PIAGGIO Beverly Tourer 125 Service Station Manual Download Page 114 | Manualshive

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Removing the cylinder head

- Remove the spark plug.

- Remove the 2 side fixings shown in the figure.

- Loosen the 4 head-cylinder fastening nuts in two

or three stages and in criss-cross fashion.

- Remove the head, the two centring dowels and

the gasket.

N.B.

IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-
OUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.

Engine

Beverly 125

ENG - 114

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Summary of Contents for Beverly Tourer 125

Page 1: ...SERVICE STATION MANUAL 664602 IT 664603 EN 664604 FR 664605 DE 664606 ES 664607 PT 664608 OL 664609 EL Beverly 125...

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

Page 3: ...visable to read the sections of this manual relating to special tools as well as the tool catalogues N B Provides key information to make the procedure easier to understand and carry out CAUTION Refer...

Page 4: ......

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

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

Page 7: ...you do not breathe in the dust produced by the wear of the friction material Even though the latter contains no asbestos inhaling dust is harmful Maintenance rules Use original PIAGGIO spare parts and...

Page 8: ...AND DIMENSIONS Specification Desc Quantity Kerb weight 161 5 kg Maximum weight allowed 350 kg Width 770 mm Length 2110 mm Wheelbase 1470 mm Height 1460 mm Engine ENGINE Specification Desc Quantity Ty...

Page 9: ...10 l Transmission oil 250 cm Cooling system fluid 1 75 l Fuel tank reserve 10 l 2 l Electrical system ELECTRICAL SYSTEM Specification Desc Quantity Ignition type Electronic capacitive discharge ignit...

Page 10: ...ith passenger 2 5 bar N B CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE REGU LATE PRESSURE ACCORDING TO THE WEIGHT OF THE RIDER AND ACCESSORIES Secondary air The SAS for 125cc leade...

Page 11: ...n the figure Now the filtered air enters the diaphragm device and then is channelled to the head The air passes through a rigid pipe connected to the head and reaches a discharge joint in order to sup...

Page 12: ...air jet 130 Throttle valve spring 100 160 g Minimum mixture set screw initial opening 2 Tapered pin 2 45 Diffuser nozzle 2 8 Starter air jet 1 5 Starter jet 42 Starter device resistance 20 Starter pin...

Page 13: ...6 Pad fastening pin 19 6 24 5 REAR SUSPENSION Name Torque in Nm Left lower shock absorber support bolt 20 25 Upper shock absorber clamp 33 41 Lower shock absorber clamp 33 41 Rear wheel axle 104 126 F...

Page 14: ...in Nm Belt support roller screw 11 13 Clutch unit nut on driven pulley 45 50 Drive pulley nut 75 83 Transmission cover screws 11 13 Driven pulley shaft nut 54 60 Rear hub cover screws 24 27 FLYWHEEL...

Page 15: ...159 0 045 0 059 Piston 1st Oversize C 1 57 211 57 218 57 159 57 166 0 045 0 059 Piston 1st Oversize D 1 57 218 57 225 57 166 57 173 0 045 0 059 Cylinder 2nd Oversize A2 57 397 57 404 57 345 57 352 0...

Page 16: ...g Type A red 1 970 1 973 Crankshaft half bearing Category B blue 1 973 1 976 Crankshaft half bearing Type C yellow 1 976 1 979 Crankshaft class 1 Crankcase class 1 C C Crankshaft class 1 Crankcase cla...

Page 17: ...Half shaft transmission side 16 6 0 0 05 A D 0 20 0 50 Flywheel side half shaft 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 Slot packing sy...

Page 18: ...B NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TOP DEAD...

Page 19: ...ratio and vice versa N B NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH...

Page 20: ...Oil scraper ring 3rd Oversize 57 6 x 1 A Oil scraper ring 3rd Oversize 57 6 x 2 5 A 0 15 0 35 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W 90 Rear hub oil SAE...

Page 21: ...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 SPEZIAL coolant Monoethylene glycol based antifreeze fluid CUNA...

Page 22: ...INDEX OF TOPICS TOOLING TOOL...

Page 23: ...PRIATE TOOLS Stores code Description 020151Y Air heater 020331Y Digital multimeter 020648Y Single battery charger 001467Y014 Pliers to extract 15 mm bearings 020412Y 15 mm guide Beverly 125 Tooling TO...

Page 24: ...Stores code Description 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47 mm adaptor 020363Y 20 mm guide Tooling Beverly 125 TOOL 24...

Page 25: ...fitting bearing on steering tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting 020382Y011 adapter for valve...

Page 26: ...424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve seal rings 020360Y Adaptor 52 x 55 mm 020364Y 25 mm guide...

Page 27: ...28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting removing the driven pulley clutch 020330Y Stroboscopic light to check timing 001467Y035 Belle for OD 47 mm bearings 020368Y driving pulley l...

Page 28: ...bilizer check tester 020287Y Clamp to assemble piston on cylinder 020263Y Sheath for driven pulley fitting 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool 020428Y Piston position check...

Page 29: ...Piston fitting fork 020425Y Punch for flywheel side oil seal 020423Y driven pulley lock wrench 020414Y 28 mm guide 020393Y Piston fitting band 020382Y Valve cotters equipped with part 012 re moval to...

Page 30: ...020455Y 10 mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum operated pump 020357Y Adaptor 32 x 35 mm 020409Y Multimeter adaptor Peak voltage detec tion Tooli...

Page 31: ...4 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut 002465Y Pliers for circlips 001330Y Tool for fitting steering...

Page 32: ...or fitting piston pin stops 200 250 020622Y Transmission side oil guard punch 020444Y011 adapter ring 020444Y009 46x55 Wrench 001467Y Extractor for bearings for holes 001467Y013 Pliers to extract 15 m...

Page 33: ...Description 020444Y010 adapter ring 020244Y 15 mm diameter punch 020115Y 18 punch 020271Y Tool for removing fitting silent bloc 020627Y Flywheel lock wrench 020467Y Flywheel extractor Beverly 125 Tool...

Page 34: ...Stores code Description 020626Y Driving pulley lock wrench 020628Y Water pump service kit Tooling Beverly 125 TOOL 34...

Page 35: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 36: ...6 000 KM Action Engine oil change Hub oil level check Spark plug electrode gap check Air filter clean Oil filter Replacement Valve clearance Check Sliding blocks variable speed rollers check Driving b...

Page 37: ...AT 48 000 KM Action Engine oil replacement Hub oil change Spark plug replacement Air filter clean Engine oil change Idle speed adjustment Sliding block variable speed rollers change Throttle lever adj...

Page 38: ...check Headlight adjustment Tyre pressure and wear check Vehicle and brake test road test See instructions in the Idle speed adjustment section AFTER 72 000 KM Action Engine oil replacement Hub oil ch...

Page 39: ...roper polarity the arrow stamped on the pincers must be pointing at the spark plug Place the light selector in central position 1 spark 1 crankshaft turn as in 2 T engines Start the engine and check t...

Page 40: ...oling 020330Y Stroboscopic light to check timing Spark advance variation REVOLUTION LIMITER Specification Desc Quantity Operation threshold First threshold 10700 50 Second threshold 11000 50 Reactivat...

Page 41: ...nding the side electrode very carefully In case of anomaly as described before replace the spark plug with another of the recommended type Fit the spark plug with the correct angle and man ually screw...

Page 42: ...again and make sure it is locked properly into place The notches on the hub oil level dipstick except for the notch indicating the MAX level refer to oth er manufacturer s models and have no specific...

Page 43: ...SIBLE OIL DEPOSITS Cleaning Wash with water and car shampoo Dry with short blasts of compressed air and a clean cloth Soak with a 50 mixture of gasoline and oil Drip dry the filtering element and then...

Page 44: ...eeding the MAX level reference mark N B THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceed the require ments of API...

Page 45: ...n any case by adding oil without ever exceeding the MAX level Restoring the level between the MIN and MAX reference marks requires 400 cm of oil Engine oil filter The cartridge filter must be replaced...

Page 46: ...The TDC reference mark is repeated also be tween the flywheel cooling fan and the flywheel cover To use this reference mark remove the spark plug and turn the engine in the opposite direction to the...

Page 47: ...t ground Undo the screw shown in the figure and remove the expansion tank cap on RHS Remove the expansion tank cap A and top up if the fluid level is near or below the MIN level ref erence mark in the...

Page 48: ...ograph Remove the tank cap by loosening the two screws remove the gasket and top up using only the liquid specified without exceeding the maxi mum level CAUTION ONLY USE DOT 4 CLASSIFIED BRAKE FLUID C...

Page 49: ...s of the scooter is per pendicular to the screen 2 Turn on the headlight and check that the limit of the projected light beam is not over 9 10 or below 7 10 of the distance from the ground to the cent...

Page 50: ...torted If there is replace it Check that the metal pipe does not have any dents To refit follow the removal procedure but in re verse order being careful to respect the direction of the rubber couplin...

Page 51: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL...

Page 52: ...Adjust the valve clearance properly Valve seat distorted Replace the head assembly Defective floating valve Check the proper sliding of the float and the functioning of the valve Rear wheel spins at i...

Page 53: ...ired Carefully clean the By Pass area Oil pump with excessive clearance Perform the dimensional checks on the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Re...

Page 54: ...Check that there is no fuel in the low pressure duct Starter inefficient Check electric wiring circuit continuity mechanical sliding and power supply Air filter blocked or dirty Remove the sponge wash...

Page 55: ...replace any damaged part Braking vibrations or noise VIBRATIONS OR NOISE WHEN BRAKING Possible Cause Operation Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge an...

Page 56: ...f irregu larities in turning the steering continue even after making the above adjustments check the seats on which the ball bearings rotate replace them if they are recessed or if the balls are flat...

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

Page 58: ...mobiliser relay 7 Engine stop relay 8 Voltage regulator 9 Rear fuse unit 10 12V socket 11 Battery 12 Starter motor 13 Start up remote control 14 Starter button 15 Stop button on rear brake 16 Front fu...

Page 59: ...t turn indicator 31 Horn 32 Horn button 33 Electric fan 34 Thermoswitch 35 Thermistor 36 Engine oil pressure sensor 37 Saddle opening switch 38 Saddle opening actuator 39 Fuel level transmitter 40 Ins...

Page 60: ...ue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Conceptual diagrams Ignition KEY 1 Electronic ignition device 2 Immobilizer aerial 4 Side stand switch 5 Engine stop switch 7 E...

Page 61: ...Side stand switch 5 Engine stop switch 7 Engine stop relay 9 Rear fuse unit 11 Battery 16 Front fuses unit 20 Light remote control 22 Light switch 24 License plate light 26 Rear light A Tail light bu...

Page 62: ...y switch Battery recharge and starting KEY 1 Electronic ignition device 3 Magneto flywheel Pick up 4 Side stand switch 5 Engine stop switch 6 Start up immobiliser relay 7 Engine stop relay 8 Voltage r...

Page 63: ...light bulb 46 Key switch Level indicators and enable signals section KEY 1 Electronic ignition device 2 Immobilizer aerial 4 Side stand switch 5 Engine stop switch 7 Engine stop relay 9 Rear fuse uni...

Page 64: ...r temperature gauge 46 Key switch Devices and accessories KEY 1 Electronic ignition device 4 Side stand switch 5 Engine stop switch 7 Engine stop relay 9 Rear fuse unit 10 12V socket 11 Battery 16 Fro...

Page 65: ...ic fuel pump 42 Fuel pump control device 46 Key switch Checks and inspections Immobiliser The electric ignition system is fed with direct cur rent and is protected by an antitheft immobilizer integrat...

Page 66: ...ins off check the control unit power supply as follows Disconnect the control unit connector Check if There is battery voltage between terminal No 4 Red Black and the ground lead There is battery volt...

Page 67: ...quence and times must be strictly observed or it will be necessary to repeat the procedure from the start Once the control unit has been programmed the control unit is inseparably matched with the MAS...

Page 68: ...ARY TO AVOID SPOILING A NEW CONTROL UNIT Specific tooling 020331Y Digital multimeter Electric characteristic immobilizer aerial 7 9 Ohm 2 FLASH CODE Example with programmed control unit no transponder...

Page 69: ...is practically irrelevant for the ignition system The Pick Up is connected to the control unit by a single cable then for the ground circuit the control unit is connected to the Pick Up by the chassi...

Page 70: ...igure If non conforming values are measured check again the HV primary coil directly on the positive and negative terminals If non conforming values are measured repair the cable harness or else re pl...

Page 71: ...ptor Peak voltage de tection Electric characteristic Voltage value 5 Volt HV coil With the control unit and HV coil connected meas ure the voltage of the coil primary during the start up test with the...

Page 72: ...epeat the checks directly to the stator In case of further rep etitions of incorrect values replace the stator or repair the wiring Voltage regulator check With a perfectly charged battery and lights...

Page 73: ...idle speed is adjusted as prescribed Connect an ammeter induction pliers to the volt age regulator positive terminal measure the bat tery voltage and turning on the vehicles lights with engine off wa...

Page 74: ...inal No 5 Green Red and the negative one to terminal No 7 White Black see figure If there is no voltage replace the control unit after making sure that the fuses are not blown other wise check the cab...

Page 75: ...t If the cable harness is in good conditions and the turn indicators still do not turn on replace the turn indicator switch because it is faulty Lights list LIGHT BULB TABLE Specification Desc Quantit...

Page 76: ...otection fuses A To reach the board of fuses A remove the screw B and then the mouldings 2 Four protection fuses C for the different cir cuits of the electrical system located inside the front case to...

Page 77: ...iring 6 Fuse No 6 Position on fuse holder 6 Capacity 10 A Protected circuits Spare fuse Location Right fairing 7 Fuse No 7 Position on fuse holder 7 Capacity 15A Protected circuits Radiator electrical...

Page 78: ...HE VEHICLE OR EVEN CAUSE A FIRE CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE INADEQUATE CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED SHORTENS THE LIFE OF...

Page 79: ...r of the fuel pump control device and the negative probe to pin 3 making sure there is bat tery voltage as indicated in the table PUMP SUPPLY Specification Desc Quantity Key set to KEY ON Supply to th...

Page 80: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE...

Page 81: ...orques Locking torques N m Nuts fixing muffler to support arm 27 30 Nut fixing muffler to cylinder head 16 18 Removal of the engine from the vehicle CAUTION SUPPORT THE SCOOTER ADEQUATELY Disconnect t...

Page 82: ...RNING CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD WARNING BE VERY CAREFUL WHEN HANDLING FUEL CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSI TIVE LEAD FIRST AND THEN THE NEGATIVE LEAD When...

Page 83: ...INDEX OF TOPICS ENGINE ENG...

Page 84: ...e figure remove the driven pulley shaft locking nut and washer Specific tooling 020423Y driven pulley lock wrench Remove the cap dipstick from the engine oil filling hole Remove the ten screws Remove...

Page 85: ...he painted surface Insert the bearing in its seat Refit the seeger ring CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM AGING THE COVER PAINT N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON RE...

Page 86: ...N m Anti flapping roller 12 16 Plastic roller Check that the roller does not show signs of wear and that it turns freely Remove the special clamping screws as indica ted in the photograph Check the o...

Page 87: ...ged Measure the clutch bell inside diameter Characteristic Max value clutch bell Max value 134 5 mm Clutch bell standard value Standard value 134 134 2 mm Checking the bell working surface eccentricit...

Page 88: ...ion F from the tool internal side Insert the adapter ring 8 in the pins Assemble the driven pulley unit on the tool intro ducing the rivets heads in the adapter ring Make sure that the clutch is perfe...

Page 89: ...NS CAN CAUSE THE CLUTCH TO TEAR CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT A VARIATION IN THE RETURN SPRING LOAD Characteristic Check minimum thickness 1 mm Pin retaining collar Simultaneou...

Page 90: ...properly using the bell as shown in the figure Specific tooling 001467Y035 Belle for OD 47 mm bearings Remove the roller bearing using the modular punch Specific tooling 020376Y Adaptor handle 020456...

Page 91: ...r 41 000 41 035 mm Refitting the driven half pulley bearing Support the pulley bushing adequately from the threaded side using a wooden surface Fit a new roller sleeve as in the figure For the fitting...

Page 92: ...Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B TH...

Page 93: ...s axis can be seen in full Insert the clutch on the adapter ring Lubricate the end of the spring that abuts against the servo system closing collar Insert the spring with its plastic holder in contact...

Page 94: ...elt unit from the tool N B FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYM METRIC THE FLATTEST SURFACE SHOULD BE MOUN TED IN CONTACT WITH THE CLUTCH N B DURING THE SPRING PRELOADING PHASE BE CARE FUL NOT...

Page 95: ...hing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Removing the driving pulley With the appropriate...

Page 96: ...s 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 Check that the O ring is not pushed out of shape CAUTION DO...

Page 97: ...ot damaged on the grooved edge Mount the complete bushing unit on the driving shaft Fit the driven pulley Clutch belt unit on the en gine Correctly refit the previously removed Bendix back to its posi...

Page 98: ...over Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover Replace the cover tightening the 10 screws at the specifi...

Page 99: ...el axis complete with gear Remove the intermediate gear Removing the hub bearings Check the state of the bearings being examined wear clearance and noisiness If faults are de tected do the following U...

Page 100: ...upport the hub cover and expel the bearing By means of the appropriate tools remove the oil guard as in the figure Specific tooling 020376Y Adaptor handle 020477Y Adaptor 37 mm 020483Y 30 mm guide 020...

Page 101: ...Remove the seeger ring shown in the figure Remove the driven pulley shaft bearing using the modular punch Specific tooling 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020363Y 20 mm guide Inspect...

Page 102: ...wn in the figure Fit the seeger ring Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur face by means of the appropriate tool used from the 52 mm si...

Page 103: ...ET Refit the driven pulley shaft bearing with a mod ular punch as shown in the figure N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN ER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SI...

Page 104: ...ng sure the breather pipe is in the correct position Place the 3 shortest screws identifiable by their different colour as shown in the figure Fasten the breather pipe support bracket with the lower s...

Page 105: ...he 4 retainers and the flywheel cover Removing the stator Remove the electric terminal of the minimum oil pressure switch Remove the two Pick Up screws and the one for the wiring harness bracket as we...

Page 106: ...s N m Stator assembly screws 3 4 Refitting the flywheel cover Place the flywheel with the top dead centre mark aligned with the crankcase Place the flywheel cover by aligning the reference marks of th...

Page 107: ...t of its seat Removing the flywheel magneto Remove the water pump shaft and crankshaft spline clip Line up the two holes in the flywheel as shown in the photo Screw in the guide bushing that is part o...

Page 108: ...tract it as shown in the photograph Specific tooling 020467Y Flywheel extractor Lock the rotation of the Flywheel with the calliper spanner tool Remove the nut Take out the flywheel CAUTION THE USE OF...

Page 109: ...adlock Loctite 243 medium strength threadlock Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly wheel itself i e with wheel seeger ring visible Lock...

Page 110: ...Flywheel nut 94 102 Fit the flywheel being careful to insert the key properly Lock the flywheel nut to the prescribed torque Check that the Pick Up air gap is between 0 34 0 76 mm The air gap cannot b...

Page 111: ...N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Remove the flywheel cover completely as de scribed in the flywheel cover section Loosen the 3 crews and remo...

Page 112: ...er Remove the central screw fastener and the au tomatic valve lifter retaining cover as shown in the figure Remove the return spring of the automatic valve lifter unit and the automatic valve lifter u...

Page 113: ...has been removed N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Removing the cam shaft Remove the two screws and the cam shaft re taine...

Page 114: ...nuts in two or three stages and in criss cross fashion Remove the head the two centring dowels and the gasket N B IN CASE OF NEED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS ROCKING LEVERS AND FIXI...

Page 115: ...020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020306Y Punch for assembling valve seal rings Removing the cylinder piston assy Remove the chain gui...

Page 116: ...rometer N B REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING Characteristic Rod small end check up Maximum diameter 15...

Page 117: ...from the piston crown in the position shown in the figure Carefully clean the seal housings Measure the coupling clearance between the seal rings and the grooves using suitable sensors as shown in th...

Page 118: ...to the directions shown in the figure Check that the head coupling surface is not worn or misshapen Pistons and cylinders are classified according to diameter The coupling is carried out in pairs A A...

Page 119: ...see figure of the sealing rings using a feeler gauge If any measurements are greater than specified replace the piston rings N B BEFORE REPLACING ONLY THE PISTON RINGS ENSURE THAT THE CLEARANCE BETWE...

Page 120: ...ted on the tool S left D right Place the wrist pin stop ring into position using a punch Fit the wrist pin stop using the plug as shown in the figure N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE...

Page 121: ...ersa N B NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WITH THE PISTON AT TO...

Page 122: ...on ratio and vice versa N B NO GASKETS AND SEALS SHOULD BE ASSEMBLED BETWEEN THE CRANKCASE AND CYL INDER AND THE DIAL GAUGE EQUIPPED WITH SUPPORT SHOULD BE SET TO ZERO FOR MEASUREMENT A TO BE TAKEN WI...

Page 123: ...ence mark facing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil N B THE TWO PISTON RINGS AR...

Page 124: ...aximum allowable run out 0 05 mm Check that the camshaft and the rocker pin ca pacities exhibit no wear Check that the cylinder head cover surface the intake manifold and the exhaust manifold are not...

Page 125: ...ve the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole as...

Page 126: ...dard diameter 5 000 5 012 mm Valve seat wear Exhaust guide Accepted limit 5 022 Valve seat wear Exhaust guide Standard diameter 5 000 5 012 mm Inspecting the valves Measure the width of the sealing su...

Page 127: ...O NOT KEEP ROTATING 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 N B DO NOT CHANGE THE...

Page 128: ...Inspecting the springs and half cones Check that the upper spring caps and the cotter halves show no signs of abnormal wear Engine Beverly 125 ENG 128...

Page 129: ...tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam shaft for signs of abnormal wear on the cams Check the cam height Check there is no wear on the cam shaft retai...

Page 130: ...85 mm Cam shaft check Maximum admissible axial clearance 0 42 mm Cam shaft check Standard axial clearance 0 11 0 41 mm Cam shaft check Standard height Outlet 29 209 mm Cam shaft check Standard height...

Page 131: ...e two screws on the outside of the timing chain side and tighten them to the specified torque N B BEFORE INSTALLING THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM PRESSED AIR JET...

Page 132: ...nkcase Holding this position insert the chain on the cam shaft control pulley Insert the pulley on the cam shaft while keeping the reference 4V in correspondence with the ref erence mark on the head A...

Page 133: ...8 mm Locking torques N m Spark plug 12 14 Refit the cylinder head cover tightening the 5 screws to the prescribed torque Make sure the gasket is positioned properly Remove the flywheel cover complete...

Page 134: ...lves First remove the following units transmission cover driving pulley driven pulley and belt rear hub cover gears bearings and oil seals as described in the transmission chapter Remove the oil sump...

Page 135: ...kcase Remove the crankshaft CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT IF YOU FAIL TO DO THIS THE CRANKSHAFT MIGHT ACCIDENTALLY FALL Remove the coupling g...

Page 136: ...NOT MODIFIED BY THE RADIUSES OF FITTINGS WITH THE CRANKSHAFT BEARINGS If the axial clearance between crankshaft and crankcase exceeds the standard and the crankshaft does not have any defect the probl...

Page 137: ...not be re placed For the same reason the connecting rod may not be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to...

Page 138: ...spect the coupling surfaces on the crankcase halves for scratches or deformation taking partic ular care with the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase...

Page 139: ...The solid half bearing is intended to stand the thrusts caused by combustion and for this reason it is arranged opposite the cylinder To prevent obstructions in the oil feeding chan nels the matching...

Page 140: ...Original B 1 29 019 29 034 Original and spare 2 29 028 29 043 C 2 29 022 29 037 Original Match the shaft with two category 1 crank webs with the category 1 crankcase or cat 2 with cat 2 Furthermore a...

Page 141: ...on one of the crankcase halves preferably on the transmission side to gether with the locating dowels Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Re...

Page 142: ...Lubrication Conceptual diagrams LUBRICATION CIRCUIT Engine Beverly 125 ENG 142...

Page 143: ...Beverly 125 Engine ENG 143...

Page 144: ...tween 3 2 4 2 atm Remove the appropriate tools once the meas urement is complete refit the oil pressure switch and washer tightening it to the specified torque and fit the fan cover If the oil pressur...

Page 145: ...readed bar onto the base of the tool and extract the oil guard Specific tooling 020622Y Transmission side oil guard punch Refitting Use a new oil seal upon refitting Prepare the new oil seal lubricati...

Page 146: ...NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT RETRACT THE OI...

Page 147: ...ooling 020425Y Punch for flywheel side oil seal Oil pump Removal Undo the two clamping screws in the figure and remove the cover over the pump control crown Block the rotation of the oil pump control...

Page 148: ...rotors in the pump body keep ing the two reference marks visible Replace the snap ring Check the clearance between the rotors in the position shown in the diagram using a thickness gauge Measure the d...

Page 149: ...the engine crankcase The pump can only be fitted in one position Tighten the screws to the prescribed torque Fit the sprocket wheel with a new O ring Fit the chain Fit the central screw and the belle...

Page 150: ...and the two rear brake fluid pipe fixing brackets Remove the screw the by pass piston the gas ket and centring dowels shown in the figure Inspecting the by pass valve Check the unloaded spring length...

Page 151: ...wheel and the transmission cover as de scribed in the Transmissions chapter When testing the lubrication system refer to chapter Crankcase and Crankshaft regard ing lubrication of the crankshaft and c...

Page 152: ...a vacuum value higher than 0 5 BAR Check that this value is kept all the time If a worn seal is detected replace it With a T bypass and flexible rubber hoses make a parallel connection between the ru...

Page 153: ...F THE CUT OFF VALVE ALSO DAMAGES IDLE FUNCTIONING Specific tooling 020329Y MityVac vacuum operated pump Fuel supply Removing the carburettor Kehin To detach the carburettor from the engine it is neces...

Page 154: ...starter support with the gasket Remove the clamp and cover with the airing filter of the diaphragm chamber Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING T...

Page 155: ...vacuum valve together with the di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Beverly 125 Engi...

Page 156: ...the tank N B CAUTION THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod a...

Page 157: ...Remove the maximum nozzle Remove diffuser Beverly 125 Engine ENG 157...

Page 158: ...flow set screw and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PROGRESSIONS AND INLET NOZZLE...

Page 159: ...ion controlled by flow screw progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the nozzle support hides other i...

Page 160: ...e minimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the sho...

Page 161: ...Spring Nozzle N B THE IN VALVE NOZZLE CORRESPONDING TO THE AC CELERATION PUMP IS MILLED Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assem...

Page 162: ...on described above Inspecting the valve and needle Kehin Check that the tapered pin of the vacuum valve does not show wear Check that the depression valve does not show threads on the external surface...

Page 163: ...pin lock Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover Tighten the screws Wash and blow dry the filter sponge of the am bient pressure i...

Page 164: ...Check that the piston slides freely from the seat to the support Check that the piston sealing gasket is not de formed The starter must be more or less functional de pending on the ambient temperatur...

Page 165: ...e starter to the carburettor being careful to position the O Ring correctly insert the plate with the machined side contacting the starter tighten the fixing screws Position the starter as shown in th...

Page 166: ...INDEX OF TOPICS SUSPENSIONS SUSP...

Page 167: ...al Removal Front wheel hub overhaul Check that the wheel bearings do not show signs of wear If you have to replace the wheel bearings proceed as follows Remove the plastic cover on the tone wheel side...

Page 168: ...ide from the odometer drive side to permit the removal of the brake disc side bearing and the spacer bushing Specific tooling 020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15 mm guide Heat the...

Page 169: ...nsert the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side installed previously Heat the bearing seat on the odometer drive side with the heat gun In...

Page 170: ...ly Tighten the wheel axle nut to the prescribed tor que N B TAKE CARE NOT TO DAMAGE THE ODOMETER DRIVE FOR THE SAKE OF SAFETY OFFSET THE INTERNAL STOP FROM THE STOP OF THE TONE WHEEL BY 90 Tighten the...

Page 171: ...itting Install the handlebars on the steering tube paying attention to the centring aligning the recess on the handlebar with that on the steering tube as shown in the figure Tighten the handlebar fix...

Page 172: ...F ABRUPTLY Specific tooling 020055Y Wrench for steering tube ring nut See also Removal Removing the front wheel Overhaul Check that the roller bearing does not show signs of wear or pricking In case o...

Page 173: ...e a new plate and a new dust guard in the steering tube Insert a new roller bearing in the roller tube Using the special tool and a mallet to move the dust guard and the bearing in abutment Specific t...

Page 174: ...er washer shown in the figure To prevent the rotation of the pumping insert a 12 mm hexagonal wrench for internal parts in the stem Remove the dust guard ring using a screwdriver as shown in the figur...

Page 175: ...ng 116 3 2 1 mm Standard length 21 turn spring 175 7 2 1 mm Allowable limit after use 15 turn spring 114 3 mm Allowable limit after use 21 turn spring 173 7 mm Check there are no signs of wear or seiz...

Page 176: ...tem end Insert the stem in the leg being careful not to let the stem guide bushing come out Inset and screw up the copper washer to the pre scribed torque To prevent the pumping member from rotating i...

Page 177: ...er cap 15 30 Lower screw with copper washer 25 35 Refitting Grease using lithium soap grease on the roller bearings Recommended products AGIP GREASE PV2 Grease for the steering bearings pin seats and...

Page 178: ...en remove the lower seat of the roller bearing by inserting the punch from the top of the headstock N B ONLY REMOVE THE UPPER BALL BEARING IF YOU REALLY NEED TO Specific tooling 020004Y Punch for remo...

Page 179: ...support bracket Remove the 5 screws shown in the photograph Refitting the rear wheel Carry out the removal operations but in reverse order observing the prescribed tightening torques Locking torques...

Page 180: ...e the swinging arm Overhaul Check that the silent bloc is not damaged If there is replace it Remove the Seeger ring shown in the photo graph Remove the full silent bloc bracket Hold the full silent bl...

Page 181: ...the silent bloc as shown in the photo Specific tooling 020271Y Tool for removing fitting silent bloc Check there is no sticking in the movement of the connection of the swinging arm on the engine side...

Page 182: ...ecial tool 020229Y Alternatively use two washers with inside diame ter of 12 mm for pins outside diameter min 30 mm and thickness min 4 mm Separate the swinging arm on the engine side from the vehicle...

Page 183: ...o arms with the relative bolt in the position shown in the photograph Adjust the bolt as shown in the photograph Position the frame side swinging arm with the most protruding part pointing towards the...

Page 184: ...t 1 to the prescribed torque Insert the swinging arm engine bolt and tighten to the prescribed torque SWINGING ARM FITTING Name Torque in Nm Part 1 64 72 Nm Part 3 5 7 Nm Part 4 90 110 Nm Part 5 64 72...

Page 185: ...t fixed to the engine on the one side and from that fixed to the muffler on the other unscrew the two upper nuts one on each side fixing the shock absorber spring assembly to the frame and remove the...

Page 186: ...ear brake to prevent the wheel from turning Remove the support arm Remove the full muffler assembly See also Exhaust assy Removal Exhaust assy Removal Overhaul Remove the circlip shown in the photogra...

Page 187: ...re stand Remove the two return springs from the centre stand Undo the nut shown in the figure Re move the bolt from the right side Remove the centre stand On refitting tighten the nut to the prescribe...

Page 188: ...temperature range between 20 C and 120 C NLGI 2 ISO L XBCIB2 Locking torques N m stand retaining bolt 20 25 Side stand Removal of the side stand Unhook the springs Loosen the nut Pull out the screw F...

Page 189: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS...

Page 190: ...REMELY CORROSIVE FOR PAINTED SURFACES BRAKE FLUID IS HYGROSCOPIC THAT IS IT ABSORBS MOISTURE FROM THE SURROUND ING AIR IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE IT WILL RE SUL...

Page 191: ...th threadlock Loctite 243 medium strength threadlock Locking torques N m Oil bleed screw 12 16 Screw tightening calliper to the support 23 25 Screw fixing rear brake calliper support to engine 20 25 B...

Page 192: ...lace the entire calliper that the guides of the fixed plate are not scratched or eroded otherwise replace the entire plate that the brake pad check spring works properly Refitting 1 insert the pistons...

Page 193: ...ston sealing rings 8 Guide protection rubbers 9 Brake pad check spring 10 Pads CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EV ERY TIME THE CALLIPER IS SERVICED Locking torques N m Brake fluid p...

Page 194: ...THE DISC WITH THE STAMPED ARROW FOR THE DIRECTION OF ROTATION MUST FACE TOWARDS THE OUTSIDE OF THE SCOOTER Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium strength threa...

Page 195: ...fixing screws Thoroughly clean the seats on the front wheel hub and on the disc See also Removing the front wheel Refitting For fitting position the disc correctly using the arrow stamped on it as ref...

Page 196: ...the brake surface is within the prescribed limits If this is not the case replace the disc and repeat the test WHEN INSTALLING THOROUGHLY CLEAN THE DISC AND ITS SEAT ON THE HUB Characteristic Max axia...

Page 197: ...ew tightening calliper to the support 20 25 Pad fastening pin 19 6 24 5 Rear brake pads Removal Proceed as follows Remove the rear brake calliper Remove the two pins holding the brake pads Remove the...

Page 198: ...the special tool to the bleed fitting Actuate the tool at the bleed fitting at the same time constantly topping up the brake system tank to prevent air being drawn into the system until no more air es...

Page 199: ...ol at the bleed fitting at the same time constantly topping up the brake system tank to prevent air being drawn into the system until no more air escapes at the bleed fitting The operation is finished...

Page 200: ...er Front Overhaul 1 Remove the brake lever by loosening the fixing screw open the cover 2 and take out the diaphragm 3 2 Remove the cap and unscrew the internal parts in the specified order 3 Check th...

Page 201: ...D INTENSELY AND OR IN HARSH CONDITIONS CHANGE THE FLUID MORE FREQUENTLY CAUTION WHEN CARRYING OUT THE OPERATION BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER CAREFULLY...

Page 202: ...EFFICIENT THEREFORE ALWAYS USE FLUID FROM SEALED CONTAINERS UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY TWO YEARS IF BRAKES ARE USED INTENSELY AND OR IN HARSH CONDI...

Page 203: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS...

Page 204: ...Circuit diagram 125 ENGINE Cooling system Beverly 125 COOL SYS 204...

Page 205: ...orming part of the tool drawing No 020440Y With an appropriate socket and punch forming part of the specific tool 020440y extract the shaft to gether with the rotor from the drive and the bearings Use...

Page 206: ...Cooling system Beverly 125 COOL SYS 206...

Page 207: ...val Place the two bearings on the specific punch Use grease to keep the bearings on the appro priate tool Use a plastic mallet to insert the bearings on the housing up to the stop Assembly the ceramic...

Page 208: ...RHEATING AS THIS MAY ALTER THE PAIN TED SURFACE N B ALWAYS USE NEW BEARINGS N B ALWAYS USE NEW CERAMIC RING AND GASKETS AS SEMBLING THE CERAMIC SEALING RING IN A MANNER OTHER THAN MANUALLY MAY DAMAGE...

Page 209: ...the thermostat Warm up the container using the heat gun Check the temperature when the thermostat starts to open Heat up until the thermostat is completely open Replace the thermostat if it does not w...

Page 210: ...up until the thermostat is completely open Opening travel 3 5 mm at 80 C CAUTION To execute the test correctly make sure neither the thermostat nor the thermometer touches the container 3 Replace the...

Page 211: ...INDEX OF TOPICS CHASSIS CHAS...

Page 212: ...screws shown 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 fro...

Page 213: ...ar cover Instrument panel Remove the rear handlebar cover Disconnect the cable harness Remove the odometer cable Remove the 3 screws shown in the photograph Remove the instrument panel See also Rear h...

Page 214: ...same time remove the fuel tank cap Remove the frame central cover by sliding it from the rear side of the scooter and disconnecting it from the cover opening transmission Legshield Remove the headligh...

Page 215: ...2 fixing screws of the fuse box in the front glove box Separate the electrical connections Remove the expansion tank Loosen the fixing screw inside the glove box and the two screws located under the c...

Page 216: ...lectrical wiring Remove the ignition key switch by removing the spring retainer shown in the figure Lightly push the master cylinder and extract the lock from the notch shown in the figure Hence extra...

Page 217: ...OUS PARAGRAPH See also Removing the ignition key switch when on off Front wheel housing Remove the shield back plate Remove the footrests Remove the front suspension Loosen the remaining retaining scr...

Page 218: ...so Frame central cover Frame central cover Side fairings Remove the saddle Remove the luggage rack Remove the central cover Remove the rear light assembly Remove the cover under the saddle by loosenin...

Page 219: ...ssy Taillight assy Frame central cover Seat Rear rack Rear mudguard Loosen the 4 fixing screws 2 of which are indi cated in the figure and the other 2 located on the opposite side under the air filter...

Page 220: ...D PREFERABLY BE PER FORMED WITH THE TANK EMPTY Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather Undo and remove the screw fixing the horn sho...

Page 221: ...connection Remove the toggle handles by loosening the 4 retaining screws Remove the support bracket by loosening the 2 retaining screws of the bracket at the frame Undo the two screws fixing the tank...

Page 222: ...emove the coolant supply and return pipes from the radiator Loosen the screw mounting the radiator to the frame Disengage the radiator and the electric fan See also Front wheel housing Flyscreen Remov...

Page 223: ...INDEX OF TOPICS PRE DELIVERY PRE DE...

Page 224: ...bolt Swinging arm bolt Engine Engine arm pin Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system Main switch Headlamps high beam low beam p...

Page 225: ...UT 15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP T...

Page 226: ...TION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch P...

Page 227: ...INDEX OF TOPICS TIME TIME...

Page 228: ...Engine ENGINE Code Action Duration 1 001001 Engine from frame Removal and re fit 2 003064 Engine oil Change 3 003057 Engine retainer Tighten nuts Time Beverly 125 TIME 228...

Page 229: ...Crankcase CRANKCASE Code Action Duration 1 001153 Crankcase halves gasket Replace ment 2 001133 Engine crankcase Replacement Beverly 125 Time TIME 229...

Page 230: ...Crankshaft CRANKSHAFT Code Action Duration 1 001099 Oil seal flywheel side Replacement 2 001117 Crankshaft Replacement Time Beverly 125 TIME 230...

Page 231: ...Cylinder assy CYLINDER PISTON Code Action Duration 1 001002 Cylinder Piston Replacement 2 001154 Pin ring piston unit Service Beverly 125 Time TIME 231...

Page 232: ...AD Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves Adjustment 4 001056 Head gasket Replacement 5 001083 Thermistor Replacement 6 001057 Thermostat Replacemen...

Page 233: ...Rocker arms support assy CAMSHAFT ROCKING LEVERS Code Action Duration 1 001148 Valve rocking levers Replacement 2 001044 Camshaft Replacement Beverly 125 Time TIME 233...

Page 234: ...cover HEAD COVER Code Action Duration 1 001093 Spark plug Replacement 2 001089 Head cover Replacement 3 001088 Head cover gasket Replacement 4 001074 Oil vapour recovery pipe Replace ment Time Beverly...

Page 235: ...Chain tensioner CHAIN TIGHTENER Code Action Duration 1 001129 Chain tensioner Service and Re placement 2 001124 By pass lubrication Replacement Beverly 125 Time TIME 235...

Page 236: ...Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor Replacement Time Beverly 125 TIME 236...

Page 237: ...PULLEY Code Action Duration 1 001022 Clutch Replacement 2 003072 Clutch unit Wear check 3 001012 Driven pulley Service 4 001110 Driven pulley Replacement 5 001155 Clutch bell housing Replacement Bever...

Page 238: ...Chain guide pads Replacement 2 001051 Belt Timing chain Replacement 3 001042 Oil pump Service 4 001112 Oil pump Replacement 5 001122 Oil pump chain Replacement 6 001121 Chain cover oil seal Replacemen...

Page 239: ...INAL DRIVE Code Action Duration 1 001010 Gear reduction unit Inspection 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement Beverly 1...

Page 240: ...AR VIEW PULLEY Code Action Duration 1 001086 rear view half pulley Replacement 2 001011 Driving belt Replacement 3 001066 Driving pulley Removal and Refit ting 4 001006 driving pulley Service Time Bev...

Page 241: ...ION COVER Code Action Duration 1 001135 Transmission cover bearing Re placement 2 001096 Transmission crankcase cover re place 3 001131 Transmission air intake Replace ment Flywheel magneto Version 25...

Page 242: ...up freewheel Replacement 6 001151 Start up driven gearing Replace ment Version 125 MAGNETO FLYWHEEL AND SECONDARY AIR Code Action Duration 1 001087 Flywheel cover Replacement 2 001113 Water pump Repl...

Page 243: ...placement Carburettor CARBURETTOR Code Action Duration 1 001013 Intake manifold Replacement 2 007020 Carburettor heat pipes Replace ment 3 001008 Carburettor Inspection 4 001063 Carburettor Replacemen...

Page 244: ...Exhaust pipe MUFFLER Code Action Duration 1 001009 Muffler Replacement 2 001095 Muffler guard Replacement 3 001092 Exhaust manifold Replacement Time Beverly 125 TIME 244...

Page 245: ...r cleaner AIR CLEANER Code Action Duration 1 001014 Air filter Replacement Cleaning 2 001015 Air filter box Replacement 3 004122 Carburettor air cleaner attachment Replacement Beverly 125 Time TIME 24...

Page 246: ...Frame CHASSIS Code Action Duration 1 004001 Chassis Replacement Time Beverly 125 TIME 246...

Page 247: ...Centre stand CENTRE AND SIDE STANDS Code Action Duration 1 004004 Stand Replacement 2 004102 Side stand Replacement 3 005079 Stand switch Replacement Beverly 125 Time TIME 247...

Page 248: ...Legshield spoiler LEGSHIELD SPOILER Code Action Duration 1 004064 Legshield Replacement 2 004053 Spoiler Replacement Time Beverly 125 TIME 248...

Page 249: ...Side fairings SIDE COVERS Code Action Duration 1 004085 Fairing 1 Replacement 2 004012 Rear side panels Replacement 3 004052 Bumper Replacement Beverly 125 Time TIME 249...

Page 250: ...Footrests MATS AND COVERS Code Action Duration 1 004075 Front mat Replacement 2 004079 Passenger footrest 1 Replace ment 3 004015 Footrests Remov and Refit Time Beverly 125 TIME 250...

Page 251: ...Rear cover REAR SHIELD Code Action Duration 1 004065 Legshield rear section Remov and Refit 2 004081 Glove box door Replacement Beverly 125 Time TIME 251...

Page 252: ...Central cover CENTRAL COVER Code Action Duration 1 004011 Frame central cover Replacement 2 002082 Fuel tank cap opening drive Re placement Time Beverly 125 TIME 252...

Page 253: ...placement Saddle opening transmis sion Replacement 2 004016 Helmet compartment Remov and Refit 3 004106 Underseat band Replacement 4 004136 License plate holder support Re placement 5 004158 Saddle o...

Page 254: ...Mudguard FRONT AND REAR MUDGUARDS Code Action Duration 1 004009 Rear mudguard Replacement 2 004002 Front mudguard Replacement Time Beverly 125 TIME 254...

Page 255: ...uel tank FUEL TANK Code Action Duration 1 005010 Tank float Replacement 2 004109 Fuel tank breather Replacement 3 004005 Fuel tank Replacement 4 004007 Fuel valve Replacement Beverly 125 Time TIME 255...

Page 256: ...tank EXPANSION TANK Code Action Duration 1 007001 Expansion tank Replacement 2 007013 Expansion tank radiator connection pipe Replacement 3 001052 Coolant and air bleeding Replace ment Time Beverly 12...

Page 257: ...tion Duration 1 007014 Radiator thermal switch Replace ment 2 007002 Radiator water Replacement 3 007016 Complete fan with support Replace ment 4 007003 Coolant delivery and return pipe Re placement B...

Page 258: ...Rear shock absorber REAR SHOCK ABSORBER Code Action Duration 1 003007 Rear shock absorber Remov and Refit Time Beverly 125 TIME 258...

Page 259: ...003079 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 Adjustmen...

Page 260: ...AR COVER Code Action Duration 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 Ti...

Page 261: ...02071 Left knob Replacement 4 002024 Front brake pump Removal and Re fitting 5 002067 Rear brake pump Replacement 6 003001 Handlebar Replacement 7 002063 Complete throttle grip transmission Replacemen...

Page 262: ...Swing arm SWINGING ARM Code Action Duration 1 001072 Swinging arm Engine chassis con nection Replacement 2 004058 Silent block Replacement Time Beverly 125 TIME 262...

Page 263: ...bleed ing plug Repl 5 003070 Front brake pads shoes Check for wear 6 003071 Rear brake pads shoes Check for wear 7 002002 Rear brake pads shoes Repl 8 002007 Front brake pads shoes Remov and Refit 9 0...

Page 264: ...Seat SADDLE Code Action Duration 1 004003 Saddle Replacement Time Beverly 125 TIME 264...

Page 265: ...Seat lock SADDLE LOCK MECHANISM Code Action Duration 1 004054 Saddle lock catch Replacement Beverly 125 Time TIME 265...

Page 266: ...Instrument panel INSTRUMENT PANEL Code Action Duration 1 005014 Odometer Replacement 2 005038 Instrument panel warning light bulbs Replacement Time Beverly 125 TIME 266...

Page 267: ...Rear rack LUGGAGE RACK Code Action Duration 1 004008 Luggage rack Replacement Beverly 125 Time TIME 267...

Page 268: ...Locks LOCKS Code Action Duration 1 005016 Key switch Replacement 2 004010 Anti theft lock Replacement Time Beverly 125 TIME 268...

Page 269: ...5008 Headlight bulbs Replacement 4 005031 Licence plate light bulb Replace ment 5 005032 Licence plate light glass Replace ment 6 005044 Front lights cable unit replace 7 005066 Rear light bulbs Repla...

Page 270: ...er cable Replacement 10 002051 Odometer transmission assembly Replacement Grease tone wheel or drive Please take note that the code has been intro duced 900001 Tone wheel drive greasing 15 Never mista...

Page 271: ...acement 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 wheel ty...

Page 272: ...ELECTRICAL START UP Code Action Duration 1 001141 Belt anti vibration roller Replace ment 2 001020 Starter motor Replacement 3 001017 Start up pinion Replacement Version 125 Time Beverly 125 TIME 272...

Page 273: ...ELECTRICAL START UP Code Action Duration 1 001020 Starter motor Replacement 2 001017 Start up pinion Replacement Fuel pump Beverly 125 Time TIME 273...

Page 274: ...1 004073 Fuel pump Replacement 2 004137 Carburettor pump hose Replace ment 3 004086 Vacuum fuel pump pipe Replace ment 4 004089 Tank pump hose Replacement 5 004072 Fuel filter Replacement Electric dev...

Page 275: ...ES Code Action Duration 1 001023 Control unit Replacement 2 001069 HV coil Replacement 3 001094 Spark plug hood Replacement 4 005001 Electrical system Replacement 5 005003 Horn Replacement Beverly 125...

Page 276: ...ectrical system Service Secondary air box SECONDARY AIR HOUSING Code Action Duration 1 001162 Secondary air housing Replace ment 2 001161 Secondary air filter Replacement Cleaning 3 001174 SAS valve R...

Page 277: ...Engine oil 43 Engine stop F Fuel 54 153 220 255 273 Fuses 76 H Headlight 49 214 215 Hub oil 42 I Identification 8 Instrument panel 213 266 L Luggage rack M Maintenance 7 36 O Oil filter 44 45 236 S Sa...

Page 278: ...Tyres 10...

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