PIAGGIO Beverly 400 E5 Скачать руководство пользователя страница 93

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- Remove the discs clearance recovery spring

- Remove a non-trimmed duct metallic disc.

- Remove a conductor disc (trimmed on both

sides).

- Remove the discs clearance recovery spring

- Remove the semi-trimmed duct disc (trimmed on

one side).

Beverly 400 E5

Engine

ENG - 93

Содержание Beverly 400 E5

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

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

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

Страница 4: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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