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WORKSHOP

MANUAL

Beverly 500 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 shown in this publication are available in all countries. The availability of single versions

should be checked at the official Piaggio sales network.

"© Copyright 2005 - 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. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

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Summary of Contents for Beverly 500 i.e.

Page 1: ...WORKSHOP MANUAL 633387 Beverly 500 i e...

Page 2: ...components parts or accessories which it considers necessary to improve the product or which are required for manufacturing or construction reasons Not all versions shown in this publication are avail...

Page 3: ...sections of this manual relating to specific tools along with the specific tool catalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to speci...

Page 4: ...CTERISTICS CHAR MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIV...

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 6: ...he compressed air jet so as to not inhale the dust produced by the wear of the friction material Even though the latter contains no asbestos dust inhalation is harmful Maintenance rules Use original P...

Page 7: ...Length 2215 mm Wheel base 1550 mm Height 1305 mm Engine ENGINE Specification Desc Quantity Engine Single cylinder four stroke Bore 92 mm Stroke 69 mm Cubic capacity 460 cm Compression ratio 10 5 1 Tim...

Page 8: ...smission With automatic expandable pulley variator with torque server V belt automatic clutch gear reduction unit and transmission housing with forced air circulation cooling Clutch This is to inform...

Page 9: ...ront disc is interlocked with a pressure distribution valve Wheels and tyres WHEELS AND TYRES Specification Desc Quantity Light alloy rims Front rim 16 x3 Light alloy rims rear rim 14 x4 50 Tyres fron...

Page 10: ...upper retainers 33 41 Swinging arm to engine retainer muffler side 66 70 swinging arm to engine retainer transmission side 100 120 Side stand clamp 15 20 Shock absorber to crankcase bracket fastener...

Page 11: ...0 Drive pulley nut 160 175 Anti vibration roller screw 16 7 19 6 M8 retainers for transmission cover 23 26 M6 retainer 11 13 Anti vibration roller retainer 17 19 Clutch ring nut 65 75 Air conveyor uni...

Page 12: ...ification Desc Quantity Cylinder diameter C 92 0 018 0 01 Piston diameter P 91 916 0 029 0 057 CATEGORIES OF COUPLING Name Initials Cylinder Piston Play on fitting Cylinder Piston A 91 990 91 997 91 9...

Page 13: ...ylinder Piston Play on fitting 1st Compression ring A 0 15 0 35 0 5 Middle piston ring A 0 25 0 50 0 65 Oil scraper ring A 0 25 0 50 0 65 Crankcase crankshaft connecting rod Diameter of crankshaft bea...

Page 14: ...NKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission side shoulder 0 8 0 025 A D 0 20 0 40 Transmission side half shaft 19 6 0 050 B D 0 20 0 40 Connecting rod 22 0 10...

Page 15: ...E GASKET TO BE DETERMINED THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE THE COMPRESSION RATIO THE BASE GASKET MUST BE THICKER THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FRO...

Page 16: ...cific additives for in creased adhesiveness AGIP CITY HI TEC 4T Engine oil SAE 5W 40 API SL ACEA A3 JASO MA Synthetic oil AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid AGIP PERMANENT SPECIAL co...

Page 17: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 18: ...reached the predicted mileage Punctual vehicle servicing is necessary for the correct use of the guarantee For all further information regarding the Guarantee application modes and the execution of th...

Page 19: ...k Variable speed rollers replacement Roller support sliding blocks check change Drive belt replacement Coolant level check Steering adjustment Brake levers greasing Transmission lubrication Brake flui...

Page 20: ...ad test AFTER 30 000 KM 42 000 KM AND 66 000 KM 80 Action Engine oil change Hub oil level check Spark plug electrode gap check Air filter cleaning Engine oil filter change Base vent check Variable spe...

Page 21: ...ring adjustment Brake levers greasing Transmission lubrication Brake fluid level check Safety fasteners check Suspensions check Electrical system and battery check Headlight adjustment Tyre inflation...

Page 22: ...from the lower part in the specific groove Disconnect the shielded spark plug cap Unscrew the spark plug Check the conditions of the spark plug make sure the insulation is intact that the electrodes...

Page 23: ...the proper amount of oil in the hub Screw the oil bar back on checking that it is tightly in place Replacement Remove the oil filler cap A Prepare a suitable container Remove the oil drainage cap B a...

Page 24: ...NTENANCE CHART Recommended products AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness N B FAILURE TO OBSERVE THE FILTERING ELEMENT CLEANING RULES...

Page 25: ...the level line will be lower in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped so as to get the correct level Oil top up The oil shou...

Page 26: ...l it comes into contact with the seal and further tighten to the prescribed torque Refit the muffler Add recommended engine oil Start the engine and let it run for a few minutes and then turn it off A...

Page 27: ...check the oil level and the lubrication system Checking the valve clearance To check the clearance in the valves collimate the references between the cam shaft control pul ley and head Use a feeler to...

Page 28: ...tank indicate the two levels MIN and MAX The coolant consists of a mixture of 50 demineralised water and ethylene glycol and corrosion inhibitors based anti freeze solution CAUTION DO NOT EXCEED THE...

Page 29: ...HE BRAKE PADS GET WORN A MINIMUM LEVEL SHOULD NOT BE REACHED IF THE LEVEL IS TOO LOW CHECK AND FIX THE SYSTEM SEALS IF RE QUIRED TOP UP THE PUMP RESERVOIR IF REQUIRED CONSIDERING THAT THE MAX LEVEL MU...

Page 30: ...G FLUID FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED OR PARTIALLY USED Characteristic Prescribed fluid TUTELA TOP 4 Under normal climatic conditions the fluid must be changed every 20 000 km or anywa...

Page 31: ...eat using a 10 mm spark plug union at the proper tightening torque Disconnect the revolution timing sensor connector Let the engine run using the starter and with the throttle body in fully open posit...

Page 32: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 33: ...12 No 3 7 5A fuses 13 Anti theft alarm fitting 14 Electric fan 15 Fuel level sender with pump 16 Side stand switch 17 Saddle opener actuator 18 HV coil 19 Lamp 20 Chassis wire unit 21 Headlight 22 Ins...

Page 34: ...essure sensor 58 Flywheel magneto 59 Frame ground 60 Ground cable 61 Starter motor wire 62 Starter motor 63 Start up solenoid 64 Battery 12V 12Ah 65 Rear fuse box 66 Fuse 30A 67 Fuse 15A 68 Two 10A fu...

Page 35: ...the passenger footrest Overturn sensor In order to access the overturn sensor remove the central union During assembly observe the installation direction shown in the figure H V coil In order to acce...

Page 36: ...nector remove the wind shield with the respective support and the metal plate holding the control unit ECU decoder and saddle opener remote control N B AFTER INSERTING THE INTERFACE CABLE OR THE ELECT...

Page 37: ...er shield back plate Specification Desc Quantity A DIODE UNIT B ELECTRIC FAN REMOTE CONTROL SWITCH C ENGINE STOP REMOTE CONTROL SWITCH D CONTROL UNIT REMOTE CONTROL SWITCH Voltage regulator To access...

Page 38: ...p remote control switch 6 Main remote control switch 7 Diode 2 A 8 Control unit remote control switch 9 Emergency stop switch 10 Side stand switch 11 Fuse No 4 5A 12 Key switch 13 Main fuse 30A 14 Bat...

Page 39: ...Quantity 1 Instrument panel 2 Duel light lamp 3 Light switch 4 Fuse No 9 7 5A 5 Light switch 6 Light remote control switch 7 Fusibile n 6 10A 8 Main remote control switch 9 Diode 2 A 10 Key switch 11...

Page 40: ...light and number plate light Battery recharge and starting START UP BATTERY RECHARGE Specification Desc Quantity 1 Stop light bulb 2 Starter button 3 Fuse No 8 7 5A 4 Fuse No 4 5A 5 Electronic contro...

Page 41: ...LEVEL INDICATORS AND ENABLE SIGNALS SECTION Specification Desc Quantity 1 Instrument panel 2 Engine water temperature sensor 3 Electronic control unit 4 Engine oil pressure sensor 5 Damper for fuel l...

Page 42: ...7 Battery 12V 12Ah 18 Voltage regulator 19 Flywheel magneto Turn signal lights TURN INDICATORS AND HORN Specification Desc Quantity 1 Instrument panel 2 Predisposizione display 3 Anti theft alarm fitt...

Page 43: ...ed directly to the ground and the battery positive terminal passing through the 30A protective fuse This system therefore requires no connection to the key switch The three phase generator provides go...

Page 44: ...E CARRYING OUT THE CHECK MAKE SURE THAT THE BATTERY IS IN GOOD WORK ING ORDER 1 Place the vehicle on its centre stand 2 With the battery correctly connected to the circuit place the multimeter leads b...

Page 45: ...he scooter CAUTION BEFORE REPLACING THE BLOWN FUSE SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING...

Page 46: ...echarging if necessary These operations should be carried out before delivering the vehicle and on a six month basis while the vehicle is stored in open circuit Besides upon pre delivery it is therefo...

Page 47: ...G INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP OUT OF REACH OF CHILDREN Remove the short closed tube and the caps then pour sulphuric acid into the cells using th...

Page 48: ...cted to the negative terminal whilst the other two red wires marked with a must be attached to the positive terminal Battery recharge WARNING BEFORE RECHARGING THE BATTERY REMOVE THE PLUGS OF EACH CEL...

Page 49: ...ONNECTOR A Specification Desc Quantity 1 Left direction warning light 2 Battery negative 3 Battery positive 4 Water thermometer 5 Right direction warning light 6 Preset indicator 7 Fuel gauge 8 Low fu...

Page 50: ...DAMPER Specification Desc Quantity 1 Fuel reserve warning light 2 Fuel level gauge output 3 Float input 4 Test not connected 5 Ground lead 6 permanent power supply Electrical system Beverly 500 i e E...

Page 51: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 52: ...ir filter sleeve and the engine earth cable Disconnect the carburettor electrical devices and the starter motor power supply cable Disconnect the fuel delivery and return pipes from the carburettor an...

Page 53: ...ce when the valve is in abutment against the set screw Check the engine oil level and top up using the recommended brand if required Top up the coolant circuit Check that throttle and electric devices...

Page 54: ...INDEX OF TOPICS ENGINE ENG...

Page 55: ...f the cap Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush Remove the nut and the two washers N B DUE TO THE HI...

Page 56: ...t the outside plastic transmission cover Air duct Remove the transmission cover Unscrew the two screws shown in the figure to remove the air conveyor Locking torques N m Air conveyor screws 11 12 Remo...

Page 57: ...ce and use the special tool so that it is adequately sup ported Pull out the bearing using the special tool N B BELL MUST BE PLACED INTO THE TRANSMISSION COV ER CLOSE TO THE BEARING SEAT AND THE WOODE...

Page 58: ...g out Install the new bearing using the special tool N B PROPERLY SUPPORT THE OUTSIDE COVER TO PRE VENT DAMAGING THE PAINTED SURFACE Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm Adaptor 02...

Page 59: ...screw to the prescribed tor que N B TURN THE DRIVEN AND OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED Locking torques N m Anti vibration roller screw 16 7 19 6 Removing the driv...

Page 60: ...ol inserting the pins into the ventilation holes Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure CAUTION THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING T...

Page 61: ...g the special tool inserted through the roller bearing pull out the ball bearing N B PROPERLY SUPPORT THE PULLEY TO PREVENT DAM AGING THE THREADING Specific tooling 020376Y Adaptor handle 020456Y 24 m...

Page 62: ...Standard diameter 50 00 0 015 0 035 mm Inspecting the driven sliding half pulley Check that the belt contact surface is free from wear Remove the 2 inside sealing rings and the 2 out side O rings Mea...

Page 63: ...NSTALLED ON THE MACHINING END RA DIUS AT THE BASE OF THE HALF PULLEY Install the half pulley on the bushing being careful not to damage the top sealing ring during the in troduction Make sure the pins...

Page 64: ...Check the thickness of the clutch mass friction material Characteristic Minimum thickness permitted 1 mm The masses must exhibit no traces of lubricants in that case check the driven pulley unit seals...

Page 65: ...insert the clutch on the driven pulley bushing N B BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END Tighten the ring nut by hand and complete the tightening using the special wrench to...

Page 66: ...ed Check the width of the belt Characteristic Minimum width 25 mm Standard width 26 2 mm Removing the driving pulley Using a 27 mm wrench turn the central pulley nut to horizontally align the central...

Page 67: ...iving half pulley Remove the bushing connection washer Move the belt downwards Suitable support the roller contrast and extract the movable driving half pulley with the relevant bushing and the rear w...

Page 68: ...rd diameter 29 959 mm Check that the rollers are not damaged or worn Characteristic Minimum admissible diameter 24 5 mm Standard diameter 24 9 mm Check the guide shoes for the variator back plate are...

Page 69: ...the inside Position the rollers on the half pulley as shown in the figure The closed side must rest on the inside thrust face of the roller container Assembly the half pulley with the roller contrast...

Page 70: ...ley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley Remove the flat washer and the spring washer as shown in the figure Insert the nut in the o...

Page 71: ...tool is resting flatly Tighten the driving pulley fastening nut to the prescribed torque Remove the special tool Locking torques N m Drive pulley nut 160 175 Refitting the transmission cover Install t...

Page 72: ...ert the washers on the driven pulley shaft N B INSERT THE SMALLER WASHER FIRST THEN THE LARGER ONE Insert the flanged nut Prepare the torque wrench for LHS locking using a machine hexagon wrench Tight...

Page 73: ...levant gasket Removing the wheel axle Remove the countershaft Remove the wheel axis complete with gear Removing the hub bearings Check all bearings wear clearance and noise In case of anomalies procee...

Page 74: ...ing using the special tool Specific tooling 020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54 mm bearings Removing the wheel axle bearings Take out the clip...

Page 75: ...ing Remove the oil guard using a screwdriver into the hub gear box Remove the Seeger ring shown in the figure Pull out the driven pulley shaft bearing from the engine crankcase using the special tool...

Page 76: ...ace is not damaged or deformed Check the capacity of the bearings In case of faults replace the hub cover Refitting the driven pulley shaft bearing Heat the crankcase using the heat gun Specific tooli...

Page 77: ...bearing seat on the crank case Insert the gear shaft bearing in the upper crank case seat using the special tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE...

Page 78: ...cial tool N B PLACE IT WITH THE BALLS FACING THE HUB THIS AP PLIES TO BEARINGS WITH PLASTIC CAGE Specific tooling 020376Y Adaptor handle 020360Y 52x55 mm Adaptor 020363Y 20 mm guide Heat the gear shaf...

Page 79: ...r position of the centring dowels Install a new gasket Fit the gearbox cover making sure the breather pipe is in the correct position Position the 7 set screws tighten them to the prescribed torque be...

Page 80: ...feed hoses and disconnect the return hose from the pump cover N B THE BANDS MUST BE REPLACED TO REMOVE THEM OPEN WITH A SCREWDRIVER OR CUT THEM BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS Removing the...

Page 81: ...pport N B THE SCREWS ARE OF 4 DIFFERENT LENGTHS NOTE THE RELEVANT POSITIONS CAUTION REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR CAUTION BE CAREFUL TO PREVENT SLIPPAGE...

Page 82: ...p seal Removing the stator Remove the two retaining screws and the cable guide bracket Unscrew the 3 fastening screws and remove sta tor and its wiring Loosen the two retaining screws and remove the r...

Page 83: ...outlet union with the relevant O ring Remove the water pump impeller by unscrewing it from the relevant shaft N B THE THREADING IS CLOCKWISE IT IS ADVISABLE TO PREVENT THE SHAFT ROTATION BY INSERTING...

Page 84: ...ant gas ket Remove the sealing ring for the pump shaft lu brication using a suitably shaped tool Remove the engine oil filling cap dipstick and the check hole cover for the distribution timing Remove...

Page 85: ...MAY RESULT IN VALUES HIGHER THAN THOSE STATED Electric characteristic Resistance 0 2 1 Check the ground insulation of each phase If a fault is found carry out a thorough check of the cable harness tha...

Page 86: ...Check that the oil filter union and matching sur face exhibit no deformations or wear Install a new oil filter lubricate the gasket screw on and finally tighten to the prescribed torque Locking torque...

Page 87: ...ing the 3 screws to the pre scribed torque N B INSERT THE RUBBER WIRING SEALING GASKET INTO THE SPECIAL SEAT ON THE CRANKCASE Locking torques N m Stator retainers 8 10 Install the wiring guide bracket...

Page 88: ...fitting the flywheel cover components Before reassembling check that all components are perfectly clean For the cover carefully check all lubrication chan nels in particular The 3 by pass channels Oil...

Page 89: ...to the prescribed torque Locking torques N m Supporting screws with bulkhead 0 3 0 4 Install a new sealing ring for the pump shaft using the special tool Install the oil minimum pressure sensor and t...

Page 90: ...ng the flywheel cover seat Insert the mechanical seal on the shaft up to the impeller abutment surface N B THE FINAL INTRODUCTION DEPTH WILL BE DETER MINED BY THE IMPELLER Screw the impeller and tight...

Page 91: ...ATION IS USEFUL PARTICULARLY IN THE EVENT OF REPAIRS WITH THE WATER PUMP COVER IN STALLED Install the flywheel cover on the engine paying attention to avoid interference between the stator and rotor W...

Page 92: ...orrectly connected to each other and to the frame YES go to 4 NO go to 5 3 Recharge and if necessary replace the battery 4 Connect the diagnostic tester see chapter Injection system Connect the induct...

Page 93: ...rotation example possible melting of the bushes and if no anomalies are found replace the starter motor 8 Low trailing speed Low electrical absorption Repeat the test bridging the power terminals of...

Page 94: ...in torque limiter The starter system has a transmission between the motor armature and engine shaft equipped with freewheel coaxial to the flywheel and torque limiter on the intermediate shaft The li...

Page 95: ...flywheel magneto N B IF YOU MUST REMOVE THE FLYWHEEL IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST Unscrew the 3 fastening screws and remove the chain guide sliding block...

Page 96: ...g sure that the pins are perfectly inserted in to the previously aligned holes and that it is per fectly abutted and almost flush with the flywheel Specific tooling 020472Y Flywheel lock wrench Loosen...

Page 97: ...SLIPPAGE WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS Insert the special removing tool Using a 27 mm wrench and a 19 mm bushing release the flywheel Specific tooling 020467Y Flywheel extractor Remove t...

Page 98: ...freewheel is coupled to the flywheel with high precision if removal is difficult use 2 screws as gripping points and as removing tools if required Extract the intermediate gear provided with tor que l...

Page 99: ...istic Inside diameter of the bushing Diameter 27 0 020 0 041 mm N B IF THE FAULTS DISCOVERED AFFECT THE HUB REPLACE THE STARTER RING GEAR AND FREEWHEEL IF ONLY THE BUSHING IS WORN IT IS POSSIBLE TO RE...

Page 100: ...ct start up manoeuvres the lim iter prevents any kicks with consequent reversal of direction of the crankshaft which would impair the engine structure The limiter assembly cannot be overhauled In case...

Page 101: ...ng visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the intermedi...

Page 102: ...turning it clockwise and inserting at the same time Refitting the flywheel magneto Insert the key on the crankshaft Install the flywheel checking the proper insertion of the key and engaging the torq...

Page 103: ...0472Y Flywheel lock wrench Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool Insert the special tool checking that the pins are perfectly introduced...

Page 104: ...Chain guide sliding block retain plate fasten ing screws 3 4 Refitting the starter motor Check that the O ring is in good working order and lubricate it Insert the starter motor Tighten the 2 fasteni...

Page 105: ...arms cover Loosen the 6 special screws with stop and the relevant rubber gaskets Remove the tappet cover with relevant gasket Removing the timing system drive Turn the engine to close the intake valve...

Page 106: ...the valve lifting mass with relevant travel end washer N B BE CAREFUL NOT TO ALLOW THE WASHER AND SPRING TO FALL INTO THE ENGINE THROUGH THE CHAIN COM PARTMENT Align the references located on the tone...

Page 107: ...shaft Remove the timing belt rim Remove the tone wheel Remove the engine revolution timing sensor and relevant O ring by loosening the fastening screw and removing the mounting band from the special h...

Page 108: ...AY BE DIFFI CULT BE CAREFUL NOT TO DAMAGE THE INSIDE HEX AGON IF NECESSARY SEPARATE THE THREADS IN ADVANCE Remove the cam shaft Remove pins and rocking levers by the transmis sion side holes Removing...

Page 109: ...he spark plug side with the thermostat support N B THE HEAD MAY BE REMOVED WITH THE CAMSHAFT ROCKING LEVER PINS AND FITTING BRACKET IF NECESSARY Loosen the 4 head cylinder fastening nuts in 2 or 3 tim...

Page 110: ...020382Y012 bush valve removing tool CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD FLY WHEEL SIDE AND TRANSMISSION SIDE Remove the oil guards using the special tool S...

Page 111: ...LINDER CAUTION TO PREVENT DAMAGING THE PISTON SUPPORT IT WHILE REMOVING THE CYLINDER Remove the 2 piston pin locking rings by the spe cific housings Extract the pin and remove the piston N B USE PAPER...

Page 112: ...ck the pin outside diameter using a micrometer Characteristic Standard diameter 22 0 0 004 mm Calculate the coupling clearance between pin and connecting rod small end Characteristic Standard clearanc...

Page 113: ...lakes Check that the head matching surface exhibits no deformations or wear Characteristic Maximum allowable run out 0 05 mm Pistons and cylinders are classified into categories based on their diamete...

Page 114: ...e opening see figure of the sealing rings using a feeler gauge If higher values than those prescribed are meas ured replace the linings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEAR...

Page 115: ...ic tooling 020470Y Pin retainers installation tool N B THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUSING Choosing the gasket Provis...

Page 116: ...er base gasket to be used for reassembly by the table below Cor rectly identify the cylinder base gasket thickness to keep the correct compression ratio Remove the special tool and the cylinder N B IF...

Page 117: ...ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Misalign the lining openings at 120 as shown in the figure Lubricate the components with engine oil The en...

Page 118: ...nt Inspecting the timing system components Check that the guide shoe and the tensioner shoe are not worn out Check that the crankshaft pinion and the cam shaft timing gear and crankshaft pinion exhibi...

Page 119: ...found to be interrupted at one or more points or is not flat re place the valve Inspecting the valve housings Clean the valve seats of any carbon residues Using the Prussian blue check the width of t...

Page 120: ...Exhaust 4 945 mm Calculate the clearance between valve and valve guide Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation with a di...

Page 121: ...ty Standard clearance 0 013 0 04 mm Admissible limit 0 08 mm EXHAUST Specification Desc Quantity Standard clearance 0 025 to 0 052 mm Admissible limit 0 09 mm STANDARD VALVE LENGTH Specification Desc...

Page 122: ...he guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT...

Page 123: ...lve cotters equipped with part 012 removal tool 020382Y012 bush valve removing tool N B DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REF ERENCE COLOUR ON COTTER SIDE TURNS W...

Page 124: ...e the defective components with new ones Check that the retaining plate seat shown in the figure exhibits no wear Check that the automatic valve lifting device cam the travel end roller and the rubber...

Page 125: ...cylinder Install the head gasket N B THE FIGURE SHOWS THE INSERTION POSITION OF THE TWO CENTRING DOWELS BETWEEN HEAD AND CYLINDER THE DIRECTION OF INSTALLATION FOR THE GASKET IS FORCED BY THE DOWELS T...

Page 126: ...the prescribed torque Locking torques N m Exhaust intake head fixing nuts 10 12 Tighten the 3 side screws to the prescribed tor que Locking torques N m Head fixing screws 10 12 Install the coolant te...

Page 127: ...lywheel side Lubricate the two rocking levers through the holes at the top Clean the camshaft by blowing with little com pressed air jets especially the retaining plate housing Lubricate the 2 shafts...

Page 128: ...the housing of the tone wheel timing peg are free from deformations or dents Insert the wheel speed sensor on the camshaft keeping the stroke reference visible Install the engine revolution timing se...

Page 129: ...INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES Using the TORX wrench remove the timing check cap Align the wheel speed sensor references with the head as shown in the figure Keeping th...

Page 130: ...ening screw Lock the mass fixing screws to the prescribed torque using the recommended product Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock Locking torques...

Page 131: ...Check that the decompression mass is free and that it is pulled by the spring Locking torques N m Valve lifter mass stop bell fixing screws 30 35 Place the engine with the valve clearance adjustment...

Page 132: ...ce determined by the injection system matches the value actually activated on the engine by means of the stroboscopic light Specific tooling 020680Y Diagnosis Tool 020330Y Stroboscopic light to check...

Page 133: ...real values of rpm and ignition advance match those measured using the diag nostic tester Specific tooling 020680Y Diagnosis Tool If the values do not match check distribution timing revolution timin...

Page 134: ...er on the cylinder using a new gasket Tighten the two fastening screws to the prescri bed torque Locking torques N m Tightener fastening screws 11 13 Insert the spring with the central screw and the w...

Page 135: ...the remaining 4 screws in a crossed se quence 3 4 5 6 N B CHECK THE PROPER POSITION OF THE GASKET Locking torques N m Tappet cover fixing screws 7 9 Install the transmission cover and the relevant me...

Page 136: ...m Intake manifold screws 11 to 13 Crankcase crankshaft Remove the outside and inside transmission cov er and the complete driving pulley as described in Automatic transmission Remove the flywheel cove...

Page 137: ...h special tool comparator Specific tooling 020262Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge Characteristic Standard clearance 0 10 0 50 mm Admissible increase limit after use...

Page 138: ...aft inserted on the flywheel side half crankcase Remove the coupling gasket N B THE BUSHING SUPPORT CAN BE LEFT IN THE FLY WHEEL SIDE HALF CRANKCASE Removing the crankshaft Before removing the cranksh...

Page 139: ...trol gear To remove the control gear loosen the 4 fasten ing screws Remove the gear only if actually required CAUTION THE SCREWS HAVE A COUNTERSUNK HEAD AND THEIR THREADING IS LOCKED BY LOCTITE BE CA...

Page 140: ...e inside Seeger ring Upturn the half crankcase Remove the bearing from the flywheel side half crankcase using the special tool and a mallet Specific tooling 020376Y Adaptor handle 020358Y 37x40 mm Ada...

Page 141: ...stall the new bearing on the half crankcase us ing the special tool N B IF A BEARING WITH PLASTIC CAGE IS USED KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE Specific tooling 020376Y Adaptor...

Page 142: ...crankshaft components Check the axial clearance on the connecting rod Characteristic Standard clearance 0 20 0 40 mm Check the connecting rod diametrical clearance Characteristic Standard clearance 0...

Page 143: ...s higher than the standard value and the crankshaft exhibits no irregularity the problem is caused by wear or by a wrong machining on the engine crankcase Check the diameters of both bearings of the c...

Page 144: ...k the connecting rod small end diameter see chapter Thermal group and timing system When cleaning the crankshaft be careful to prevent any impurity from entering into the shaft lubrication hole N B IN...

Page 145: ...TER IT IS ESPECIALLY IMPORTANT THAT THE BY PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE ADJUSTMENT PISTON THE HEAD LUBRICATION C...

Page 146: ...red with the crankshaft axial clearance of the limiting surface N B TO KEEP THE BUSHINGS ON THE CRANKCASE IN SUCH POSITION DRIVING IS FORCED ON CAST IRON RINGS INSERTED IN THE CASTING OF BOTH CRANKCAS...

Page 147: ...es Spare shafts have half shafts of the same category N B TO REPLACE THE HALF SHAFTS REMOVE THE COUNTERSHAFT BEARINGS AS DESCRIBED ABOVE REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI FLAPPING ROLLER...

Page 148: ...ning screws Insert the control gear on the crankshaft with the hole countersink visible Tighten the 4 fastening screws to the prescribed torque N B TO AVOID DAMAGING THE SCREW CONTROL HEXAGON IT IS PR...

Page 149: ...l pump closing plate Tighten the 2 flanged fastening screws to the prescribed torque Locking torques N m Bulkhead screws for oil pump housing cover 8 10 Refitting the crankcase halves Remove the oil g...

Page 150: ...t tightening Insert the 14 fastening screws by arranging the single shorter screw A and the single longer screw B as shown in the figure Tighten the screws thoroughly and tighten to the prescribed tor...

Page 151: ...the relevant mesh filter and the outside transmission cover as described in the Automatic transmission chapter See also Flywheel cover Cylinder assy and timing system Lubrication TECHNICAL SPECIFICAT...

Page 152: ...pecification Desc Quantity Type mesh plastic OIL FILTER Specification Desc Quantity Type Paper with pressure relief and anti drain back by pass valves OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH Speci...

Page 153: ...ics The lubrication system is divided into two sections High pressure Low pressure The high pressure section includes all components located on the engine crankcase whereas the low pressure section on...

Page 154: ...compensated by the oil supplied to the smaller diameter bearing The camshaft supplies the lubricant to the rocking levers via the holes provided these are installed in a position to ensure that the l...

Page 155: ...a few millimetres Specific tooling 020331Y Digital multimeter AHEAD go to 5 5 Measure the pressure with cold and idling engine STANDARD VALUES Specification Desc Quantity 20 C Temperature 1400 rpm app...

Page 156: ...ce the faulty components Flywheel cover chapter 16 Overhaul the engine Crankcase and crankshaft chapter 17 Open the engine crankcase and remove the oil pump as described in the Crankcase and crank sha...

Page 157: ...E SYSTEM PRESSURE 1 If oil consumption is above 250 g 1000 km on a run in engine proceed as follows AHEAD go to 2 2 Check the presence of oil in the scavenge duct on the filter box YES go to 3 NO go t...

Page 158: ...the 2 retaining screws through the eyes machined in the gearing proper Remove the gasket Remove the two screws and the oil pump cover Remove the inside rotor retaining snap ring turn ing it to move t...

Page 159: ...haft with the gear and install the lock ring then turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body Using a thickness gauge check the distanc...

Page 160: ...Refitting Lubricate the internal rotors Check there are no signs of scoring or wear on the oil pump cover If non conforming values or signs of wear are found replace the pump Fit the pump cover in th...

Page 161: ...otors with the pump body Locking torques N m Screws fixing oil pump to the crankcase 5 to 6 Insert the countershaft with gearing into the fly wheel side half crankcase Install the special tool in the...

Page 162: ...Countershaft fixing nut 25 29 Engine Beverly 500 i e ENG 162...

Page 163: ...INDEX OF TOPICS INJECTION INJEC...

Page 164: ...tch The electric fan system is powered by a remote control switch connected to the continuous power supply controlled by the electronic control unit of the injection system The electronic control unit...

Page 165: ...te the electric fan diagnostic func tion Check acoustically for rotation of the electric fan Wait for the exit from the diagnostic tester YES go to 3 NO go to 4 3 Test successful The fan is rotating Y...

Page 166: ...for continuity between pin 86 of the remote control switch connector and pin 5 of the electronic control unit 86 green white 5 0 continuity YES go to 14 NO go to15 14 Check the earth insulation 5 23 1...

Page 167: ...on is managed by modifying the injector opening time The fuel supply pressure is kept constant based on the ambient pressure The fuel supply circuit consists of Fuel pump Fuel filter Injector Pressure...

Page 168: ...longer present the data storage is automatically cleared after 16 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required to adjust the idle mixture...

Page 169: ...lows 1 Idle carburetion adjustment must be performed on an engine ready for precision adjustment Check in advance spark plug that air filter is clean that throttle body is clean intake system for seal...

Page 170: ...ate the exhaust fumes analyser and check the following conditions are present CO 1 25 0 25 CO2 14 50 1 YES go to 9 NO go to 10 9 The adjustment is correct 10 If a different CO value is read adjust the...

Page 171: ...to 15 15 Select PARAMETERS and ECU DATA to confirm the new trimmer change has been stor ed N B WHEN THE CO PERCENTAGE IS RIGHT AND THE CO2 PERCENTAGE DOES NOT FALL INTO THE SPECIFIED VALUES THE LAMBDA...

Page 172: ...ific tooling 020625Y Kit for sampling gas from the exhaust manifold 494929Y Exhaust fumes analyser Connect the gas collection kit at the muffler outlet being careful to ensure that it is sealed and st...

Page 173: ...fuel 7 When washing the vehicle be careful with the electric components and wiring 8 When an ignition fault is detected start the checks from the battery and the injection system con nections 9 Befor...

Page 174: ...tor 11 Throttle potentiometer signal 12 Engine Speed sensor 13 Injector control negative 14 Stepper motor Stepper motor 15 Instrument panel injection warning light negative 16 Decoder serial Overturn...

Page 175: ...ation Desc Quantity 1 2 Immobilizer LED control negative 3 Base power supply positive 4 Negative 5 6 Electronic control unit EMS serial 7 8 Continuous power supply positive Immobilizer aerial Beverly...

Page 176: ...ification Desc Quantity 1 EMS electronic injection control unit 2 Instrument panel 3 Fuel injector 4 Coolant temperature sensor 5 Air temperature sensor 6 Throttle potentiometer 7 Stepper motor Steppe...

Page 177: ...on Immobiliser enabling signal System 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 In...

Page 178: ...on timing 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 Ad...

Page 179: ...essure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system sealing infiltrations Manifold head Manifold muffler Analyser socket Muffler welding Analysis of exhaust fumes before t...

Page 180: ...tor capacity Engine knocking PRESENCE OF KNOCKING OVERHEAD KNOCKING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay H V coil Injector revolution timing sensor Air...

Page 181: ...in dicates that the switch is in position ON and that the deterrent flashing is on YES go to 2 NO go to 7 2 The decoder is properly programmed YES go to 3 3 Switch set to ON with side stand raised and...

Page 182: ...l tool to check the control unit power supply Pin 17 battery positive Pin 23 battery negative YES go to 12 NO go to 13 12 Control unit with proper base power supply 13 If the battery negative is not p...

Page 183: ...rking order of the fuse no 4 and 5 located in the fuse holder on the right side YES go to 5 NO go to 6 5 Place the special tool between control unit and injection system YES go to 7 Specific tooling 0...

Page 184: ...of the decoder CPU power supply line Pin 26 electronic control unit Pin 87 engine stop remote control switch continuity Pin 8 decoder Pin 87 engine stop remote control switch continuity YES go to 12 N...

Page 185: ...the tester positive with 86 negative with earth When the polarity is inverted there should be no continuity Diagnostic circuit CONNECTOR FOR DIAGNOSTIC TESTER A INJECTION CONTROL UNIT Connect the dia...

Page 186: ...terface wiring 5 Check the following conditions PIN 1 diagnostic socket PIN 10 control unit continuity PIN 2 diagnostic socket PIN 23 control unit continuity with earth PIN 3 diagnostic socket PIN 9 c...

Page 187: ...UN STANDARD VALUES Battery voltage The injection telltale light is controlled upon every switching to ON by the 3 second timing generated by the digital instrument This step is normally interrupted by...

Page 188: ...etects a fault When the fault disappears the light goes back off however the related operating tests need to be carried out The light can go on whether the engine is able to run or not Self diagnosis...

Page 189: ...table by the auto diagnosis may refer to the following system circuits or sectors of the control unit Throttle valve position signal ambient pressure signal coolant temperature signal intake air tempe...

Page 190: ...ng and retain bracket for the injector The pipes are crossed and fixed to the intake manifold to prevent wear of the quick unions connected to the T union for the injector N B BEFORE WORKING ON THE FU...

Page 191: ...coil 8 Fuel pump 9 Injector 10 Electronic injection control unit 11 Main remote control switch 12 Engine stop switch 13 Stand switch Removing the injector N B ONLY REMOVE THE INJECTOR FROM THE MANIFO...

Page 192: ...lly check to make sure the components are clean Fit new O rings and grease them Apply the recommended product to the set screws and tighten to the prescribed torque Recommended products Loctite 243 Me...

Page 193: ...good condition CAUTION IF AIR GETS IN IT CAN JEOPARDISE THE OPERATION OF THE INJECTION SYSTEM ESPECIALLY WHEN THE EN GINE IS IDLING Make sure the throttle valve and related conduit are clean Make sure...

Page 194: ...ouling cleaning should not be carried out when still covered by the warranty After cleaning the throttle body check and if necessary adjust C0 If these indications occur when the injection warning lig...

Page 195: ...system YES go to 6 Specific tooling 020680Y Diagnosis Tool 6 Try to start up Select the function ERRORS in the menu Check whether there are any failures YES go to 7 YES go to 8 NO go to 28 7 Pump cont...

Page 196: ...eginning 15 Set the switch to ON with switch to RUN and side stand raised Wait more than two sec onds and check the following conditions 19 23 battery voltage YES go to 16 NO go to 17 16 Replace the c...

Page 197: ...n and replace the fuse 24 Check the ground insulation of the primary winding of the HV coil and of the injector coil YES go to 25 25 Check the pump winding resistance approx 1 5 YES go to 26 NO go to...

Page 198: ...ng system components To perform the inspections it is necessary to use the special tooling kit for fuel pressure check Specific tooling 020480Y Petrol pressure check kit Before disconnecting any faste...

Page 199: ...ide Connect the manometer to the outlet duct RHS and the extension tube to the inlet duct LHS CAUTION BEFORE REASSEMBLING CHECK THE TOOL DUCTS ARE CLEAN Pressure regulator check 1 Connect the diagnost...

Page 200: ...uct by the extension of the specific tool the serial pipe does not allow this operation fuel pressure over 300 kPa 3 BAR YES go to 8 NO go to 9 8 Replace the pressure regulator 9 Replace the fuel pump...

Page 201: ...ES go to 5 NO go to 6 Specific tooling 020680Y Diagnosis Tool 4 If pressure is lower carefully check the voltage with pump under stress If voltage is higher than 12 V replace the pump 5 The system sea...

Page 202: ...ions Repeat the test clamping the pipe of the special tool in the portion between the branch and the pump Check whether pressure decreases much more slowly YES go to 14 NO go to 15 Specific tooling 02...

Page 203: ...rty Replace the pump support Pump electrics check This section describes the operations to be carried out to perform electric checks on the pump Resistor check Disconnect the connector from the pump s...

Page 204: ...AGE approx 12 V PUMP RUN IN SYSTEM PRESSURE 300 kPa 3 BAR FUEL FILTER CLEAN Electric characteristic Current consumption approx 3 5 4 2 A A dirty filter causes an increase of input If the pressure reli...

Page 205: ...rn pipes by the fast release fittings CAUTION PREVENT ANY FUEL SPRAYING Loosen the pump support mounting ring nut RH threading Remove the pump support and the sealing gas ket N B UPON EXTRACTING IT BE...

Page 206: ...level indicator wires Moving the float arm check that the resistance is subject to gradual variations according to the arm motion LIMIT VALUES Specification Desc Quantity 1 Empty tank position 95 105...

Page 207: ...assembly 3 Fuel pump Note the position of the power supply wires on the support pos 1 positive red pos 4 negative black Disconnect the power supply cables Cut the delivery pipe fastening clamp on the...

Page 208: ...a new clamp for the delivery pipe and a new pump mounting washer N B TO CLEAN THE PRE FILTER USE PETROL AND COMPRESSED AIR Orientate the pump properly 4 Fuel filter The fuel filter is supplied already...

Page 209: ...Screw the mounting ring nut and tighten thoroughly Locking torques N m Electric pump locking ring nut 20 Connect the feeding circuit pipes again and check the proper introduction by pulling and turnin...

Page 210: ...020680Y Diagnosis Tool 2 Enable the function with continuous power sup ply on and engine off The control unit controls the fuel pump continuously and at the same time starts the injector opening The i...

Page 211: ...9 Select the menu on the ERRORS function Check whether the injector failure message only is displayed YES go to 14 NO go to 10 10 There are also fault messages for pump relay YES go to 13 NO go to 11...

Page 212: ...resistance between pin 13 and pin 87 black green cable of the pump remote control switch 13 black green 14 5 5 resistance of the injector YES go to 19 NO go to 18 18 No continuity Disconnect the conn...

Page 213: ...20480Y Petrol pressure check kit 2 Prepare a graduated container with minimum capacity of 100 cm3 and a resolution of 10 20 cm3 Connect the injector to the wire supplied with the injection tester The...

Page 214: ...us formed impinges both in take valves N B AN INJECTOR WITH LOW FLOW RATE AFFECTS THE MAXIMUM PERFORMANCE AN INJECTOR WITH POOR SEAL AFFECTS IDLING AND THE START UP FEATURES AFTER A SHORT STOP WITH HO...

Page 215: ...MS control unit check the whole system carefully If the fault is fixed by replacing the EMS control unit install the original control unit again and check whether the fault occurs again 4 For troubles...

Page 216: ...12 Immobilizer LED 13 Decoder 14 Immobilizer aerial 15 Electronic control unit ECU Virgin circuit When control unit ECU and decoder are not pro grammed the following conditions occur Key switch set to...

Page 217: ...by connecting the ter minals to the battery poles or the specific connec tor to the socket inside the gloves compartment Set the switch to ON and select the diagnostic tester menu to the immobiliser f...

Page 218: ...beginning Once the system has been programmed master key transponder decoder and control unit are strictly matched With this link established it is now possible to encode new service keys in the event...

Page 219: ...A new 48 h cycle starts by switching from OFF to ON and OFF again Checking master box data Connect the diagnostic tester Set to ON and select the immobilizer function Scroll the pages the find the dat...

Page 220: ...he original master key A copy may also be requested using the scooter CODE CARD Program the system again using the master key and all service keys see System programming N B THE CODE CARD CAN ONLY BE...

Page 221: ...o to 7 NO go to 6 6 Disconnect the battery replace the control unit connect the battery Repeat the programming 7 The system is OK Code 2 Code no 2 denotes a system where the decoder does not perceive...

Page 222: ...Replace the decoder and check the presence of the code Code 3 Code no 3 denotes a system where the decoder perceives a transponder not provided for by pro gramming Start up disabled Injection telltal...

Page 223: ...ck 7 5A fuse No 10 located on the front glove box YES go to 4 NO go to 3 3 Check for any short circuits on the instrument unit power supply line check that the instrument unit has not short circuited...

Page 224: ...circuit to the decoder and of the central control unit Tachometer Electric characteristic TERMINAL 7 12 CONDITIONS Start up speed STANDARD approx 0 8 4 5 V CIRCUIT LAYOUT Specification Desc Quantity 1...

Page 225: ...f diagnosis is enabled on this circuit in 2 different ways based on use conditions Right after turning to ON Power under the panel present in the CPU the continuity and isolation of the sensor and rel...

Page 226: ...any faults on the Signal panel YES go to 2 NO go to 3 Specific tooling 020680Y Diagnosis Tool 2 THE FAULT HAS BEEN RECORDED IN MEMORISED STATUS The signal panel may be synchronised with possibility o...

Page 227: ...ling 020481Y Control unit interface wiring 10 Install the connection connector between the rpm timing sensor and injection system Measure the sensor resistance by connecting a multimeter between the t...

Page 228: ...tly by the sensor YES go to 17 NO go to 14 14 Higher or infinite resistance YES go to 15 NO go to 16 15 Check the connectors carefully Disconnect and check the continuity between connector and pin 7 1...

Page 229: ...n trying to start If not carefully check the ECU connection connector and replace it if necessary 21 Check the air gap and magnetic activity of the sensor See the Combustion unit and distribution chap...

Page 230: ...The ignition power is increased during the engine start up The injection system recognises the 4 stroke cycle and therefore ignition is only controlled during compression To check the ignition circuit...

Page 231: ...d to the pump rotation 2 seconds If you want to increase the test time enable the pump relay diagnosis function 30 seconds YES go to 7 NO go to 8 7 The coil primary control circuit is efficient Carefu...

Page 232: ...connector and pin 20 Electric characteristic Pink black 20 Continuity YES go to 12 NO go to 11 11 Check the continuity of the pink black wire in the two systems Electric characteristic Pink black coi...

Page 233: ...h the menu on ACTIVE DIAGNOSIS H V coil control simulation Delete the errors stored in memory 15 Check the continuity of the H V coil primary See figure Electric characteristic Primary resistance 0 5...

Page 234: ...inals and the spark plug cable output Electric characteristic Primary HV cable output 3 1 K 9 YES go to 18 NO go to 19 18 The coil is conforming 19 Replace the coil Inspecting the spark plug shielded...

Page 235: ...d on the engine rpm The ignition advance value is detectable at any time using the diagnostic tester It is possible to check whether the ignition advance determined by the injection system matches the...

Page 236: ...s menu Select the stroboscopic light control in the tradi tional four stroke engine position 1 spark 2 revs Check that the real values of rpm and ignition advance match those measured using the diag n...

Page 237: ...ailure of this circuit causes the switching on of the injection telltale light and the tripping of the safeties among which the electric fan continuous start In these conditions the engine works even...

Page 238: ...ES go to 5 5 Check the following values coolant temperature intake air temperature ambient temperature The three indications are equal or they are slightly different e g 1 C YES go to 6 NO go to 7 6 T...

Page 239: ...stance is detected 1MW check the continuity between the two lines with disconnected connectors Electric characteristic Blue white 4 0W continuity Light blue green 22 0 ohm Continuity YES point 12 12 R...

Page 240: ...tch to RUN and side stand raised YES go to 16 Specific tooling 020481Y Control unit interface wiring 16 Measure voltage at terminals 4 and 22 TEMPERATURE VOLTAGE Specification Desc Quantity 1 X V 10 C...

Page 241: ...as per table YES go to 22 NO go to 23 22 The temperature signal is conforming 23 Replace the temperature sensor N B FOR A MORE ACCURATE CHECK OF THE SENSOR RE MOVE IT FROM THE ENGINE AND CHECK ITS RES...

Page 242: ...onal layout as the coolant temperature sensor This signal is used to optimise the engine perform ance Anyway this data is less important than the coolant temperature signal A failure of this circuit c...

Page 243: ...RS menu YES go to 5 5 Check the following values coolant temperature intake air temperature ambient temperature indicated by the digital instrument The three indications are equal or they are slightly...

Page 244: ...al to the value directly detected at the sensor YES go to 13 NO go to 11 11 If slightly higher values are detected check the connectors If infinite resistance is detected 1M check the continuity of th...

Page 245: ...the fluid temp lines YES go to 13 15 Connect the special tool to the control unit Set the switch to ON with switch in RUN and side stand raised YES go to 16 Specific tooling 020481Y Control unit inte...

Page 246: ...heck YES go to 19 NO go to 20 19 Check the control unit connector Check the control unit power supply Replace the control unit if necessary 20 Repair or replace the cable harness 21 Start the engine a...

Page 247: ...e pressure sensor YES go to 2 NO go to 3 Specific tooling 020680Y Diagnosis Tool 2 Replace the injection control unit 3 Select the menu on the PARAMETERS function Check that the pressure value in mm H...

Page 248: ...e body This sensor receives a 5 V power supply from the control unit and transmit a gradually increasing voltage to the same with an increase of the throttle valve opening The control unit converts th...

Page 249: ...c tooling 020680Y Diagnosis Tool 2 Select the diagnostic tester menu on the PA RAMETERS function Check whether the control unit recognises the ex treme positions Throttle valve to minimum Throttle val...

Page 250: ...place the injection wiring YES go to 6 8 Check the earth insulation of the three circuit lines Electric characteristic 22 23 infinite 1M 1 23 infinite 1M 11 23 infinite 1M YES go to 10 NO go to 9 9 Re...

Page 251: ...ve position sensor connector Repeat the voltage measurement between terminals 1 and 22 of the special tool Electric characteristic 1 22 5 0 2 V YES go to 13 NO go to 14 13 Measure voltage between term...

Page 252: ...idling This regulation must not be tampered with in any way whatsoever The injection system will complete the management of the idling through the Stepper motor and the variation of the ignition adva...

Page 253: ...le valve with the control is supporting the stop screw Guaranteeing that this position will be kept send a confirmation for the TPS reset procedure Select the PARAMETERS function and check that the TP...

Page 254: ...le body is provided with an auxiliary air circuit This is enabled by a piston valve controlled by a Stepper motor The Stepper is powered by the control unit only when the opening must be changed The r...

Page 255: ...ise the speed In case of irregular speed before carrying out electric checks inspect the throttle valve and the auxiliary air circuit cleaning To check the Stepper and the relevant circuit pro ceed as...

Page 256: ...the Stepper controls some rev olution variations and wait for the diagnostic tester response N B THE ECU ENABLES THE DIAGNOSIS ONLY WHEN THE IDLE SPEED IS WITHIN THE SPECIFI CATIONS YES go to 6 NO go...

Page 257: ...replace the throttle body 10 Replace the throttle body 11 Connect the special tool For these checks do not connect the special tool to the control unit Check the continuity of the 4 power supply line...

Page 258: ...M infinite 6 23 1 M infinite 21 23 1 M infinite 24 23 1 M infinite YES go to 14 NO go to 13 13 Repair or replace the wiring YES go to 11 14 Connect the Stepper connector Repeat the continuity check w...

Page 259: ...the Stepper command lines Set up for direct voltage measurements N B PULSES ARE USED TO CHANGE THE STEPPER POSITION Electric characteristic 14 24 V pulses for a few seconds 6 21 V pulses for a few sec...

Page 260: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 261: ...ment in the odometer Check that the wheel axle does not show signs of wear or deformations If it does replace it Locking torques N m Wheel axle fixing screws 6 7 Nm Front wheel axle nut 45 50 Front wh...

Page 262: ...ting of adaptor handle 15 mm adaptor and guide on the odometer movement sensor side to facilitate removing the left side bearing and the spacer bushing Specific tooling 020376Y Adaptor handle 020456Y...

Page 263: ...earing on the od ometer movement sensor side with the heat gun Fit the 2 bearings using the punch con sisting of adaptor handle 32x35 mm adaptor and 15 mm guide and drive it until it stops Specific to...

Page 264: ...on the shield back plate Using the special tool loosen and remove the up per ring nut the spacer washer and the counter ring nut Extract the fork N B TAKE CARE TO SUPPORT THE FORK SO AS TO PREVENT IT...

Page 265: ...ED ONLY IF STRICTLY NECESSARY In case of replacement proceed as follows Using a bearing removal punch inserted from the bottom remove the top seat on the steering head Then remove the bottom seat of t...

Page 266: ...ember rota tion insert an inside 22 mm hexagon spanner into the stem Remove the pumping member Remove the dust guard ring using a screwdriver as shown in the figure N B BE CAREFUL NOT TO DAMAGE THE DU...

Page 267: ...ecommended products AGIP GREASE PV2 Grease for steering bear ings pin seats and swinging arm White anhydrous calcium based grease to protect roller bearings temperature range between 20 C and 120 C wi...

Page 268: ...retaining screws of the brake calliper to the support Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Fixing screw handlebar to steering tube 45 50 Holding torque of low...

Page 269: ...r Insert the pumping member into the stem Insert the stem into the fork leg being careful not to let the guiding bushing come out of the stem Insert and screw the pumping member screw with a new coppe...

Page 270: ...oosen the fork clamp screws and move the stem closing cap in abutment with the clamp Tighten the clamp screws to the prescribed tor que Locking torques N m Fork clamp screws 20 25 Steering bearing Rem...

Page 271: ...g tapered bearing seats Using the special tool reassemble the tapered bearing housings on the head as described below Place a new top housing on the head and a new bearing seat on the bottom side Inse...

Page 272: ...uard in the steering tube Insert the a new tapered bearing in the steering tube Using the special tool and a mallet to move the dust guard and the bearing in abutment Specific tooling 006029Y Punch fo...

Page 273: ...orm the previous operations in the reverse order Locking torques N m Wheel fastening screws 33 37 Swing arm Removal Remove the helmet compartment Remove the air filter Remove the rear mudguard Remove...

Page 274: ...der the oil sump Remove the nut of the pin mounting the swinging arm to the chassis Remove the lock nut then using a 15 mm fork spanner loosen the pin mounting the swinging arm to the chas sis Remove...

Page 275: ...gine Prevent the rotation of the pin connect ing the swinging arm to the engine us ing a 19 mm fork spanner Remove the nut and the washer from the scooter left side Pull out the pin from the right sid...

Page 276: ...no wear or dents on the roller bearing connection In case of irregularities replace the pin and the roller bearing Check that the pin connecting the swinging arm to the engine exhibits no wear at the...

Page 277: ...28 x 30 mm adaptor 020376Y Adaptor handle Overhaul Properly support the swinging arm in the vice Remove the Seeger ring Remove the ball bearing bushing Extract the ball bearing using the spe cial too...

Page 278: ...ng the special tool Specific tooling 020357Y 32x35 mm Adaptor 020362Y 12 mm guide 020376Y Adaptor handle Heat the bearing seat on the swinging arm Insert the bearing to abutment using the special tool...

Page 279: ...using the modular punch To install the right bearing lower the engine N B WHEN HEATING THE LEFT SEAT MOVE THE HOSE FOR OIL TO THE BRAKE CLAMP AWAY FROM THE ENGINE CRANKCASE FOR THE RIGHT PART REMOVE A...

Page 280: ...e washer and the flanged nut and move them close without tighten ing Check that the tie rod silent block is free from wear if not replace the com plete tie rod Check that the 2 tie rod spring pads are...

Page 281: ...e prescribed torque Locking torques N m bolt securing swinging arm to chassis 14 17 Lock nut 40 50 Tighten the right end of the chassis connecting pin to the prescribed tor que using a new nut Locking...

Page 282: ...rs Remove the muffler Loosen the shock absorber spring unit fastening screw from the support fixed to the engine and from that fixed to the muffler support Loosen the two top nuts one by side mounting...

Page 283: ...nuts Remove the centre stand On refitting tighten the nut to the specified torque Locking torques N m Central stand retainers 25 30 Side stand Release the springs Loosen the nut Extract the screw FITT...

Page 284: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 285: ...ased Remove the screws fixing the brake calliper to the bracket then remove the brake calliper com plete with pipe Complete the extraction of the pad retention pin the spring and the pads N B IF BRAKE...

Page 286: ...liper N B WHEN REMOVING THE O RINGS BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER SEATS Check that the pistons and their seats show no scratches Wash and blow all the components carefully Fit new sealin...

Page 287: ...tion as shown in the photograph Insert the pad fixing pin and the retention spring being careful to position its ends pointing towards the bleed screw as shown in the photograph Insert the circlips on...

Page 288: ...XING THE PLATE TO THE CRANKCASE Locking torques N m Pipe brake calliper coupling 20 to 25 Rear calliper support on crankcase retainer 20 25 Front brake calliper Removal Remove the two front break call...

Page 289: ...stons into their seats and lubricate with brake fluid Couple the half calliper and tighten the two screws to the prescribed torque Locking torques N m Calliper coupling screws 20 25 N m Refitting The...

Page 290: ...locking nuts Refitting To reassemble the brake disc on the hub carry out the removal operations in the reverse order ar ranging the brake disc on the hub on the side opposed the wheel keying Follow th...

Page 291: ...ts on the disc Check that the measurement does not deviate over 0 1 mm Check that the brake disc assembly ro tates smoothly using the appropriate tool fixed onto the brake calliper as shown in the pho...

Page 292: ...ns in the reverse order according to the direc tion of rotation of the disc as shown by the arrow on the disc Tighten the 5 screws to the prescribed torque Locking torques N m Brake disc tightening to...

Page 293: ...rn and check the disc deviation Specific tooling 020335Y Magnetic mounting for dial gauge Characteristic Max deviation allowed 0 1 mm Front brake pads Removal Remove the front brake calliper Remove th...

Page 294: ...d the reten tion spring being careful to position its ends pointing towards the bleed screw as shown in the photograph Insert the circlips on the break pad fix ing pin Keep the brake pad in contact wi...

Page 295: ...rding to the direction of rotation of the brake disc as indicated by the arrow on the anti vibration pad Insert the pad mounting pin and the re tain spring with its ends facing the bleed screw as show...

Page 296: ...t calliper To access the regulating valve it is necessary to remove the front shield Top up the brake fluid to the right level in the tank N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID...

Page 297: ...er the bleed screw Top up the brake fluid to the right level in the reservoir N B DURING THE BLEEDING OPERATIONS MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAM...

Page 298: ...THAT THE MAX LEVEL MUST ONLY BE OBTAINED WITH NEW PADS For re assembly perform the operations for removal in the reverse order according to the tightening torque of the tank cover screws Top up CAUTIO...

Page 299: ...he front handlebar cover Remove the two screws mounting the brake pump to the handlebar as shown in the figure Remove the oil pipe fitting from the pump undoing the screw indicated in the figure Remov...

Page 300: ...Handlebar pump 7 to 10 Oil pipe joint to the pump 20 25 Braking system Beverly 500 i e BRAK SYS 300...

Page 301: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 302: ...ator cold box is connected to the lower side of the expansion tank in the fluid When the engine is cold the thermostat output to the radiator is closed even though there is still a little flow for de...

Page 303: ...iator Starts opening 82 2 C ELECTRIC VENTILATION Specification Desc Quantity Type With piston Electric ventilation starts at 107 C Electric ventilation stops at 103 C WATER PUMP Specification Desc Qua...

Page 304: ...c ventilation temperature check the temperature sensor on the head and the relevant injection circuit see Injec tion chapter N B THE ELECTRIC VENTILATION TEMPERATURE AT 106 C CAN ONLY BE MANAGED WITH...

Page 305: ...N WILL IRRETRIEVABLY DEFORM THE SEALING GASKETS Coolant replacement System filling instructions Prepare the mixture of 50 water and 50 cool ant Fill the system to reach a level ranging between the MIX...

Page 306: ...ed in the Body chapter Remove the muffler to access the fly wheel cover as described in the En gine chapter Empty the cooling system removing the hoses located on the water pump cover and the loading...

Page 307: ...such cases we recommend cleaning the casing in order to be able to check again for leaks after a distance of more than 1500 km If leaks continue or in the event of real losses the ceramic seal should...

Page 308: ...Heat up the container using the ther mal gun Heat the water and periodically pull the thermostat out until its opening be comes visible Insert a thin copper wire between the seat and the thermostat c...

Page 309: ...head gasket seal see Thermal group and timing system chapter 3 Replace the cap Cooling fluid consumption 1 Check the system outer seals as described above YES go to 2 NO go to 3 2 Check the head gaske...

Page 310: ...INDEX OF TOPICS CHASSIS CHAS...

Page 311: ...wn in the figure one on each side Rear rack Loosen the two mounting screws and remove the battery cover Remove the plastic cover of the rear luggage rack by removing the two side screws from the lower...

Page 312: ...Remove the rear view mirrors and the windscreen Remove the upper coupling screws Remove the two lower mounting screws Remove the two rear handlebar cover screws Disconnect the electric wiring and re m...

Page 313: ...t Front handlebar cover Remove the rear handlebar cover Unscrew the two mounting screws shown in the figure and remove the front handlebar cover with headlight Headlight assy Remove the front handleba...

Page 314: ...Remove the chassis central cover by sliding it from the rear side of the scoot er and disconnecting it from the door opening transmission Legshield Remove Piaggio badge using a screw driver being care...

Page 315: ...the central cover Remove the two lower retainers indi cated in the figure Remove the whole front shield Knee guard Remove the front shield Disengage the fuse holder rubber cap and loosen the two scre...

Page 316: ...ton and of the fuel level damper device Remove the expansion tank fixing screw inside the glove box Remove the shield back plate central fixing screw Remove the two transmissions saddle opening and fu...

Page 317: ...itch when on off Remove the rear shield Remove the immobilizer aerial shown in the figure Lightly push the master cylinder and extract the lock from the notch shown in the figure Hence extract the mas...

Page 318: ...EL AND SET THE LOCK BODY INSIDE AND OUTSIDE PART TO OFF THEN PROCEED AS DE SCRIBED IN PARAGRAPH REMOVAL LOCK IN OFF PO SITION See also Removing the ignition key switch when on off Taillight assy Remov...

Page 319: ...disconnect the electric connector Footrest Remove the central cover Remove the six screws shown in the figure Remove the three retainers shown in the figure Remove the diagnosis socket RHS footrest o...

Page 320: ...w shown in the figure Remove the central cover Remove the rear light unit Remove the rear luggage rack Remove the three front side mounting screws shown in the figure Remove the rear side mounting scr...

Page 321: ...T INSIDE WALL Remove the plastic parts of the footrests and the sides License plate holder Remove the side panels Remove the side retainers from the li cence plate holder tail highlighted in the figur...

Page 322: ...by and condensate exhaust pipe cap Loosen the intake hose screw band Loosen the blow by pipe band Pull out the complete air filter box Rear mudguard Remove the air filter box Disconnect the rear brak...

Page 323: ...p remote control switch mounting screw Disconnect the two connectors alter nated and direct three phase of the voltage regulator remove the chassis system strap and the cable stop on the three phase T...

Page 324: ...s fixing the spoiler Fuel tank Remove the front shield Remove the footrest Remove the upper retainer and the two lower retainers of the spoiler N B THIS OPERATION SHOULD PREFERABLY BE PER FORMED WITH...

Page 325: ...RETTOR PIPING SINCE AN EXCESSIVE FORCE MAY DAM AGE THE PLASTIC INSERTS ON THE PUMP BODY UPON REASSEMBLY IT IS THEREFORE NECESSARY TO SLIGHTLY PRESS THE PIPING AND THE RETAIN RIM TO WARDS THE PUMP THE...

Page 326: ...mbly perform the operations in the reverse order paying attention to the following tightening torques Locking torques N m Chassis cross member lower screws 16 25 Chassis front cross member upper screw...

Page 327: ...e right front break pipes Remove the retainer C from the fork leg left cover Remove the retainer D from the left front break pipes Remove the two lower retainers E from the fork leg covers Remove the...

Page 328: ...ner for the coolant Remove the expansion tank outlet and return pipes Remove the coolant supply and return pipes from the radiator Loosen the screw mounting the radiator to the frame Disengage the rad...

Page 329: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 330: ...ube 45 50 Upper steering ring nut 36 39 Steering lower ring nut 10 13 tighten and loosen by 90 Cover retaining screws Electrical system Electrical System Main switch Headlamps high beams low beams sid...

Page 331: ...MEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO ENSURE ADEQUATE VENTILATION...

Page 332: ...on Engine Check for correct general operation and make sure there is no unusual noise Other Check documents Check the frame and engine numbers Check tool kit License plate fitting Check locks Check ty...

Page 333: ...INDEX OF TOPICS TIME TIME...

Page 334: ...Engine ENGINE Code Action Duration 1 001001 Engine from chassis replacement 2 003057 Engine retainer Tighten nuts Time Beverly 500 i e TIME 334...

Page 335: ...Crankcase CRANKCASE Code Action Duration 1 001100 Oil seal clutch side Replacement 2 001133 Engine crankcase Replacement 3 001153 Crankcase half gasket Replace ment Beverly 500 i e Time TIME 335...

Page 336: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement 2 001098 Countershaft Replacement Time Beverly 500 i e TIME 336...

Page 337: ...er assy CYLINDER ASSEMBLY Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pistonsrings pin assembly Service 3 001129 Chain tensioner Service and Re placement Beverly 500 i e Time TI...

Page 338: ...001045 Valves Replacement 2 001049 Valves adjust 3 001056 Head gasket change 4 001126 Head Replacement 5 005081 Temperature sensor Replacement 6 005116 Rpm timing sensor Replacement 7 007012 Coolant b...

Page 339: ...Rocker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001044 Camshaft Replacement 2 001148 Valve rocking levers Replacement Beverly 500 i e Time TIME 339...

Page 340: ...Cylinder head cover HEAD COVER Code Action Duration 1 001089 Head cover Replacement 2 001093 Spark plug Replacement 3 001088 Head cover gasket Replacement Time Beverly 500 i e TIME 340...

Page 341: ...01123 Oil filter Replacement 4 001124 By pass valve Replacement 5 001057 Thermostat Replacement 6 001062 Water pump command shaft Re placement 7 001150 Flywheel cover gasket change 8 001160 Minimum oi...

Page 342: ...LEY Code Action Duration 1 001022 Clutch Replacement 2 003072 Clutch unit Wear check 3 001012 Driven pulley overhaul 4 001110 Driven pulley Replacement 5 001155 Clutch bell Replacement Oil pump Time B...

Page 343: ...pump change 4 001125 Chain guide pads Replacement Final gear assy FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 1 001010 Geared reduction unit Service 2 001156 Gear reduction unit cover Replace m...

Page 344: ...ction Duration 1 001086 Driving half pulley Replacement 2 001011 Drive belt Replacement 3 001006 Driving pulley Service 4 001141 Belt anti flapping roller Replace ment 5 001066 rear view pulley Replac...

Page 345: ...1 001065 Internal transmission cover Re placement 2 001096 External transmission cover Re placement 3 001131 Transmission air intake Replace ment 4 001135 Transmission cover bearing Re placement 5 001...

Page 346: ...Starter motor STARTER MOTOR Code Action Duration 1 001020 Starter motor Replacement 2 001017 Start up pinion Replacement 3 003064 Engine oil change Time Beverly 500 i e TIME 346...

Page 347: ...eto MAGNETO FLYWHEEL Code Action Duration 1 001058 Flywheel Replacement 2 001067 Stator Replacement 3 001104 Start up freewheel Replacement 4 001151 Starter driven gearing Replacement Beverly 500 i e...

Page 348: ...Butterfly valve THROTTLE BODY Code Action Duration 1 001013 Intake manifold change 2 001047 Injector Replacement 3 001166 Throttle body Replacement Time Beverly 500 i e TIME 348...

Page 349: ...pe SILENCER Code Action Duration 1 001009 Silencer Replacement 2 001092 Exhaust manifold Replacement 3 001095 Silencer heatshield Replacement 4 001136 Exhaust emissions Adjustment Beverly 500 i e Time...

Page 350: ...Code Action Duration 1 001015 Air filter box Replacement 2 001014 Air filter Replacement cleaning 3 004122 Cleaner Throttle body union Re placement 4 001074 Oil vapour recovery pipe Replace ment Time...

Page 351: ...Frame CHASSIS Code Action Duration 1 004001 Chassis Replacement 2 006001 Frame Painting Centre stand Beverly 500 i e Time TIME 351...

Page 352: ...nd Replacement 3 005079 Stand switch Replacement Legshield spoiler SPOILER FRONT SHIELD Code Action Duration 1 004064 Legshield front section Replace ment 2 006012 Front shield Paintwork 3 004053 Spoi...

Page 353: ...VERS Code Action Duration 1 004085 Fairing 1 Replacement 2 006005 Side covers Painting 3 004129 Bumper fairing Replacement 4 004012 Fairings 2 Replacement 5 004159 Plates Stickers Replacement Beverly...

Page 354: ...AND COVERS Code Action Duration 1 004075 Front mat Replacement 2 004079 Passenger footrest 1 Replace ment 3 004015 Footrest Replacement 4 004059 Spark plug inspection flap Replace ment Time Beverly 50...

Page 355: ...Rear cover REAR SHIELD Code Action Duration 1 004065 Shield back plate Replacement 2 004081 Top box lid Replacement 3 005121 Saddle opening button Replace ment Beverly 500 i e Time TIME 355...

Page 356: ...VER Code Action Duration 1 004011 Central chassis cover Replacement 2 002082 Fuel tank door opening drive Re placement 3 004135 Fuel tank port Replacement 4 004157 Fuel port coupling Replacement Time...

Page 357: ...Helmet compartment Replacement 2 004106 Under saddle band Replacement 3 004136 License plate holder mounting Re placement 4 005046 Battery cover change 5 005033 Under seat light switch Replace ment 6...

Page 358: ...Mudguard MUDGUARD Code Action Duration 1 004009 Rear mudguard Replacement 2 004002 Front mudguard change 3 006003 Mudguard Painting Time Beverly 500 i e TIME 358...

Page 359: ...Fuel tank FUEL TANK Code Action Duration 1 004109 Fuel tank breather change 2 004005 Fuel tank Replacement Beverly 500 i e Time TIME 359...

Page 360: ...tank EXPANSION TANK Code Action Duration 1 007001 Expansion tank Replacement 2 001052 Coolant and air bleed Replacement 3 007013 Expansion tank radiator connecting hose Replacement Time Beverly 500 i...

Page 361: ...RADIATOR Code Action Duration 1 007002 Water cooling radiator Replace ment 2 007016 Fan complete with support Re placement 3 007003 Delivery line and coolant return Re placement Beverly 500 i e Time...

Page 362: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorbers Replace ment Time Beverly 500 i e TIME 362...

Page 363: ...03079 Fork stem Replacement 3 003048 Fork oil seal Replacement 4 004119 Bearing upper steering fifth wheel Replacement 5 003002 Steering fifth wheel Replacement 6 003073 Steering clearance Adjustment...

Page 364: ...ration 1 004018 Handlebar front section Replace ment 2 004019 Handlebar rear section Replace ment 3 006013 Handlebar front part Painting 4 006014 Handlebar rear part Painting 5 005091 Turn indicator g...

Page 365: ...nt 4 002024 Front brake pump replace 5 002088 Integral brake pump Replacement 6 003001 Handlebar Replacement 7 002063 Throttle control transmission Re placement 8 002059 Right hand grip Replacement 9...

Page 366: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Engine chassis connection swinging arm Replacement 2 003082 Damper arm Replacement Time Beverly 500 i e TIME 366...

Page 367: ...e piping Replacement 3 002047 Front brake fluid and air bleed sys tem Replacement 4 002084 Integral brake pump pipe device Replacement 5 002085 Integral front brake pipes 6 002089 Integral braking dev...

Page 368: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement 2 004144 Saddle cover Replacement Time Beverly 500 i e TIME 368...

Page 369: ...dle opening transmission Re placement 2 002092 Transmission splitter hook transmis sion Replacement 3 004054 Saddle lock catch Replacement 4 004158 Saddle opening splitter Replace ment 5 005099 Electr...

Page 370: ...ent panel LIGHT ASSEMBLY Code Action Duration 1 005014 Instrument panel Replacement 2 005038 Instrument panel warning light bulbs Replacement 3 005078 Odometer glass Replacement Time Beverly 500 i e T...

Page 371: ...Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement 2 006002 Luggage rack Painting 3 004062 Luggage rack cover Replacement Beverly 500 i e Time TIME 371...

Page 372: ...Locks LOCKS Code Action Duration 1 005016 Key switch Replacement 2 004010 Antitheft lock Replacement Time Beverly 500 i e TIME 372...

Page 373: ...placement 4 005031 number plate light bulb Replace ment 5 005032 number plate light glass Replace ment 6 005044 Front lights cable unit replace 7 005066 Rear light bulbs Replacement 8 005067 Front tur...

Page 374: ...7 Front tyre Replacement 8 003063 Tyre pressure Check 9 004123 Front wheel Replacement 10 006018 Wheel rim Paintwork Grease tone wheel or drive Please take note that the code has been intro duced 9000...

Page 375: ...Replacement 2 001071 Rear wheel rim Removal and Refit ting 3 002070 Rear brake disc Replacement 4 003063 Tyre pressure Check 5 003077 muffler rear shock absorber support arm Service 6 004126 Rear whe...

Page 376: ...Fuel pump FUEL PUMP Code Action Duration 1 004073 Fuel pump Replacement 2 004137 Injector pump pipe Replacement Time Beverly 500 i e TIME 376...

Page 377: ...005115 Fuel level electrical damper Re placement 8 005080 Front fuse holder Replacement 9 005035 Headlight solenoid Replacement 10 005117 Electric fan contactor Replacement 11 005118 Arrows remote con...

Page 378: ...ghts switch Replacement 2 005006 Light or turning indicator switch Re placement 3 005040 Horn button Replacement 4 005041 Starter button Replacement 5 005047 Emergency stop switch change 6 004117 Top...

Page 379: ...ery change 3 005009 Voltage regulator Replacement 4 005011 Starter relay Replacement 5 005026 Helmet compartment bulb Replace ment 6 005027 Helmet compartment bulb support Replacement 7 005073 Immobil...

Page 380: ...2 002007 Front brake pads Replacement 3 002039 Front brake calliper Replacement 4 002040 Front brake calliper Check 5 002048 Rear brake calliper Replacement 6 002068 Rear brake calliper Check 7 003070...

Page 381: ...43 Coolant 236 305 E Electric 303 377 Engine oil 24 F Fuel 11 190 200 204 324 359 376 Fuses 45 H Headlight 30 313 Horn Hub oil 22 I Identification 7 Immobilizer Instrument panel 313 370 L Luggage rack...

Page 382: ...Switch T Tank 11 324 359 360 Technical Data Transmission 8 55 71 345 Turn indicators Tyres 9 V Vehicle 7 52...

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