PIAGGIO Beverly Tourer 250 i.e. Service Station Manual
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PIAGGIO Beverly Tourer 250 i.e. Service Station Manual

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SERVICE STATION MANUAL
664962
Beverly Tourer 250 i.e.

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Summary of Contents for PIAGGIO Beverly Tourer 250 i.e.

  • Page 1 SERVICE STATION MANUAL 664962 Beverly Tourer 250 i.e.
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 Beverly Tourer 250 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 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 250 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 M28801 Engine prefix M288M...
  • Page 9 Beverly Tourer 250 i.e. Characteristics Dimensions and mass VEHICLE EARTHING Specification Desc./Quantity Kerb weight 163 kg ± 5 kg Maximum weight allowed 350 kg Engine MOTORE Specification Desc./Quantity Type Single-cylinder, 4-stroke Cubic capacity 244 cm³ Bore x Stroke 72 x 60 mm Compression ratio 11 ±...
  • Page 10 Beverly Tourer 250 i.e. Characteristics Specification Desc./Quantity Exhaust muffler Absorption-type exhaust muffler with a 3-way catalytic convert- er and lambda probe. Emission regulations EURO 3 Transmission RANSMISSION Specification Desc./Quantity Transmission Automatic expandable pulley variator with torque server, V- belt, self-ventilating dry automatic centrifugal clutch and trans- mission housing with forced-circulation air cooling.

  • Page 11: Wheels And Tyres

    Beverly Tourer 250 i.e. Characteristics Brakes FRENI Specification Desc./Quantity Front brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar right lever. Rear brake Ø 260-mm disc brake with hydraulic control activated by han- dlebar left lever. Wheels and tyres RUOTE E PNEUMATICI Specification Desc./Quantity...

  • Page 12: Front Brake

    Beverly Tourer 250 i.e. Characteristics Name Torque in Nm Muffler arm clamping screws 27 ÷ 30 FRONT BRAKE Name Torque in Nm Brake fluid pump-hose fitting 16 ÷ 20 Brake fluid pipe-calliper fitting 16 ÷ 20 Calliper to fork tightening screw 20 ÷...

  • Page 13: Assembly Clearances

    Beverly Tourer 250 i.e. Characteristics Name Torque in Nm Rear hub cap screws 24 ÷ 27 FLYWHEEL Name Torque in Nm Flywheel cover screw 11 ÷ 13 Stator assembly screws 3 - 4 (Apply LOCTITE 242 medium-strength threadlock) Flywheel nut 94 ÷...
  • Page 14 Beverly Tourer 250 i.e. Characteristics ENGINE COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder 72.01 ÷ 72.017 71.953 ÷ 71.960 0.050 - 0.064 Cylinder 72.017 ÷ 72.024 71.960 ÷ 71.967 0.050 - 0.064 Piston 72.024 ÷ 72.031 71.967 ÷ 71.974 0.050 - 0.064 Piston 72.031 ÷...
  • Page 15 Beverly Tourer 250 i.e. Characteristics CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half-shaft, transmission 16.6 +0-0.05 D = 0.20 - 0.50 side Flywheel-side half-shaft 16.6 +0-0.05 D = 0.20 - 0.50 Connecting rod 18 -0.10 -0.15 D = 0.20 - 0.50 Spacer tool 51.4 +0.05 D = 0.20 - 0.50...
  • Page 16 Beverly Tourer 250 i.e. Characteristics ENGINE 250 SHIMMING Name Measure A Thickness shimming 3.70 - 3.60 0.4 ± 0.05 shimming 3.60 - 3.40 0.6 ± 0.05 shimming 3.40 - 3.30 0.8 ± 0.05 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-...
  • Page 17 INDEX OF TOPICS TOOL OOLING...
  • Page 18 Beverly Tourer 250 i.e. Tooling APPROPRIATE TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Pliers to extract ø 15-mm bearings 005095Y Engine support 002465Y Pliers for circlips 006029Y Punch for fitting fifth wheel seat on steer- ing tube 020004Y Punch for removing fifth wheels from headstock...
  • Page 19 Beverly Tourer 250 i.e. Tooling Stores code Description 020074Y Support base for checking crankshaft alignment 020150Y Air heater support 020151Y Air heater 020193Y Oil pressure gauge 020262Y Crankcase splitting strip 020263Y Sheath for driven pulley fitting TOOL - 19...
  • Page 20 Beverly Tourer 250 i.e. Tooling Stores code Description 020306Y Punch for assembling valve seal rings 020329Y MityVac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter 020332Y Digital rev counter TOOL - 20...
  • Page 21 Beverly Tourer 250 i.e. Tooling Stores code Description 020648Y Single battery charger 020335Y Magnetic support for dial gauge 020357Y 32 x 35 mm adaptor 020359Y 42x47-mm adaptor 020360Y Adaptor 52 x 55 mm 020363Y 20 mm guide TOOL - 21...
  • Page 22 Beverly Tourer 250 i.e. Tooling Stores code Description 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re- moval tool 020382Y011 adapter for valve removal tool 020393Y Piston fitting band 020412Y 15 mm guide TOOL - 22...
  • Page 23 Beverly Tourer 250 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 control fitting 020444Y Tool for fitting/ removing the driven pulley clutch TOOL - 23...
  • Page 24 Beverly Tourer 250 i.e. Tooling Stores code Description 020456Y Ø 24 mm adaptor 020477Y Adaptor 37 mm 020483Y 30 mm guide 020489Y Hub cover support stud bolt set 020428Y Piston position check support 020460Y Scooter diagnosis and tester TOOL - 24...
  • Page 25 Beverly Tourer 250 i.e. Tooling Stores code Description 020621Y HV cable extraction adaptor 020481Y Control unit interface wiring 001467Y035 Belle for OD 47-mm bearings 020626Y Driving pulley lock wrench 001467Y013 Pliers to extract ø 15-mm bearings 020627Y Flywheel lock wrench TOOL - 25...
  • Page 26 Beverly Tourer 250 i.e. Tooling Stores code Description 020467Y Flywheel extractor 020454Y Tool for fitting piston pin stops (200 - 250) 020622Y Transmission-side oil guard punch 020480Y Petrol pressure check set 020244Y 15 mm diameter punch 020115Y Ø 18 punch TOOL - 26...
  • Page 27 Beverly Tourer 250 i.e. Tooling Stores code Description 020271Y Tool for removing-fitting silent bloc 020638Y 250 I. E. ENGINE - ABS SOFTWARE 020469Y Reprogramming kit for scooter diagnosis tester 020487Y Fork oil seal extractor 020458Y Puller for lower bearing on steering tube TOOL - 27...
  • Page 28 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 29: Maintenance Chart

    Beverly Tourer 250 i.e. Maintenance Maintenance chart MAINTENANCE TABLE ●Replacement ■ Check * Replace every 2 years km x 1,000 ■ ■ ■ ■ ■ ■ ■ ■ Driven pulley roller casing (greasing) ■ ■ ■ ■ ■ Safety locks ●...
  • Page 30 Beverly Tourer 250 i.e. Maintenance - Rotate the driving pulley fan using a screwdriver until the reference marks between the flywheel and flywheel cover coincide as shown in the pho- tograph. - Bring the reference mark onto the transmission side between the fan and the transmission cover as shown in the photograph.

  • Page 31: Spark Plug

    Beverly Tourer 250 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 32 Beverly Tourer 250 i.e. Maintenance Check -Park the vehicle on its centre stand on flat ground; - Remove the oil dipstick «A», dry it with a clean cloth and put it back into its hole tightening it completely; Remove the dipstick and check that the oil level is slightly over the second notch starting from the lower end;...
  • Page 33 Beverly Tourer 250 i.e. Maintenance Air filter To access the air filter: - Undo the nine screws «A». - Remove the air-box cover «B» Cleaning: - Wash the sponge with water and mild soap. - Dry it with a clean cloth and short blasts of com- pressed air.
  • Page 34 Beverly Tourer 250 i.e. Maintenance 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. - Once all the oil has drained through the drainage hole, unscrew and remove the oil cartridge filter «C ».

  • Page 35: Engine Oil Filter

    Beverly Tourer 250 i.e. Maintenance 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. - Make sure the adjustment of the rear suspension is set to the minimum preloading position.

  • Page 36: Checking The Ignition Timing

    Beverly Tourer 250 i.e. Maintenance Oil pressure warning light The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been star- ted.
  • Page 37 Beverly Tourer 250 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 38: Braking System

    Beverly Tourer 250 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 handlebars. Proceed as follows: - Rest the vehicle onto the centre stand, with the handlebar centred.

  • Page 39: Headlight Adjustment

    Beverly Tourer 250 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 40 Beverly Tourer 250 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 41 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 42 Beverly Tourer 250 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 OOR PERFORMANCE Possible Cause Operation Fuel pump Check the injection load relay Excess of encrustations in the combustion chamber...
  • Page 43 Beverly Tourer 250 i.e. Troubleshooting Possible Cause Operation Misshapen/worn valve seats Replace the head assembly 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 44: Noisy Suspension

    Beverly Tourer 250 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 45 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 46 Beverly Tourer 250 i.e. Electrical system Components arrangement 1. Statore: per accedere al connettore rimuovere la fiancata laterale destra. 2. Batteria: per accedervi rimuovere il coperchio batteria situato nel vano sottosella. Characteristic Battery 12V-12Ah 3. Teleruttore di avviamento: per accedervi rimuo- vere la fiancata laterale destra.
  • Page 47 Beverly Tourer 250 i.e. Electrical system 5. Bobina A.T. : per accedervi rimuovere la fian- cata laterale destra. Characteristic HV coil resistance primary value: ~ 0.9 Ω HV coil secondary resistance value: ~ 3.4 kΩ 6. Regolatore di tensione: per accedervi rimuovere la fiancata laterale destra.
  • Page 48 Beverly Tourer 250 i.e. Electrical system 10. Clacson: per accedervi rimuovere il controscu- 11. Antenna Immobilizer: per accedervi rimuovere lo scudo anteriore. 12. Commutatore a chiave: per accedervi rimuo- vere lo scudo anteriore. ELE SYS - 48...
  • Page 49 Beverly Tourer 250 i.e. Electrical system 13. Dispositivo comando lampeggiatori: per acce- dervi rimuovere lo scudo anteriore. 14. Teleruttori: per accedervi rimuovere lo scudo anteriore. A. Teleruttore luci B. Teleruttore elettroventola C. Teleruttore carichi iniezione 15. Fusibili secondari: situati nel vano portaoggetti anteriore.
  • Page 50 Beverly Tourer 250 i.e. Electrical system 17. Interruttore cavalletto: per accedervi rimuo- vere la pedana poggiapiedi sinistra. 18. Attuatore aprisella: per accedervi rimuovere la fiancata laterale sinistra. 19. Centralina elettronica per iniezione: per acce- dervi rimuovere il coperchio di ispezione situato nel vano sottosella.
  • Page 51 Beverly Tourer 250 i.e. Electrical system ELE SYS - 51...
  • Page 52 Beverly Tourer 250 i.e. Electrical system 1. Statore: per accedere al connettore rimuovere la fiancata laterale destra. 2. Batteria: per accedervi rimuovere il coperchio batteria situato nel vano sottosella. Characteristic Battery 12V-12Ah 3. Teleruttore di avviamento: per accedervi rimuo- vere la fiancata laterale destra. 4.
  • Page 53 Beverly Tourer 250 i.e. Electrical system 5. Bobina A.T. : per accedervi rimuovere la fian- cata laterale destra. Characteristic HV coil resistance primary value: ~ 0.9 Ω HV coil secondary resistance value: ~ 3.4 kΩ 6. Regolatore di tensione: per accedervi rimuovere la fiancata laterale destra.
  • Page 54 Beverly Tourer 250 i.e. Electrical system 9. Candela: per accedervi rimuovere il coperchio sul lato destro del veicolo. 10. Clacson: per accedervi rimuovere il controscu- 11. Antenna Immobilizer: per accedervi rimuovere lo scudo anteriore. 12. Commutatore a chiave: per accedervi rimuo- vere lo scudo anteriore.
  • Page 55 Beverly Tourer 250 i.e. Electrical system 13. Dispositivo comando lampeggiatori: per acce- dervi rimuovere lo scudo anteriore. 14. Teleruttori: per accedervi rimuovere lo scudo anteriore. A. Teleruttore luci B. Teleruttore elettroventola C. Teleruttore carichi iniezione 15. Fusibili secondari: situati nel vano portaoggetti anteriore.
  • Page 56 Beverly Tourer 250 i.e. Electrical system 17. Interruttore cavalletto: per accedervi rimuo- vere la pedana poggiapiedi sinistra. 18. Attuatore aprisella: per accedervi rimuovere la fiancata laterale sinistra. 19. Centralina elettronica per iniezione: per acce- dervi rimuovere il coperchio di ispezione situato nel vano sottosella.
  • Page 57 Beverly Tourer 250 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 58 Beverly Tourer 250 i.e. Electrical system Front side 1. Immobilizer aerial 2. Pre-installation for antitheft 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 59 Beverly Tourer 250 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 60 Beverly Tourer 250 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 61 Beverly Tourer 250 i.e. Electrical system Back side 1. Saddle opening actuator 2. To internal light 3. Battery positive ELE SYS - 61...
  • Page 62 Beverly Tourer 250 i.e. Electrical system 1. Starter remote control 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 63 Beverly Tourer 250 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 license plate light ELE SYS - 63...
  • Page 64 Beverly Tourer 250 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 Checks and inspections...
  • Page 65 Beverly Tourer 250 i.e. Electrical system Immobiliser L'impianto di accensione elettronica viene gestito dalla centralina nella quale è integrato il sistema Immobilizer. L'Immobilizer è un sistema antifurto che permette il funzionamento del veicolo solo se questo viene avviato mediante delle chiavi codifi- cate e riconosciute dalla centralina.
  • Page 66 Beverly Tourer 250 i.e. Electrical system - presenza delle alimentazioni alla centralina come di seguito specificato: 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). If there is no voltage, check that fuse 6 and its cable harness are in working order.
  • Page 67 Beverly Tourer 250 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 68 Beverly Tourer 250 i.e. Electrical system become un-coded, 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 69 Beverly Tourer 250 i.e. Electrical system - 1-flash code - 2-flash code - 3-flash code Diagnostic code - 1 flash The one-flash code indicates a system where the serial line is not present or is not detected. Check the Immobilizer aerial wiring and change it if nec- essary.
  • Page 70 Beverly Tourer 250 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 71 Beverly Tourer 250 i.e. Electrical system The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability. Stator check Stator winding check-up WARNING THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED. 1) Rimuovere la fiancata laterale destra.
  • Page 72 Beverly Tourer 250 i.e. Electrical system 4) With the ignition key always «OFF», the reading indicated by the ammeter must be must be ≤ 0.5 Check the charging current WARNING BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK- ING ORDER.
  • Page 73 Beverly Tourer 250 i.e. Electrical system LEGENDA 1. Motorino d'avviamento 2. Teleruttore d'avviamento 3. Batteria 4. Fusibile n°1 5. Contatti del commutatore a chiave 6. Fusibile n°7 7. Pulsanti stop 8. Pulsante d'avviamento 9. Centralina elettronica per iniezione WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
  • Page 74 Beverly Tourer 250 i.e. Electrical system 2. Fuse No. 1 3. Key switch contacts 4. Fuse No. 8 5. Horn button 6. Horn WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check fuses No. 1 and 8, key switch contacts and the horn button. 2) If the components are not damaged, check wiring for continuity.
  • Page 75 Beverly Tourer 250 i.e. Electrical system WARNING ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. 1) Check the working order of bulbs. 2) Check fuses No. 1 and 10 and the key switch contacts. 3) Check if there is intermittent voltage between the Blue-Black cable of the turn indicator control device and the ground connection.
  • Page 76 Beverly Tourer 250 i.e. Electrical system Specification Desc./Quantity Front tail light bulb Type: All glass Quantity: 1 Power: 12V - 5W Turn indicator bulbs Type: Spherical Quantity: 4 Power: 12V - 10W Rear tail light bulb Type: All glass Quantity: 2 Power: 12V - 3W Stop light bulb Type: Spherical...
  • Page 77 Beverly Tourer 250 i.e. Electrical system BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE THE FUSE WITH ANY OTHER MATERIAL (E.G., A PIECE OF ELECTRIC WIRE). CAUTION MODIFICATIONS OR REPAIRS TO THE ELECTRICAL SYS- TEM, PERFORMED INCORRECTLY OR WITHOUT STRICT ATTENTION TO THE TECHNICAL SPECIFICATIONS OF THE SYSTEM, CAN CAUSE ERRORS IN FUNCTIONING...
  • Page 78 Beverly Tourer 250 i.e. Electrical system Dashboard 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 M = Clock controls...
  • Page 79 Beverly Tourer 250 i.e. Electrical system Sealed battery If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit.
  • Page 80 Beverly Tourer 250 i.e. Electrical system - Wit the battery charger drw. 020333Y and/or drw. 020334Y operate the battery charger control by selecting the position corresponding to that capacity; - Otherwise, charge the battery with direct current equal to 1/10 of rated capacity (e.g. for a battery with a 9Ah rated capacity, the charging current should be 0.9-1.0A) for approximately a 4-6 hour charge.
  • Page 81 Beverly Tourer 250 i.e. Electrical system ENGINE STOP SWITCH STARTER BUTTON LIGHT SWITCH TURN INDICATOR SWITCH ELE SYS - 81...
  • Page 82 Beverly Tourer 250 i.e. Electrical system HORN BUTTON HELMET COMPARTMENT LIGHT SWITCH SADDLE OPENING SWITCH Connectors CONNETTORE GRUPPO STRUMENTI «A» 1. Spia lampeggiatori SX (Rosa) 2. Immobilizer (Rosso-Verde) 3. Alimentazione da batteria (Rosso-Nero) 4. Sensore temperatura liquido di raffreddamento (Verde-Giallo) 5.
  • Page 83 Beverly Tourer 250 i.e. Electrical system CONNETTORE GRUPPO STRUMENTI «B» 1. Spia luci abbaglianti (Viola) 2. Massa (Nero) 3. Spia iniezione (Marrone-Nero) 4. Sensore pressione olio (Rosa-Bianco) 5. Alimentazione sotto chiave (Bianco) 6. Illuminazione strumento (Giallo-Nero) IMMOBILIZER AERIAL CONNECTOR 1. Live supply (Red-White) 2.
  • Page 84 Beverly Tourer 250 i.e. Electrical system CONNETTORE PICK-UP 1. Positivo da centralina sensore giri motore (Ros- 2. Negativo da centralina sensore giri motore (Marrone) 3. Sensore pressione olio (Bianco-Rosa) ANTITHEFT DEVICE PRE-INSTALLATION CONNECTOR 1. LHS Turn indicator bulbs (Pink) 2. RHS Turn indicator bulbs (White-Blue) 3.
  • Page 85 Beverly Tourer 250 i.e. Electrical system CONNETTORE CENTRALINA ELETTRONICA PER INIEZIONE 1. Spia iniezione (Marrone-Nero) 2. Non collegato 3. Non collegato 4. Negativo sonda lambda (Bianco-Verde) 5. Alimentazione sotto chiave (Rosso-Bianco) 6. Alimentazione da batteria (Arancio-Nero) 7. Antenna Immobilizer (Arancio-Bianco) 8.
  • Page 86 Beverly Tourer 250 i.e. Electrical system HV COIL CONNECTOR 1. Control unit negative (Pink-Black) 2. Power via remote control (Black-Green) CONNETTORE TRASMETTITORE LIVELLO CARBURANTE 1. Spia riserva carburante (Grigio-Nero) 2. Massa (Nero) 3. Segnale livello carburante (Bianco-Verde) CONNETTORE SENSORE TEMPERATURA LIQUIDO DI RAFFREDDAMENTO 1.
  • Page 87 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 88 Beverly Tourer 250 i.e. Engine from vehicle Questa sezione descrive le operazioni da effettuare per lo smontaggio del motore dal veicolo. Exhaust assy. Removal - Remove the RHS footrest. - Remove the Lambda probe from its support and disconnect it. - Cut the fastening clamp on the lambda probe ca- ble.
  • Page 89 Beverly Tourer 250 i.e. Engine from vehicle Remove the lambda probe from the manifold. Removal of the engine from the vehicle - Disconnect the battery - Remove the engine cover inside the helmet compartment. - Remove the side fairings and the footrests. Remove the full muffler assembly.
  • Page 90 Beverly Tourer 250 i.e. Engine from vehicle - Remove the coolant outlet pipe from the motor as indicated. - Remove the spark plug caps. - Remove the coolant temperature sensor con- nector indicated in the photo. - Remove the throttle cable from the throttle body by undoing the nut shown in the photo.
  • Page 91 Beverly Tourer 250 i.e. Engine from vehicle - Disconnect the connectors from the flywheel wir- ing harness. - Disconnect the relevant cable from the retaining clamps. - Remove the screws indicated in the figure. ENG VE - 91...
  • Page 92 Beverly Tourer 250 i.e. Engine from vehicle Remove the retaining bolts of the rear brake cal- liper. Remove the lower screw of the left-hand shock absorber. - Use a jack to support the vehicle properly. Re- move the engine-swinging arm fixing pin by undo- ing the nut and the head of the pin as shown in the photograph.
  • Page 93 Beverly Tourer 250 i.e. Engine from vehicle PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY. ENG VE - 93...
  • Page 94 INDEX OF TOPICS NGINE...

  • Page 95: Automatic Transmission

    Beverly Tourer 250 i.e. Engine This section describes the operations to be carried out on the engine and the tools to be used. Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes.
  • Page 96 Beverly Tourer 250 i.e. Engine - Remove the five screws on two different levels as well as the small casing. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover. - Remove the bearing from the crankcase by means of: Specific tooling 020376Y Adaptor handle...

  • Page 97: Removing The Driven Pulley

    Beverly Tourer 250 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 photograph - Check the outside 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 98: Inspecting The Clutch Drum

    Beverly Tourer 250 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 99: Removing The Clutch

    Beverly Tourer 250 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 No. 11 with the cham- fering 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 100 Beverly Tourer 250 i.e. Engine 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 DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.
  • Page 101 Beverly Tourer 250 i.e. Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 102 Beverly Tourer 250 i.e. Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets and the two O-rings. - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws. - Check the riveted joints are functional.
  • Page 103 Beverly Tourer 250 i.e. 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 104 Beverly Tourer 250 i.e. Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the spring, while it is re- laxed. Characteristic Standard length 123 mm acceptable limit after use: 118 mm Refitting the clutch - Support the driven pulley spring compressor ap-...
  • Page 105 Beverly Tourer 250 i.e. Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.

  • Page 106: Removing The Driving Pulley

    Beverly Tourer 250 i.e. Engine Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic 250 4T Transmission belt/minimum width 19.5 mm 250 4T Transmission belt/standard width 21.3 ± 0.2 mm During the wear checks in the scheduled servicing programme, you are advised to check the rim bot- tom of the toothing does not show signs of inci- sions or cracking (see figure): The rim bottom of...
  • Page 107 Beverly Tourer 250 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 108 Beverly Tourer 250 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 permitted Ø...
  • Page 109 Beverly Tourer 250 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 110 Beverly Tourer 250 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 111 Beverly Tourer 250 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 112 Beverly Tourer 250 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 113 Beverly Tourer 250 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 114 Beverly Tourer 250 i.e. Engine Refitting the hub cover bearings For the fitting of the hub box bearings the engine crankcase and the cover must be heated with the special heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
  • Page 115 Beverly Tourer 250 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 116: Removing The Stator

    Beverly Tourer 250 i.e. Engine Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the 10 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 117 Beverly Tourer 250 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 ÷ 4 Refitting the flywheel cover - Position the spline clip on the crankshaft and ori- ent the end as shown in the figure.

  • Page 118: Removing Flywheel Magneto

    Beverly Tourer 250 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 photo - Screw in the guide bushing that is part of the...
  • Page 119 Beverly Tourer 250 i.e. Engine - Insert the special flywheel stop tool on the fly- wheel as shown in the photo Specific tooling 020627Y Flywheel lock wrench - Remove the plate indicated in the photo. - Remove the flywheel nut with its washer - Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally on extraction...
  • Page 120 Beverly Tourer 250 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 121 Beverly Tourer 250 i.e. Engine - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque -Refit the retention plate Specific tooling 020627Y Flywheel lock wrench Locking torques (N*m) Flywheel nut 94 ÷ 102 Refitting the starter motor - Fit a new O-ring on the starter motor and lubricate - Fit the starter on the crankcase, locking the two...
  • Page 122 Beverly Tourer 250 i.e. Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring and by-pass piston, oil pump pulley cover, O-ring on the crankshaft and the sprocket wheel separa- tion washer.
  • Page 123 Beverly Tourer 250 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 124: Removing The Cylinder Head

    Beverly Tourer 250 i.e. Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes. N.B.

  • Page 125: Removing The Valves

    Beverly Tourer 250 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 126: Inspecting The Small End

    Beverly Tourer 250 i.e. Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING. Characteristic Rod small end check-up: Maximum diameter 15.030 mm...
  • Page 127 Beverly Tourer 250 i.e. Engine - If the clearance is greater than that indicated in the table, replace the piston. N.B. MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE. N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.

  • Page 128: Removing The Piston

    Beverly Tourer 250 i.e. Engine Inspecting the piston rings Sealing rings - Alternately insert the three sealing rings into the cylinder, in the area where it retains its original di- ameter. Using the piston, insert the rings perpen- dicularly to the cylinder axis. - Measure the opening (see figure) of the sealing rings using a feeler gauge.
  • Page 129 Beverly Tourer 250 i.e. Engine N.B. THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS- ING. Specific tooling 020454Y Tool for fitting piston pin stops (200 - 250) Choosing the gasket The shimming system allows the compression ra- tio to be adjusted correctly.
  • Page 130 Beverly Tourer 250 i.e. 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 131: Inspecting The Cylinder Head

    Beverly Tourer 250 i.e. Engine 020393Y Piston fitting band 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 132 Beverly Tourer 250 i.e. Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Alternatively check the intake and exhaust valves. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
  • Page 133 Beverly Tourer 250 i.e. Engine Inspecting the valves - Measure the width of the sealing surface on the valve seats and on the valves. Sealing surface width: After use: Intake and ex- haust: 1.6 mm - If any of the sealing surfaces on the valves is wider than the specified limit or is damaged in one or more points, or curved, replace the valve with a new one.
  • Page 134 Beverly Tourer 250 i.e. Engine Valve check standard clearance Inlet: 0.013 ÷ 0.040 mm Valve check Minimum admissible diameter Outlet: 4.95 mm Valve check Minimum admissible diameter Inlet: 4.96 mm Valve check Standard diameter: Inlet: 4.972 ÷ 4.987 mm Valve check Standard diameter: Outlet: 4.96 ÷...
  • Page 135 Beverly Tourer 250 i.e. Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. 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.
  • Page 136 Beverly Tourer 250 i.e. Engine Inspecting the cam shaft - Inspect the cam shaft for signs of abnormal wear on the cams. - Check the cam height. - Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new...
  • Page 137 Beverly Tourer 250 i.e. Engine Diameter 11.977 - 11.985 mm Cam shaft check: Maximum admissible axial clearance 0.42 mm Cam shaft check: Standard axial clearance: 0.11 - 0.41 mm Cam shaft check: Standard height Outlet: 29.209 mm Cam shaft check: Standard height Inlet: 30.285 mm Cam shaft check: Minimum admissible diame- Bearing B diameter: 19.950 mm...
  • Page 138 Beverly Tourer 250 i.e. Engine Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 - Refit the lower timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft.
  • Page 139 Beverly Tourer 250 i.e. Engine -Fit the end-stop ring on the automatic valve-lifter cam and fit the automatic valve-lifter cam to the cam shaft. - Fit the automatic valve-lifter return spring. - During this operation the spring must be loaded by approximately 180°.
  • Page 140 Beverly Tourer 250 i.e. 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 ENG - 140...
  • Page 141 Beverly Tourer 250 i.e. Engine Refitting the intake manifold Fit the intake manifold and do up the three screws. Locking torques (N*m) Inlet manifold screws 11 ÷ 13 Crankcase - crankshaft Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft.
  • Page 142 Beverly Tourer 250 i.e. Engine not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase. - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfa- ces shown in the figure.
  • Page 143 Beverly Tourer 250 i.e. Engine Crankshaft bearings: Standard diameter: Cat. 29.000 ÷ 29.006 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 144 Beverly Tourer 250 i.e. Engine N.B. THE MAIN BEARINGS ARE NOT GRINDABLE Specific tooling 020074Y Support base for checking crankshaft alignment Characteristic Off-line maximum admitted A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts.
  • Page 145 Beverly Tourer 250 i.e. Engine - Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and di- mensions.
  • Page 146 Beverly Tourer 250 i.e. Engine Crankcase - crankshaft - connecting rod Refitting the crankcase halves - Fit the internal bulkhead by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the specified torque.
  • Page 147 Beverly Tourer 250 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 photograph. If it varies signifi- cantly from the driving depth indicated, it means that the stud bolt has yielded.
  • Page 148 Beverly Tourer 250 i.e. Engine Conceptual diagrams LUBRICATION CIRCUIT ENG - 148...
  • Page 149 Beverly Tourer 250 i.e. Engine ENG - 149...

  • Page 150: Oil Pressure Check

    Beverly Tourer 250 i.e. Engine Oil pressure check - Disconnect the electrical minimum oil pressure connection and remove the switch. - Check the oil pressure reading is between 0.5 and 1.2 atm with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 151 Beverly Tourer 250 i.e. Engine 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 152 Beverly Tourer 250 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 end of the oil guard driving stroke - Remove all of the tool components following the inverse procedure...
  • Page 153 Beverly Tourer 250 i.e. Engine Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes.
  • Page 154 Beverly Tourer 250 i.e. Engine - Check the clearance between the rotors in the position shown in the diagram using a thickness 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 155 Beverly Tourer 250 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 156 Beverly Tourer 250 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 157 INDEX OF TOPICS INJEC NJECTION...
  • Page 158 Beverly Tourer 250 i.e. Injection DISPOSIZIONE COMPONENTI Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Battery 12V - 12 Ah Water temperature sensor HV coil Engine rpm sensor Lambda sensor Diagnostics socket connector Fuel pump Electric fan remote control Injection load remote control Fuel injector MIU injection system...
  • Page 159 Beverly Tourer 250 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 160 Beverly Tourer 250 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 161 Beverly Tourer 250 i.e. Injection d. Connectors B: Chassis earthing C: Fuel supply a. Broken fuel pump b. Dirty fuel filter D: Ignition system a. Faulty spark plug b. Broken coil c. Broken shielded cap E: Intake circuit a. Dirty air filter b.
  • Page 162 Beverly Tourer 250 i.e. Injection 6. If the scooter 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 wiring. 8.
  • Page 163 Beverly Tourer 250 i.e. Injection DISPOSIZIONE TERMINALI Specification Desc./Quantity Injection warning light Lambda probe negative Live supply Battery-powered Immobilizer aerial Electric fan remote control Water temperature sensor Lambda probe positive Engine stop switch R.P.M. sensor (+) Fuel injector R.P.M. sensor (-) Diagnostics socket output Immobilizer LED Side stand...
  • Page 164 Beverly Tourer 250 i.e. Injection SCHEMA IMPIANTO Specification Desc./Quantity Injection ECU Diagnostics socket connector Fuel pump Water temperature sensor Fuel injector HV coil Engine rpm sensor Lambda sensor Injection load remote control Starter remote control Battery 12V - 12 Ah Main fuses Electric fan remote control Electric fan...
  • Page 165 Beverly Tourer 250 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 Rpm-timing sensor Ignition advance Fuel supply Fuel pressure (low) Injector capacity (low) Injector seal (poor) Correctness of the parameters Coolant temperature...
  • Page 166 Beverly Tourer 250 i.e. Injection Possible Cause Operation Filter box Fuel feed (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 167 Beverly Tourer 250 i.e. Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ ENGINE IRREGULAR PROGRESS 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 sensor...
  • Page 168 Beverly Tourer 250 i.e. Injection Removing the butterfly valve Remove the fuel piping clamping screw indicated in the figure. INJEC - 168...
  • Page 169 Beverly Tourer 250 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 - 169...
  • Page 170 Beverly Tourer 250 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 photograph Refitting the butterfly valve To refit, perform the operations in the reverse or- der from the removal operations being careful to position the clip fixing the throttle body to the air filter bellows at 45°...
  • Page 171 Beverly Tourer 250 i.e. Injection Pump supply circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 171...
  • Page 172 Beverly Tourer 250 i.e. Injection Specification Desc./Quantity Electric fan remote control When switched to «ON», the fuel pump starts to rotate for 2 seconds and then stops. When the engine starts up, in the presence of rpm timing signal the pump is continuously supplied. ELECTRICAL DATA •...
  • Page 173 Beverly Tourer 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the...
  • Page 174 Beverly Tourer 250 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 175 Beverly Tourer 250 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 176 Beverly Tourer 250 i.e. Injection Remove the clip fixing the piping to the filter shown in the photograph Separate the lower part of the pump support as shown in the photograph. Remove the filter from the pump support INJEC - 176...
  • Page 177 Beverly Tourer 250 i.e. Injection Inspecting the injector circuit INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 177...
  • Page 178 Beverly Tourer 250 i.e. Injection Specification Desc./Quantity Electric fan remote control 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 179 Beverly Tourer 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the...
  • Page 180 Beverly Tourer 250 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 181 Beverly Tourer 250 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 182 Beverly Tourer 250 i.e. Injection Components location DISPOSIZIONE COMPONENTI Specification Desc./Quantity Throttle body and electronic injection control unit (MIU) Battery 12V - 12 Ah Water temperature sensor HV coil Engine rpm sensor Lambda sensor Diagnostics socket connector Fuel pump Electric fan remote control Injection load remote control Fuel injector INJEC - 182...
  • Page 183 Beverly Tourer 250 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 184 Beverly Tourer 250 i.e. Injection With the interface wiring disconnected from the control unit and rpm sensor connector, check that the red and brown cables (pin 13 - 15) are isolated from each other and insulated from the earth. Specific tooling 020481Y Control unit interface wiring 020331Y Digital multimeter INJEC - 184...
  • Page 185 Beverly Tourer 250 i.e. Injection HT coil INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 185...
  • Page 186 Beverly Tourer 250 i.e. Injection Specification Desc./Quantity Electric fan remote control 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 187 Beverly Tourer 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the...
  • Page 188 Beverly Tourer 250 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 189 Beverly Tourer 250 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 190 Beverly Tourer 250 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 191 Beverly Tourer 250 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 192 Beverly Tourer 250 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 photograph. INJEC - 192...
  • Page 193 Beverly Tourer 250 i.e. Injection Lambda probe INJECTION LOADS Specification Desc./Quantity Battery 12V - 12 Ah Fuse 10 A Fuse 30 A Key switch contacts Fuse 7.5 A Injection load remote control Fuel pump HV coil Fuel injector Lambda sensor INJEC - 193...
  • Page 194 Beverly Tourer 250 i.e. Injection Specification Desc./Quantity Electric fan remote control The Lambda sensor or oxygen sensor is a sensor which provides indications concerning the oxygen content in the exhaust gas. The signal generated is not of the proportional type but of the ON/OFF type, i.e.
  • Page 195 Beverly Tourer 250 i.e. Injection Check the power supply line of the injection load remote control energising coil: after switching to «ON», make sure there is battery voltage, for 2 seconds, between the Red-White cable and the Black-Purple cable of the remote control base. If there is not, check the continuity of the Red-White cable between the fuse box and the remote control base and of the Black-Purple cable between the...
  • Page 196 Beverly Tourer 250 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 197 Beverly Tourer 250 i.e. Injection Install the electronic control unit interface wiring. Start the engine and warm up until the electric fan switches on. Use an analogue multimeter with a direct voltage scale measuring down to 2 V. Place the tips of the multimeter between pins 4 (-) and 11 (+) With the engine running at idle speed, check that the voltage oscillates between 0V and 1V...
  • Page 198 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 199: Removing The Front Wheel

    Beverly Tourer 250 i.e. 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. See also Removal Front wheel hub overhaul...
  • Page 200 Beverly Tourer 250 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 201 Beverly Tourer 250 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 202 Beverly Tourer 250 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 203: Front Fork

    Beverly Tourer 250 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 front shield. See also Rear handlebar cover Refitting - Install the handlebars on the steering tube, pay-...
  • Page 204 Beverly Tourer 250 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 205 Beverly Tourer 250 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 leg diameter 35.10 mm...
  • Page 206 Beverly Tourer 250 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 207 Beverly Tourer 250 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 208 Beverly Tourer 250 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 209 Beverly Tourer 250 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 photograph.

  • Page 210: Steering Column

    Beverly Tourer 250 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 211 Beverly Tourer 250 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 212 Beverly Tourer 250 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 213 Beverly Tourer 250 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 214 Beverly Tourer 250 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 215 Beverly Tourer 250 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 216 Beverly Tourer 250 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 fifth wheels from headstock SUSP - 216...
  • Page 217 Beverly Tourer 250 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 218: Removing The Rear Wheel

    Beverly Tourer 250 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 support bracket - Remove the 5 screws shown in the photograph Refitting the rear wheel - Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
  • Page 219 Beverly Tourer 250 i.e. 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. - Loosen the nut on the inside of the frame from the left-hand side (see figure) and remove the rel- evant spindle;...
  • Page 220 Beverly Tourer 250 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 photo Specific tooling...
  • Page 221 Beverly Tourer 250 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 222 Beverly Tourer 250 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...
  • Page 223 Beverly Tourer 250 i.e. Suspensions 5. Screw on and tighten part 5 to the prescribed torque 6. Tighten part 1 to the prescribed torque Insert the swinging arm - engine bolt and tighten to the prescribed torque SWINGING ARM FITTING Name Torque in Nm Part 1...

  • Page 224: Shock Absorbers

    Beverly Tourer 250 i.e. Suspensions Shock absorbers Removal Proceed as follows: - place the scooter on its centre stand; - lift the engine a little with a jack so as to free the two shock absorbers; - remove the muffler - undo the shock absorber spring assembly clamp- ing screw from the support fixed to the engine on the one side and from that fixed to the muffler on...
  • Page 225 Beverly Tourer 250 i.e. Suspensions Removal - Loosen and remove the lower retaining bolt of the right-hand shock absorber at the support arm. - Loosen the 2 retaining screws between arm and engine. - Remove the split pin and safety cover; unscrew the wheel axle nut;...

  • Page 226: Side Stand

    Beverly Tourer 250 i.e. Suspensions - Heat the bearing seat using the heat gun - Using the special punch, install a new bearing in the seat as shown in the photograph Specific tooling 020376Y Adaptor handle 020151Y Air heater Refitting To refit, carry out the removal operations in reverse order, observing the prescribed tightening torques.
  • Page 227 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 228: Rear Brake Calliper

    Beverly Tourer 250 i.e. Braking system This section è is devoted to the description of the braking 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 229 Beverly Tourer 250 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 photo- graph. 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...
  • Page 230 Beverly Tourer 250 i.e. Braking system Removal - Remove the two retainers fastening the front brake calliper to the support as shown in the pho- tograph. N.B. SHOULD IT BE NECESSARY TO REPLACE THE CALLIP- ER, FIRST LOOSEN THE FITTING CONNECTING THE PIPE TO THE BRAKE CALLIPER.

  • Page 231: Front Brake Disc

    Beverly Tourer 250 i.e. Braking system Refitting - For the installation, position the disc correctly using the arrow stamped on it as reference. - Tighten the screws to the prescribed torque and apply the recommended product. N.B. THE SURFACE OF THE DISC WITH THE STAMPED ARROW FOR THE DIRECTION OF ROTATION MUST FACE TOWARDS THE OUTSIDE OF THE SCOOTER.
  • Page 232 Beverly Tourer 250 i.e. Braking system Removal Proceed as follows: - Remove the front wheel. - Loosen the five disc fixing screws. - Thoroughly clean the seats on the front wheel hub and on the disc. See also Removing the front wheel Refitting For fitting, position the disc correctly using the arrow stamped on it as reference.

  • Page 233: Front Brake Pads

    Beverly Tourer 250 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 234 Beverly Tourer 250 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 235 Beverly Tourer 250 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 236 Beverly Tourer 250 i.e. Braking system Rear - combined - Remove the rubber hood 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 237 Beverly Tourer 250 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 238 Beverly Tourer 250 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 239 Beverly Tourer 250 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 240 INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 241: Circuit Diagram

    Beverly Tourer 250 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 Electric fan check - Check and, if necessary, restore the correct battery voltage.
  • Page 242 Beverly Tourer 250 i.e. Cooling system Characteristic Battery voltage - Check that the electric ventilation relay is working properly. - If the relay is not working, replace it. - If the relay is working, remove it and jump the red - red black (85 - 86) wires.
  • Page 243 Beverly Tourer 250 i.e. Cooling system - Tighten the bleed valve respecting the maximum torque. - Bring the coolant up to the correct level inside the expansion tank Locking torques (N*m) Bleed screw Removal - Loosen the two screws indicated in the figure and remove the thermostat cover.
  • Page 244 Beverly Tourer 250 i.e. Cooling system Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check: Opening start temperature 85 ÷ 1.5°C Refitting - Place the thermostat with the bleeding hole at the highest point. - Make sure that the rubber gasket is positioned properly.
  • Page 245 INDEX OF TOPICS CHAS HASSIS...
  • Page 246 Beverly Tourer 250 i.e. Chassis This section è is devoted to the operations that can be carried out on the vehicle's bodywork. Seat - Remove the saddle by loosening the three re- taining screws indicated in the figure; Side fairings - Remove the side bumper, loosening the retaining screw shown in the figure.
  • Page 247 Beverly Tourer 250 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 248 Beverly Tourer 250 i.e. Chassis Instrument panel - Remove the rear handlebar cover. - Undo the four screws shown in the photograph. - 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 249 Beverly Tourer 250 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 250 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 251 Beverly Tourer 250 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 252 Beverly Tourer 250 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 spring to be pressed out.
  • Page 253 Beverly Tourer 250 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 - 253...
  • Page 254 Beverly Tourer 250 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 255: Rear Mudguard

    Beverly Tourer 250 i.e. Chassis Air filter - Undo the two screws indicated. - Reach the inspection compartment inside the helmet compartment. - Disconnect the two manifold clamps. - Scollegare le tre fascette di collegamenti della tubazione Blow-By. 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 256 Beverly Tourer 250 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 257 Beverly Tourer 250 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 258: Front Mudguard

    Beverly Tourer 250 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 259 Beverly Tourer 250 i.e. Chassis Flyscreen - Undo the screw indicated. - Undo the four screws indicated and remove the windshield. CHAS - 259...
  • Page 260 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 261 Beverly Tourer 250 i.e. 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 - Visually check that there is a yellow mark on the following clamps: FRONT SUSPENSION •...
  • Page 262 Beverly Tourer 250 i.e. Pre-delivery - Regulating the headlights according to the regulations currently in force • Front and rear stop light buttons and relative light •Turn indicators and relative telltales • Instrument lighting • instruments: fuel and temperature indicator •Instrument panel lights •...
  • Page 263 Beverly Tourer 250 i.e. Pre-delivery - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise Static test Static control after the test ride: • Hot engine restart • Minimum seal (turning the handlebar) •...
  • Page 264 INDEX OF TOPICS TIME...
  • Page 265 Beverly Tourer 250 i.e. Time This section is devoted to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit.
  • Page 266 Beverly Tourer 250 i.e. Time Crankcase CRANKCASE Code Action Duration 001153 Crankcase halves gasket - Replace- ment 001133 Engine crankcase- Replacement 001124 Lubrication by-pass - Replacement TIME - 266...
  • Page 267 Beverly Tourer 250 i.e. Time Crankshaft CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 267...
  • Page 268 Beverly Tourer 250 i.e. Time Cylinder assy. CYLINDER - PISTON Code Action Duration 001002 Cylinder-Piston - Replacement 001154 Pin-ring-piston assembly - Service 001176 Rings / Pin - Replacement TIME - 268...
  • Page 269 Beverly Tourer 250 i.e. Time Cylinder head assy. VALVE HEAD Code Action Duration 001126 Head - Replacement 001045 Valves - Replacement 001049 Valves - Adjustment 001056 Head gasket - Replacement 000235 Coolant temperature sensor - Re- plac. 001057 Thermostat - Replacement 007012 Coolant bleed valve - Replacement TIME - 269...
  • Page 270 Beverly Tourer 250 i.e. Time Rocker arms support assy. CAMSHAFT Code Action Duration 001148 Rocking lever valve - Replacement 001044 Camshaft - Replacement 001169 Decompressor - Replacement TIME - 270...

  • Page 271: Cylinder Head Cover

    Beverly Tourer 250 i.e. Time Cylinder head cover HEAD 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 - 271...

  • Page 272: Oil Filter

    Beverly Tourer 250 i.e. Time Oil filter OIL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Replacement 001102 Net oil filter - Replacement / Cleaning TIME - 272...
  • Page 273 Beverly Tourer 250 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001150 Flywheel cover gasket - Replace- ment 007007 Water pump rotor - Replacement 001113 Water pump / Pump rotor - Replace- ment 001099 Oil seal, flywheel side - Replacement TIME - 273...

  • Page 274: Driven Pulley

    Beverly Tourer 250 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell - Replacement TIME - 274...
  • Page 275 Beverly Tourer 250 i.e. Time Oil pump OIL PUMP Code Action Duration 001125 Chain guide sliders - Replacement 001051 Distribution belt - chain - Replace- ment 001042 Oil pump - Service 001112 Oil pump - Replacement 001122 Oil pump chain - Replacement 001172 Chain cover flap - change 001130...
  • Page 276 Beverly Tourer 250 i.e. Time Final gear assy. FINAL REDUCTION GEAR Code Action Duration 001010 Reduction gear - Replacement 003065 Gear box oil - Replacement 001156 Geared reduction unit cover - Re- placement 004125 Rear wheel axle - Replacement 004180 Reduction gear breather pipe - Re- placement TIME - 276...
  • Page 277 Beverly Tourer 250 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001066 Driving pulley - Removal and refitting 001177 Variator rollers / shoes - Replace- ment 001141 Belt anti-flapping roller - Replace- ment 001006 rear-view pulley - Service...
  • Page 278 Beverly Tourer 250 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 - 278...

  • Page 279: Water Pump

    Beverly Tourer 250 i.e. Time Water pump WATER PUMP Code Action Duration 007017 Water pump cover - Replacement 007009 Head-pump by-pass rubber coupling - Replacement TIME - 279...
  • Page 280 Beverly Tourer 250 i.e. Time Starter motor ELECTRICAL START-UP Code Action Duration 001020 Starter motor - Replacement 001151 Start-up driven gearing - Replace- ment 001017 Start-up pinion - Replacement TIME - 280...

  • Page 281: Flywheel Magneto

    Beverly Tourer 250 i.e. Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001067 Stator - Removal and Refitting 001173 Rotor - Replacement 001058 Complete flywheel - Replacement 001104 Start-up freewheel - Replacement TIME - 281...
  • Page 282 Beverly Tourer 250 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001166 Throttle body - Replacement 001047 Injector - Replacement 001013 Intake manifold - Replacement TIME - 282...
  • Page 283 Beverly Tourer 250 i.e. Time Exhaust pipe MUFFLER Code Action Duration 005138 Lambda probe - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement 001009 Muffler - Replacement TIME - 283...

  • Page 284: Air Cleaner

    Beverly Tourer 250 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 - 284...
  • Page 285 Beverly Tourer 250 i.e. Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 004147 Footrest support bracket, one side - Replacement 004148 Footrest support bracket, both sides - Replacement 004146 Front frame - Replacement TIME - 285...
  • Page 286 Beverly Tourer 250 i.e. Time Centre-stand STAND Code Action Duration 001053 Stand bolt - Replacement 004004 Stand - Replacement 004179 Stand buffer - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement TIME - 286...
  • Page 287 Beverly Tourer 250 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 - 287...
  • Page 288 Beverly Tourer 250 i.e. Time Side fairings SIDE COVERS Code Action Duration 004012 Rear side panels - Replacement 004129 Rear fairing - Replacement TIME - 288...
  • Page 289 Beverly Tourer 250 i.e. Time Rear cover REAR SHIELD Code Action Duration 004065 Shield back plate - Replacement 004081 Glove box door - Replacement TIME - 289...
  • Page 290 Beverly Tourer 250 i.e. Time Central cover CENTRAL COVER Code Action Duration 004135 Fuel tank lid - Replacement 004011 Central chassis cover - Replacement 004059 Spark plug inspection flap - Replace- ment 004015 Footrest - Replacement TIME - 290...
  • Page 291 Beverly Tourer 250 i.e. Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004106 Underseat band - Replacement 005033 Glove-box light switch - Replace- ment 004016 Helmet compartment - Replacement 004112 Cock / carburettor hose - Replace- ment 005046 Battery cover - Replacement 005026 Helmet compartment light - Replace- ment...
  • Page 292 Beverly Tourer 250 i.e. Time Plate holder LICENSE PLATE HOLDER Code Action Duration 004136 License plate holder support - Re- placement 005048 Licence plate holder - Replacement TIME - 292...
  • Page 293 Beverly Tourer 250 i.e. Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004053 Spoiler - Replacement 004009 Rear mudguard - Replacement TIME - 293...
  • Page 294 Beverly Tourer 250 i.e. Time Fuel tank FUEL TANK Code Action Duration 004109 Fuel tank breather - Replacement 004005 Fuel tank - Replacement 005010 Tank float - Replacement TIME - 294...
  • Page 295 Beverly Tourer 250 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 - 295...

  • Page 296: Handlebar Covers

    Beverly Tourer 250 i.e. Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004018 Front handlebar covers - Replace- ment 004019 Rear handlebar cover - Replacement TIME - 296...
  • Page 297 Beverly Tourer 250 i.e. Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Complete throttle control - Replace- ment 002059 Right-hand knob - Replacement TIME - 297...
  • Page 298 Beverly Tourer 250 i.e. Time Code Action Duration 003001 Handlebar - Replacement 003061 Accelerator transmission - Adjust- ment 002063 Throttle control transmission - Re- placement 002071 Left knob - Replacement 002037 Brake lever - Replacement 002067 Rear brake pump - Replacement 002024 Front brake pump - Replacement 004162...
  • Page 299 Beverly Tourer 250 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 bleeding system - Replacement 002020 Rear brake disc piping - Replace-...
  • Page 300 Beverly Tourer 250 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 300...
  • Page 301 Beverly Tourer 250 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 - 301...
  • Page 302 Beverly Tourer 250 i.e. Time Rear rack LUGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement 004062 Luggage rack cover - Replacement TIME - 302...
  • Page 303 Beverly Tourer 250 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 - 303...

  • Page 304: Turn Signal Lights

    Beverly Tourer 250 i.e. Time Turn signal lights INDICATOR LIGHTS Code Action Duration 005002 Front light - Replacement 005008 Headlight bulbs - Replacement TIME - 304...
  • Page 305 Beverly Tourer 250 i.e. Time Code Action Duration 005067 Front turn indicator bulb - Replace- ment 005012 Front direction indicators - Replace- ment 005066 Rear light bulbs - Replacement 005005 Taillight - Replacement 005032 Licence plate light glass - Replace- ment 005031 Licence plate light bulb - Replace-...

  • Page 306: Rear Wheel

    Beverly Tourer 250 i.e. Time Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Replacement 002070 Rear brake disc - Replacement TIME - 306...

  • Page 307: Fuel Pump

    Beverly Tourer 250 i.e. Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 307...
  • Page 308 Beverly Tourer 250 i.e. Time Electric devices VOLTAGE REGULATOR Code Action Duration 005009 Voltage regulator - Replacement 001069 HV coil - Replacement 001094 Spark plug cap - Replacement TIME - 308...
  • Page 309 Beverly Tourer 250 i.e. Time REMOTE CONTROLS Code Action Duration 005035 Headlight remote control - Replace- ment 005096 Remote control for injection compo- nents - Replacement 005117 Electric fan remote control - Replace- ment 005003 Horn - Replacement 005011 Start-up remote control switch - Re- placement 005007 Battery - Replacement...
  • Page 310 Beverly Tourer 250 i.e. Time WIRE UNIT Code Action Duration 005054 Fuse holder - Replacement 005052 Fuse - Replacement 005001 Electrical system - Replacement TIME - 310...
  • Page 311 Beverly Tourer 250 i.e. Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Headlight switch - Replacement 005006 Light switch or turn indicators - Re- placement 005040 Horn button - Replacement 005121 Saddle opening button - Replace- ment 005041 Starter button - Replacement 005077 Emergency stop switch - Replace- ment...
  • Page 312 Beverly Tourer 250 i.e. Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002082 Fuel tank cap opening drive - Re- placement TIME - 312...
  • Page 313 Beverly Tourer 250 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 thrust washer - Replace- ment 003073 Steering clearance - Adjustment...
  • Page 314 Beverly Tourer 250 i.e. Time Cooling system RADIATOR Code Action Duration 007001 Expansion tank - Replacement 007024 Expansion tank cap - Replacement 007013 Expansion tank - radiator connection pipe - Replacement 007016 Fan with support - Replacement 001052 Coolant and air bleed - Replacement 007003 Coolant delivery and return pipe - Re- placement...
  • Page 315 Beverly Tourer 250 i.e. Time Windscreen WINDSHIELD Code Action Duration 004028 Windshield glass - Replacement TIME - 315...
  • Page 316 Beverly Tourer 250 i.e. Time Stickers TRANSFERS Code Action Duration 004159 Plates / Stickers - Replacement TIME - 316...
  • Page 317 Air filter: 33, 255 Battery: 70, 79 Brake: 228–231, 233, 234, 237, 238, 299 Brake fluid: 237 Coolant: 189 Engine oil: 33 Fuel: 167, 175, 257, 294, 307 Fuses: 76 Headlight: 39, 248, 250 Horn: 73 Hub oil: 31 Identification: 8 Instrument panel: 57, 248, 301 Luggage rack: Maintenance: 7, 29...
  • Page 318 Transmission: 10, 43, 95, 109, 278 Tyres: 11...

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