Page 1 SERVICE STATION MANUAL xxxxxx (IT) - xxxxxx (EN) - xxxxxx (FR) - xxxxxx (DE) - xxxxxx (ES) - xxxxxx (PT) -xxxxxx (NL) - xxxxxx (EL) Beverly Tourer 300 i.e.
Page 2 Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official Piaggio sales network. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 Beverly Tourer 300 i.e. 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
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 COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: 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 8: Vehicle Identification
Beverly Tourer 300 i.e. Characteristics Vehicle identification To read the chassis prefix, lift the saddle and re- move the lid «A». The engine prefix «B» is stamped near the rear left shock absorber lower support. VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix M28A00 Engine prefix M28MM...
Page 9: Dimensions And Mass
Beverly Tourer 300 i.e. Characteristics Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Length 2110 mm Width to handlebar 770 mm Wheelbase 1470 mm Height 1500 mm Kerb weight 165 kg ± 5 kg Maximum weight allowed 350 kg Engine ENGINE Specification Desc./Quantity...
Page 10: Wheels And Tyres
Beverly Tourer 300 i.e. Characteristics Specification Desc./Quantity Fuel system Electronic injection with Ø 32-mm throttle body and electric fuel pump. Cooling Forced coolant circulation system. Fuel Unleaded petrol (95 RON) Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con- verter and lambda probe.
Page 11 Beverly Tourer 300 i.e. Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar right-side lever. Rear brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar left-side lever. Wheels and tyres WHEELS AND TYRES Specification Desc./Quantity...
Page 12 Beverly Tourer 300 i.e. Characteristics Name Torque in Nm Upper shock absorber retainer 40 ÷ 45 FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 16 ÷ 20 Oil bleed screw 12 - 16 Pad fixing pin 19.6 ÷ 24.5 Screw tightening calliper to support 24 ÷...
Page 13: Crankcase And Crankshaft
Beverly Tourer 300 i.e. Characteristics Name Torque in Nm Driven pulley shaft nut 54 to 60 Rear hub cap screws 24 to 27 FLYWHEEL Name Torque in Nm Flywheel cover screw 11 to 13 Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock) Flywheel nut 94 - 102 Pickup fixing screws...
Page 14 Beverly Tourer 300 i.e. Characteristics CYLINDER - PISTON Specification Desc./Quantity Plunger diameter 74.967 +0.014 -0.014 mm Cylinder diameter 75 +0.038 +0.01 mm COUPLING CATEGORIES Name Initials Cylinder Piston Play on fitting cylinder-piston 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064 cylinder-piston 75.017 ÷...
Page 15 Beverly Tourer 300 i.e. Characteristics - Carefully clean the sealing ring housings. - Measure the coupling clearance between the sealing rings and the piston grooves using suitable sensors, as shown in the diagram. - If the clearance is greater than that indicated in the table, replace the piston.
Page 16 Beverly Tourer 300 i.e. Characteristics AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmissionside half- 16.6 +0-0.05 D = 0.20 to 0.50 shaft Flywheel-side halfshaft 16.6 +0-0.05 D = 0.20 to 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 to 0.50 Spacer tool 51.4 +0.05...
Page 17 Beverly Tourer 300 i.e. Characteristics RANKSHAFT Specification Desc./Quantity Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm CHAR - 17...
Page 18 Beverly Tourer 300 i.e. Characteristics MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm CHAR - 18...
Page 19 Beverly Tourer 300 i.e. Characteristics Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.43 mm - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 20 Beverly Tourer 300 i.e. Characteristics COUPLINGS BUSHING CATEGORY CRANKCASE BUSHING INSIDE DIAMETER AFTER FITTING HALVES CATEGORY 29.024 ÷ 29.054 29.024 ÷ 29.054 29.018 ÷ 29.048 29.018 ÷ 29.048 Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2). Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories.
Page 21: Cylinder Head
Beverly Tourer 300 i.e. Characteristics If a crankshaft comprising two half-shafts of different categories needs to be replaced, also replace both 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 position of the springs and the valves so as not to change the original position during refitting - Using a trued bar and a feeler gauge check that the cylinder head surface is not worn or distorted.
Page 22 Beverly Tourer 300 i.e. Characteristics Measure the camshaft bearing seats and rocking lever support pins with a bore meter HEAD BEARINGS Specification Desc./Quantity bearing «A» Diameter 12.000 - 12.018 mm bearing «B» Ø 20.000 ÷ 20.021 mm bearing «C» Ø 37.000 - 37.025 mm Measure the unloaded spring length Characteristic Standard length...
Page 23 Beverly Tourer 300 i.e. Characteristics - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Intake: 4.987 - 4.972 mm Exhaust: 4.975 - 4.960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Intake: 4.96 mm Exhaust:...
Page 24 Beverly Tourer 300 i.e. Characteristics - Check the concentricity of the valve head by ar- ranging a dial gauge at right angle relative to the valve head and rotate it on a "V" shaped abutment. Characteristic Admissible limit: 0.03 mm Measure the valve guide.
Page 25 Beverly Tourer 300 i.e. Characteristics - If no faults are found during the above checks, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping com- pound. During the grinding, keep the cylinder head with the valve axes in a horizontal position.
Page 26 Beverly Tourer 300 i.e. Characteristics -Using a gauge, measure the cam height. TANDARD HEIGHT Specification Desc./Quantity Camshaft check: Standard height Intake: 30.285 mm Camshaft check: Standard height Exhaust: 29.209 mm Check the axial clearance of the camshaft AMSHAFT AXIAL CLEARANCE Specification Desc./Quantity Camshaft check: Standard axial clearance:...
Page 27 Beverly Tourer 300 i.e. Characteristics OCKING LEVERS AND PIN DIAMETER Specification Desc./Quantity Rocking lever inside diameter: Standard diameter Diameter 12.000 - 12.011 mm Rocking lever pin diameter: Standard diameter Diameter 11.977 - 11.985 mm Slot packing system Characteristic Compression ratio 10.5 ÷...
Page 28 Beverly Tourer 300 i.e. Characteristics N.B. 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 300 SHIMMING Name Measure A Thickness SHIMMING 3.70 - 3.60...
Page 29: Index Of Topics
INDEX OF TOPICS TOOL OOLING...
Page 30: Specific Tools
Beverly Tourer 300 i.e. Tooling SPECIFIC TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Calliper to extract ø 15-mm bearings 005095Y Engine support 002465Y Calliper for circlips 006029Y Punch for fitting fifth steering bearing on steering tube 020004Y Punch for removing steering bearings from headstock...
Page 31 Beverly Tourer 300 i.e. Tooling Stores code Description 020074Y Support base for checking crankshaft alignment 020150Y Air heater mounting 020151Y Air heater 020193Y Oil pressure check gauge 020262Y Crankcase splitting plate 020263Y Driven pulley assembly sheath TOOL - 31...
Page 32 Beverly Tourer 300 i.e. Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rpm indicator TOOL - 32...
Page 33 Beverly Tourer 300 i.e. Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic mounting for dial gauge 020357Y 32x35-mm Adaptor 020359Y 42x47-mm Adaptor 020360Y 52x55-mm Adaptor 020363Y 20-mm guide TOOL - 33...
Page 34 Beverly Tourer 300 i.e. Tooling Stores code Description 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020393Y Piston assembly band 020412Y 15-mm guide TOOL - 34...
Page 35 Beverly Tourer 300 i.e. 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 check fitting 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 35...
Page 36 Beverly Tourer 300 i.e. Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y 37 mm adaptor 020483Y 30-mm guide 020489Y Hub cover support stud bolt kit 020428Y Piston position check mounting 020680Y Diagnosis Tool TOOL - 36...
Page 37 Beverly Tourer 300 i.e. Tooling Stores code Description 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Bearing housing, outside ø 47 mm 020626Y Driving pulley lock wrench 001467Y013 Calliper to extract ø 15-mm bearings 020627Y Flywheel lock wrench TOOL - 37...
Page 38 Beverly Tourer 300 i.e. Tooling Stores code Description 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil seal punch 020480Y Petrol pressure check kit 020244Y 15-mm diameter punch 020115Y Ø 18 punch TOOL - 38...
Page 39 Beverly Tourer 300 i.e. Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020638Y 250 l ENGINE SOFTWARE E. - ABS 020469Y Reprogramming kit for vehicle diagnostic tester 020487Y Fork oil seal extractor 020458Y Puller for lower bearing on steering tube TOOL - 39...
Page 40: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 41: Maintenance Chart
Beverly Tourer 300 i.e. Maintenance Maintenance chart AINTENANCE TABLE I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Replace every 2 years Km x 1,000 Driven pulley roller casing Safety fasteners Ignition spark plug Centre stand bracket Driving belt...
Page 42 Beverly Tourer 300 i.e. Maintenance - Remove the transmission compartment air intake cover shown in the picture. - Rotate the driving pulley fan using a screwdriver until the reference marks between the flywheel and flywheel cover coincide as shown in the pic- ture.
Page 43: Spark Plug
Beverly Tourer 300 i.e. Maintenance Spark plug To service the spark plug the engine must be cold; proceed as follows: - Remove the spark plug inspection lid placed on the right side of the vehicle by undoing the speci- fied screw. - Remove the spark plug cap.
Page 44 Beverly Tourer 300 i.e. Maintenance Electrode gap 0.7 to 0.8 mm Locking torques (N*m) Spark plug 12 to 14 Hub oil Check -Place the vehicle on the 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;...
Page 45: Air Filter
Beverly Tourer 300 i.e. Maintenance Capacity approximately 250 cc Locking torques (N*m) Hub oil drainage screw 15 to 17 Nm Air filter To reach the air filter: - Undo the nine screws «A». - Remove the air-box cover «B» Cleaning: - Wash the sponge with water and mild soap.
Page 46: Engine Oil
Beverly Tourer 300 i.e. Maintenance Engine oil Replacement Change oil and replace filter as indicated in the scheduled maintenance table. - In order to facilitate oil drainage, unscrew the cap/ dipstick «A». - Unscrew the mesh pre-filter drainage plug «B» on the flywheel side and let the oil drain off.
Page 47: Engine Oil Filter
Beverly Tourer 300 i.e. Maintenance SAE 5W-40 Synthetic oil that exceed the require- ments of API SL, ACEA A3, JASO MA specifica- tions Characteristic Engine oil 1.3 l Check This operation must be carried out with the en- gine cold and following the procedure below: - Place the vehicle on its centre stand and on flat ground.
Page 48: Oil Pressure Warning Light
Beverly Tourer 300 i.e. Maintenance Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications Oil pressure warning light The vehicle is equipped with a telltale light on the dashboard that lights up when the key is turned to the «ON»...
Page 49: Level Check
Beverly Tourer 300 i.e. Maintenance Level check Check coolant when the engine is cold and as in- dicated in the scheduled maintenance tables, fol- lowing the steps below. - Set the vehicle upright on the stand and remove the cover by undoing screw «A». - Remove the expansion tank cover «B»...
Page 50: Braking System
Beverly Tourer 300 i.e. Maintenance Monoethylene glycol-based antifreeze fluid, CU- NA NC 956-16 Braking system Level check The front and rear brake fluid reservoirs are both positioned on the handlebar. Proceed as follows: - Rest the vehicle onto the centre stand, with the handlebar centred.
Page 51: Headlight Adjustment
Beverly Tourer 300 i.e. Maintenance - Undo the screw «B», then remove cover «C» in order to get access to the reservoir cap below. - Loosen the two fixing screws «D» and remove cover «E». Top-up the brake fluid level using only the prescribed brake fluid and without exceeding the maximum level.
Page 52 Beverly Tourer 300 i.e. Maintenance higher than 9/10 or lower than 7/10 f the height from the ground to the centre of vehicle headlamp; - Otherwise, adjust the headlight. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS.
Page 53: Index Of Topics
INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 54: Poor Performance
Beverly Tourer 300 i.e. Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation Fuel pump Check the injection load relay Excess of scales in the combustion chamber...
Page 55 Beverly Tourer 300 i.e. Troubleshooting Possible Cause Operation Misshapen/worn valve seats Replace the head unit Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings fitted properly Oil leaks from the couplings or from the gaskets...
Page 56: Noisy Suspension
Beverly Tourer 300 i.e. Troubleshooting Steering and suspensions Heavy steering STEERING HARDENING Possible Cause Operation Steering hardening Check the tightening of the top and bottom ring nuts. If irregu- larities continue in turning the steering even after making the above adjustments, check the rotation seats and the steering fifth wheels.
Page 57: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 58 Beverly Tourer 300 i.e. Electrical system 1. bulbs for turn indicator warning lights 2. turn indicator bulbs 3. turn indicator switch 4. turn indicator control device 5. clock 6. immobilizer LED 7. fuel gauge 8. engine temperature gauge 9. injection telltale light 10.
Page 59 Beverly Tourer 300 i.e. Electrical system 20. HV coil 21. engine revolution sensor 22. lambda probe 23. horn 24. horn button 25. injection load remote control 26. stop light bulb 27. helmet compartment light bulb 28. helmet compartment light control switch 29.
Page 60 Beverly Tourer 300 i.e. Electrical system Components arrangement 1. Stator: remove the right side fairing to reach the connector. 2. Battery: remove the battery cover located in the helmet compartment to reach it. Characteristic Battery 12V-12Ah 3. Start-up remote control switch: remove the right side fairing to reach it.
Page 61 Beverly Tourer 300 i.e. Electrical system 5. HV coil: remove the right side fairing in order to reach it. Characteristic HV coil resistance primary value: ~ 0.9 Ω HV coil secondary resistance value: ~ 3.4 kΩ 6. Voltage regulator: remove the right side fairing to reach it.
Page 62 Beverly Tourer 300 i.e. Electrical system 10. Horn: remove the shield back plate to reach it. 11. Immobilizer Aerial: remove the legshield to reach it. 12. Key switch: remove the legshield to reach it. ELE SYS - 62...
Page 63 Beverly Tourer 300 i.e. Electrical system 13. Turn indicator control device: remove the leg- shield to reach it. 14. Remote controls: remove the legshield to reach them. A. Light remote control B. Electric fan remote control C. Injection load remote control 15.
Page 64 Beverly Tourer 300 i.e. Electrical system 17. Stand switch: remove the left footrest to reach 18. Saddle opening actuator: remove the left side panel to reach it. 19. Injection ECU: remove the inspection cover lo- cated in the helmet compartment to reach it. 20.
Page 65 Beverly Tourer 300 i.e. Electrical system ELE SYS - 65...
Page 66 Beverly Tourer 300 i.e. Electrical system 1. Stator: remove the right side fairing to reach the connector. 2. Battery: remove the battery cover located in the helmet compartment to reach it. Characteristic Battery 12V-12Ah 3. Start-up remote control switch: remove the right side fairing to reach it.
Page 67 Beverly Tourer 300 i.e. Electrical system 5. HV coil: remove the right side fairing in order to reach it. Characteristic HV coil resistance primary value: ~ 0.9 Ω HV coil secondary resistance value: ~ 3.4 kΩ 6. Voltage regulator: remove the right side fairing to reach it.
Page 68 Beverly Tourer 300 i.e. Electrical system 9. Spark plug: remove the cover on the vehicle right side to reach it. 10. Horn: remove the shield back plate to reach it. 11. Immobilizer Aerial: remove the legshield to reach it. 12. Key switch: remove the legshield to reach it. ELE SYS - 68...
Page 69 Beverly Tourer 300 i.e. Electrical system 13. Turn indicator control device: remove the leg- shield to reach it. 14. Remote controls: remove the legshield to reach them. A. Light remote control B. Electric fan remote control C. Injection load remote control 15.
Page 70 Beverly Tourer 300 i.e. Electrical system 17. Stand switch: remove the left footrest to reach 18. Saddle opening actuator: remove the left side panel to reach it. 19. Injection ECU: remove the inspection cover lo- cated in the helmet compartment to reach it. 20.
Page 71: Electrical System Installation
Beverly Tourer 300 i.e. Electrical system Instrument panel A = Immobilizer LED B = Speedometer (mph) C = Total Odometer D = Speedometer (km/h) E = Injection telltale light F = High-beam warning light G = Oil pressure warning light H = Digital clock I = Low fuel warning light L = Right turn indicator warning light...
Page 72: Front Side
Beverly Tourer 300 i.e. Electrical system Front side 1. Immobilizer aerial 2. Pre-installation for anti-theft ECU 3. Saddle opening switch 4. To fuel gauge 5. To fuel pump 6. Towards right fairing 7. To helmet compartment light switch 8. Engine ground lead 9.
Page 73 Beverly Tourer 300 i.e. Electrical system 11.Horn 12.To electric fan 13.Front fuse-box 14.Electric fan remote control 15.Injection load remote control 1. Immobilizer aerial 2. Turn indicator control device 3. Injection load remote control 4. On the left side 5. Light remote control 6.
Page 74 Beverly Tourer 300 i.e. Electrical system 1. To instrument panel 2. To front position light 3. To headlight 4. To right turn indicator 5. To front brake stop button 6. To engine stop switch 7. To light switch 8. To starter button 9.
Page 75: Back Side
Beverly Tourer 300 i.e. Electrical system Back side 1. Saddle opening actuator 2. To internal light 3. Battery positive ELE SYS - 75...
Page 76 Beverly Tourer 300 i.e. Electrical system 1. Start-up remote control switch 2. Pick-up connection 3. Flywheel - regulator connection 4. Regulator - system connection 5. Spark plug cap 6. Main wire unit 7. Diagnostics socket 8. Voltage regulator 9. HV coil 10.Rear fuse-box 11.Plug socket for accessories 12.Battery negative...
Page 77 Beverly Tourer 300 i.e. Electrical system 1. To internal light 2. To actuator 3. To battery positive 4. To battery negative 5. To plug socket for accessories 6. To rear light 7. To the license plate light ELE SYS - 77...
Page 78 Beverly Tourer 300 i.e. Electrical system 1. Flywheel cables 2. To wire unit 3. Starter motor positive wire 4. Lambda sensor 5. Oil pressure sensor 6. Lambda probe connector 7. Injection ECU 8. Injector 9. To lambda probe 10.Engine temperature sensor 11.Starter motor positive 12.Starter motor ground lead clamping Conceptual diagrams...
Page 79 Beverly Tourer 300 i.e. Electrical system Ignition 6. immobilizer LED 14. immobilizer aerial 15. injection ECU 20. HV coil 21. engine revolution sensor 25. injection load remote control 29. battery 30. main fuses unit: fuses 1,2,4 49. key switch contacts 54.
Page 80 Beverly Tourer 300 i.e. Electrical system Battery recharge and starting 15. injection ECU 26. stop light bulb 29. battery 30. main fuses unit: Fuses 1 34. voltage regulator 35. magneto flywheel 38. starter button 39. starter motor 40. start-up remote control switch 42.
Page 81: Devices And Accessories
Beverly Tourer 300 i.e. Electrical system 9. injection telltale light 10. low fuel warning light 11. Fuel level transmitter 12. oil pressure warning light 13. oil pressure sensor 15. injection ECU 18. engine temperature sensor 19. fuel injector 21. engine revolution sensor 22.
Page 82 Beverly Tourer 300 i.e. Electrical system 51. pre-installation for anti-theft device 54. auxiliary fuses unit: fuses 8,9,10 Lights and turn indicators 1. bulbs for turn indicator warning lights 2. turn indicator bulbs 3. turn indicator switch 4. turn indicator control device 26.
Page 83: Checks And Inspections
Beverly Tourer 300 i.e. Electrical system 52. high-beam warning light 53. headlight remote control 54. auxiliary fuses unit: fuses 7,8,10 55. stop buttons Checks and inspections This section is dedicated to the checks on the electrical system components. Immobiliser The electronic ignition system is controlled by the control unit with the integrated Immobilizer sys- tem.
Page 84 Beverly Tourer 300 i.e. Electrical system - there is battery voltage - fuses No. 1; 2; 6 and 9 are in working order - there is power to the control unit as specified be- low: 2 With the key switch set to OFF: - if there is battery voltage between terminals 6-26 and terminal 6-chassis ground (fixed power sup- ply).
Page 85 Beverly Tourer 300 i.e. Electrical system Remove the protective base from the connector. With the ignition key switch at «ON» check if 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 86: Diagnostic Codes
Beverly Tourer 300 i.e. Electrical system becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In any case it is advisable to use resistive spark plugs. Diagnostic codes The Immobilizer system is tested each time the key switch is turned from «OFF»...
Page 87 Beverly Tourer 300 i.e. Electrical system - 1-flash code - 2-flash code - 3-flash code Diagnostic code - 1 flash A one-flash code indicates a system where the se- rial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if necessa- Diagnostic code - 2 flashes A two-flash code shows a system where the con-...
Page 88: Ignition Circuit
Beverly Tourer 300 i.e. Electrical system Ignition circuit No spark plug WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. HV coil primary resistance value: Disconnect the connector of the HV coil and meas- ure the resistance between the two terminals. Characteristic HV coil resistance primary value: ~ 0.9 Ω...
Page 89: Engine Stop Switch
Beverly Tourer 300 i.e. Electrical system The three-phase alternator provides good recharge power and at low revs a good compromise is ach- ieved between generated power and idle stability. Remote controls check To check the operation of a solenoid: 1) Check that, given regular conditions, there is no continuity between terminals 87 and 30.
Page 90 Beverly Tourer 300 i.e. Electrical system STARTER BUTTON LIGHT SWITCH TURN INDICATOR SWITCH HORN BUTTON ELE SYS - 90...
Page 91: Stator Check
Beverly Tourer 300 i.e. Electrical system HELMET COMPARTMENT LIGHT SWITCH SADDLE OPENING SWITCH Stator check Checking the stator windings WARNING THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Remove the right side panel. 2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the picture.
Page 92 Beverly Tourer 300 i.e. Electrical system Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine. Voltage should not exceed 15 Volt. In case higher voltages are detected, replace the regulator.
Page 93: Voltage Regulator/Rectifier
Beverly Tourer 300 i.e. Electrical system VOLTAGE REGULATOR/RECTIFIER Specification Desc./Quantity Type Non-adjustable three-phase transistor Voltage 14 to 15V at 5000 rpm with lights off Starter motor 1. Starter motor 2. Starter remote control 3. Battery 4. Fuse No. 1 5. Key switch contacts 6.
Page 94: Horn Control
Beverly Tourer 300 i.e. Electrical system 4) If components are in good conditions, check that the wiring connecting them is not interrupted. 5) Check if there is continuity of the Orange-Blue cable between the start-up remote control switch and the control unit connector. Horn control 1.
Page 95 Beverly Tourer 300 i.e. Electrical system Turn signals system check 1. Battery 2. Fuse No. 1 3. Key switch contacts 4. Fuse No. 10 5. Turn indicator control device 6. Turn indicator switch 7. LH turn indicators 8. RH turn indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
Page 96 Beverly Tourer 300 i.e. Electrical system 7) Check that the Pink and White-Blue cables connecting the bulbs and the turn indicator switches are not interrupted. 8) Check the bulbs ground connection. level indicators WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
Page 97 Beverly Tourer 300 i.e. Electrical system Specification Desc./Quantity License plate light bulb Type: All glass Quantity: 1 Power: 12V - 5W Tail lights and instrument panel lighting line In the event of a malfunction, check: - Efficiency of the bulbs - Fuses No.
Page 98 Beverly Tourer 300 i.e. Electrical system FUSES Specification Desc./Quantity Fuse No. 1 Capacity:30 A Protected circuits:Battery recharge circuit. Live:Fuses No.7-8-9-10. Fuse No. 2 Capacity:5A Protected circuits:Clock, Immobilizer. Fuse No. 3 Capacity:15A Protected circuits:Plug socket, helmet compartment light switch, electric fan (with remote control), pre-instal- lation for anti-theft device.
Page 99 Beverly Tourer 300 i.e. Electrical system C = Total Odometer D = Speedometer (km/h) E = Injection telltale light F = High-beam warning light G = Oil pressure warning light H = Digital clock I = Low fuel warning light L = Right turn indicator warning light M = Clock controls N = Fuel gauge...
Page 100: Battery Installation
Beverly Tourer 300 i.e. Electrical system - Charge time: Maximum 5 h Battery installation VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF) WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL- PHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX.
Page 101 Beverly Tourer 300 i.e. Electrical system 3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals.
Page 102 Beverly Tourer 300 i.e. Electrical system 12.8 - 13.15 V Bring the battery to full charge, us- ing the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and...
Page 103 Beverly Tourer 300 i.e. Electrical system g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge pro- cedure of the new battery, otherwise go to point i...
Page 104 Beverly Tourer 300 i.e. Electrical system INSTRUMENT PANEL CONNECTOR «B» 1. High-beam warning light (Violet) 2. Ground lead (Black) 3. Injection warning light (Brown-Black) 4. Oil pressure sensor (Pink-White) 5. Live power supply (White) 6. Instrument panel lighting (Yellow-Black) IMMOBILIZER AERIAL CONNECTOR 1.
Page 105 Beverly Tourer 300 i.e. Electrical system PICKUP CONNECTOR 1.Engine speed sensor ECU positive (Red) 2.Engine speed sensor ECU negative (Brown) 3. Oil pressure sensor (White-Pink) ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. Left turn indicator bulbs (Pink) 2. Right turn indicator bulbs (White-Blue) 3.
Page 106 Beverly Tourer 300 i.e. Electrical system 7. Immobilizer aerial (Orange-White) 8. Electric fan remote control (Blue-Yellow) 9. Coolant temperature sensor (Sky blue-Green) 10. Not connected 11. Lambda probe positive (Sky blue-Black) 12. Engine stop switch (Green-Black) 13. Engine rpm sensor positive (Red) 14.
Page 107 Beverly Tourer 300 i.e. Electrical system FUEL LEVEL TRANSMITTER CONNECTOR 1. Low fuel warning light (Grey-Black) 2. Ground lead (Black) 3. Fuel level indicator (White-Green) COOLANT TEMPERATURE SENSOR CON- NECTOR 1. Ground lead (Grey-Green) 2.Instrument panel (Green-Yellow) 3. Injection ECU (Sky blue-Green) 4.
Page 108: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 109 Beverly Tourer 300 i.e. Engine from vehicle This section describes the operations to carry out when removing the engine from the vehicle. Exhaust assy. Removal - Remove the RH footrest. - Remove the Lambda probe from its support and disconnect it. - Cut the fastening clamp on the lambda probe ca- ble.
Page 110 Beverly Tourer 300 i.e. Engine from vehicle Remove the lambda probe from the manifold. Removal of the engine from the vehicle CAUTION SUPPORT THE VEHICLE ADEQUATELY. Disconnect the battery. - Remove the side fairings. - Remove the inspection cover in helmet compart- ment.
Page 111 Beverly Tourer 300 i.e. Engine from vehicle - Get a + 2 l container in order to collect the coolant and place it under the vehicle. - Remove the pipe that feeds coolant into the pump as shown in the picture and then empty the sys- tem.
Page 112 Beverly Tourer 300 i.e. Engine from vehicle - Remove the throttle cables from the throttle body by undoing the nuts indicated in the picture. - Remove the positive and negative wiring from the starter motor as shown in the picture. - Disconnect the connectors from the flywheel wir- ing harness.
Page 113 Beverly Tourer 300 i.e. Engine from vehicle - Remove the cables from the retainer clamps on the flywheel cover. - Remove the clamp indicated. - Disconnect the oil minimum pressure sensor. - Remove the lower screws of the right and left shock absorber.
Page 114 Beverly Tourer 300 i.e. Engine from vehicle Upon refitting the engine to the vehicle, carry out the removal operations but in reverse order, and respect the tightening torques shown in the «Spec- ifications» Chapter. - Check that there is a small clearance when the valve is in abutment against the set screw.
Page 115 INDEX OF TOPICS NGINE...
Page 116: Automatic Transmission
Beverly Tourer 300 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. 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...
Page 117: Removing The Driven Pulley Shaft Bearing
Beverly Tourer 300 i.e. Engine - Remove the 5 screws, found on two different lev- els, 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 means of: Specific tooling 020376Y Adaptor handle...
Page 118: Removing The Driven Pulley
Beverly Tourer 300 i.e. 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 picture - Check the outer diameter of the roller does not have defects that could jeopardise belt functioning - For refitting, place the roller with the belt contain- ment edge on the engine crankcase side...
Page 119: Inspecting The Clutch Drum
Beverly Tourer 300 i.e. 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 120: Removing The Clutch
Beverly Tourer 300 i.e. 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 11 with the chamfering facing the inside of the tool. - Fit the driven pulley unit on the tool with the in- sertion of the 3 pins in the ventilation holes in the mass holder support.
Page 121 Beverly Tourer 300 i.e. Engine Characteristic Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
Page 122 Beverly Tourer 300 i.e. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Bearing housing, outside ø 47 mm - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
Page 123 Beverly Tourer 300 i.e. Engine Inspecting the driven sliding half-pulley - Remove the two seal rings and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the faying surface with the belt to make sure there are no flaws. - Check the riveted joints are functional.
Page 124: Refitting The Driven Pulley
Beverly Tourer 300 i.e. Engine Refitting the driven pulley - Insert the new oil seals 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 125 Beverly Tourer 300 i.e. Engine Inspecting the clutch spring - Measure the length of the spring when it is re- laxed. Characteristic Standard length 123 mm Acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor spe- cific tool with the control screw in vertical axis.
Page 126 Beverly Tourer 300 i.e. Engine - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool. N.B.
Page 127: Removing The Driving Pulley
Beverly Tourer 300 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Driving belt - minimum width 19.5 mm Driving belt - standard width 21.3 ± 0.2 mm During the wear checks in foreseen in the sched- uled maintenance program, you are advised to check that the rim bottom of the toothing does not show signs of incisions or cracking (see figure):...
Page 128 Beverly Tourer 300 i.e. 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 129 Beverly Tourer 300 i.e. Engine 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 allowed Ø...
Page 130 Beverly Tourer 300 i.e. 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 131 Beverly Tourer 300 i.e. Engine End gear 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 132 Beverly Tourer 300 i.e. 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 133 Beverly Tourer 300 i.e. 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. - Remove the oil guard using a screwdriver, work- ing from inside the bearing and being careful not to damage the housing, make it come out of the...
Page 134 Beverly Tourer 300 i.e. 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. - Fit the Seeger ring.
Page 135 Beverly Tourer 300 i.e. Engine Refitting the hub cover bearings In order to fit 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: - The 42-mm side of the adapter must be turned towards the bearing.
Page 136 Beverly Tourer 300 i.e. 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 137: Removing The Stator
Beverly Tourer 300 i.e. Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the 10 clamps - 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 138 Beverly Tourer 300 i.e. 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 to 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.
Page 139: Removing The Starter Motor
Beverly Tourer 300 i.e. 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 - Line up the two holes in the flywheel as shown in the picture - Screw in the guide bushing that is part of the...
Page 140 Beverly Tourer 300 i.e. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the picture Specific tooling 020627Y Flywheel lock wrench Remove the plate indicated in the picture. - Remove the flywheel nut with its washer - Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally on extraction...
Page 141 Beverly Tourer 300 i.e. 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 142: Removing The Intake Manifold
Beverly Tourer 300 i.e. Engine - Using the special flywheel lock wrench, 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 - Fit a new O-ring on the starter motor and lubricate - Fit the starter motor on the crankcase and lock...
Page 143 Beverly Tourer 300 i.e. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: 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 144 Beverly Tourer 300 i.e. 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. - Remove the camshaft control pulley with its washer.
Page 145: Removing The Cam Shaft
Beverly Tourer 300 i.e. Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes. N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, ROCKER PINS AND FIXING BRACKET.
Page 146: Removing The Valves
Beverly Tourer 300 i.e. Engine 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. - Remove the lower spring supports. CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOG- NISE THEIR ORIGINAL POSITION ON THE HEAD.
Page 147 Beverly Tourer 300 i.e. Engine Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Crankcase - crankshaft - connecting rod Inspecting the wrist pin N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 148: Removing The Piston
Beverly Tourer 300 i.e. Engine 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 retainer ring onto the appropriate tool - With opening in the position indicated on the tool S = left D= right...
Page 149 Beverly Tourer 300 i.e. Engine - By means of the table, see the Specifications chapter identify the cylinder base gasket thickness to be used for refitting. Correctly identify the cylinder base gasket thickness to keep the correct compres- sion ratio. - Remove the special tool and the cylinder.
Page 150: Inspecting The Cylinder Head
Beverly Tourer 300 i.e. 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, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL.
Page 151 Beverly Tourer 300 i.e. Engine Inspecting the valve sealings N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. See also Cylinder Head Inspecting the valves N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
Page 152: Inspecting The Cam Shaft
Beverly Tourer 300 i.e. Engine DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON COTTER SIDE (TURNS WITH GREATER PITCH). Specific tooling 020306Y Punch for assembling valve seal rings 020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool Inspecting the cam shaft...
Page 153 Beverly Tourer 300 i.e. Engine - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - Holding this position insert the chain on the cam- shaft control pulley. - Insert the pulley on the camshaft while keeping the reference 4V in correspondence with the ref- erence mark on the head.
Page 154 Beverly Tourer 300 i.e. Engine - Fit the timing chain guide slider. - 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. - Tighten up the nuts to an initial pre-torque of 7±1 N·m - Tighten up the nuts to a second pre-torque of 10 ±1 N·m...
Page 155 Beverly Tourer 300 i.e. Engine - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque. N.B. BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM- PRESSED AIR JET.
Page 156: Crankcase - Crankshaft
Beverly Tourer 300 i.e. Engine Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge.
Page 157 Beverly Tourer 300 i.e. Engine CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH- INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT.
Page 158 Beverly Tourer 300 i.e. 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 shown in the diagram, could cause a drop in the oil pressure lubricating the main bushings and connecting rod.
Page 159 Beverly Tourer 300 i.e. Engine - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder. - To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be perfectly orthogonal to the cylinder axis, as shown in the figure.
Page 160 Beverly Tourer 300 i.e. 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 picture. If it varies significantly from the driving depth indicated, it means that the stud bolt has yielded.
Page 161: Lubrication Circuit
Beverly Tourer 300 i.e. Engine By working on two fitted cylinder head fixing nuts, nut and lock nut, as shown in the picture, remove 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 162 Beverly Tourer 300 i.e. Engine ENG - 162...
Page 163: Oil Pressure Check
Beverly Tourer 300 i.e. Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check that 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 164 Beverly Tourer 300 i.e. Engine Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil seal using the screws provided. Specific tooling 020622Y Transmission-side oil seal punch - Screw the threaded bar onto the base of the tool and extract the oil seal.
Page 165 Beverly Tourer 300 i.e. 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 can see the end of the oil seal driving stroke - Remove all the tool components following the procedure but in reverse order...
Page 166 Beverly Tourer 300 i.e. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control sprocket. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
Page 167 Beverly Tourer 300 i.e. Engine - Check the clearance between the rotors in the position shown in the diagram using a feeler gauge. 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.
Page 168 Beverly Tourer 300 i.e. 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 169 Beverly Tourer 300 i.e. 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 170: Index Of Topics
INDEX OF TOPICS INJEC NJECTION...
Page 171: Component Layout
Beverly Tourer 300 i.e. Injection COMPONENT LAYOUT Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Battery 12V - 12 Ah Water temperature sensor HV coil Engine Speed sensor Lambda probe Diagnostics socket connector Fuel pump Electric fan solenoid Injection load solenoid Fuel injector MIU injection system...
Page 172 Beverly Tourer 300 i.e. Injection The system implements an idle feeding correction with cold engine through a Stepper motor on a by- pass circuit of the throttle valve. The control unit manages the Stepper motor and the injector opening time, thereby ensuring the idle steadiness and the proper combustion. In all conditions of use, mixture preparation is managed by modifying the injector opening time.
Page 173 Beverly Tourer 300 i.e. Injection The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel. Failures are detected and restored by the diag- nostic tester. In any case, when the fault is no longer present, the data storage is automatically cleared after 16 cycles of use (cold start, running at regular engine temperature, stop).
Page 174 Beverly Tourer 300 i.e. Injection d.Connectors B: Chassis ground C: Fuel system a. Faulty fuel pump b.Dirty fuel filter D: Ignition system a.Faulty spark plug b. Faulty coil c. Faulty screened cap E: Intake circuit a.Air filter dirty b. Dirty by-pass circuit c.
Page 175 Beverly Tourer 300 i.e. Injection 6. If the vehicle is expected to remain unused for a long time, refill the tank up to a little over half the level. This will ensure the pump will be covered by fuel. 7. When washing the vehicle, be careful with the electric components and cable harnesses. 8.
Page 176: Terminal Layout
Beverly Tourer 300 i.e. Injection TERMINAL LAYOUT Specification Desc./Quantity Injection telltale light Lambda probe negative Live supply Battery-powered Immobilizer aerial Electric fan solenoid Water temperature sensor Lambda probe positive Engine stop switch Engine speed sensor (+) Fuel injector Engine speed sensor (-) Diagnostics socket output Immobilizer LED Side stand...
Page 177: System Diagram
Beverly Tourer 300 i.e. Injection SYSTEM DIAGRAM Specification Desc./Quantity Injection ECU Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector HV coil Engine Speed sensor Lambda probe Injection load solenoid Start-up solenoid Battery 12V - 12 Ah Main fuses Electric fan solenoid Electric fan Stand switch...
Page 178 Beverly Tourer 300 i.e. Injection Possible Cause Operation Battery Ground connections End of compression pressure End of compression pressure Power to the spark plug Spark plug Shielded cap HV coil Speed-timing sensor Ignition advance Fuel system Fuel pressure (low) Injector capacity (low) Injector sealing (poor) Correctness of the parameters Coolant temperature...
Page 179 Beverly Tourer 300 i.e. Injection Possible Cause Operation Filter box Fuel system (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector...
Page 180 Beverly Tourer 300 i.e. Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PERFORM- ANCE ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay HV coil Injector Revolution timing sensor Air temperature Coolant temperature Lambda probe...
Page 181 Beverly Tourer 300 i.e. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. INJEC - 181...
Page 182 Beverly Tourer 300 i.e. Injection Remove the fast-release fittings from the injector support. 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. INJEC - 182...
Page 183 Beverly Tourer 300 i.e. Injection Remove the MIU ECU connector. Remove the clip fixing the throttle body to the air cleaner bellows. Remove the gas command fitting as indicated in the picture 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 184 Beverly Tourer 300 i.e. Injection Pump supply circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition key contacts Fuse 7.5 A Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe INJEC - 184...
Page 185: Electrical Data
Beverly Tourer 300 i.e. Injection Specification Desc./Quantity Electric fan solenoid When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine starts, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA •...
Page 186 Beverly Tourer 300 i.e. Injection Check the power supply line of the injection load solenoid energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the solenoid base. If there is not, check the continuity of the Red-White cable between the fuse box and the solenoid base and of the Black- Purple cable between the pin 20 of the control unit...
Page 187 Beverly Tourer 300 i.e. 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. 4 10 A) and the remote control base.
Page 188 Beverly Tourer 300 i.e. Injection Check during regular operation by placing the ap- propriate tool between the pump and the injector. With the battery voltage> 12 V check that the fuel pressure is 2.5 BAR and that the input current is 1.4 to 1.8 A With the battery voltage >...
Page 189 Beverly Tourer 300 i.e. Injection Remove the clip fixing the piping to the filter shown in the picture Separate the lower part of the pump mounting as shown in the picture. Remove the filter from the pump mounting INJEC - 189...
Page 190 Beverly Tourer 300 i.e. Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition key contacts Fuse 7.5 A Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe INJEC - 190...
Page 191 Beverly Tourer 300 i.e. Injection Specification Desc./Quantity Electric fan solenoid Check the resistance at the injector ends: 14.5 ± 5% Ohm Check the efficiency of 10 A fuse N° 4 injection load. Check the efficiency of 7.5 A fuse No. 9 key-con- trolled control unit power supply.
Page 192 Beverly Tourer 300 i.e. Injection Check the power supply line of the injection load solenoid energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the solenoid base. If there is not, check the continuity of the Red-White cable between the fuse box and the solenoid base and of the Black- Purple cable between the pin 20 of the control unit...
Page 193 Beverly Tourer 300 i.e. 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 injector disconnected and control unit connected, between the Black-Green cable of the injector con- nector and the ground lead...
Page 194 Beverly Tourer 300 i.e. Injection Install the appropriate tool for checking fuel pres- sure and position the manifold over a container graduated by at least 100 cm³. Connect the injec- tor with the cable making up part of the supply for the injection tester.
Page 195: Components Location
Beverly Tourer 300 i.e. Injection Components location COMPONENT LAYOUT Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Battery 12V - 12 Ah Water temperature sensor HV coil Engine Speed sensor Lambda probe Diagnostics socket connector Fuel pump Electric fan solenoid Injection load solenoid Fuel injector INJEC - 195...
Page 196 Beverly Tourer 300 i.e. Injection 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 197 Beverly Tourer 300 i.e. Injection With the interface wiring and rpm sensor connec- tor disconnected from the control unit, check that the Red and Brown cables (pin 13 - 15) are isola- ted from each other and insulated from the ground. Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter...
Page 198 Beverly Tourer 300 i.e. Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition key contacts Fuse 7.5 A Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe INJEC - 198...
Page 199 Beverly Tourer 300 i.e. Injection Specification Desc./Quantity Electric fan solenoid The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. 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 200 Beverly Tourer 300 i.e. Injection Check the power supply line of the injection load solenoid energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the solenoid base. If there is not, check the continuity of the Red-White cable between the fuse box and the solenoid base and of the Black- Purple cable between the pin 20 of the control unit...
Page 201 Beverly Tourer 300 i.e. 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. 4 10 A) and the remote control base.
Page 202: Coolant Temperature Sensor
Beverly Tourer 300 i.e. Injection Coolant temperature sensor TEMPERATURE SENSOR Specification Desc./Quantity Instrument panel Electronic control unit Water temperature sensor Engine stop switch Side stand switch 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 203 Beverly Tourer 300 i.e. Injection With the connector on the control unit side discon- nected and the coolant temperature connector dis- connected, check the continuity between pin 9 of the interface cable harness and the light-blue/ green cable of the connector. Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter...
Page 204 Beverly Tourer 300 i.e. Injection Make sure that the throttle valve with the control is supporting the stop screw. Guaranteeing that this position will be kept, send a confirmation for the TPS reset procedure. Reset should be performed in the following cases: - on first fitting.
Page 205 Beverly Tourer 300 i.e. Injection Given that the TPS resetting is also done when the control unit is replaced, place the control unit - filter box bellows at 45° during the refitting operation as shown in the picture. INJEC - 205...
Page 206: Lambda Probe
Beverly Tourer 300 i.e. Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Ignition key contacts Fuse 7.5 A Injection load solenoid Fuel pump HV coil Fuel injector Lambda probe INJEC - 206...
Page 207 Beverly Tourer 300 i.e. Injection Specification Desc./Quantity Electric fan solenoid The Lambda probe 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 208 Beverly Tourer 300 i.e. Injection Check the power supply line of the injection load solenoid energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Pur- ple cable of the solenoid base. If there is not, check the continuity of the Red-White cable between the fuse box and the solenoid base and of the Black- Purple cable between the pin 20 of the control unit...
Page 209: Signal Control
Beverly Tourer 300 i.e. 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. 4 10 A) and the remote control base.
Page 210: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 211: Removing The Front Wheel
Beverly Tourer 300 i.e. Suspensions Front Removing the front wheel - Remove the front brake calliper. - Loosen the wheel axle lock-nut. - Loosen the two wheel axle safety screws on the fork leg, on the brake calliper side. - Pull out the wheel axle. See also Removal Front wheel hub overhaul...
Page 212 Beverly Tourer 300 i.e. 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, 15 mm adaptor and guide) from the odometer drive side to permit the removal of the brake disc side bearing and the spacer bushing.
Page 213 Beverly Tourer 300 i.e. 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 - Turn over the wheel and insert the internal spacer with the part fitted with the Seeger ring facing the bearing on the brake disc side installed previously.
Page 214: Refitting The Front Wheel
Beverly Tourer 300 i.e. 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 215 Beverly Tourer 300 i.e. Suspensions Removal - Remove the rear handlebar cover. - Remove the pin mounting the handlebar to the steering tube. - Remove the handlebar and place it on the rear cover of the legshield. See also Rear handlebar cover Refitting - Install the handlebars on the steering tube, pay- ing attention to the centring, aligning the recess on...
Page 216 Beverly Tourer 300 i.e. Suspensions - Support the fork leg properly, remove the main spring and drain off the fork leg oil. - Remove the hydraulic rod fixing screw with the corresponding sealing gasket: - With a 19-mm hexagonal spanner, lock hydraulic rod rotation.
Page 217 Beverly Tourer 300 i.e. Suspensions - Remove the circlip retaining the oil seal. - Take out the stem. - Check there are no signs of wear or seizing between the stem and the fork leg. Otherwise, replace the damaged parts. Characteristic Maximum fork leg diameter 35.10 mm...
Page 218: Component Check
Beverly Tourer 300 i.e. Suspensions - Hold the tie rod manually so that it does not fall into the fork leg and/or that both half-rings are not in their position. - Fit the bell. - Tighten the nut until it stops. - Act on the tool until the oil seal is completely re- moved.
Page 219 Beverly Tourer 300 i.e. Suspensions - Check that hydraulic rod caulkings, the return spring to the unloaded the end of stroke and the hydraulic rod sealing ring are in good conditions. - Check that the main spring exhibits no signs of yielding or abnormal wear.
Page 220 Beverly Tourer 300 i.e. Suspensions Refitting - First grease the splitting chamber of the two seal- ing lips of a new oil seal. - Fit the sealing ring on the stem and keep the identification words facing upwards. - Drive the oil seal as far as it will go using the ap- propriate tool.
Page 221 Beverly Tourer 300 i.e. Suspensions - Fit the oil seal retaining circlip. - Grease and fit a new dust guard. - Fit the fork leg together with the stem on the fork supporting clamp until it stops. - Tighten the two screws to the prescribed torque in the sequence indicated in the picture.
Page 222: Steering Column
Beverly Tourer 300 i.e. Suspensions - Bleed the hydraulic rod by actuating the stem re- peatedly. - Fit the spring into the stem. - Lubricate the closing cap O-ring of the stem. - Preload the spring, fit the closing cap and tighten to the prescribed torque.
Page 223 Beverly Tourer 300 i.e. Suspensions Removal - Remove the front wheel. - Remove the front mudguard - Remove the front brake calliper - Remove the front and rear handlebar covers. - Remove the pin mounting the handlebar to the steering tube. - Remove the handlebar and rest it on the shield back plate.
Page 224 Beverly Tourer 300 i.e. Suspensions ing surface of driven pulley spring (only pulley side) Soap-based lithium and zinc oxide grease con- taining NLGI 2; ISO-L-XBCIB2 - Fit the upper steering fifth wheel. CAUTION INSERT THE UPPER FIFTH WHEEL WITH THE CAGE FAC- ING UPWARDS.
Page 225 Beverly Tourer 300 i.e. Suspensions - Insert the lower tightening ring nut, screw until it stops and, with the specific tool, tighten to the pre- scribed torque. Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering tube lower ring nut 14 ÷...
Page 226: Steering Bearing
Beverly Tourer 300 i.e. Suspensions Insert the collar shown in the figure and restore the cable passage as shown in the figure. - Fit the front wheel. Steering bearing Removal - Clean thoroughly and visually inspect if the com- ponents are in good conditions. - Check the upper steering fifth wheel for wear.
Page 227 Beverly Tourer 300 i.e. Suspensions - Check the lower steering fifth wheel for wear. - Visually inspect that the steering fifth wheel tracks, the headstock and the steering tube exhibit no scores or abnormal wear. Otherwise, replace them. STEERING FIFTH WHEEL TRACK REMOVAL - Remove the steering fifth wheel tracks on the chassis with the specific tool, following the indica- ted procedure.
Page 228 Beverly Tourer 300 i.e. Suspensions - Repeat the procedure for the lower steering fifth wheel track. - Remove the lower fifth wheel seat on the steering tube using the specific tool. Specific tooling 020004Y Punch for removing steering bearings from headstock SUSP - 228...
Page 229 Beverly Tourer 300 i.e. Suspensions Refitting STEERING FIFTH WHEEL TRACK FITTING - Thoroughly clean the track seats on the head- stock and the steering tube. - Fit the new tracks of the headstock with the spe- cific tool. - Screw the nut until the tracks are fully inserted. N.B.
Page 230: Removing The Rear Wheel
Beverly Tourer 300 i.e. Suspensions Soap-based lithium and zinc oxide grease con- taining NLGI 2; ISO-L-XBCIB2 Rear Removing the rear wheel - Remove the muffler mounting bracket - Remove the 5 screws shown in the picture Refitting the rear wheel - Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
Page 231 Beverly Tourer 300 i.e. Suspensions - Loosen the nut and lock nut on the left-hand side of the scooter (see figure) and unscrew the pin from the opposite side. - Remove the retaining screw of the rear brake pipe shown in the figure. - Loosen the nut on the inside of the frame from the left-hand side (see figure) and remove the rel- evant pin;...
Page 232 Beverly Tourer 300 i.e. 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 - Using the appropriate tool, fit the silent bloc as shown in the picture Specific tooling...
Page 233 Beverly Tourer 300 i.e. Suspensions - In order to check the clearance of the swinging arm on the frame side, prepare a retainer using the fixing pin of the swinging arm on the frame and two rings from the special tool 020229Y. Alternatively, use two washers with inside diame- ter of 12 mm for pins, outside diameter min.
Page 234 Beverly Tourer 300 i.e. Suspensions - Using an appropriate tool plant new roller cas- ings, being careful to position the bearings with the O-rings facing outwards Specific tooling 020115Y Ø 18 punch 020244Y 15-mm diameter punch SWINGING ARM SERVICE Specification Desc./Quantity Length of the internal swinging arm spacer on the frame side 228 -0.2/-0.4 mm...
Page 235 Beverly Tourer 300 i.e. Suspensions - Position the swinging arm, inserting part « 2». - Tighten part «3» to the prescribed torque. - Screw and tighten part «4» to the prescribed tor- que. - Screw and tighten part «5» to the prescribed tor- que.
Page 236: Shock Absorbers
Beverly Tourer 300 i.e. Suspensions - Tighten part «1» to the prescribed torque. - Insert the swinging arm - engine pin and tighten to the prescribed torque. SWINGING ARM FITTING Name Torque in Nm Part 1 64 - 72 Part 3 5 - 7 Part 4 90 - 110...
Page 237 Beverly Tourer 300 i.e. Suspensions See also Exhaust assy. Removal Refitting Carry out the previous operations but in reverse order. Locking torques (N*m) Left shock absorber lower retainer 33 ÷ 41 Right shock absorber lower retainer 40 ÷ 45 Upper shock absorber retainer 40 ÷...
Page 238 Beverly Tourer 300 i.e. Suspensions Overhaul - Remove the circlip shown in the picture - Support the muffler support bracket sufficiently - Using the special punch, remove the bearing from its seat as shown in the picture Specific tooling 020376Y Adaptor handle 020456Y Ø...
Page 239: Centre-Stand
Beverly Tourer 300 i.e. Suspensions Centre-stand - Remove the two return springs from the centre stand. - Undo the nut shown in the figure. - Remove the pin from the right side. - Remove the centre stand. - On refitting tighten the nut to the specified torque. Locking torques (N*m) Centre stand bolt 40 ÷...
Page 240: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 241: Rear Brake Calliper
Beverly Tourer 300 i.e. Braking system This section è is dedicated to the description of the brake system components. Interventions rules WARNING BRAKING SYSTEM FLUID IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THE CONTACT AREA WELL WITH ABUNDANT WATER.
Page 242 Beverly Tourer 300 i.e. Braking system Removal - Remove the rear wheel. - Remove the two rear brake calliper devices fas- tening them to the support as shown in the picture. N.B. SHOULD THE BRAKE CALLIPER BE REPLACED, BEFORE REMOVING THE FITTINGS FIXING THE CALLIPER TO THE SUPPORTING BRACKET, FIRST LOOSEN THE OIL HOSE FITTING AFTER HAVING EMPTIED THE SYSTEM OF THE CIRCUIT BEING INSPECTED.
Page 243 Beverly Tourer 300 i.e. Braking system Removal - Remove the two retainers fastening the front brake calliper to the support as shown in the pic- ture. N.B. SHOULD IT BE NECESSARY TO REPLACE THE CALLIP- ER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER.
Page 244 Beverly Tourer 300 i.e. Braking system - Remove the rear wheel. - Act on the disc five fixing screws shown in the picture. See also Removing the rear wheel REAR WHEEL WITH INTEGRATED HUB - Remove the rear wheel. - Act on the disc five fixing screws shown in the picture.
Page 245: Disc Inspection
Beverly Tourer 300 i.e. Braking system For fitting, position the disc correctly using the ar- row stamped on it as reference. N.B. THE ARROW STAMPED ON THE DISC INDICATING THE RUNNING DIRECTION MUST BE FITTED TOWARDS THE OUTSIDE OF THE VEHICLE. - Tighten the screws to the prescribed torque and apply the recommended product.
Page 246 Beverly Tourer 300 i.e. Braking system Front brake disc 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 fitting, position the disc correctly using the arrow stamped on it as reference.
Page 247: Front Brake Pads
Beverly Tourer 300 i.e. 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 248: Rear Brake Pads
Beverly Tourer 300 i.e. Braking system See also Front brake calliper Refitting To fit, proceed as follows: - Insert the two pads in the callipers. - Screw the two pad lock pins to the correct torque, and apply the recommended product. - Fit the calliper on its support, tightening the two screws to the prescribed torque.
Page 249 Beverly Tourer 300 i.e. Braking system - The replacement must be made with greater re- sidual thickness if the pad has not worn evenly. A 0.5 mm thickness difference in the residual friction material is permitted. See also Removal Refitting To fit, proceed as follows: - Insert the two pads in the callipers.
Page 250 Beverly Tourer 300 i.e. Braking system Rear - combined - Remove the rubber cap from the bleed screw. - Insert a rubber pipe in the bleed screw to permit the brake fluid to be recovered. - With the brake lever, load the system and bring it up to the required pressure.
Page 251 Beverly Tourer 300 i.e. Braking system DURING THE BLEEDING OPERATIONS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE BODYWORK SO AS NOT TO DAMAGE IT. FURTHERMORE, DURING THE BLEEDING OPERATIONS REGARDING THE BRAKE CALLIPERS, MAKE SURE THE BRAKE FLUID DOES NOT COME INTO CONTACT WITH THE DISC BRAKES AND WITH THE BRAKE PADS.
Page 252 Beverly Tourer 300 i.e. Braking system WARNING BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND- ING AIR. IF THE LEVEL OF MOISTURE IN THE FLUID EXCEEDS A GIVEN VALUE, BRAKING WILL BE INEFFICIENT. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS FLUID EVERY TWO YEARS.
Page 253 Beverly Tourer 300 i.e. Braking system WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DE- GREASE THE DISC SHOULD THERE BE BRAKE FLUID ON IT. Locking torques (N*m) Oil bleed screw 12 - 16 Hydraulic line fixing screw: 16 ÷...
Page 254: Index Of Topics
INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 255: Circuit Diagram
Beverly Tourer 300 i.e. Cooling system Circuit diagram A = Expansion tank B = Radiator C = Radiator intake pipe D = Water pump E = Delivery pipe to cylinder F = By-Pass pipe G = Thermostat H = Radiator delivery pipe COOL SYS - 255...
Page 256 Beverly Tourer 300 i.e. Cooling system TECHNICAL SPECIFICATIONS Specification Desc./Quantity Cooling system capacity 1.75 l Recommended fluid AGIP PERMANENT SPEZIAL (ready for use) Sealing pressure Cap calibrated at 0.9 bar THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening at 85 ±...
Page 257 Beverly Tourer 300 i.e. Cooling system - If the relay is not working, replace it. - If the relay is working, remove it and jump the red - red black (85 - 86) wires. The electric ventilation starts if the key switch is set to «ON» and all com- ponents are working.
Page 258 Beverly Tourer 300 i.e. Cooling system Removal - Remove the helmet compartment inspection cov- - Place a + 2.0 l container under the vehicle to col- lect the coolant. - Undo the two screws indicated, lift the cover and remove the thermostat. Check 1) Visually inspect that the thermostat is not dam- aged.
Page 259 Beverly Tourer 300 i.e. Cooling system 020331Y Digital multimeter 020151Y Air heater THERMOSTAT Specification Desc./Quantity Type Wax-type, with deviator Starts opening at 85±2°C Refitting - Follow the removal steps but in reverse order; be careful to tighten screws to the prescribed torque. Locking torques (N*m) Thermostat cover screws 3 to 4 - Once the cooling circuit is restored, refill using the recommended product and purge the circuit as...
Page 260 INDEX OF TOPICS CHAS HASSIS...
Page 261 Beverly Tourer 300 i.e. Chassis This section è is dedicated 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 262 Beverly Tourer 300 i.e. Chassis Rear handlebar cover - Remove the windshield. - Remove the rear-view mirrors. - On both sides of the handlebar undo the screw indicated and remove the brake pump compart- ment inspection cover. - Undo the screw indicated. - From below undo the screw fixing it to the front handlebar cover.
Page 263 Beverly Tourer 300 i.e. Chassis Instrument panel - Remove the rear handlebar cover. - Undo the four screws shown in the picture. - Remove the instrument panel. See also Rear handlebar cover Front handlebar cover - Remove the rear handlebar cover. - Disconnect the electrical connectors of the head- lamp and turn indicators.
Page 264 Beverly Tourer 300 i.e. Chassis Frame central cover - Open the fuel tank access port. - Loosen the 4 screws shown in the figure. - Remove temporarily the fuel tank cap and pull out the rubber protector. - Remove the central frame cover, separating it from the rear section of the scooter, then separat- ing it from the transmission for the opening of the access cover.
Page 265 Chassis - Remove the central frame cover, then unscrew the 2 screws indicated in the figure. - Remove the Piaggio symbol from the shield, then remove the screw. - Remove the legshield to the front. - To reassemble, follows the steps in reverse or- der, paying attention to the correct seating of the shield on the shield back plate.
Page 266 Beverly Tourer 300 i.e. Chassis See also Legshield Removing the ignition key-switch when on *off* - Remove the shield back plate. - Remove the immobilizer aerial as shown in the figure. - Detach the electrical wiring. - Remove the ignition key-switch, by removing the spring retainer shown in the figure.
Page 267 Beverly Tourer 300 i.e. Chassis Knee-guard Removing the ignition key-switch when on *lock* In position "Lock", it is not possible to access the cylinder retaining spring. The spring must then be removed as shown in the figure, allowing the lock cylinder to be pressed out.
Page 268 Beverly Tourer 300 i.e. Chassis See also Rear rack Side fairings Footrest - Remove the central cover. - Remove the mat of the footrest. - Loosen the eight footrest mounting screws. - Remove the footrest. See also CHAS - 268...
Page 269 Beverly Tourer 300 i.e. Chassis 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 270: Rear Mudguard
Beverly Tourer 300 i.e. Chassis Air filter - Undo the two screws indicated. - Reach the inspection compartment inside the helmet compartment. - Disconnect the two manifold clamps. - Disconnect the three clamps connecting the Blow-By pipe. 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 271 Beverly Tourer 300 i.e. Chassis Helmet bay - Remove the side fairings. - Disconnect the battery and the electrical cable harness. - Disconnect the cable from the electric saddle opening device. - Remove the 10 screws indicated in the figure. - Remove the helmet compartment in advance.
Page 272 Beverly Tourer 300 i.e. 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 PER- FORMED WITH THE TANK EMPTY. - Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather;...
Page 273: Front Mudguard
Beverly Tourer 300 i.e. Chassis See also Knee-guard Front wheel housing Footrest Front mudguard - Remove the retaining screw of the cable lead through support on the right-hand side of the mud- guard. - Loosen the 3 fixing retaining screws indi- cated in the figure and remove the mudguard.
Page 274 Beverly Tourer 300 i.e. Chassis Flyscreen - Undo the screw indicated. - Undo the four screws indicated and remove the windshield. CHAS - 274...
Page 275 INDEX OF TOPICS PRE DE DELIVERY...
Page 276 Beverly Tourer 300 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Handle fuel with care. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection - Visually check that there is a yellow mark on the following clamps: FRONT SUSPENSION •...
Page 277 Beverly Tourer 300 i.e. Pre-delivery •Instrument panel lights • Horn • Electrical 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 278: Static Test
Beverly Tourer 300 i.e. 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. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Page 279 INDEX OF TOPICS TIME...
Page 280 Beverly Tourer 300 i.e. Time This section is dedicated to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from chassis - Removal and refit.
Page 281 Beverly Tourer 300 i.e. Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replace- ment 001133 Engine crankcase - Replacement 001124 Lubrication by pass - Replacement TIME - 281...
Page 282 Beverly Tourer 300 i.e. Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 282...
Page 283: Cylinder Assy
Beverly Tourer 300 i.e. Time Cylinder assy. CYLINDER - PISTON Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pistonsrings-pin assembly - Service 001176 Rings / Pin - Replacement TIME - 283...
Page 284: Cylinder Head Assy
Beverly Tourer 300 i.e. Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - adjust 001056 Head gasket - change 000235 Coolant temperature sensor - Repl. 001057 Thermostat - Replacement 007012 Coolant bleed valve - Replacement TIME - 284...
Page 285 Beverly Tourer 300 i.e. Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rockers valves - Replacement 001044 Camshaft - Replacement 001169 Pressure reducer - Replacement TIME - 285...
Page 286: Cylinder Head Cover
Beverly Tourer 300 i.e. Time Cylinder head cover EAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace- ment TIME - 286...
Page 287: Oil Filter
Beverly Tourer 300 i.e. Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - change 001102 Net oil filter - change / Cleaning TIME - 287...
Page 288: Flywheel Cover
Beverly Tourer 300 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001150 Flywheel cover gasket - change 007007 Water pump rotor - Replacement 001113 Water pump / Pump rotor - Replace- ment 001099 Flywheel-side oil seal - Replacement TIME - 288...
Page 289: Driven Pulley
Beverly Tourer 300 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001155 Clutch bell - Replacement TIME - 289...
Page 290: Oil Pump
Beverly Tourer 300 i.e. Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide pads - Replacement 001051 Distribution belt - chain - Replace- ment 001042 Oil pump - overhaul 001112 Oil pump - change 001122 Oil pump chain - Replacement 001172 Chain cover flap - change 001130...
Page 291 Beverly Tourer 300 i.e. Time Final gear assy. FINAL REDUCTION GEAR Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Reduction gear cover - Replacement 004125 Rear wheel axle - Replacement 004180 Reduction gear pipe - replace TIME - 291...
Page 292: Driving Pulley
Beverly Tourer 300 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Drive belt - Replacement 001066 Driving pulley - Removal and refitting 001177 CVT rollers / sliders - Replacement 001141 Belt anti-flapping roller - Replace- ment 001006 Driving pulley - Service...
Page 293: Transmission Cover
Beverly Tourer 300 i.e. Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - Re- placement 001135 Transmission cover bearing - Re- placement 001170 Air deflector - Replacement TIME - 293...
Page 294: Water Pump
Beverly Tourer 300 i.e. Time Water pump WATER PUMP Code Action Duration 007017 Water pump cover - Replacement 007009 Head-pump by-pass rubber sleeve - Replacement TIME - 294...
Page 295: Electrical Start-Up
Beverly Tourer 300 i.e. Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001151 Starter driven gearing - Replacement 001017 Start-up pinion - Replacement TIME - 295...
Page 296: Flywheel Magneto
Beverly Tourer 300 i.e. Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - change 001104 Start-up freewheel - Replacement TIME - 296...
Page 297: Butterfly Valve
Beverly Tourer 300 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - change TIME - 297...
Page 298: Exhaust Pipe
Beverly Tourer 300 i.e. Time Exhaust pipe MUFFLER Code Action Duration 005138 Lambda probe - Replacement 001092 Exhaust manifold - Replacement 001095 Silencer heatshield - Replacement 001009 Silencer - Replacement TIME - 298...
Page 299: Air Cleaner
Beverly Tourer 300 i.e. Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Air cleaner/ carburettor union - Re- placement TIME - 299...
Page 300 Beverly Tourer 300 i.e. Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004147 footboard support bracket one side - Replacement 004148 Footrest support bracket, both sides - Replacement 004146 Front chassis - Replacement TIME - 300...
Page 301 Beverly Tourer 300 i.e. Time Centre-stand STAND Code Action Duration 001053 Stand pin - Replacement 004004 Stand - Replacement 004179 Stand bumper - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 301...
Page 302 Beverly Tourer 300 i.e. Time Legshield spoiler LEGSHIELD - SPOILER Code Action Duration 004064 Legshield, front section - Replace- ment 004023 Shield rim - Replacement 004149 shield central cover - Replacement TIME - 302...
Page 303: Side Covers
Beverly Tourer 300 i.e. Time Side fairings SIDE COVERS Code Action Duration 004012 Rear side panels - Replacement 004129 Rear fairing - Replacement TIME - 303...
Page 304: Rear Cover
Beverly Tourer 300 i.e. Time Rear cover REAR SHIELD Code Action Duration 004065 Shield back plate - Replacement 004081 Top box lid - Replacement TIME - 304...
Page 305 Beverly Tourer 300 i.e. Time Central cover CENTRAL COVER Code Action Duration 004135 Fuel tank port - Replacement 004011 Central chassis cover - Replacement 004059 Spark plug inspection flap - Replace- ment 004015 Footrest - Replacement TIME - 305...
Page 306: Underseat Compartment
Beverly Tourer 300 i.e. Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004106 Helmet compartment band - Re- placement 005033 Glove-box light switch - Replace- ment 004016 Helmet compartment - Replacement 004112 Cock / carburettor hose - Replace- ment 005046 Battery cover - change 005026 Helmet compartment bulb - Replace-...
Page 307 Beverly Tourer 300 i.e. Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 number plate holder - Replacement TIME - 307...
Page 308 Beverly Tourer 300 i.e. Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - change 004053 Spoiler - Replacement 004009 Rear mudguard - Replacement TIME - 308...
Page 309 Beverly Tourer 300 i.e. Time Fuel tank FUEL TANK Code Action Duration 004109 Fuel tank breather - change 004005 Fuel tank - Replacement 005010 Tank float - Replacement TIME - 309...
Page 310: Rear Shock Absorber
Beverly Tourer 300 i.e. Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003077 Muffler supporting arm/ rear shock absorber - Replacement 003007 Rear shock absorber - Replacement TIME - 310...
Page 311: Handlebar Covers
Beverly Tourer 300 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar covers - Replace- ment TIME - 311...
Page 312: Handlebar Components
Beverly Tourer 300 i.e. Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Complete throttle control - Replace- ment 002059 Right-hand knob - Replacement TIME - 312...
Page 313: Swinging Arm
Beverly Tourer 300 i.e. Time Code Action Duration 003001 Handlebar - Replacement 003061 Accelerator transmission - adjust 002063 Complete throttle transmission - Re- placement 002071 Left knob - Replacement 002037 Brake lever - Replacement 002067 Rear brake pump - Replacement 002024 Front brake pump - Replacement 004162...
Page 314: Brake Hoses
Beverly Tourer 300 i.e. Time Brake hoses BRAKE PIPING Code Action Duration 002021 Front brake piping - Replacement 003070 Front brake pads/shoes - Check for wear 002007 Front brake pads - Replacement 002039 Front brake calliper - Replacement 002047 Front brake fluid and air bleed sys- tem - Replacement 002020 Rear brake disc piping - Replace-...
Page 315 Beverly Tourer 300 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 315...
Page 316: Instrument Panel
Beverly Tourer 300 i.e. Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement 005078 Odometer glass - Replacement 005038 Dashboard warning/telltale lights - Replacement 005076 Clock / Cell - Replacement TIME - 316...
Page 317: Luggage Rack
Beverly Tourer 300 i.e. Time Rear rack LUGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement 004062 Luggage rack cover - Replacement TIME - 317...
Page 318 Beverly Tourer 300 i.e. Time Locks LOCKS Code Action Duration 004010 Anti-theft lock - Replacement 004054 Saddle lock catch - Replacement 005099 Electric saddle opening device - Re- placement 002083 Saddle opening transmission - Re- placement 005072 Immobilizer aerial - Replacement TIME - 318...
Page 319: Turn Signal Lights
Beverly Tourer 300 i.e. Time Turn signal lights INDICATOR LIGHTS Code Action Duration 005002 Front light - replacement 005008 Headlight bulbs - Replacement TIME - 319...
Page 320: Front Wheel
Beverly Tourer 300 i.e. Time Code Action Duration 005067 Front turning indicator bulb - replace- ment 005012 Front turning indicators - Replace- ment 005066 Rear light bulbs - Replacement 005005 Taillight - change 005032 number plate light glass - Replace- ment 005031 number plate light bulb - Replace-...
Page 321: Rear Wheel
Beverly Tourer 300 i.e. Time Rear wheel EAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Replacement 002070 Rear brake disc - Replacement TIME - 321...
Page 322: Fuel Pump
Beverly Tourer 300 i.e. Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 322...
Page 323: Electric Devices
Beverly Tourer 300 i.e. Time Electric devices VOLTAGE REGULATOR Code Action Duration 005009 Voltage regulator - Replacement 001069 HV coil - Replacement 001094 Spark plug cap - Replacement TIME - 323...
Page 324 Beverly Tourer 300 i.e. Time CONTACTORS Code Action Duration 005035 Headlight solenoid - Replacement 005096 Injection Component contactor - Re- placement 005117 Electric fan contactor - Replacement 005003 Horn - Replacement 005011 Starter relay - Replacement 005007 Battery - change TIME - 324...
Page 325 Beverly Tourer 300 i.e. Time WIRE UNIT Code Action Duration 005054 Fuse holder - Replacement 005052 Fuse - Replacement 005001 Electrical system - Replacement TIME - 325...
Page 326: Electronic Controls
Beverly Tourer 300 i.e. Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005121 Saddle opening button - Replace- ment 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment...
Page 327 Beverly Tourer 300 i.e. Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002082 Fuel tank door opening drive - Re- placement TIME - 327...
Page 328 Beverly Tourer 300 i.e. Time Front suspension FRONT SUSPENSION Code Action Duration 003051 Complete fork - Replacement 003010 Front suspension - Service 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment TIME - 328...
Page 329 Beverly Tourer 300 i.e. Time Cooling system RADIATOR Code Action Duration 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007013 Radiator expansion tank connection pipe - change 007016 Fan with support - Replacement 001052 Coolant and air bleed - Replacement 007003 Coolant delivery and return pipe - change...
Page 330 Beverly Tourer 300 i.e. Time Windscreen WINDSCREEN Code Action Duration 004028 Windshield glass - Replacement TIME - 330...
Page 331 Beverly Tourer 300 i.e. Time Stickers TRANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 331...
Page 332 Air filter: 45, 270 Battery: 80, 88, 99, 100 Brake: 241–243, 246–248, 251, 252, 314 Brake fluid: 251 Bulbs: Checks: 83 Coolant: 202 Electric: 256, 323 Engine oil: 46 Fuel: 180, 188, 272, 309, 322 Fuses: 97 Headlight: 51, 263, 265 Horn: 94 Hub oil: 44 Identification: 8...
Page 333 Spark plug: 43, 88 Stand: 239 Start-up: Suspension: 56, 328 Tank: 272, 309 Transmission: 10, 55, 116, 130, 293 Turn indicators: 82 Tyres: 11 Vehicle: 8, 109, 110...

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