump shaft 4 6 Beverly 400 E5 Engine ENG 153...

Page 154: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 155: ...PROCEDURE MUST BE PER FORMED EACH TIME A TYRE IS REPLACED EVEN IF ON LY ONE OF THE TYRES IS REPLACED FOR THE CALIBRATION OF THE ASR SYSTEM PERFORM THE PROCEDURE BELOW WARNING THE ASR SYSTEM PREVENTS...

Page 156: ...flashing then when the engine is started the icons turn off if the programming is suc cessful Programming phase failed Icon ASR OFF on steady when en gine is started if the programming has failed Man...

Page 157: ...sition 8 If the procedure has been completed cor rectly the next time the starter switch is turned to the ON position the ASR icon lights up with 1Hz slow flashing 1 flash per second When starting the...

Page 158: ...IS NECESSARY TO CHECK FOR WEAR AND OR THE STATE OF INFLATION OF TYRES FIRST CAUTION IT IS EMPHASISED THAT THE RIDING AUXILIARY SYSTEM CANNOT CHANGE THE PHYSICAL LIMITS OF GRIP AND IS NOT A SUBSTITUTE...

Page 159: ...B Bulbs F Fuses 78 I Identification 19 Instrument panel 68 K Keys 80 M Maintenance 18 54 R Recommended products 55 S Start up 11 Suspension T Technical Data 18 Transmission 84 109 V Vehicle 19...

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PIAGGIO Beverly 400 E5, Service Manual

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