Page 1 SERVICE STATION MANUAL 664675 - 664682 BEVERLY Cruiser 250ie...
Page 2 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 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 SERVICE STATION MANUAL BEVERLY Cruiser 250ie This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE INJEC NJECTION SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 9: Vehicle Identification
BEVERLY Cruiser 250ie Characteristics Vehicle identification Frame prefix: ZAPM28802 Engine prefix: M288M Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight 168 ± 5 kg Maximum weight al- 350 kg lowed Overall height 1,230 mm Width 770 mm Wheelbase...
Page 10 BEVERLY Cruiser 250ie Characteristics Specification Desc./Quantity Alternative spark plug Fuel supply Electronic injection with Ø 32-mm throttle body and electric fuel pump. Fuel Unleaded petrol (95 RON) Exhaust muffler Absorption-type exhaust muffler with 3-way cata- lytic converter and lambda probe.
Page 11: Wheels And Tyres
BEVERLY Cruiser 250ie Characteristics Specification Desc./Quantity Rear suspension Two double-acting shock absorbers, adjustable to four positions at preloading. Rear suspension travel 95.5 mm Brakes BRAKES Specification Desc./Quantity Front brake Ø 260 disc brake with hydraulic control activated by handlebar right lever.
Page 12: Table Of Contents
BEVERLY Cruiser 250ie Characteristics FRONT SUSPENSION Name Torque in Nm Fixing screw for pumping elements to lower fork 20 ÷ 25 plate Front wheel shaft 45 ÷ 50 Fork leg screw 6 ÷ 7 fixing screw for front mudguard to plate 4.5 ÷...
Page 13 BEVERLY Cruiser 250ie Characteristics Name Torque in Nm Oil pump cover plate screws 4 ÷ 6 Oil sump screws 10 ÷ 14 Minimum oil pressure sensor 12 ÷ 14 CYLINDER HEAD Name Torque in Nm Spark plug 12 ÷ 14 Head cover screws 6 ÷...
Page 14: Assembly Clearances
BEVERLY Cruiser 250ie Characteristics Overhaul data Assembly clearances Cylinder - piston assy. ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064 Piston 72.024 ÷...
Page 15 BEVERLY Cruiser 250ie Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, trans- 16.6 +0-0.05 D = 0.20 - 0.50 mission side Flywheel-side half- 16.6 +0-0.05 D = 0.20 - 0.50 shaft Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05...
Page 16 BEVERLY Cruiser 250ie Characteristics MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK- CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE ENGINE 250 SHIMMING Name Measure A Thickness shimming 3.70 - 3.60...
Page 17 INDEX OF TOPICS TOOL OOLING...
Page 18 BEVERLY Cruiser 250ie Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Pliers to extract ø 15-mm bear- ings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steering tube...
Page 19 BEVERLY Cruiser 250ie Tooling Stores code Description 020074Y Support base for checking crank- shaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting TOOL - 3...
Page 20 BEVERLY Cruiser 250ie Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light for timing con- trol 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 4...
Page 21 BEVERLY Cruiser 250ie Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide TOOL - 5...
Page 22 BEVERLY Cruiser 250ie Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool 020393Y Piston fitting band 020412Y 15 mm guide TOOL - 6...
Page 23 BEVERLY Cruiser 250ie Tooling Stores code Description 020423Y driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020431Y Valve oil seal extractor 020434Y Oil pressure control fitting 020444Y Tool for fitting/ removing the driv-...
Page 24 BEVERLY Cruiser 250ie Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020460Y Scooter diagnosis and tester TOOL - 8...
Page 25 BEVERLY Cruiser 250ie Tooling Stores code Description 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bear- ings 020627Y Flywheel lock wrench...
Page 26 BEVERLY Cruiser 250ie Tooling Stores code Description 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15-mm diameter punch 020115Y Ø 18 punch TOOL - 10...
Page 27 BEVERLY Cruiser 250ie Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020638Y 250 I. E. ENGINE - ABS SOFT- WARE 020469Y Reprogramming kit for scooter diagnosis tester 020487Y Fork oil seal extractor 020458Y Puller for lower bearing on steer-...
Page 28 BEVERLY Cruiser 250ie Tooling TOOL - 12...
Page 29 INDEX OF TOPICS MAIN AINTENANCE...
Page 30: Maintenance Chart
BEVERLY Cruiser 250ie Maintenance Maintenance chart AFTER 1,000 KM Action Safety locks - check Throttle lever - adjustment Engine oil - change Electrical system and battery - check Coolant level - check Brake fluid level - check Engine oil - replacement...
Page 31 BEVERLY Cruiser 250ie Maintenance AFTER 20,000 KM; 40,000 KM; 80,000 KM 150' Action Spark plug - replacement Driving belt - replacement Throttle lever - adjustment Air filter - clean Engine oil - change Valve clearance - check Electrical system and battery - check...
Page 32: Checking The Spark Advance
BEVERLY Cruiser 250ie Maintenance Action Coolant level - check Brake fluid level - check Engine oil - replacement Hub oil - change Brake pads - check condition and wear Sliding block / variable speed rollers - change Tyre pressure and wear - check...
Page 33 BEVERLY Cruiser 250ie Maintenance - Refit the spark plug. - Refit the plastic cap on the flywheel cover. - Adjust the spark gap to the contact position (no reference mark visible) and install it on engine be- tween the spark plug and spark plug cap...
Page 34: Spark Plug
BEVERLY Cruiser 250ie Maintenance Spark plug Remove the port on the right-hand side panel of the vehicle by undoing the clamping screw and using a small screwdriver in the rear recess shown in the figure, then do the following : 1.
Page 35 BEVERLY Cruiser 250ie Maintenance Check - Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely; Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end;...
Page 36: Air Filter
BEVERLY Cruiser 250ie Maintenance Air filter - Remove the left-hand footrest. - Remove the air cleaner cap after undoing the clamping screws, then extract the filter element. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- pressed air.
Page 37 BEVERLY Cruiser 250ie Maintenance Replacement Replace oil and filter as indicated in the scheduled maintenance table. The engine must be emptied by draining off the oil through the drainage plug "B" of the mesh pre-filter, flywheel side. Moreover, to facilitate oil drainage, remove the mesh filter and loosen the cap/dipstick "A".
Page 38: Oil Filter
BEVERLY Cruiser 250ie Maintenance Check This operation must be carried out with the engine cold and following the procedure below: 1. Place the vehicle on its centre stand and on flat ground. 2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down com- pletely.
Page 39: Checking The Ignition Timing
BEVERLY Cruiser 250ie Maintenance Oil pressure warning light Warning light (low oil pressure) The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the "ON" position. However, this light should switch off once the engine has been star- ted.
Page 40: Braking System
BEVERLY Cruiser 250ie Maintenance Top-up The fluid level inspection should be carried out every 6,000 km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground. - Undo the screw shown in the figure and remove the expansion tank cap on RHS.
Page 41 BEVERLY Cruiser 250ie Maintenance Level check - Position the vehicle on a flat surface and on the centre stand - Check the brake fluid level via the special indi- cator located on the pump. N.B. THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED.
Page 42: Headlight Adjustment
BEVERLY Cruiser 250ie Maintenance VALUE, IT WILL LEAD TO INEFFICIENT BRAK- ING; FOR THIS REASON, NEVER USE BRAK- ING FLUID FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED. Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT4 Synthetic fluid Given normal climatic conditions, change fluid as indicated in the scheduled maintenance table.
Page 43 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 44 BEVERLY Cruiser 250ie Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given. Engine Excessive oil consumption/Exhaust smoke EXCESSIVE CONSUMPTION Possible Cause...
Page 45 BEVERLY Cruiser 250ie Troubleshooting Insufficient braking INEFFICIENT BRAKING SYSTEM Possible Cause Operation Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are not worn, scored or warped. Check the correct level of fluid in the pumps and replace brake fluid if necessary.
Page 46: Noisy Suspension
BEVERLY Cruiser 250ie Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension NOISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...
Page 47 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 48 BEVERLY Cruiser 250ie Electrical system 1. Immobilizer aerial 2. Diagnosis connector 3. Engine temperature sensor 4. Saddle opening actuator 5. Saddle opening relay 6. Magneto flywheel 7. Saddle opening button 8. Engine stop switch 9. Electric fan motor 10. Electric fan relay 11.
Page 49 BEVERLY Cruiser 250ie Electrical system 20. Stop button on rear brake 21. Stop button on front brake 22. Light switch 23. Wiring for antitheft device 24. Helmet compartment light control button 25. High-beam light relay 26. Low-beam light relay 27. Helmet compartment internal light 28.
Page 50 BEVERLY Cruiser 250ie Electrical system 43. Turn indicator control device 44. Injection load remote control 45. Fuel pump 46. Lambda probe 47. Injector 48. Side stand switch 49. HV coil 50. Injection ECU Ar: Orange Az: Sky blue Bi: White Bl: Blue Gi: Yellow Gr:Grey...
Page 51 BEVERLY Cruiser 250ie Electrical system Component layout Electronic control unit In order to access the electronic control unit it is necessary to: Remove the cover of the motor compartment in- side the helmet compartment. The control unit is integrated into the throttle body.
Page 52 BEVERLY Cruiser 250ie Electrical system Lambda probe The lambda probe is mounted on the exhaust manifold Electrical system installation ELE SYS - 6...
Page 53 BEVERLY Cruiser 250ie Electrical system Front side 1. Immobilizer aerial 2. To the headlight 3. From the cable harness left side ELE SYS - 7...
Page 54 BEVERLY Cruiser 250ie Electrical system 1. To the engine stop switch 2. To the instrument panel 3. To the light switch 4.To the turn indicator switch 5.To the horn button 6. To the left stop button 7. Key switch contacts 8.
Page 55 BEVERLY Cruiser 250ie Electrical system 11. Immobilizer aerial 12. To the right stop button 13. To the starter button 1. Key switch contacts 2. Injection load remote control 3. Remote controls 4. Fuse-box 5. Horn 6. To the stand switch 7.
Page 56 BEVERLY Cruiser 250ie Electrical system 8.Frame to earth 9. Direct cable harness to the right fairing 10. To the fuel pump 11. To the fuel gauge 12.To the electric fan 13. To the saddle opening switch Back side 1. 12V - 12Ah Battery...
Page 57 BEVERLY Cruiser 250ie Electrical system 1. Spark plug cap 2. Voltage regulator 3. HV coil 4. Fuse-box 5. Foldable clamp 6. Belt for battery 7. Start-up remote control switch 8. Pick-up connection 9. Foldable clamp 10. Flywheel-regulator connection 11. Clamp 12.
Page 58 BEVERLY Cruiser 250ie Electrical system 1. Battery breather pipe 2. To the light 3.To the license plate light 4. To the rear light 5.To the lighter 6. To the battery negative (-) terminal 7. To the battery positive (+) terminal...
Page 59 BEVERLY Cruiser 250ie Electrical system 1. Clamp 2. Battery breather pipe 3. Saddle opening actuator Conceptual diagrams ELE SYS - 13...
Page 60 BEVERLY Cruiser 250ie Electrical system Ignition 1. Immobilizer aerial 11. Key switch 13. Rear fuse unit 14. Front fuses unit 16. Battery 44. Injection load remote control 49. HV coil 50. Injection ECU ELE SYS - 14...
Page 61 BEVERLY Cruiser 250ie Electrical system Battery recharge and starting 6. Magneto flywheel 8. Engine stop switch 11. Key switch 12. Voltage regulator 13. Rear fuse unit 14. Front fuses unit 16. Battery 17. Starter motor 18. Start-up remote control switch 19.
Page 62 BEVERLY Cruiser 250ie Electrical system 50. Injection ECU Level indicators and enable signals section 1. Immobilizer aerial 3. Engine temperature sensor 11. Key switch 13. Rear fuse unit 14. Front fuses unit 16. Battery 37. Oil pressure sensor 38. Instrument panel B.
Page 63 BEVERLY Cruiser 250ie Electrical system 40. Fuel level transmitter 41. Revolution sensor 44. Injection load remote control 46. Lambda probe 47. Injector 50. Injection ECU Devices and accessories 4. Saddle opening actuator 5. Saddle opening relay 7. Saddle opening button 9.
Page 64 BEVERLY Cruiser 250ie Electrical system 24. Helmet compartment light control button 27. Helmet compartment internal light 35. Horn button 36. Horn 44. Injection load remote control 45. Fuel pump 50. Injection ECU Lights and turn indicators 11. Key switch 13. Rear fuse unit 14.
Page 65 BEVERLY Cruiser 250ie Electrical system A. Tail light bulbs B. Stop light bulb 31. Rear right turn indicator 32. Front left turn indicator 33. Headlight A. Tail light bulb B. Low-beam bulb C. High-beam bulb 34. Front right turn indicator 38.
Page 66 BEVERLY Cruiser 250ie Electrical system - Diagnostic LED The diagnosis LED also works as a blinking light to deter theft. This function is activated every time the ignition switch is turned to the "OFF" position, or the emergency stop switch is turned to the "OFF"...
Page 67 BEVERLY Cruiser 250ie Electrical system With the key switch in the OFF position: • there is battery voltage between termi- nals 5-26 and terminal 5-frame earth (fixed power supply). If there is no volt- age, check the key switch contacts, that fuse no.
Page 68 BEVERLY Cruiser 250ie Electrical system With the ignition key switch at ON check there is battery voltage between the Red-White and Black cables With MIU connector disconnected check the con- tinuity between the Orange-White cable and pin 7 of the interface wiring .
Page 69 BEVERLY Cruiser 250ie Electrical system first key to be stored to memory: this becomes particularly important because it is the only key that enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.
Page 70 BEVERLY Cruiser 250ie Electrical system ted but with a limitation imposed on the number of revs. 2. Previously unused control unit - transpond- er absent or cannot be used: The LED is per- manently ON; in this condition, no operations are possible, including starting of the vehicle.
Page 71 BEVERLY Cruiser 250ie Electrical system Diagnostic code - 2 flashes Two-flash code shows a system where the control unit does not show the transponder signal. This might depend on the inefficiency of the immobiliser aerial or the transponder. Turn the switch to ON using several keys: if the code is repeated even with the Master key, check the aerial wiring and change it if necessary.
Page 72 BEVERLY Cruiser 250ie Electrical system Electric characteristic Resistance: 0.2 - 1 Ω 4) Check that there is insulation between the each yellow cable and the ground. 5) If values are incorrect, replace the stator. Recharge system voltage check Look for any leakage 1) Access the battery by removing its cover under the saddle.
Page 73 BEVERLY Cruiser 250ie Electrical system Specification Desc./Quantity Voltage 14 ÷ 15V at 5000 rpm with lights off Turn signals system check In the case it does not work, it is necessary to: • Check if the light bulb is in working or- •...
Page 74 BEVERLY Cruiser 250ie Electrical system • If the twin-filament bulb is in working order • If fuses No. 5 are in working order • If the light switch is in working order when in HIGH and LOW modes • If the light remote controls are in working order With the main switch in position "ON", check:...
Page 75 BEVERLY Cruiser 250ie Electrical system CAUTION BEFORE REPLACING THE BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYSTEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING AND RISK OF FIRE.
Page 76 BEVERLY Cruiser 250ie Electrical system ELE SYS - 30...
Page 77 BEVERLY Cruiser 250ie Electrical system Dashboard A = Low fuel warning light B = Fuel gauge C = Trip odometer D = Trip odometer reset E = Speedometer F = Total Odometer G = Water temperature warning light H = Oil pressure warning light...
Page 78 BEVERLY Cruiser 250ie Electrical system The instrument panel is equipped with a 12-pin connector shown in the figure. CONNECTOR 1. Left turn indicator warning light 2. Live positive 3.Panel lighting and headlight warning light 4.Water temperature warning light 5. Positive from battery 6.
Page 79 BEVERLY Cruiser 250ie Electrical system 10 to 12 h recommended Minimum 6 h Maximum 24 h 3) Constant current battery charge mode - Charge current equal to 1/10 of the battery rated capacity - Charge time: Maximum 5 h ELE SYS - 33...
Page 80 BEVERLY Cruiser 250ie Electrical system ELE SYS - 34...
Page 81 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 82 BEVERLY Cruiser 250ie Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the RHS footrest. - Remove the Lambda probe from its support and disconnect it.
Page 83 BEVERLY Cruiser 250ie Engine from vehicle Remove the lambda probe from the manifold. Removal of the engine from the vehicle - Disconnect the battery - Remove the engine cover inside the helmet compartment. - Remove the side fairings and the footrests.
Page 84 BEVERLY Cruiser 250ie Engine from vehicle - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cable from the throttle body by undoing the nut shown in the photo.
Page 85 BEVERLY Cruiser 250ie Engine from vehicle - Disconnect the connectors from the flywheel wir- ing harness. - Disconnect the relevant cable from the retaining clamps. - Remove the screws indicated in the figure. ENG VE - 5...
Page 86 BEVERLY Cruiser 250ie Engine from vehicle Remove the retaining bolts of the rear brake cal- liper. Remove the lower screw of the left-hand shock absorber. - Use a jack to support the vehicle properly. Re- move the engine-swinging arm fixing pin by undo- ing the nut and the head of the pin as shown in the photograph.
Page 87 BEVERLY Cruiser 250ie Engine from vehicle PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE COMMAND TRANSMISSION PROPERLY. ENG VE - 7...
Page 88 BEVERLY Cruiser 250ie Engine from vehicle ENG VE - 8...
Page 89 INDEX OF TOPICS NGINE...
Page 90: Automatic Transmission
BEVERLY Cruiser 250ie Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
Page 91 BEVERLY Cruiser 250ie Engine - Remove the five screws on two different levels as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by...
Page 92: Removing The Driven Pulley
BEVERLY Cruiser 250ie Engine 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 outer diameter of the roller does not...
Page 93: Inspecting The Clutch Drum
BEVERLY Cruiser 250ie Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø...
Page 94: Removing The Clutch
BEVERLY Cruiser 250ie Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring No. 11 with the cham- fering facing the inside of the tool.
Page 95 BEVERLY Cruiser 250ie Engine 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 - Simultaneously turn and pull the collar manually to remove it.
Page 96 BEVERLY Cruiser 250ie Engine - Support the pulley 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 020456Y Ø 24 mm adaptor...
Page 97 BEVERLY Cruiser 250ie Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws.
Page 98 BEVERLY Cruiser 250ie Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
Page 99 BEVERLY Cruiser 250ie Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm acceptable limit after use:...
Page 100 BEVERLY Cruiser 250ie Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.
Page 101: Removing The Driving Pulley
BEVERLY Cruiser 250ie Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic 250 4T Transmission belt/minimum width 19.5 mm 250 4T Transmission belt/standard width 21.3 ± 0.2 mm During the wear checks in the scheduled servicing...
Page 102 BEVERLY Cruiser 250ie Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
Page 103 BEVERLY Cruiser 250ie Engine 26.000 - 26.021 mm Movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 ÷ 25.98 mm Sliding bushing: Minimum admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
Page 104 BEVERLY Cruiser 250ie Engine - Fit the steel shim in contact with the bushing and the stationary drive pulley. - Install the appropriate tool as described in the re- moval phase. -Tighten the nut with washer to the prescribed tor- que.
Page 105 BEVERLY Cruiser 250ie Engine Removing the hub cover - Empty the rear hub through the oil drainage plug. - Remove the 7 flanged screws indicated in the figure. - Remove the hub cover and its gasket. Removing the wheel axle - Remove the wheel axis complete with gear.
Page 106 BEVERLY Cruiser 250ie Engine Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following. - Use the specific bearing extractor to remove the three 15 mm bearings (2 in the crankcase and 1 in the hub cover).
Page 107 BEVERLY Cruiser 250ie Engine Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil guard, remove the transmission cover as described above. - Extract the driven pulley shaft from its bearing.
Page 108 BEVERLY Cruiser 250ie Engine Refitting the wheel axle bearing - Support the hub cover on a wooden surface. - Heat the crankcase cover with the specific heat gun. - Fit the wheel shaft bearing with a modular punch as shown in the figure.
Page 109 BEVERLY Cruiser 250ie Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
Page 110 BEVERLY Cruiser 250ie Engine Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els. - Seal the gasket of the breather pipe using black silicone sealant.
Page 111: Removing The Stator
BEVERLY Cruiser 250ie Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the ten fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
Page 112 BEVERLY Cruiser 250ie Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.
Page 113 BEVERLY Cruiser 250ie Engine Removing the starter motor - Remove the two screws indicated in the figure. - Take the starter motor out of its seat Removing the flywheel magneto - Remove the water pump shaft and crankshaft spline clip...
Page 114 BEVERLY Cruiser 250ie Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer...
Page 115 BEVERLY Cruiser 250ie Engine - 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 the six clamping screws in criss-cross fash- ion to the prescribed torque.
Page 116 BEVERLY Cruiser 250ie Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102 Refitting the starter motor...
Page 117 BEVERLY Cruiser 250ie Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
Page 118 BEVERLY Cruiser 250ie Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.
Page 119: Removing The Cylinder Head
BEVERLY Cruiser 250ie Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes.
Page 120: Removing The Valves
BEVERLY Cruiser 250ie Engine MOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the oil guards with the appropriate tool.
Page 121: Inspecting The Small End
BEVERLY Cruiser 250ie Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 122: Inspecting The Piston
BEVERLY Cruiser 250ie Engine Inspecting the piston - Measure the diameter of the wrist pin seat on the piston. - Calculate the piston pin coupling clearance. - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis.
Page 123 BEVERLY Cruiser 250ie Engine Inspecting the cylinder - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the head coupling surface is not worn or misshapen.
Page 124: Removing The Piston
BEVERLY Cruiser 250ie Engine scraper ring Standard opening: 0.20 ÷ 0.40 mm Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin stop ring onto the appropriate tool...
Page 125 BEVERLY Cruiser 250ie Engine MEASUREMENT "A" MUST BE TAKEN WITHOUT ANY GASKET FITTED BETWEEN THE CRANK- CASE AND CYLINDER AND AFTER RESETTING THE GAUGE, EQUIPPED WITH A SUPPORT, ON A GROUND PLANE ENGINE 250 SHIMMING Name Measure A Thickness shimming 3.70 - 3.60...
Page 126: Inspecting The Cylinder Head
BEVERLY Cruiser 250ie Engine Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retain- ing band, refit the cylinder as shown in the figure. N.B. BEFORE FITTING THE CYLINDER, CAREFUL- LY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Page 127 BEVERLY Cruiser 250ie Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
Page 128 BEVERLY Cruiser 250ie Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
Page 129 BEVERLY Cruiser 250ie Engine Inlet: 94.6 mm Valve check Maximum admissible clearance Outlet: 0.072 mm Valve check Maximum admissible clearance Inlet: 0.062 mm Valve check standard clearance Outlet: 0.025 ÷ 0.052 mm Valve check standard clearance Inlet: 0.013 ÷ 0.040 mm Valve check Minimum admissible diameter Outlet: 4.95 mm...
Page 130 BEVERLY Cruiser 250ie Engine - Measure the width of the sealing surface on the valve seats and on the valves. Sealing surface width: After use: Intake and ex- haust: 1.6 mm - If any of the sealing surfaces on the valves is...
Page 131 BEVERLY Cruiser 250ie Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seals. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
Page 132 BEVERLY Cruiser 250ie Engine - Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Internal rocker arm diameter: Standard diame- Diameter 12.000 - 12.011 mm...
Page 133 BEVERLY Cruiser 250ie Engine Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading.
Page 134 BEVERLY Cruiser 250ie Engine - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que.
Page 135 BEVERLY Cruiser 250ie Engine GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE EN- GINE. Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 Spark plug 12 ÷ 14 Starter ground screw 7 ÷...
Page 136 BEVERLY Cruiser 250ie Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
Page 137 BEVERLY Cruiser 250ie Engine - Remove the two screws and the internal cover shown in the diagram. - Remove the oil guard on the flywheel side. - Remove the oil filter fitting shown in the diagram. - Check the axial clearance on the connecting rod.
Page 138 BEVERLY Cruiser 250ie Engine 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Axial crankshaft/crankcase clearance: Stand- ard clearance 0.15 - 0.40 mm (when cold) Axial connecting rod - crankshaft clearance Standard clearance 0.20 ÷ 0.50 mm Radial connecting rod - crankshaft clearance Standard clearance 0.036 ÷...
Page 139 BEVERLY Cruiser 250ie Engine crankshaft, be very careful that no impurities get in through the shaft's lubrication holes. In order to prevent damaging the connecting rod bushings, do not attempt cleaning the lubrication duct with compressed air. - Make sure that the 2 caps on the crankpin are properly fitted.
Page 140 BEVERLY Cruiser 250ie Engine - Inspect 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 coupling gasket be- tween the crankcase halves or the mating surfaces...
Page 141 BEVERLY Cruiser 250ie Engine Inspecting the crankshaft plain bearings o obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure (3,2 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 142 BEVERLY Cruiser 250ie Engine TYPE IDENTIFICATION BLUE YELLOW Type "A" Type "B" Type "C" - RED - BLUE - YEL- Main half- 1.970 ÷ 1.9703 ÷ 1.976 ÷ bearing 1.973 1.976 1.979 Bush- Crank- Internal bush- Possible ing cat- case...
Page 143: Oil Filter On Crankcase Fitting
BEVERLY Cruiser 250ie Engine N.B. DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION. N.B. CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED...
Page 144 BEVERLY Cruiser 250ie Engine Studs Check that the stud bolts have not worked loose from their seat in the crankcase. Check the depth of stud bolt driving with a gauge, as indicated in the photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
Page 145 BEVERLY Cruiser 250ie Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the photograph, re- move the stud bolt from its seat. Clean the threaded seat on the carter thoroughly. Refit a new stud bolt and apply the special product on the threading crankcase side.
Page 146 BEVERLY Cruiser 250ie Engine ENG - 58...
Page 147: Oil Pressure Check
BEVERLY Cruiser 250ie Engine Oil pressure check - Disconnect the electrical minimum oil pressure connection and remove the switch. - Check the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
Page 148 BEVERLY Cruiser 250ie Engine Removal - Remove the transmission cover and the com- plete driving pulley beforehand - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
Page 149: Oil Pump
BEVERLY Cruiser 250ie Engine - Orientate the oil guard by inserting the bracket which is part of the appropriate tool - Tighten the threaded bar onto the crankshaft as far as it will go. - Use the nut to move the base of the tool until you...
Page 150 BEVERLY Cruiser 250ie Engine 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 pulley with a screwdriver inserted through one of its two holes.
Page 151 BEVERLY Cruiser 250ie Engine Measure the distance between the outer rotor and the pump body (see figure). - Check the axial clearance of the rotors using a trued bar as shown in the figure. Characteristic Axial rotor clearance Limit values admitted: 0.09 mm...
Page 152: Oil Pump Control Crown Screw
BEVERLY Cruiser 250ie Engine - Fit the sprocket wheel with a new O-ring. - Fit the chain. - Fit the central screw and the belleville washer. Tighten to the prescribed torque. - Fit the oil pump cover by tightening the two screws to the prescribed torque.
Page 153 BEVERLY Cruiser 250ie Engine Inspecting the by-pass valve - Check the unloaded spring length. - Check that the small piston is not scored. - Ensure that it slides freely on the crankcase and that it guarantees a good seal. - If not, eliminate any impurities or replace defec- tive parts.
Page 154 BEVERLY Cruiser 250ie Engine ENG - 66...
Page 155 INDEX OF TOPICS INJEC NJECTION...
Page 156 BEVERLY Cruiser 250ie Injection 1. Battery 2. Injector 3. Instrument panel 4. Injection load remote control 5. Electric fan relay 6. Water temperature sensor 7. Fuel pump 8. HV coil 9. Diagnosis connector 10. Revolution sensor 11. Lambda probe 12.Throttle body and injection electronic control unit (MIU)
Page 157 BEVERLY Cruiser 250ie Injection MIU injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. The injection and ignition are timed on the four-stroke cycle by means of a tone wheel keyed on to the crankshaft (24-2 teeth) and pick-up sensor.
Page 158 BEVERLY Cruiser 250ie Injection Of course, this cannot happen when the rev counter signal is missing, or when the failure involves the control circuits: - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel.
Page 159 BEVERLY Cruiser 250ie Injection a. Battery voltage b. Blown fuse c. Remote controls d. Connectors B: Chassis earthing C: Fuel supply a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c. Broken shielded cap E: Intake circuit a.
Page 160 BEVERLY Cruiser 250ie Injection 4. When functional checks are performed, check that the battery voltage is more than 12V. 5. Before trying to start up, check to make sure there is at least two litres of fuel in the tank. Failure to respect this norm will damage the fuel pump.
Page 161 BEVERLY Cruiser 250ie Injection Specification Desc./Quantity - Lambda probe + battery under permanent power supply + Battery Immobilizer aerial Electric fan starter Water temperature sensor + Lambda probe Engine stop switch R.P.M. sensor (+) Fuel injector R.P.M. sensor (-) Diagnostics socket output...
Page 162 BEVERLY Cruiser 250ie Injection EMS circuit diagram 1. Battery 2. 30A Fuse 3. 7.5A Fuse 4. Revolution sensor 5. Engine temperature sensor 6. Immobilizer aerial 7. Side stand switch 8. Engine stop switch 9. 7.5A Fuse 10. Key switch contacts 11.
Page 163 BEVERLY Cruiser 250ie Injection 17. Electric fan relay 18. Start-up remote control switch 19. Starter motor 20. Electric fan motor 21. Fuel pump 22. HV coil 23. Injector 24. Lambda probe 25. To the analogue rpm indicator 26. To the engine warning light 27.To the immobilizer LED...
Page 164 BEVERLY Cruiser 250ie Injection Possible Cause Operation revolution timing sensor Air temperature Coolant temperature Start-up speed Starter motor and remote control Battery Ground connections End of compression pressure End of compression pressure Power to the spark plug Spark plug Shielded cap...
Page 165 BEVERLY Cruiser 250ie Injection Engine does not rev down ENGINE DOES NOT RETURN TO THE IDLING SPEED/IDLING SPEED TOO HIGH Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature...
Page 166 BEVERLY Cruiser 250ie Injection Engine revs irregularly ENGINE IRREGULAR PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Additional air pipe and Stepper Intake system seal Intake sleeve Filter box Ignition system...
Page 167 BEVERLY Cruiser 250ie Injection Engine knocking PRESENCE OF KNOCKING (HEAD KNOCKING) Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector revolution timing sensor Air temperature Coolant temperature Lambda sensor Ignition efficiency Spark plug...
Page 168 BEVERLY Cruiser 250ie Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. Remove the fast-release fitting from the injector support INJEC - 14...
Page 169 BEVERLY Cruiser 250ie Injection Remove the injector connector Remove the three screws fixing the manifold to the cylinder head and the clip fixing the throttle body to the manifold. Remove the MIU connector INJEC - 15...
Page 170 BEVERLY Cruiser 250ie Injection Remove the gas command fitting as indicated in the photograph Refitting the butterfly valve To refit, perform the operations in the reverse or- der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
Page 171 BEVERLY Cruiser 250ie Injection Pump supply circuit 1. Battery 2. 30A Fuse 3. Key switch contacts 4. 7.5A Fuse 5. 10A Fuse 6. Injection load remote control 7. Fuel pump 8. HV coil INJEC - 17...
Page 172 BEVERLY Cruiser 250ie Injection 9. Injector 10. Lambda probe 11. Electric fan relay When switched to "ON", the fuel pump starts to rotate for two seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied.
Page 173 BEVERLY Cruiser 250ie Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If...
Page 174 BEVERLY Cruiser 250ie Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
Page 175 BEVERLY Cruiser 250ie Injection pump circuit 6 Check, on switching to "ON", that there is battery voltage, for about two seconds, to the Black-Green cable of the pump connector and earth with pump connector disconnected. Otherwise check the continuity of the Black-Grey cable between the pump connector and the base of the remote con- trol.
Page 176 BEVERLY Cruiser 250ie Injection Circuit leak test Install the appropriate tool for fuel pressure control with the pipe fitted with the pressure gauge on the delivery pipe.. Check during regular operation by placing the ap- propriate tool between the pump and the injector.
Page 177 BEVERLY Cruiser 250ie Injection Remove the screw shown in the photograph Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support...
Page 178 BEVERLY Cruiser 250ie Injection Inspecting the injector circuit 1. Battery 2. 30A Fuse 3. Key switch contacts 4. 7.5A Fuse 5. 10A Fuse 6. Injection load remote control 7. Fuel pump 8. HV coil INJEC - 24...
Page 179 BEVERLY Cruiser 250ie Injection 9. Injector 10. Lambda probe 11. Electric fan relay Check the resistance at the injector ends: 14.5 ± 5% Ohm Check that the injection load 10A fuse No. 3 is in good conditions. Check the efficiency of 7.5 A fuse No. 9 key-con- trolled control unit power supply.
Page 180 BEVERLY Cruiser 250ie Injection Check the power supply line of the injection load remote control energising coil: after switching to "ON", make sure there is battery voltage, for two seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If...
Page 181 BEVERLY Cruiser 250ie Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
Page 182 BEVERLY Cruiser 250ie Injection With the control unit and the injector disconnected, check the continuity of the Red-Yellow cable be- tween pin 14 of the interface wiring and the injector connector Switch to "ON" and check if there is voltage, with...
Page 183 BEVERLY Cruiser 250ie Injection Inspecting the injector hydraulics To carry out the injector check, remove the intake manifold by removing the three clamping screws at the head and the clip connecting the control unit to the manifold. Install the appropriate tool for checking fuel pres- sure and position the manifold over a container graduated by at least 100 cm³.
Page 184 BEVERLY Cruiser 250ie Injection Components location 1. Battery 2. Injector 3. Instrument panel 4. Injection load remote control 5. Electric fan relay 6. Water temperature sensor 7. Fuel pump 8. HV coil 9. Diagnosis connector 10. Revolution sensor 11. Lambda probe...
Page 185 BEVERLY Cruiser 250ie Injection 12.Throttle body and injection electronic control unit (MIU) Tachometer With wiring disconnected from the control unit and connected to the system, check that the sensor resistance between pins 13 - 15 is between 100 and 150 Ohm at an engine temperature of approx- imately 20°...
Page 186 BEVERLY Cruiser 250ie Injection With the interface cable harness disconnected from the control unit, check continuity between pin 13 and the red cable of the rpm sensor connector and between pin 15 and the brown cable of the rpm sensor connector...
Page 187 BEVERLY Cruiser 250ie Injection HT coil 1. Battery 2. 30A Fuse 3. Key switch contacts 4. 7.5A Fuse 5. 10A Fuse 6. Injection load remote control 7. Fuel pump 8. HV coil INJEC - 33...
Page 188 BEVERLY Cruiser 250ie Injection 9. Injector 10. Lambda probe 11. Electric fan relay The ignition system is integrated with the injection and is of the inductive high efficiency type. The control unit manages two important parameters: - Ignition advance This is optimised according to the engine rpm, to the engine load, temperature and ambient pressure With idle engine, it is optimised to obtain the stabilisation of the speed at 1450 ±...
Page 189 BEVERLY Cruiser 250ie Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 190 BEVERLY Cruiser 250ie Injection INJEC - 36...
Page 191 BEVERLY Cruiser 250ie Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
Page 192 BEVERLY Cruiser 250ie Injection Check the resistance of the primary coil between pin 22 of the interface wiring and the green black cable of the injection load remote control base with the control unit disconnected and the remote con- trol disconnected.
Page 193 BEVERLY Cruiser 250ie Injection Coolant temperature sensor 1. Engine stop switch 2. Side stand switch 3. Water temperature sensor 4. To the water warning light 5. Injection electronic control unit (MIU) Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter...
Page 194 BEVERLY Cruiser 250ie Injection With the connector on the control unit side discon- nected and the coolant temperature sensor con- nector connected, check that the resistance val- ues between pin 9 and the ground lead correspond with the engine temperature.
Page 195 BEVERLY Cruiser 250ie Injection The throttle body after the pre-calibration has an opened valve with an angle that can vary depending on the tolerances of the machining of the pipe and the valve itself. The valve position sensor can also assume various fitting positions. For these reasons the mV of the sensor with the valve at idle can vary from one throttle body to another.
Page 196 BEVERLY Cruiser 250ie Injection Reset should be performed in the following cases: - on first fitting. - if the injection control unit is replaced. N.B. THE TPS RESETTING PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION.
Page 197 BEVERLY Cruiser 250ie Injection Lambda probe 1. Battery 2. 30A Fuse 3. Key switch contacts 4. 7.5A Fuse 5. 10A Fuse 6. Injection load remote control 7. Fuel pump 8. HV coil INJEC - 43...
Page 198 BEVERLY Cruiser 250ie Injection 9. Injector 10. Lambda probe 11. Electric fan relay The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e.
Page 199 BEVERLY Cruiser 250ie Injection Check the efficiency of the injection load remote control: Check the resistance of the energising coil between pins 86 and 85: 40 to 80 Ohm Apply a voltage of 12V to pins 86 and 85; make sure that there is continuity between pins 30 and 87 of the remote control.
Page 200 BEVERLY Cruiser 250ie Injection Check the presence of fixed voltage between the grey/black cable of the remote control base and earth. If there is none check the continuity of the grey/black cable between the fuse box (No. 3 10 A) and the remote control base.
Page 201 BEVERLY Cruiser 250ie Injection Check there is voltage between pins 21 and 26 of the interface wiring, for around two seconds, when switching to «ON». With the engine cold, check the resistance of the Lambda sensor heater between pin 21 of the in-...
Page 202 BEVERLY Cruiser 250ie Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-)
Page 203 INDEX OF TOPICS SUSP USPENSIONS...
Page 204: Removing The Front Wheel
BEVERLY Cruiser 250ie Suspensions This section is devoted to operations that can be carried out on the suspension. Front Removing the front wheel - Loosen the wheel axle lock-nut. - Loosen the two wheel axle safety screws on the fork leg, on the brake calliper side.
Page 205 BEVERLY Cruiser 250ie Suspensions * Either tool can be used. - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle,...
Page 206 BEVERLY Cruiser 250ie Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube...
Page 207 BEVERLY Cruiser 250ie Suspensions - Refit the cap and tighten the five fixing screws. Refitting the front wheel - Grease the wheel axle, then install it from the tone wheel side and install the tone wheel proper- - Tighten the wheel axle nut to the prescribed tor- que.
Page 208: Front Fork
BEVERLY Cruiser 250ie Suspensions Removal - Remove the instrument panel. - Disconnect the electrical controls wiring on the handlebar. - Remove the brake pumps. - Remove the throttle control. - Remove the handlebar, undoing the handlebar fixing pin. Refitting - To refit, carry out the removal operations but in reverse order.
Page 209 BEVERLY Cruiser 250ie Suspensions 020055Y Wrench for steering tube ring nut Overhaul - Check that the roller bearing does not show signs of wear or pricking. In case of replacement, proceed as follows: - Support the fork in a vice.
Page 210 BEVERLY Cruiser 250ie Suspensions - Insert the 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.
Page 211 BEVERLY Cruiser 250ie Suspensions - Remove the dust guard ring using a screwdriver as shown in the figure. - Remove the oil guard safety lock using a screw- driver. - Using the appropriate special tool, remove the oil seal. - Insert the tie rod complete with cable into the oil guard.
Page 212 BEVERLY Cruiser 250ie Suspensions Check there are no signs of wear or seizing up between the stem and the leg. If there are, replace the damaged part. Characteristic Maximum leg diameter 35.10 mm Minimum stem diameter 34.90 mm Check that the oil holes on the pumping element are not clogged.
Page 213 BEVERLY Cruiser 250ie Suspensions - Insert the contrast spring into the pumping mem- ber. - Insert the pumping element inside the stem. - Insert the pumping element guide bushing at the lower stem end. - Insert the stem in the leg being careful not to let the stem guide bushing come out.
Page 214 BEVERLY Cruiser 250ie Suspensions - Loosen the fork clamp screws and ensure the stem closure cap is fitted properly on the clamp. - Tighten the clamp screws to the prescribed tor- que. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor Locking torques (N*m) Fork clamp screws 20 ÷...
Page 215 BEVERLY Cruiser 250ie Suspensions Removal - Remove the fork - Check that the upper ball bearing and the seat of the lower roller bearings do not show signs of wear or pricking. In case of replacement, proceed as follows: - Using a punch to remove the bearings, insert it from the bottom and remove the ball bearing above the headstock.
Page 216: Shock Absorber Lower Clamp
BEVERLY Cruiser 250ie Suspensions Removing the rear wheel - Remove the exhaust silencer. - Unscrew the shock absorber lower clamp and rotate the shock absorber towards the scooter rear part. - Remove the cotter pin and the cap. - Loosen the nut and collect the spacer.
Page 217: Fixing Screw For Wheel Rim To Hub
BEVERLY Cruiser 250ie Suspensions - Remove the five screws fixing the wheel to the hub. - Remove the wheel and collect the conical spacer. Refitting the rear wheel - Carry out the operations in the reverse order to the removal, observing the prescribed tightening torques.
Page 218 BEVERLY Cruiser 250ie Suspensions - Loosen the nut on the inside of the frame from the left-hand side (see figure) and remove the rel- evant spindle; - Remove the swinging arm. Overhaul - Check that the silent bloc is not damaged. If there is, replace it.
Page 219 BEVERLY Cruiser 250ie Suspensions - Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket...
Page 220 BEVERLY Cruiser 250ie Suspensions - Separate the swinging arm on the engine side from the vehicle side arm. - Remove the internal spacer shown in the photo- graph - Using a suitable pin remove the roller casings as shown in the photographs...
Page 221 BEVERLY Cruiser 250ie Suspensions Specification Desc./Quantity Length of the swinging arm tube on the engine side 182.5 -0.1/-0.3 mm Length of the swinging arm tube on the frame side 227.1+0.2/0 mm - Lubricate the roller bearing housings with grease - Insert the spacers...
Page 222: Shock Absorbers
BEVERLY Cruiser 250ie Suspensions 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 Nm Engine-swinging arm bolt 64 - 72...
Page 223 BEVERLY Cruiser 250ie Suspensions Removal Proceed as follows: - place the scooter on its centre stand; - lift the engine a little with a jack so as to free the two shock absorbers; - remove the muffler - undo the shock absorber spring assembly clamp-...
Page 224: Rear Wheel Axle
BEVERLY Cruiser 250ie Suspensions See also Exhaust assy. Removal Overhaul - Remove the circlip shown in the photograph - Support the muffler support bracket sufficiently - Using the special punch, remove the bearing from its seat as shown in the photograph...
Page 225 BEVERLY Cruiser 250ie Suspensions Centre-stand Removal - Support the scooter adequately. - Remove the two return springs from the stand. - Unscrew the fixing nut. - Remove the pin and the stand. - Push the internal spacer to take it out, paying at- tention to collect the O-rings from both sides.
Page 226: Side Stand
BEVERLY Cruiser 250ie Suspensions Side stand Removal of the side stand - Unhook the springs; - Loosen the nut; - Pull out the screw; Fitting Carry out the previous operations in reverse order. Locking torques (N*m) Side stand fixing bolt 35 ÷ 40...
Page 227 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 228: Rear Brake Calliper
BEVERLY Cruiser 250ie Braking system This section è is devoted to the description of the braking system components. Interventions rules WARNING THE FLUID FOR THE BRAKE SYSTEM IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE CONTACT AREA WELL WITH COPIOUS AMOUNTS OF WATER.
Page 229 BEVERLY Cruiser 250ie Braking system Removal - Inspect the condition of the hoses, packing and joint. In the event of fluid leaks from the calliper, this must be replaced. - Detach the brake fluid pipe from calliper, pouring the fluid inside a container.
Page 230: Oil Bleed Screw
BEVERLY Cruiser 250ie Braking system - Remove the internal parts from the floating body with short blasts of compressed air through the brake liquid pipe to facilitate expelling the plung- ers. - Check: • that the plates and the body are whole and in good condition;...
Page 231 BEVERLY Cruiser 250ie Braking system Rear - combined Front brake calliper Removal - Inspect the condition of the hoses, packing and joint. In the event of fluid leaks from the calliper, this must be replaced. - Detach the brake fluid pipe from calliper, pouring the fluid inside a container.
Page 232 BEVERLY Cruiser 250ie Braking system - Remove the fixed plate by undoing the screw shown in the photograph. - Remove the internal parts from the floating body with short blasts of compressed air through the brake liquid pipe to facilitate expelling the plung- ers.
Page 233: Front Brake Disc
BEVERLY Cruiser 250ie Braking system See also Front Rear brake disc Refitting - For the installation, position the disc correctly using the arrow stamped on it as reference. - Tighten the screws to the prescribed torque and apply the recommended product.
Page 234 BEVERLY Cruiser 250ie Braking system Removal Proceed as follows: - Remove the front wheel. - Loosen the five disc fixing screws. - Thoroughly clean the seats on the front wheel hub and on the disc. See also Removing the front wheel Refitting For the fitting, position the disc correctly using the arrow stamped on it as reference.
Page 235: Front Brake Pads
BEVERLY Cruiser 250ie Braking system - Remove the wheel and check using the appro- priate tools that the axial run-out of the brake surface is within the prescribed limits. - If this is not the case, replace the disc and repeat the test.
Page 236: Pad Fastening Pin 19.6 ÷
BEVERLY Cruiser 250ie Braking system Screw 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.
Page 237 BEVERLY Cruiser 250ie Braking system Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Through the bleed screw on the brake calliper, bleed the system using a hose of adequate diam- eter.
Page 238 BEVERLY Cruiser 250ie Braking system Oil bleed screw 12 - 16 Front Proceed as follows: - Position the vehicle on a flat surface and on the stand - Loosen the two screws shown in the figure and open the front brake fluid reservoir.
Page 239 BEVERLY Cruiser 250ie Braking system 020329Y MityVac vacuum-operated pump Locking torques (N*m) Oil bleed screw 12 - 16 Front brake pump Removal - Remove the rear-view mirror undoing the nut «A» and remove the plastic cover «B». - Remove the two fixing screws from the brake pump to the handlebar indicated in the photo- graph.
Page 240 BEVERLY Cruiser 250ie Braking system 2) Remove the cap and unscrew the internal parts in the specified order; 3) Check that: - The body of the pump shows no signs of internal damage or corrosion; - The piston shows no sign of damage or abnormal wear;...
Page 241 BEVERLY Cruiser 250ie Braking system Rear brake pump - combined Removal - To remove the pump, carry out the same proce- dure followed to remove the front brake pump. Characteristic Plunger diameter Ø 13 mm See also Rear - combined Refitting - Upon refitting, perform the operation but in reverse order.
Page 242 BEVERLY Cruiser 250ie Braking system BRAK SYS - 16...
Page 243 INDEX OF TOPICS CHAS HASSIS...
Page 244: Rear Rack
BEVERLY Cruiser 250ie Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the saddle by loosening the three re- taining screws indicated in the figure; Side fairings - Remove the side bumper, loosening the retaining screw shown in the figure.
Page 245: Instrument Panel
BEVERLY Cruiser 250ie Chassis Instrument panel - Remove the front shield. - Remove the odometer cable. - Release the cable harness of the instrument pan- - Undo the three screws and remove the instru- ment panel. Headlight assy. - Operating from both sides, remove the two fixing screws as shown in the figure and detach the con- nector.
Page 246 Legshield • Remove Piaggio badge using a screw- driver being careful not to damage the front shield. • Remove the screw shown in the figure.
Page 247 BEVERLY Cruiser 250ie Chassis - Remove the screw placed near the fuel gauge. • Remove the expansion tank flap. • Remove the fixing screw shown in the figure. • Remove the central cover. • Remove the two lower retainers indi- cated in the figure.
Page 248 BEVERLY Cruiser 250ie Chassis Knee-guard - Remove the front shield. - Remove the central frame cover. - Release the rubber cap from the fuse box and, undoing the two screws indicated in the figure, re- move the fuse box. - Disconnect the connector from the fuel indicator.
Page 249 BEVERLY Cruiser 250ie Chassis • Remove the two transmissions (saddle opening and fuel tank lid opening). • Remove the cover and rubber gasket from the expansion tank filler. • Detach the shield back plate and re- lease the expansion tank filler from the hole on the shield back plate.
Page 250 BEVERLY Cruiser 250ie Chassis • To refit place the spring on the right side hole. • Insert the master-cylinder and the lock body and, using a pair of pliers, drive the stop spring until it stops. Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the...
Page 251 BEVERLY Cruiser 250ie Chassis Taillight assy. • Remove the two side bumpers. • Remove the two side securing screws from the light unit shown in the figure. • Remove the rear luggage rack plastic cover removing the screw shown and undo the three screws fixing the lug- gage rack.
Page 252 BEVERLY Cruiser 250ie Chassis See also 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 loosening the retaining screw located under the saddle mounting plate.
Page 253: Rear Mudguard
BEVERLY Cruiser 250ie Chassis Rear rack Frame central cover Seat 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 254 BEVERLY Cruiser 250ie Chassis Fuel tank - Remove the shield back plate. - Remove the two lower screws of the front wheel housing. - Remove the footrest. N.B. THIS OPERATION SHOULD PREFERABLY BE PERFORMED WITH THE TANK EMPTY. - Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather;...
Page 255: Front Mudguard
BEVERLY Cruiser 250ie Chassis N.B. BE VERY CAREFUL WHEN PULLING OUT THE CARBURETTOR PIPING SINCE AN EXCES- SIVE FORCE MAY DAMAGE THE PLASTIC IN- SERTS ON THE PUMP BODY. UPON REAS- SEMBLY, IT IS THEREFORE NECESSARY TO SLIGHTLY PRESS THE PIPING AND THE RE-...
Page 256 BEVERLY Cruiser 250ie Chassis - Remove the clamp «B» from the front brake pipe. - Undo the two screws «C» fixing the fork leg cov- ers. - Undo the four screws «D» fixing it to the plate and the frame.
Page 257 BEVERLY Cruiser 250ie Chassis Radiator fan - Remove the front wheel housing. - Prepare a container 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.
Page 258 BEVERLY Cruiser 250ie Chassis CHAS - 16...
Page 259 INDEX OF TOPICS PRE DE DELIVERY...
Page 260 BEVERLY Cruiser 250ie Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance checks: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks...
Page 261 BEVERLY Cruiser 250ie Pre-delivery •Instrument panel lights • Horn • electric start up • Engine stopping with emergency stop switch • electric saddle opening button CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
Page 262 BEVERLY Cruiser 250ie Pre-delivery - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) • Uniform steering rotation • Possible losses • electric radiator fan operation CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 263 INDEX OF TOPICS TIME...
Page 264 BEVERLY Cruiser 250ie Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine MOTORE Code Action Duration 001001 Engine from frame - Removal and refit.
Page 265 BEVERLY Cruiser 250ie Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 3...
Page 266 BEVERLY Cruiser 250ie Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service 001129 Chain tightener - Overhaul and replacement TIME - 4...
Page 267 BEVERLY Cruiser 250ie Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 001083 Thermistor - Replacement 001057 Thermostat - Replacement TIME - 5...
Page 268 BEVERLY Cruiser 250ie Time Rocker arms support assy. ALBERO A CAMME Code Action Duration 001148 Rocking lever valve - Re- placement 001044 Camshaft - Replacement 001169 Decompressor - Replace- ment 888146 Verifica ed eventuale ripristi- no fasatura distribuzione TIME - 6...
Page 269 BEVERLY Cruiser 250ie Time Cylinder head cover COPERCHIO TESTA Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement 001091 Anello tenuta coperchio testa...
Page 270 BEVERLY Cruiser 250ie Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Re- placement 001102 Net oil filter - Replacement / Cleaning TIME - 8...
Page 271 BEVERLY Cruiser 250ie Time Flywheel cover OPERCHIO VOLANO Code Action Duration 001087 Flywheel cover - replace 001150 Flywheel cover gasket - Re- placement 007007 Water pump rotor cover 007017 Water pump cover - Replace- ment 007003 Coolant delivery and return...
Page 272 BEVERLY Cruiser 250ie Time Driven pulley PULEGGIA CONDOTTA Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement 003072 Clutch assembly - Check wear Oil pump TIME - 10...
Page 273 BEVERLY Cruiser 250ie Time POMPA OLIO Code Action Duration 001125 Chain guide pads - Replace- ment 001051 Belt/Timing chain - Change 001042 Oil pump - Service 001112 Oil pump - change 001122 Oil pump chain - Replace- ment 001130 Oil sump - Replacement...
Page 274 BEVERLY Cruiser 250ie Time Code Action Duration 004125 Rear wheel axle - Replace- ment 004180 Reduction gear pipe - Re- placement Driving pulley PULEGGIA MOTRICE Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066...
Page 275 BEVERLY Cruiser 250ie Time Transmission cover OPERCHIO TRASMISSIONE Code Action Duration 001096 Transmission crankcase cov- er - Replacement 001135 Transmission cover bearing - Replacement 001131 Transmission air intake - Re- placement TIME - 13...
Page 276 BEVERLY Cruiser 250ie Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001104 Start-up freewheel - Replace- ment 001151 Start-up driven gearing - Re- placement 001017 Start-up pinion - Replace- ment TIME - 14...
Page 277 BEVERLY Cruiser 250ie Time Flywheel magneto VOLANO MAGNETE Code Action Duration 001067 Stator - Removal and Refit- ting 001173 Rotor - Replacement 001058 Complete flywheel - Replace- ment 888105 Viti fissaggio ruota libera sul volano - Sostituzione TIME - 15...
Page 278 BEVERLY Cruiser 250ie Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 16...
Page 279 BEVERLY Cruiser 250ie Time Exhaust pipe MARMITTA Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replace- ment 001095 Muffler guard - Replacement 005138 Lambda probe - Replace- ment 001136 Exhaust emissions - Adjust- ment TIME - 17...
Page 280 BEVERLY Cruiser 250ie Time Air cleaner DEPURATORE ARIA Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor fitting - Replacement TIME - 18...
Page 281 BEVERLY Cruiser 250ie Time Frame FRAME Code Action Duration 004001 Frame - Replacement TIME - 19...
Page 282 BEVERLY Cruiser 250ie Time Centre-stand CENTRE AND SIDE STANDS Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 20...
Page 283 BEVERLY Cruiser 250ie Time Legshield spoiler SCUDO ANTERIORE SPOILER Code Action Duration 004064 Front shield, front section - Replacement 004053 Spoiler - Replacement TIME - 21...
Page 284 BEVERLY Cruiser 250ie Time Side fairings COPERTURE LATERALI Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear side panels - Replace- ment 004052 Bumper - Replacement 004159 Plates / Stickers - Replace- ment TIME - 22...
Page 285 BEVERLY Cruiser 250ie Time Footrests MATS AND COVERS Code Action Duration 004075 Front mat - Replacement 004079 Passenger footrest (1) - Re- placement 004015 Footrest - removal and instal- lation TIME - 23...
Page 286 BEVERLY Cruiser 250ie Time Rear cover SCUDO POSTERIORE Code Action Duration 004065 Front shield rear section - re- moval and installation 004081 Glove box door - Replace- ment 004083 Glove box - Replacement TIME - 24...
Page 287 BEVERLY Cruiser 250ie Time Central cover CENTRAL COVER Code Action Duration 004011 Central frame cover - Re- placement 002082 Fuel tank cap opening drive - Replacement TIME - 25...
Page 288 BEVERLY Cruiser 250ie Time Underseat compartment VANO SOTTOSELLA-APERTURA ELETTRICA SELLA-PORTATARGA Code Action Duration 002083 Saddle opening transmission - Replacement 004016 Helmet compartment - re- moval and installation 004106 Under-saddle band - Re- placement 004136 License plate support - re- place...
Page 289 BEVERLY Cruiser 250ie Time Mudguard FRONT AND REAR MUDGUARDS Code Action Duration 004009 Rear mudguard - Replace- ment 004002 Front mudguard - Replace- ment TIME - 27...
Page 290 BEVERLY Cruiser 250ie Time Fuel tank ERBATOIO CARBURANTE Code Action Duration 004005 Fuel tank - Replacement 005010 Tank float - Replacement 004109 Fuel tank breather - Replace- ment 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replace- ment...
Page 291 BEVERLY Cruiser 250ie Time Expansion tank VASO ESPANSIONE Code Action Duration 007001 Expansion tank - Replace- ment 007013 Radiator expansion tank con- nection pipe - change 001052 Coolant and air bleeding - Change 007024 Expansion tank cap - Re- placement...
Page 292 BEVERLY Cruiser 250ie Time Radiator RADIATOR Code Action Duration 007014 Radiator thermal switch - Re- placement 007002 Radiator water - Replace- ment 007016 Complete fan with support - Replacement 007003 Coolant delivery and return pipe - change TIME - 30...
Page 293 BEVERLY Cruiser 250ie Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - re- moval and installation TIME - 31...
Page 294: Handlebar Covers
BEVERLY Cruiser 250ie Time Steering column bearings RALLE STERZO Code Action Duration 003051 Fork unit - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 004119 Bearing/upper steering fifth wheel - Replacement 003002 Steering fifth wheel - Re-...
Page 295 BEVERLY Cruiser 250ie Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Throttle grip - Replacement 002037 Brake or clutch lever - Re- placement 002071 Left knob - Replacement 002024 Front brake pump - Removal and Refitting 002067 Rear brake pump - Replace-...
Page 296 BEVERLY Cruiser 250ie Time Swing-arm BRACCIO OSCILLANTE Code Action Duration 001072 Swinging arm - Engine-chas- sis connection - Replacement 004058 Silent block - Replacement 003057 Engine retainer - Tighten nuts TIME - 34...
Page 297 BEVERLY Cruiser 250ie Time Brake hoses TUBAZIONI FRENO Code Action Duration 002039 Front brake calliper - Re- placement 002040 Front brake calliper - Service 002021 Front brake piping - Replace- ment 002047 Front brake fluid and system bleeding plug - Change...
Page 298 BEVERLY Cruiser 250ie Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 36...
Page 299 BEVERLY Cruiser 250ie Time Seat lock SADDLE CLOSING MECHANISM Code Action Duration 004054 Saddle lock catch - Replace- ment TIME - 37...
Page 300 BEVERLY Cruiser 250ie Time Instrument panel GRUPPO STRUMENTI Code Action Duration 005014 Instrument panel - Replace- ment 005038 Instrument panel warning light bulbs - Replacement 005078 Odometer glass - Replace- ment 005014 Odometer - Replacement 004099 Odometer housing - Replace-...
Page 301 BEVERLY Cruiser 250ie Time Rear rack PORTAPACCHI Code Action Duration 004008 Luggage rack - Replacement TIME - 39...
Page 302 BEVERLY Cruiser 250ie Time Locks SERRATURE Code Action Duration 005016 Key switch - Replacement 004010 Antitheft lock - Replacement 005072 Immobilizer aerial - Replace- ment TIME - 40...
Page 303: Turn Signal Lights
BEVERLY Cruiser 250ie Time Turn signal lights INDICATORS AND LIGHTS Code Action Duration 005002 Front headlamp - change 005005 Taillight - Replacement 005008 Front headlamp bulbs - Re- placement 005031 Licence plate light bulb - Re- placement 005032 Transparent licence plate...
Page 304: Front Wheel
BEVERLY Cruiser 250ie Time Front wheel RUOTA ANTERIORE Code Action Duration 002041 Brake disc - Replacement 003037 Front wheel rim - removal and installation 003038 Front wheel axle - removal and installation 003040 Front wheel bearings - Re- placement 003047...
Page 305: Rear Wheel
BEVERLY Cruiser 250ie Time Rear wheel RUOTA POSTERIORE Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Removal and Refitting 002070 Rear brake disc - Replace- ment 003063 Tyre pressure - check 003077 Muffler supporting arm/ rear...
Page 306 BEVERLY Cruiser 250ie Time ELECTRICAL START UP Code Action Duration 001141 Belt anti-vibration roller - Re- placement 001020 Starter motor - Replacement 001017 Start-up pinion - Replace- ment TIME - 44...
Page 307 BEVERLY Cruiser 250ie Time Electric devices ELECTRIC DEVICES Code Action Duration 004142 Plug socket - Replacement 005007 Battery - Replacement 005009 Voltage regulator - replace 005011 Start-up remote control switch - Replacement 005026 Helmet compartment bulb - Replacement 005027 Helmet compartment bulb...
Page 308 BEVERLY Cruiser 250ie Time DISPOSITIVI ELETTRICI Code Action Duration 001069 HV coil - replace 005054 Fuse holder - Replacement 001094 Spark plug cap - Replace- ment 005001 Electrical system - Replace- ment 005003 Horn - Replacement 005052 Fuse (1) - Replacement...

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