Page 1 WORKSHOP MANUAL 633574 Beverly 250 USA...
Page 2 Not all versions shown in this publication are available in all Countries. The availability of individual versions should be confirmed with the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 WORKSHOP MANUAL Beverly 250 USA This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 8: Safety Rules
Even though the latter contains no asbestos, inhaling dust is harmful. Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 9: Vehicle Identification
Beverly 250 USA Characteristics Vehicle identification VEHICLE IDENTIFICATION Specification Desc./Quantity Chassis prefix ZAPM 289 L36S Engine prefix M285M÷1001 Dimensions and mass WEIGHTS AND DIMENSIONS Specification Desc./Quantity Kerb weight in running 149 kg order Width (over mirrors) 837 mm Length 2100 mm...
Page 10: Electrical System
Beverly 250 USA Characteristics Transmission TRASMISSION Specification Desc./Quantity Transmission With automatic expandable pulley variator with tor- que server, V belt, self-ventilating automatic cen- trifugal dry clutch, gear reduction unit and trans- mission housing with forced air circulation cooling. Capacities CAPACITIES Specification Desc./Quantity...
Page 11: Wheels And Tyres
Beverly 250 USA Characteristics Brakes BRAKES Specification Desc./Quantity Front brake Disc brake, diameter 260 mm and floating calliper with twin plungers and hydraulic control (lever on the far right of the handlebar) Rear brake Disc brake, diameter 260 mm and calliper with two...
Page 12 Beverly 250 USA Characteristics air-box «C» where it is filtered by filtering element «D». The filtered air now enters membrane device «A», through duct «E» and is then guided towards the head. Flowing through pipe «F», flanged to the head,...
Page 13: Tightening Torques
Beverly 250 USA Characteristics Specification Desc./Quantity Idle mixture adjustment screw initial opening 2½ ± ¼ Conical pin Ø 2,530 Diffuser nozzle Ø 2.8 Starter air jet Ø 1,5 Starter jet ~ 20 Ω Starter device resistance Venturi choke Ø 29 Throttle valve Ø...
Page 14 Beverly 250 USA Characteristics FRAME ASSEMBLY Name Torque in Nm Engine-swinging arm bolt 64 - 72 Chassis-swinging arm pin nut 64 - 72 Spacer locking threaded bushing 13 ÷ 17 Spacer locking threaded bushing lock nut 90 ÷ 110 Frame arm-engine arm coupling pin nut 33 ÷...
Page 15 Beverly 250 USA Characteristics MUFFLER Name Torque in Nm Screw fixing manifold to muffler 15.5 ÷ 18.5 Muffler heat guard fixing screw 5 - 6 Exhaust fumes inlet screw 22 ÷ 26 Screw fixing muffler support arm to crankcase 33 ÷ 41 Nuts fixing muffler to support arm 27 ÷...
Page 16: Assembly Clearances
Beverly 250 USA Characteristics CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead (transmis- 4 ÷ 6 sion-side half shaft) screws Engine-crankcase coupling screws 11 ÷ 13 Starter motor screws 11 ÷ 13 Crankcase timing system cover screws (°) 3.5 ÷...
Page 17 Beverly 250 USA Characteristics CATEGORIES COUPLING Name Initials Cylinder Piston Play on fitting Cylinder / piston 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044 Cylinder / piston 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044 Cylinder / piston 72.004 ÷...
Page 18 Beverly 250 USA Characteristics Name Description Dimensions Initials Quantity Crankcase Category 1 32.959 ÷ 32.965 Crankcase Class 2 32.953 ÷ 32.959 Fitting clearance Crankshaft/ crankcase axial clearance 0.15 - 0.40 mm (when cold) CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions...
Page 19 Beverly 250 USA Characteristics N.B. MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.
Page 20 Beverly 250 USA Characteristics Oversizes OVERSIZES Name Description Dimensions Initials Quantity Compression ring 57.2 x 1 0.15 ÷ 0.30 1st oversize Oil scraper ring 1st 57.2 x 1 0.10 ÷ 0.30 Oversize Oil scraper ring 1st 57.2 x 2.5 0.15 ÷ 0.35...
Page 21 Beverly 250 USA Characteristics Product Description Specifications AGIP GP 330 Grease for brake control levers, White calcium complex soap- throttle, stand based spray grease with NLGI 2; ISO-L-XBCIB2 AGIP CITY HI TEC 4T Oil to lubricate flexible transmis- Oil for 4-stroke engines...
Page 22 Beverly 250 USA Characteristics CHAR - 16...
Page 23 INDEX OF TOPICS TOOL OOLING...
Page 24 Beverly 250 USA Tooling APPROPRIATE TOOLS Stores code Description 020151Y Air heater 020331Y Digital multimeter 020648Y Single battery charger 001467Y014 Pliers to extract ø 15-mm bear- ings 020412Y 15 mm guide TOOL - 2...
Page 25 Beverly 250 USA Tooling Stores code Description 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47-mm adaptor 020363Y 20 mm guide TOOL - 3...
Page 26 Beverly 250 USA Tooling Stores code Description 020459Y Punch for fitting bearing on steer- ing tube 020458Y Puller for lower bearing on steer- ing tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting 020382Y011 adapter for valve removal tool...
Page 27 Beverly 250 USA Tooling Stores code Description 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve seal rings 020360Y Adaptor 52 x 55 mm 020364Y 25-mm guide TOOL - 5...
Page 28 Beverly 250 USA Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting/ removing the driv- en pulley clutch 020330Y Stroboscopic light for timing con- trol 001467Y035 Belle for OD 47-mm bearings 020368Y...
Page 29 Beverly 250 USA Tooling Stores code Description 020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cyl- inder 020263Y Sheath for driven pulley fitting 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool 020428Y Piston position check support TOOL - 7...
Page 30 Beverly 250 USA Tooling Stores code Description 020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston fitting band 020382Y Valve cotters equipped with part 012 removal tool TOOL - 8...
Page 31 Beverly 250 USA Tooling Stores code Description 020455Y 10-mm guide 020442Y Pulley lock wrench 020440Y Water pump service tool 020329Y MityVac vacuum-operated pump 020357Y 32 x 35 mm adaptor 020409Y Multimeter adaptor - Peak volt- age detection TOOL - 9...
Page 32 Beverly 250 USA Tooling Stores code Description 020456Y Ø 24 mm adaptor 020332Y Digital rev counter 020074Y Support base for checking crank- shaft alignment 020055Y Wrench for steering tube ring nut 002465Y Pliers for circlips 001330Y Tool for fitting steering seats...
Page 33 Beverly 250 USA Tooling Stores code Description 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020444Y011 adapter ring 020444Y009 46x55 Wrench 001467Y Extractor for bearings for holes 001467Y013 Pliers to extract ø 15-mm bear-...
Page 34 Beverly 250 USA Tooling Stores code Description 020444Y010 adapter ring 020244Y 15 mm diameter punch 020115Y Ø 18 punch 020271Y Tool for removing-fitting silent bloc 020627Y Flywheel lock wrench 020467Y Flywheel extractor TOOL - 12...
Page 35 Beverly 250 USA Tooling Stores code Description 020626Y Driving pulley lock wrench 020628Y Water pump service kit TOOL - 13...
Page 36 Beverly 250 USA Tooling TOOL - 14...
Page 37 INDEX OF TOPICS MAIN AINTENANCE...
Page 38: Maintenance Chart
Beverly 250 USA Maintenance Maintenance chart EVERY 3,000 KM Action Engine oil - level check/ top-up EVERY 2 YEARS Action Coolant - change Brake fluid - change 1000 K FTER Action Engine oil - replacement Hub oil - change Engine oil - change...
Page 39 Beverly 250 USA Maintenance Action Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change Idle speed (*) - adjustment Sliding block / variable speed rollers - change Throttle lever - adjustment Coolant level - check...
Page 40 Beverly 250 USA Maintenance Action Brake pads - check condition and wear Brake fluid level - check Transmission elements - lubrication Safety locks - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check...
Page 41 Beverly 250 USA Maintenance Action Secondary air filter - cleaning Valve clearance - check (*) See regulations in section «Idling speed adjustment» AT 72000 KM 270' Action Engine oil - replacement Hub oil - change Spark plug / electrode gap - check / replacement...
Page 42: Checking The Spark Advance
Beverly 250 USA Maintenance 1. Diaphragm cover - 2. Throttle valve spring - 3. Conical needle support - 4. Conical needle spring - 5. Conical needle - 6. Throttle valve diaphragm - 7. Automatic starting device - 8. Idle speed adjust- ing screw - 9.
Page 43 Beverly 250 USA Maintenance - Remove the transmission compartment air intake cover shown in the photograph. - Using a screwdriver rotate the fan, mounted onto the drive pulley, until the marking on the flywheel is aligned with that stamped on the flywheel cover, as shown in the picture.
Page 44 Beverly 250 USA Maintenance Spark advance variation SPARK ADVANCE VARIATION Specification Desc./Quantity Operation threshold First threshold : 9600±50 Second threshold : 9800±50 Reactivation threshold First threshold : 9500±50 Second threshold : 9700±50 Spark elimination First threshold : 1 spark on 7...
Page 45: Spark Plug
Beverly 250 USA Maintenance Spark plug - Put the vehicle on the central stand. - Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw.
Page 46: Air Filter
Beverly 250 USA Maintenance Check -Stand the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tighten- ing it completely; -Take out the dipstick checking that the oil level reaches the dipstick bottom notch (see figure);...
Page 47: Engine Oil
Beverly 250 USA Maintenance FLOWS AT REGULAR ENGINE RUNNING). EV- ERY 6,000 KM, UPON SERVICING, REMOVE THE RETAINER AND RUBBER COVER UNDER THE FILTER HOUSING AS SHOWN IN THE FIG- URE AND DRAIN ALL POSSIBLE OIL DEPOS- ITS. Cleaning (Every 12,000 km): - Wash with water and car shampoo.
Page 48 Beverly 250 USA Maintenance five minutes, check the level and top-up if neces- sary, without exceeding the MAX mark. N.B. THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED. Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the require-...
Page 49: Engine Oil Filter
Beverly 250 USA Maintenance ~ 1200 cc The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level between the MIN and MAX reference marks requires ~ 400 cm³ of oil.
Page 50: Checking The Valve Clearance
Beverly 250 USA Maintenance To use this reference mark, remove the spark plug and turn the engine in the opposite direction to the normal direction using a calliper spanner applied to the camshaft command pulley casing. N.B. TIME THE TIMING SYSTEM UNIT IF IT IS NOT IN PHASE.
Page 51: Braking System
Beverly 250 USA Maintenance Top-up The fluid level inspection should be carried out every 6,000 km when the motor is cold, following the methods indicated below: Place the scooter on its centre stand and on flat ground. - Undo the screw shown in the figure and remove the expansion tank cap on RHS.
Page 52 Beverly 250 USA Maintenance Level check The brake fluid tanks for the front and rear brakes are located on the pumps under the handlebar cover. Proceed as follows: - Bring the scooter onto the centre stand and with the handlebar centred; - check the fluid level at the sight glass as shown in the figure.
Page 53: Headlight Adjustment
Beverly 250 USA Maintenance NEVER USE BRAKE LIQUID IN OPEN OR PAR- TIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS. Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid...
Page 54 Beverly 250 USA Maintenance - Suitably orientate all the components. - Shut the gas outlet terminal of the tool. - Start the engine and let it warm up until the elec- tric fan activates. - Stop the engine. - Disconnect the SAS check valve vacuum hose shown in the figure.
Page 55 Beverly 250 USA Maintenance THE FUEL SUPPLY SYSTEM AND THE DE- PRESSION SEALS WORK ADEQUATELY N.B. IN CASE OF 1000 PPM UNBURNED HYDRO- CARBONS (HC) >, CHECK THE IGNITION SYS- TEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS.
Page 56 Beverly 250 USA Maintenance - Remove the filter indicated in the photograph - Check that the gasket is in good conditions - Check the SAS filter housing for dents or defor- mations - Clean the SAS filter carefully. Replace the filter if it is damaged or deformed.
Page 57 Beverly 250 USA Maintenance Specification Desc./Quantity 3. Roll-over valve 4. Safety valve 5. Canister 6. Vacuum fuel tap Removing system components • Canister Removal Gain access to the canister by removing the cover located inside the helmet compartment. Release the retaining belt and metallic clamps, then re- move the hoses.
Page 58 Beverly 250 USA Maintenance • Roll-over and/or Safety Valve Removal Remove the cover, release the metallic clamps, and then remove the hoses. The two valves are not supported. Refitting system components • Replace the components inserting the piping properly and fastening them with new metal strips.
Page 59 Beverly 250 USA Maintenance To check the Canister, it is necessary to proceed with its removal, whilst keeping the two hoses at- tached. • Shake the Canister and ensure it emits no noise. • Using a compressed air gun, blow the 3 ducts and ensure this does not result in a pressure build- up inside the Canister.
Page 60 Beverly 250 USA Maintenance Characteristic Standard opening vacuum 200 ÷ 260 mbar Roll-over valve check The valve should allow the following results: • Tank aeration when running (ambient air enters into the tank based on the volume of fuel used).
Page 61 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 62: Rear Wheel Spins At Idle
Beverly 250 USA Troubleshooting Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty; fuel pump or vacuum valve Remove, wash with solvent and dry with com- damaged pressed air or replace Excess of encrustations in the combustion cham-...
Page 63 Beverly 250 USA Troubleshooting Starting difficulties DIFFICULT STARTING Possible Cause Operation Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill Rpm too low at start-up or engine and start-up Check the starter motor, the system and the torque...
Page 64 Beverly 250 USA Troubleshooting Insufficient lubrication pressure POOR LUBRICATION PRESSURE Possible Cause Operation By-Pass remains open Check the By-Pass and replace if required. Care- fully clean the By-Pass area. Oil pump with excessive clearance Perform the dimensional checks on the oil pump...
Page 65 Beverly 250 USA Troubleshooting Excessive exhaust noise EXCESSIVE EXHAUST NOISE Possible Cause Operation Secondary air device cut-off valve not working Replace the secondary air device Depression intake pipe of the secondary air device Replace the pipe disconnected or dented Reed valve of the secondary air device does not...
Page 66 Beverly 250 USA Troubleshooting Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Faulty clutch Check that there is no grease on the masses. Check that the clutch mass contact surface with the casing is mainly in the centre with equivalent characteristics on the three masses.
Page 67 Beverly 250 USA Troubleshooting Battery BATTERY Possible Cause Operation Battery This is the device in the system that requires the most frequent attention and the most thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery needs to be re- charged periodically.
Page 68: Noisy Suspension
Beverly 250 USA Troubleshooting Possible Cause Operation if they are recessed or if the balls are squashed, replace them. Noisy suspension OISY SUSPENSION Possible Cause Operation Malfunctions in the suspension system If the front suspension is noisy, check: the efficien- cy of the front shock absorbers;...
Page 69 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 70 Beverly 250 USA Electrical system LEGENDA Specification Desc./Quantity Rear stop light switch Light switch with flash Turn signal switch Horn button Horn Engine stop remote control switch Light remote control switch Intercom pre-wiring Front fuse holder box Side stand switch...
Page 71 Beverly 250 USA Electrical system Specification Desc./Quantity Engine oil pressure sensor Starter motor Automatic starter Thermistor H.V. coil Voltage regulator fuel sender Starter relay Diode Ignition key-switch Immobilizer aerial Electronic ignition device Start up button Front brake stop light switch...
Page 72 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit To engine cut-off switch Installing the electrical circuit To instrument panel Installing the electrical circui To headlight switch Installing the electrical circuit To turn signal switch...
Page 73 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit To antenna Installing the electrical circuit Clamp Installing the electrical circuit Ignition master-box (ECU) Installing the electrical circuit To headlight INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity...
Page 74 Beverly 250 USA Electrical system Specification Desc./Quantity Installing the electrical circuit Clamp Installing the electrical circuit To fuel level gauge Installing the electrical circuit Seat opening cable Installing the electrical circuit Earth cable fixing onto frame. Installing the electrical circuit...
Page 75 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit Starter motor earth cable Installing the electrical circuit Starter motor positive (+) cable Installing the electrical circuit Screw - tighten up to 10 ÷ 13 Nm Installing the electrical circuit Screw - tighten up to 6 ÷...
Page 76 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit To the plafoniera Installing the electrical circuit Choke device diagnostic port Installing the electrical circuit Battery restraining belt Installing the electrical circuit Seat opening actuator...
Page 77 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit To battery (-) Installing the electrical circuit To the plafoniera Installing the electrical circuit Clamp Installing the electrical circuit To actuator Installing the electrical circuit...
Page 78 Beverly 250 USA Electrical system INSTALLING THE ELECTRICAL CIRCUIT Specification Desc./Quantity Installing the electrical circuit Secure the metallic clamp on the red binding so that the cable harness remains under- neath the frame tube. Installing the electrical circuit To 12V - 180W power outlet underneath the...
Page 79 Beverly 250 USA Electrical system Ignition IGNITION Specification Desc./Quantity Pick - up Magneto flywheel Fuse 15A (N° 7) Electronic ignition device Spark plug HV coil Voltage regulator Battery 12V - 10Ah ELE SYS - 11...
Page 80 Beverly 250 USA Electrical system Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity electronic control unit Carburettor heater Automatic starter Key switch Main fusible Battery 12V-9Ah Headlamp relay Light switch High-beam fuse 7,5A Low-beam and dashboard lights fuse...
Page 81 Beverly 250 USA Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP Specification Desc./Quantity Electronic ignition device Voltage regulator Magneto flywheel Pick - up Fuse 15 A (N°7) Battery 12V-12Ah Key switch contacts ELE SYS - 13...
Page 82 Beverly 250 USA Electrical system Specification Desc./Quantity Fuse 4A (N° 2) Front and rear brake light button Brake light bulbs 12V-10W Start up button Diodo Remote starter switch Starter motor Engine stop remote control switch Fuse 7,5A (N°1) Engine disabled warning light bulb...
Page 83 Beverly 250 USA Electrical system Level indicators and enable signals section LEVEL INDICATORS AND ENABLE SIGNALS SECTION Specification Desc./Quantity Electronic ignition device Fuse 4A (N° 5) Fuse 7,5A (N°1) Key switch contacts Fuse 15 A (N°7) Battery 12V-12Ah Radiatore electric fan motor...
Page 84 Beverly 250 USA Electrical system Specification Desc./Quantity Thermal switch for electric fan Thermistor Oil Pressure Warning Light Bulb 12V - 1,2W Motor Oil pressure sensor Reserve Fuel Warning Light Bulb 12V - 1,2W Fuel level sender Fuel gauge Digital clock...
Page 85 Beverly 250 USA Electrical system Turn signal lights DIRECTION INDICATORS, HORN, UTILITIES Specification Desc./Quantity Turn indicator switch Rh turn indicator warning light bul 12V - 1,2W Lh turn indicator warning light bulb 12V - 1,2W Four turn indicator bulbs N°4 12V-10W...
Page 86 Beverly 250 USA Electrical system Specification Desc./Quantity Key switch contacts Fuse 15 A (N°7) Saddle electrical opening button Saddle opening actuator Plug socket 12 V - 180 W MAX Fuse 15 A (N°8) Battery 12V-12Ah Helmet compartment lighting button Helmet compartment lamp bulb...
Page 87 Beverly 250 USA Electrical system In case the LED turns off and remains so even when switching over to «ON», check if: - there is battery voltage - 15A main fuse (No. 7) is in working order. If the deterring LED remains off, check the control unit power supply as follows: - Disconnect the control unit connector.
Page 88 Beverly 250 USA Electrical system - Insert the MASTER key, turn it to "ON" and keep it in that position for 2 seconds (limit values: 1 ÷ 3 seconds). - Alternately insert all the available black keys and turn each one of them to "ON" for 2 seconds.
Page 89 Beverly 250 USA Electrical system If no failures are found in the aerial, replace the control unit. CAUTION BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT...
Page 90 Beverly 250 USA Electrical system Ignition circuit Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a spark in the spark plug. The battery provides the basic power supply. The system is adjusted so that the start-up system im- mediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition system.
Page 91 Beverly 250 USA Electrical system - HV primary coil check Disconnect the control unit connector and check that the cable between terminals No. 3 and No. 8 is not interrupted (see figure). If non-conforming values are measured, check again the HV primary coil directly on the positive and negative terminals.
Page 92 Beverly 250 USA Electrical system Specific tooling 020409Y Multimeter adaptor - Peak voltage de- tection Electric characteristic Voltage value > 5 Volt - HV coil With the control unit and HV coil connected, meas- ure the voltage of the coil primary during the start-...
Page 93 Beverly 250 USA Electrical system Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further rep- etitions of incorrect values replace the stator or repair the wiring.
Page 94 Beverly 250 USA Electrical system engine off, wait for the voltage to set at about 12 V. Start the engine and measure the current gen- erated by the system with lights on and a high running engine. In case the generated current value is lower than 10A, repeat the test using a new regulator and/ stator alternatively.
Page 95 Beverly 250 USA Electrical system Turn signals system check If the turn signal lights fail to operate, proceed as follows: - Detach the control unit connector and check for potential difference at terminal no. 4 (red/black) with respect to earth (p.d. must be equal to battery voltage).
Page 96 Beverly 250 USA Electrical system Lights list LIGHT BULB TABLE Specification Desc./Quantity High-beam light bulb Type: HALOGEN (H7) Power: 12V - 55W Quantity: 1 Low-beam bulb Type: HALOGEN (H1) Power: 12V - 55W Quantity: 1 Front tail light bulb Type: ALL GLASS...
Page 97 Beverly 250 USA Electrical system Fuses The electrical equipment is protected by: 1. Four fuses "A" protecting the outside electrical socket, located under the right-hand side panel. 2. Four fuses "B" protecting the different circuits, located in the upper left portion of the glove com- partment.
Page 98 Beverly 250 USA Electrical system Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the vehicle and, afterwards, every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.
Page 99 Beverly 250 USA Electrical system Dry-charge battery COMMISSIONING A NEW DRY-CHARGED BATTERY - Remove the battery air pipe stop cap and each single element caps. - Fill the battery with electrolyte of 1.270+/-0.01 kg/l density (corresponding to 31+/-1 Bé) with an am- bient temperature not below 15°C, until it reaches the upper level indicated on the block.
Page 100 Beverly 250 USA Electrical system ELE SYS - 32...
Page 101 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 102 Beverly 250 USA Engine from vehicle Exhaust assy. Removal - Undo the two exhaust manifold fixings on the head. - Undo the three screws fixing the muffler to the support arm. Remove the full muffler unit. To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
Page 103 Beverly 250 USA Engine from vehicle - Detach the inlet and outlet carburettor fuel lines and the cooling circuit hoses (head outlet and ther- mostat inlet). - Remove the canister safety valve vacuum hose. - Detach the spark plug H.T. cable.
Page 104 Beverly 250 USA Engine from vehicle ENG VE - 4...
Page 105 INDEX OF TOPICS NGINE...
Page 106: Automatic Transmission
Beverly 250 USA Engine Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.
Page 107 Beverly 250 USA Engine 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 020375Y Adaptor 28 x 30 mm...
Page 108 Beverly 250 USA Engine Refitting - Heat the roller and insert the bearing using the specific punch: Specific tools: Specific tooling 020455Y 10-mm guide - Refit the roller with the special screw. - Tighten to the specified torque. - Refit the intake throat with the O-ring, the sump sealing gasket and a the fan housing.
Page 109: Inspecting The Clutch Drum
Beverly 250 USA Engine Removing the driven pulley - Remove the spacer, the clutch bell and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Inspecting the clutch drum - Check that the clutch bell is not worn or damaged.
Page 110: Removing The Clutch
Beverly 250 USA Engine - Using a feeler pin gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell. Specific tooling 020074Y Support base for checking crankshaft...
Page 111 Beverly 250 USA Engine 020444Y Tool for fitting/ removing the driven pulley clutch Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.
Page 112 Beverly 250 USA Engine - Remove the four torque server pins and pull the pulley halves apart. Removing the driven half-pulley bearing - Check there are no signs of wear and/or noisi- ness; - Replace with a new one if there are.
Page 113 Beverly 250 USA Engine Inspecting the driven fixed half-pulley - Measure the pulley bushing outside diameter. - Check that the contact surface with the belt is free from abnormal wear. - Check the riveting. - Check the belt contact surface planarity.
Page 114 Beverly 250 USA Engine MOVABLE DRIVEN HALF-PULLEY DIMENSIONS Specification Desc./Quantity Wear limit 0.3 mm standard diameter Diameter 41.000 - 41.035 mm maximum allowable diameter Ø 41.08 mm Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface.
Page 115: Refitting The Driven Pulley
Beverly 250 USA Engine Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure. - Fit the half-pulley over the bushing using the spe- cific tool.
Page 116 Beverly 250 USA Engine Inspecting the clutch spring - Measure the free length of the mobile driven half- pulley spring. Characteristic Standard length 123 mm acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor ap- propriate tool with the control screw in vertical axis.
Page 117 Beverly 250 USA 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.
Page 118: Removing The Driving Pulley
Beverly 250 USA Engine Drive-belt - Ensure the drive-belt is not damaged. - Check the drive-belt width. Characteristic Driving belt - standard width 21,3 ± 0,2 mm Driving belt - minimum width 19,5 mm During the wear checks foreseen in the scheduled maintenance services at 6,000 km;...
Page 119 Beverly 250 USA Engine - Insert the adaptor sleeve of the appropriate tool in the hole shown in the photograph - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping...
Page 120 Beverly 250 USA Engine - Ensure the fixed driving pulley exhibits no abnor- mal wear on the grooved profile and on the belt contact surface. - Ensure the O-ring is not deformed. CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS...
Page 121 Beverly 250 USA Engine Refitting the driving pulley - 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 122 Beverly 250 USA Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
Page 123 Beverly 250 USA Engine Removing the wheel axle - Remove the wheel axis complete with gear. - Remove the intermediate gear. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following.
Page 124 Beverly 250 USA Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil guard as in the figure.
Page 125 Beverly 250 USA Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents. Inspecting the hub cover - Check that the fitting surface is not dented or distorted.
Page 126 Beverly 250 USA Engine Refitting the hub cover bearings In order to fitting of the hub box bearings, the en- gine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
Page 127 Beverly 250 USA Engine - Refit the driven pulley shaft bearing with a mod- ular punch as shown in the figure. N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAINER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.
Page 128 Beverly 250 USA Engine 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. - Fit the gearbox cover, making sure the breather pipe is in the correct position.
Page 129: Removing The Stator
Beverly 250 USA Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the ten fixings - Remove the flywheel cover. Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure.
Page 130 Beverly 250 USA Engine Refitting the stator - Refit the stator and flywheel carrying out the re- moval procedure in reverse, tightening the retain- ers to the specified torque. Locking torques (N*m) Stator assembly screws (°) 3 ÷ 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.
Page 131 Beverly 250 USA 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 - Lock the rotation of the Flywheel with the calliper spanner tool.
Page 132 Beverly 250 USA Engine - Line up the two holes in the flywheel as shown in the photo - Screw in the guide bushing that is part of the special flywheel stop tool on the flywheel as shown in the photo.
Page 133 Beverly 250 USA Engine Refitting the free wheel - Make sure the freewheel faying surfaces are in good condition. - Thoroughly clean the free wheel to remove LOCTITE residue. - Degrease the threading of the holes in the free wheel and the clamping screws.
Page 134 Beverly 250 USA Engine A VARIATION IN THE AIR GAP DISTANCE MODIFIES THE IGNITION SYSTEM IDLE SPEED Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Flywheel nut 54 ÷ 60 - Remove the freewheel retaining plate indicated in the photograph...
Page 135 Beverly 250 USA Engine Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter on the crankcase, locking the two screws to the prescribed torque. Locking torques (N*m) Starter motor screws 11 ÷ 13 Cylinder assy.
Page 136 Beverly 250 USA Engine 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 137 Beverly 250 USA Engine - Remove the camshaft control pulley with its washer. - Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The chain tensioning pad must be removed from the transmission side.
Page 138: Removing The Cylinder Head
Beverly 250 USA Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. - Remove the head, the two centring dowels and the gasket.
Page 139: Removing The Valves
Beverly 250 USA 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 RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD.
Page 140: Inspecting The Small End
Beverly 250 USA Engine Inspecting the small end - Measure the internal diameter of the rod small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAME- TER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Page 141: Inspecting The Piston
Beverly 250 USA Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod end. Characteristic Pin diameter: Standard clearance 0.015 ÷ 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm...
Page 142: Removing The Piston
Beverly 250 USA Engine 0.001 ÷ 0.010 mm piston diameter 71.953 - 71.981 mm Fitting clearance Top piston ring - standard coupling clearance 0.015 - 0.06 mm Top piston ring - maximum clearance allowed after use 0.07 mm Middle piston ring - standard coupling clearance 0.015 - 0.06 mm Middle piston ring - maximum clear-...
Page 143 Beverly 250 USA Engine - Fit the wrist pin stop using the plug as shown in the figure N.B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUSING. Specific tooling...
Page 144 Beverly 250 USA Engine N.B. MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND VICE VERSA.
Page 145 Beverly 250 USA Engine Refitting the piston rings Fitting the sealing rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston.
Page 146: Inspecting The Cylinder Head
Beverly 250 USA Engine Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocker pin ca- pacities exhibit no wear.
Page 147 Beverly 250 USA Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
Page 148 Beverly 250 USA Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
Page 149 Beverly 250 USA Engine - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the surface of contact with the articulated register terminal. - If the checks above give no failures, you can use the same valves. For best sealing results, it is advisable to grind the valves.
Page 150 Beverly 250 USA Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. ENG - 46...
Page 151 Beverly 250 USA Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seals. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
Page 152 Beverly 250 USA Engine - Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Internal rocker arm diameter: Standard diame- Diameter 12.000 - 12.011 mm...
Page 153 Beverly 250 USA Engine Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head. - Lubricate the stud bolt threading.
Page 154 Beverly 250 USA Engine - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que.
Page 155 Beverly 250 USA Engine GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE EN- GINE. Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 Spark plug 12 ÷ 14 Starter ground screw 7 ÷...
Page 156 Beverly 250 USA Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening the 5 clamping screws to the prescribed torque. - Make sure the gasket is positioned properly. Locking torques (N*m) Tappet cover screws 6 - 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws.
Page 157 Beverly 250 USA Engine 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. - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
Page 158 Beverly 250 USA Engine THE THREADED SHAFT ENDS DO NOT INTER- FERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAM- AGE THE MAIN BUSHINGS. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPA- RATING IT.
Page 159 Beverly 250 USA Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
Page 160 Beverly 250 USA Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
Page 161 Beverly 250 USA Engine AND CONNECTING ROD LUBRICATION PRES- SURE. N.B. THE HEAD LUBRICATION CHANNEL IS PRO- VIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICA- TION AND THE TIMING MECHANISMS.
Page 162 Beverly 250 USA Engine - There is only one type of main bushing housing hole in the crankcase The standard bushing diameter after driving is var- iable on the basis of a coupling selection. - The bushing housings in the crankcase are avail- able in two categories, Cat.
Page 163 Beverly 250 USA Engine Crankcase Engine half Bushing halves shaft Cat. 1 Cat. 1 Cat. 2 Cat. 2 Cat. 1 Cat. 2 Cat. 2 Cat. 1 N.B. TO KEEP THIS POSITION OF THE BUSHINGS ON THE CRANKCASE, FITTING IS FORCED ON STEEL RINGS INSERTED IN THE CASTING OF BOTH CRANKCASE HALVES.
Page 164 Beverly 250 USA Engine - Insert the filter on the engine with the relative cap. Tighten to the prescribed torque. Locking torques (N*m) Internal engine crankcase bulkhead (transmis- sion-side half shaft) screws 4 ÷ 6 Engine- crankcase coupling screws 11 ÷ 13 Oil filter on crankcase fitting 27 ÷...
Page 165 Beverly 250 USA Engine ENG - 61...
Page 166: Oil Pressure Check
Beverly 250 USA Engine Oil pressure check - After removing the flywheel cover as described in the "Flywheel" chapter, remove the electric con- nexion of the minimum oil pressure switch and then remove the switch. - With the engine idling at 1650 rpm and the oil temperature at ~90°C, check that the oil pressure...
Page 167 Beverly 250 USA Engine Crankshaft oil seals Removal - First remove the transmission cover and the com- plete driving pulley - Install the base of the appropriate tool on the oil guard using the screws provided. Specific tooling 020622Y Transmission-side oil guard punch - Screw the threaded bar onto the base of the tool and extract the oil guard.
Page 168 Beverly 250 USA Engine Refitting - Use a new oil seal upon refitting. - Prepare the new oil seal, lubricating the sealing lip. - Preassemble the oil seal with the specific tool, positioning the screws. - Place the sheath over the crankshaft.
Page 169: Oil Pump
Beverly 250 USA Engine Oil pump Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
Page 170 Beverly 250 USA Engine - Remove the oil pump seal. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN OR- DER TO ENSURE THAT THE INITIAL DIREC- TION OF ROTATION IS MAINTAINED. Inspection - Remove the two screws and the oil pump cover.
Page 171 Beverly 250 USA Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
Page 172 Beverly 250 USA Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Trans- mission" chapter. - Drain the oil as described previously.
Page 173 Beverly 250 USA Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.
Page 174 Beverly 250 USA Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump.
Page 175: Fuel Supply
Beverly 250 USA Engine the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it. N.B.
Page 176 Beverly 250 USA Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
Page 177 Beverly 250 USA Engine - Remove the vacuum valve together with the di- aphragm. - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure.
Page 178 Beverly 250 USA Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
Page 179 Beverly 250 USA Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 75...
Page 180 Beverly 250 USA Engine - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
Page 181 Beverly 250 USA Engine Walbro To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connexion, the clamps anchoring the carburettor to the filter housing and to the inlet manifold, the air delivery pipe to the diaphragm, and the intake fitting.
Page 182 Beverly 250 USA Engine Remove the 4 fixing screws indicated in the figure and the vacuum chamber cover. N.B. DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY. Remove the vacuum valve together with the dia- phragm.
Page 183 Beverly 250 USA Engine Unscrew the bayonet joint 1/8 of a turn, remove it, take out the spring and vacuum valve plunger Remove the 4 screws shown in the figure. Remove the tank with the intake pump, its control and gasket.
Page 184 Beverly 250 USA Engine Remove the acceleration pump piston with the ring nut, the hood, the O-Ring and the spring from the tank as shown in the figure. Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side.
Page 185 Beverly 250 USA Engine Remove the cover of the duct from the carburettor to the starter nozzle as shown in the figure. -Remove the maximum nozzle. -Remove diffuser. Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY.
Page 186 Beverly 250 USA Engine Remove the minimum flow screw with the O-ring, the washer and the spring. -Remove the 2 fixing screws, the cover, the spring, and the cut-off device diaphragm. CAUTION DO NOT ATTEMPT REMOVING PARTS EM- BEDDED IN THE CARBURETTOR BODY SUCH...
Page 187 Beverly 250 USA Engine Kehin - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
Page 188 Beverly 250 USA Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
Page 189 Beverly 250 USA Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
Page 190 Beverly 250 USA Engine - Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body. - The screw final position should be determined by an exhaust fume analysis.
Page 191 Beverly 250 USA Engine - For the starter circuit, blow the connection pipe properly with the jet.This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE OUTLET IS EX- TREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
Page 192 Beverly 250 USA Engine Level check Kehin - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
Page 193 Beverly 250 USA Engine - Remove the drainage screw from the tank, wash and blow the tank properly and make sure the ac- celeration pump intake and supply valve are clean. - Being the valves unidirectional, blow them care- fully with compressed air, at the inner side of the tank for the intake valve and at the pump piston housing for the supply valve.
Page 194 Beverly 250 USA Engine - Prepare the carburettor for adjustment by rotating the screw 3 turns from the close position. - Check that the rocking lever control of the accel- erating pump does not show abnormal wear. - Check that the end of stroke screw of the rocking lever protrudes 3.2 mm.
Page 195 Beverly 250 USA Engine N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION. - Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover.
Page 196 Beverly 250 USA Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Walbro - Check that the pin does not show signs of wear and that the lock is in the 3rd of the 3 notches.
Page 197 Beverly 250 USA Engine - Check that the diaphragm is not worn or has hardened. If it does, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is in the correct position on the plunger and inserted in its housing.
Page 198 Beverly 250 USA Engine Inspecting the automatic choke device - Check that the piston of the automatic starter is not deformed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the sealing gasket of the piston is not deformed.
Page 199 Beverly 250 USA Engine 5 min Electric characteristic Check the automatic starter: Resistance around 30 Ω Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support.
Page 200 Beverly 250 USA Engine TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION NOT TO GENERATE SHORT CIR- CUITS USE A CABLE SECTION WITH A TER- MINAL SUITABLE TO BE CONNECTED TO THE STARTER. Characteristic Check the automatic starter: Kehin: Protrusion value XX ÷...
Page 201 Beverly 250 USA Engine - If protrusion, resistance or timing values are dif- ferent from the ones prescribed, replace the start- Characteristic Check the auto starter: Protrusion Value for Walbro 12.5 ÷ 13 mm at approx. 20°C Check the automatic starter: Walbro maximum protrusion 18.5 ÷...
Page 202 Beverly 250 USA Engine ENG - 98...
Page 203 INDEX OF TOPICS SUSP USPENSIONS...
Page 204: Removing The Front Wheel
Beverly 250 USA Suspensions Front Removing the front wheel - Remove the front 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.
Page 205 Beverly 250 USA Suspensions * Either tool can be used. - Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle,...
Page 206 Beverly 250 USA Suspensions - Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm adaptor 020412Y 15 mm guide 020201Y Spacer bushing driving tube...
Page 207 Beverly 250 USA Suspensions - Refit the cap and tighten the five fixing screws. Refitting the front wheel - Grease the wheel axle, then install it from the tone wheel side and install the tone wheel proper- - Tighten the wheel axle nut to the prescribed tor- que.
Page 208: Front Fork
Beverly 250 USA 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 front shield. See also Rear handlebar cover...
Page 209 Beverly 250 USA Suspensions Removal - Remove the front wheel. - Remove the handlebar. - Using the appropriate tool, loosen and remove the upper ring nut, the distancing washer, the counter ring nut and the spacer ring. - Extract the fork.
Page 210 Beverly 250 USA Suspensions - Insert the retaining band of the two half-rings. - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering tube - Insert the a new plate and a new dust guard in the steering tube - Insert a new roller bearing in the roller tube.
Page 211 Beverly 250 USA Suspensions - Loosen the stem support clamp and remove fork leg and stem. - Remove the first spring consisting of 15 windings. - Remove the spring support plate. - Remove the second spring consisting of 21 wind- ings.
Page 212 Beverly 250 USA Suspensions - Keeping the tie rod in vertical position, insert the bell for the Ø 35 mm stems. - Insert the nut in the thread and take out the oil guard Specific tooling 020487Y Fork oil seal extractor - Check the length of the springs.
Page 213 Beverly 250 USA Suspensions - Insert a new oil guard with the special adaptor handle and take it to the stop. - Insert the safety clip. - Insert a new dust guard. - Insert the contrast spring into the pumping mem- ber.
Page 214 Beverly 250 USA Suspensions - Insert the stem into the fork clamp. - Do up the clamp once to allow the stem closure upper cap to be tightened. - Check that the sealing ring on the cap is in good working order, then tighten the cap on the stem to the prescribed torque.
Page 215 Beverly 250 USA Suspensions Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m) Steering lower ring nut 10 ÷ 13 then loosen by 90° Upper steering ring nut 30 ÷ 36 Steering bearing Removal - Remove the fork...
Page 216: Removing The Rear Wheel
Beverly 250 USA Suspensions - Using two 24 mm wrenches, tighten the screw until the seat and the bearing are fully set in place. N.B. ALWAYS USE A NEW BEARING AND A NEW SEAT. Specific tooling 001330Y Tool for fitting steering seats...
Page 217 Beverly 250 USA Suspensions - Loosen the nut and lock nut on the left-hand side of the scooter (see figure) and unscrew the spindle from the opposite side. - Remove the retaining screw of the rear brake pipe shown in the figure.
Page 218 Beverly 250 USA Suspensions - Install a new silent bloc, making sure it aligns properly with the reference tooth. - Fit the silent blocs, making sure the chamfered part of the silent bloc matches the chamfered part of the bracket...
Page 219 Beverly 250 USA 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.
Page 220 Beverly 250 USA 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...
Page 221 Beverly 250 USA Suspensions Refitting For correct installation of the swinging arm on the scooter, proceed as follows: 1. Position the silent block supporting clamp with part 3 inserted, and slightly tighten part 1 2. Position the swinging arm, inserting part 2 3.
Page 222: Shock Absorbers
Beverly 250 USA Suspensions SWINGING ARM FITTING Name Torque in Nm Part 1 64 ÷ 72 Nm Part 3 5 - 7 Nm Part 4 90 ÷ 110 Nm Part 5 64 ÷ 72 Nm Engine-swinging arm bolt 64 - 72...
Page 223 Beverly 250 USA Suspensions Refitting Carry out the previous operations but in reverse order. Locking torques (N*m) Shock absorber lower clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41 Exhaust bracket Removal - Loosen and remove the lower retaining bolt of the right-hand shock absorber at the support arm.
Page 224 Beverly 250 USA Suspensions - Support the muffler support bracket sufficiently - Using the special punch, remove the bearing from its seat as shown in the photograph Specific tooling 020376Y Adaptor handle 020456Y Ø 24 mm adaptor - Heat the bearing seat using the heat gun...
Page 225: Side Stand
Beverly 250 USA Suspensions Removal - Unhook the springs. - Loosen the nut. - Pull out the screw. Reassembly - Install the sealing rings on the support tube of the stand; - Carry out the operations described above in re- verse order, then insert the sealing rings into their seats.
Page 226 Beverly 250 USA Suspensions SUSP - 24...
Page 227 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 228: Rear Brake Calliper
Beverly 250 USA Braking system Interventions rules WARNING THE FLUID FOR THE BRAKE SYSTEM IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE CONTACT AREA WELL WITH COPIOUS AMOUNTS OF WATER. THE BRAKE FLUID DRAINED FROM THE SYSTEM IS HARMFUL TO THE ENVIRONMENT. COL- LECTION AND DISPOSAL MUST BE CARRIED OUT IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
Page 229 Beverly 250 USA Braking system Refitting - Fix the brake calliper support plate to the crank- case and the brake calliper to the bracket, tight- ening the screws to the prescribed torque. - Apply the recommended product to the fixing screws of the brake calliper to the bracket.
Page 230 Beverly 250 USA Braking system Overhaul Proceed as follows: 1) remove the two male hexagonal screws (1) and take out the two pads (10); 2) remove the two male hexagonal screws (2) and remove the reaction plate (3); 3) take out the fixed plate (4) from the guide;...
Page 231 Beverly 250 USA Braking system The body and the reaction plate body work inte- grally and can move axially with respect of the fixed plate that is integral to the strut. The pistons, forced by pressure to push the pad to the disk, cause the reaction plate to push in turn the other pad towards the disc.
Page 232 Beverly 250 USA Braking system Rear brake disc Removal - Remove the rear wheel. - Remove the hub and the brake disc. - Carry out the same procedure with the front brake disc. See also Removing the rear wheel Refitting - For the installation, position the disc correctly using the arrow stamped on it as reference.
Page 233: Front Brake Disc
Beverly 250 USA 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 234: Front Brake Pads
Beverly 250 USA Braking system Disc Inspection Checking the disc is important; it must be perfectly clean, with no sign of rust, oil or grease or other dirt and must not show signs of deep scoring. Characteristic Thickness of a new front disc 4.0 mm...
Page 235 Beverly 250 USA Braking system 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 236 Beverly 250 USA Braking system Pad fastening pin 19.6 ÷ 24.5 Screw tightening calliper to the support 20 ÷ 25 Fixing screws for the calliper support on the engine 20 ÷ 25 Fill Rear - combined Proceed as follows: - Position the vehicle on a flat surface and on the...
Page 237 Beverly 250 USA Braking system CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE DISC. Specific tooling 020329Y MityVac vacuum-operated pump Locking torques (N*m) Oil bleed screw 12 - 16 Front Proceed as follows: - Position the vehicle on a flat surface and on the...
Page 238 Beverly 250 USA Braking system CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM THE BLEED SCREW ON THE CALLIPER AND ON THE DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER AND DEGREASE THE BRAKE DISC. Specific tooling 020329Y MityVac vacuum-operated pump...
Page 239 Beverly 250 USA Braking system 1. Tank cover screw 2. Tank cover 3. Diaphragm 4. Bellows 5. Seal ring 6. Piston 7. Gasket 8. Spring 9. Tank CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
Page 240 Beverly 250 USA Braking system Removal - Remove the rear handlebar cover. - Drain the brake system. - Disconnect the brake fluid line from the pump, paying attention to a possible escape of remaining brake fluid. - Remove the front and rear brake stop button from the lever.
Page 241 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 242 Beverly 250 USA Cooling system Circuit diagram COOLING CIRCUIT Specification Desc./Quantity Carburettor heating circuit Thermostat with by-pass Expansion tank Radiator COOL SYS - 2...
Page 243 Beverly 250 USA Cooling system Water pump - overhaul - Remove the complete flywheel cover - Remove the stator - Remove the pump cover by loosening the 3 fixing screws - Remove the sealing gasket The pump can be services using the special tool and a press.
Page 244 Beverly 250 USA Cooling system Install the pin that is part of the special tool on the press piston. Turn the flywheel cover until it permits insertion of the pin inside the joint and eject the pump shaft from the joint and bearings.
Page 245 Beverly 250 USA Cooling system Centre the cover until it permits insertion of the pin and then eject the seal ring and the two ball bear- ings. Specific tooling 020628Y Water pump service kit Before you reassemble, wash all the components and continue with the following checks.
Page 246 Beverly 250 USA Cooling system Shaft: Check to be sure there is no oxidation. Check that the impeller is in perfect condition. Ceramic seal: Check that the ceramic seals are not worn, cracked or scored. Check that the two rub- ber seals are in perfect condition.
Page 247 Beverly 250 USA Cooling system Let the flywheel cover guard cool down and then manually mount the static part of the ceramic seal with the relative rubber seal. N.B. PAY ATTENTION TO MOUNTING THE CERAM- IC RING CORRECTLY. THE CHAMFER ON THE INTERNAL DIAMETER MUST BE TURNED AWAY FROM THE SIDE OF THE BEARINGS.
Page 248 Beverly 250 USA Cooling system Manually insert the pump shaft in the relative bear- ings. While keeping the bearings in contact with the support base, line up the shaft with the press pis- ton and proceed with the driving. The driving depth is determined by the beat of the punch when it is in contact with the flywheel cover.
Page 249 Beverly 250 USA Cooling system Install the oil seal on the flywheel cover all the way to the depth determined by the punch. Specific tooling 020628Y Water pump service kit Fit the punch with the template of the entrainment joint to the press punch.
Page 250 Beverly 250 USA Cooling system Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject. This component is intended to guarantee the leak tightness of the coolant in relation to the pump shaft. The seal achieved via two special ceramics, a static one and a spinning one, kept in contact by the thrust of a spring, coaxially mounted onto the pump shaft.
Page 251 Beverly 250 USA Cooling system - Warm up the container using the heat gun. - Check the temperature when the thermostat starts to open: - Heat up until the thermostat is completely open - Replace the thermostat if it does not work prop- erly.
Page 252 Beverly 250 USA Cooling system Refitting - Place the thermostat with the bleeding hole at the highest point. - Make sure that the rubber gasket is positioned properly. - Fit the thermostat cover with the connection for the carburettor heating pipe facing the flywheel.
Page 253 INDEX OF TOPICS CHAS HASSIS...
Page 254: Rear Rack
Beverly 250 USA Chassis Seat - Remove the saddle by loosening the three re- taining screws indicated in the figure; Side fairings - Remove side bumpers by removing the mounting screws shown in the figure (one on each side). Rear rack - Loosen the two mounting screws and remove the battery cover.
Page 255: Instrument Panel
Beverly 250 USA Chassis Rear handlebar cover - Remove the front handlebar cover. - Remove the 3 screws shown in the photograph. - Remove the 2 screws on the rear part of the han- dlebar cover shown in the photograph.
Page 256 Beverly 250 USA Chassis Headlight assy. - Remove the headlight assembly by loosening the 4 fixing screws, two of which are shown in the fig- ure and two located further down. - Separate the electrical connectors; - Pull out the headlight as- sembly.
Page 257 Beverly 250 USA Chassis - Loosen the 2 screws shown in the figure. - Remove the front shield. See also Headlight assy. Frame central cover Knee-guard - Remove the front shield; - Remove the 2 fixing screws of the fuse box in the front glove box; - Separate the electrical connections;...
Page 258 Beverly 250 USA Chassis 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 259 Beverly 250 USA Chassis 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 spring to be pressed out.
Page 260 Beverly 250 USA Chassis Footrest - Remove the central cover. - Remove the RHS footrest mat. - Loosen the eight footrest mounting screws. - Remove the RHS footrest. - Repeat the same operations for the LHS footrest. See also Frame central cover...
Page 261: Rear Mudguard
Beverly 250 USA Chassis See also Seat Rear rack Frame central cover Taillight assy. Frame central cover Rear rack Taillight assy. Seat Rear mudguard - Loosen the 4 fixing screws, 2 of which are indi- cated in the figure and the other 2 located on the opposite side under the air filter;...
Page 262: Fuel Tank
Beverly 250 USA Chassis Helmet bay - Remove the canister cover from inside the helmet compartment and hence remove all of its compo- nents (see the "Maintenance - Anti-evaporative System - Components Removal" chapter). - Rimuovere il coperchio dell'impianto Canister all'interno del vano portacasco quindi - Remove the side panels.
Page 263: Front Mudguard
Beverly 250 USA Chassis - Undo the two screws fixing the tank to the chas- sis; - Remove the tank by tilting it downwards and pull- ing out from below. See also Footrest Knee-guard Front wheel housing Front mudguard - Remove the retaining screw of the cable lead through support on the right-hand side of the mud- guard.
Page 264 Beverly 250 USA Chassis Flyscreen - Remove the front handlebar cover - Remove the 3 screws shown in the photograph. See also Front handlebar cover CHAS - 12...
Page 265 INDEX OF TOPICS PRE DE DELIVERY...
Page 266 Beverly 250 USA Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks...
Page 267 Beverly 250 USA Pre-delivery - Horn - Starter 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 268 Beverly 250 USA Pre-delivery - Abnormal noise Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 269 INDEX OF TOPICS TIME...
Page 270 Beverly 250 USA Time Engine ENGINE Code Action Duration 001001 Engine from frame - remove and install 003064 Engine oil - change 003057 Engine retainer - tighten nuts TIME - 2...
Page 271 Beverly 250 USA Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replacement 001133 Engine crankcase - replace TIME - 3...
Page 272 Beverly 250 USA Time Crankshaft CRANKSHAFT Code Action Duration 001099 Oil seal, flywheel side - Re- placement 001117 Crankshaft - Replacement TIME - 4...
Page 273 Beverly 250 USA Time Cylinder assy. CYLINDER- PISTON Code Action Duration 001002 Cylinder-Piston - Replace- ment 001154 Pin ring piston unit - Service TIME - 5...
Page 274 Beverly 250 USA Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - change 001083 Thermistor - Replacement 001057 Thermostat - Replacement TIME - 6...
Page 275 Beverly 250 USA Time Rocker arms support assy. CAMSHAFT - ROCKING LEVERS Code Action Duration 001148 Valve rocking levers - Re- placement 001044 Camshaft - Replacement TIME - 7...
Page 276 Beverly 250 USA Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replace- ment 001074 Oil vapour recovery pipe - Re- placement TIME - 8...
Page 277 Beverly 250 USA Time Chain tensioner CHAIN TIGHTENER Code Action Duration 001129 Chain tensioner - Service and Replacement 001124 By pass lubrication - Re- placement TIME - 9...
Page 278 Beverly 250 USA Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Re- placement TIME - 10...
Page 279: Driven Pulley
Beverly 250 USA Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 003072 Clutch unit - Wear check 001012 Driven pulley - overhaul 001110 Driven pulley - Replacement 001155 Clutch bell housing - Re- placement TIME - 11...
Page 280 Beverly 250 USA Time Oil pump PUMP - OIL SUMP UNIT Code Action Duration 001125 Chain guide pads - Replace- ment 001051 Belt/ Timing chain - Replace- ment 001042 Oil pump - overhaul 001112 Oil pump - change 001122 Oil pump chain - Replace-...
Page 281 Beverly 250 USA Time Final gear assy. FINAL DRIVE Code Action Duration 001010 Gear reduction unit - Inspec- tion 001156 Gear reduction unit cover - Replacement 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replace- ment TIME - 13...
Page 282 Beverly 250 USA Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replace- ment 001011 Driving belt - Replacement 001066 Driving pulley - Removal and Refitting 001006 driving pulley - Service TIME - 14...
Page 283 Beverly 250 USA Time Transmission cover TRANSMISSION COVER Code Action Duration 001135 Transmission cover bearing - Replacement 001096 Transmission crankcase cov- er - replace 001131 Transmission air intake - Re- placement Flywheel magneto Versione 250 TIME - 15...
Page 284 Beverly 250 USA Time MAGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - replace 001113 Water pump - Replacement 001173 Rotor - replace 001067 Stator - Replacement 001104 Start-up freewheel - Replace- ment 001151 Start-up driven gearing - Re- placement...
Page 285 Beverly 250 USA Time Code Action Duration 001173 Rotor - Replacement 001067 Stator - Replacement 001161 Secondary air filters - Re- placement / Cleaning 001162 Secondary air housing - Re- placement 001174 SAS valve - Replacement 001163 SAS valve / Head connection...
Page 286 Beverly 250 USA Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001092 Exhaust manifold - Replace- ment TIME - 18...
Page 287: Air Cleaner
Beverly 250 USA Time Air cleaner AIR CLEANER Code Action Duration 001014 Air filter - Replacement/ Cleaning 001015 Air filter box - Replacement 004122 Carburettor air cleaner at- tachment - Replacement TIME - 19...
Page 288 Beverly 250 USA Time Frame FRAME Code Action Duration 004001 Frame - Replacement TIME - 20...
Page 289 Beverly 250 USA Time Centre-stand CENTRE AND SIDE STANDS Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 21...
Page 290 Beverly 250 USA Time Legshield spoiler FRONT SHIELD - SPOILER Code Action Duration 004064 Front shield - Replacement 004053 Spoiler - Replacement TIME - 22...
Page 291 Beverly 250 USA Time Side fairings SIDE COVERS Code Action Duration 004085 Fairing (1) - Replacement 004012 Rear side panels - Replace- ment 004052 Bumper - Replacement TIME - 23...
Page 292 Beverly 250 USA Time Footrests MATS AND COVERS Code Action Duration 004075 Front mat - Replacement 004079 Passenger footrest (1) - Re- placement 004015 Footrest - removal and instal- lation TIME - 24...
Page 293 Beverly 250 USA Time Rear cover REAR SHIELD Code Action Duration 004065 Front shield rear section - re- moval and installation 004081 Glove-box lid - Replacement TIME - 25...
Page 294 Beverly 250 USA Time Central cover CENTRAL COVER Code Action Duration 004011 Central frame cover - Re- placement 002082 Fuel tank cap opening drive - Replacement TIME - 26...
Page 295 Beverly 250 USA Time Underseat compartment UNDER-SADDLE COMPARTMENT-ELECTRIC SEAT OPENING-LICENCE PLATE SUP- PORT Code Action Duration 002083 Saddle opening transmission - replacement Saddle open- ing transmission - replace- ment 004016 Helmet compartment - re- moval and installation 004106 Underseat band - Replace-...
Page 296 Beverly 250 USA Time Mudguard FRONT AND REAR MUDGUARDS Code Action Duration 004009 Rear mudguard - Replace- ment 004002 Front mudguard - Replace- ment TIME - 28...
Page 297 Beverly 250 USA Time Fuel tank FUEL TANK Code Action Duration 005010 Tank float - Replacement 004109 Fuel tank breather - change 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement TIME - 29...
Page 298 Beverly 250 USA Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replace- ment 007013 Radiator expansion tank con- nection pipe - change 001052 Coolant and air bleeding - Change TIME - 30...
Page 299 Beverly 250 USA Time Radiator RADIATOR Code Action Duration 007014 Radiator thermal switch - Re- placement 007002 Radiator water - Replace- ment 007016 Complete fan with support - Replacement 007003 Coolant delivery and return pipe - change TIME - 31...
Page 300 Beverly 250 USA Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - re- moval and installation TIME - 32...
Page 301 Beverly 250 USA Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Fork unit - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 004119 Bearing/upper steering fifth wheel - Replacement 003002 Steering fifth wheel - Re-...
Page 302: Handlebar Covers
Beverly 250 USA Time Handlebar covers HANDLEBAR COVER Code Action Duration 004018 Handlebar front section - Re- placement 004019 Handlebar rear section - Re- placement 006013 Handlebar front part - Paint- 006014 Handlebar rear part - Painting TIME - 34...
Page 303 Beverly 250 USA Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Throttle grip - Replacement 002037 Brake or clutch lever - Re- placement 002071 Left knob - Replacement 002024 Front brake pump - Removal and Refitting 002067 Rear brake pump - Replace-...
Page 304 Beverly 250 USA Time Swing-arm SWINGING ARM Code Action Duration 001072 Swinging arm - Engine-chas- sis connection - Replacement 004058 Silent block - Replacement TIME - 36...
Page 305 Beverly 250 USA Time Brake hoses BRAKE PIPING Code Action Duration 002039 Front brake calliper - Re- placement 002040 Front brake calliper - Service 002021 Front brake piping - Replace- ment 002047 Front brake fluid and system bleeding plug - Change...
Page 306 Beverly 250 USA Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement TIME - 38...
Page 307 Beverly 250 USA Time Seat lock SADDLE CLOSING MECHANISM Code Action Duration 004054 Saddle lock catch - Replace- ment TIME - 39...
Page 308 Beverly 250 USA Time Instrument panel INSTRUMENT PANEL Code Action Duration 005014 Odometer - Replacement 005038 Instrument panel warning light bulbs - Replacement TIME - 40...
Page 309 Beverly 250 USA Time Rear rack LUGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement TIME - 41...
Page 310 Beverly 250 USA Time Locks LOCKS Code Action Duration 005016 Key switch - Replacement 004010 Antitheft lock - Replacement TIME - 42...
Page 311: Turn Signal Lights
Beverly 250 USA Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005005 Taillight - Replacement 005008 Headlight bulbs - Replace- ment 005031 Licence plate light bulb - Re- placement 005032 Licence plate light glass - Re-...
Page 312: Front Wheel
Beverly 250 USA Time Front wheel FRONT WHEEL Code Action Duration 002041 Brake disc - Replacement 003037 Front wheel rim - removal and installation 003038 Front wheel axle - removal and installation 003040 Front wheel bearings - Re- placement 003047...
Page 313: Rear Wheel
Beverly 250 USA Time Grease tone wheel or drive Please take note that the code has been intro- duced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sen- sor replacement) and 005089 (tone wheel replace- ment) in the event of noise of the indicated components.
Page 314: Electric Start
Beverly 250 USA Time Code Action Duration 001071 Rear wheel rim - Removal and Refitting 002070 Rear brake disc - Replace- ment 003063 Tyre pressure - check 003077 muffler/rear shock absorber support arm - Service 004126 Rear wheel tyre - Replace-...
Page 315 Beverly 250 USA Time ELECTRICAL START UP Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replace- ment TIME - 47...
Page 316: Fuel Pump
Beverly 250 USA Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Carburettor pump hose - Re- placement 004086 Vacuum fuel pump pipe - Re- placement 004089 Tank-pump hose - Replace- ment 004072 Fuel filter - Replacement...
Page 317 Beverly 250 USA Time Electric devices ELECTRIC DEVICES Code Action Duration 004142 Plug socket - Replacement 005007 Battery - change 005009 Voltage regulator - replace 005011 Start-up remote control switch - Replacement 005026 Helmet compartment light - Replacement TIME - 49...
Page 318 Beverly 250 USA Time ELECTRIC DEVICES Code Action Duration 005039 Headlight switch - replace 005077 Emergency stop switch - Re- placement 005006 Light switch or turn indicators - replace 005040 Horn button - Replacement 005041 Starter button - replace TIME - 50...
Page 319 Beverly 250 USA Time ELECTRIC DEVICES Code Action Duration 001023 Control unit - Replacement 001069 H.V. coil - Replacement 001094 Spark plug hood - Replace- ment 005001 electric system - change 005003 Horn - Replacement 005035 Headlight remote control -...
Page 320 Beverly 250 USA Time Secondary air box ECONDARY AIR HOUSING Code Action Duration 001162 Secondary air housing - Re- placement 001161 Secondary air filter - Replace- ment / Cleaning 001174 SAS valve - Replacement 001163 SAS valve / Head connection...

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