PIAGGIO Beverly 400 E5 Service Manual
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PIAGGIO Beverly 400 E5 Service Manual

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MANUALE STAZIONE DI SERVIZIO
1Q000884
Beverly 400 E5

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Summary of Contents for PIAGGIO Beverly 400 E5

  • Page 1 MANUALE STAZIONE DI SERVIZIO 1Q000884 Beverly 400 E5...
  • Page 2 Not all the versions shown in this publication are available in every country. Availability of the individual versions must be verified with the official PIAGGIO sales network. © Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or in part is prohibited.
  • Page 3 SERVIZIO Beverly 400 E5 Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle officine dei concessionari e sub-agenzie Piaggio. Si presuppone che chi utilizza questa pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli.

  • Page 5: Index Of Topics

    INDEX OF TOPICS ENERAL MANDATORY REQUIREMENTS NORM PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM NGINE BRAK SYS RAKING SYSTEM...
  • Page 6 INDEX OF TOPICS NORM ENERAL MANDATORY REQUIREMENTS...

  • Page 7: Warnings And Important Notes

    Beverly 400 E5 General mandatory requirements General information This section contains general information about using the manual and the vehicle. as well as important notes about safety. WARNINGS AND IMPORTANT NOTES Each symbol has a precise meaning. as shown below.

  • Page 8: General Safety Warnings

    Beverly 400 E5 General mandatory requirements GENERAL SAFETY WARNINGS: 1. Always wear protective goggles and suitable clothing. 2. Always use a safety support for operating under the vehicle. 3. Make sure the ignition switch is always OFF. unless otherwise specified in the procedure.
  • Page 9 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 10 Beverly 400 E5 Pre-delivery Electrical system • Remote control and ignition switch • Lights: high beam lights, low beam lights, tail lights and their warning lights - Headlight adjustment according to the regulations currently in force • Brake light operation by using the RH and LF brake lever •...

  • Page 11: Clock Setting

    Beverly 400 E5 Pre-delivery Instruments start-up DIGITAL DISPLAY MEASUREMENT UNIT CON- VERSION (Km-mi, l-gal, °C-°F) • With the ignition switch turned to "OFF", press and hold the MODE key on the instrument cluster and simulta- neously turn the ignition switch to "ON";...
  • Page 12 Beverly 400 E5 Pre-delivery rent value, if no changes were made) - the minutes value «mm» now starts flashing; • press the SET button briefly and re- peatedly to set the correct minutes val- ue; press and hold the SET button to cycle the minutes value rapidly;...
  • Page 13 Beverly 400 E5 Pre-delivery THE ASR SYSTEM PREVENTS THE APPLICATION OF HIGH SPEED ROTATION ON THE REAR WHEEL WITH THE VEHICLE ON THE CENTRE STAND. IT IS RECOMMENDED TO NOT INSIST WITH THE THROT- TLE GRIP IN THIS SPECIFIC SITUATION, BECAUSE THIS MAY CAUSE ABNORMAL STOPS AND/OR DAMAGE TO THE CATALYSTS.
  • Page 14 Beverly 400 E5 Pre-delivery Manual calibration procedure of the ASR sys- tem. In order to maintain the efficiency of the ASR sys- tem when one or both tires are replaced, a cali- bration procedure of the ASR system must be...
  • Page 15 Beverly 400 E5 Pre-delivery 8. If the procedure has been completed cor- rectly, the next time the starter switch is turned to the "ON" position, the "ASR" icon lights up with 1Hz slow flashing (1 flash per second). When starting the engine, the "ASR" icon turns off and the ASR system will be ACTIVE.
  • Page 16 Beverly 400 E5 Pre-delivery N.B. THE DEVICE PREVENTS IMPRESSING ON THE REAR HIGH SPEED ROTATION WHEEL WITH THE VEHICLE ON THE CENTRE STAND. IT IS RECOMMENDED NOT TO INSIST WITH THE THROTTLE GRIP IN THIS PARTICULAR CONDITION. N.B. IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR SYSTEM.
  • Page 17 INDEX OF TOPICS ECHNICAL...

  • Page 18: 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 spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
  • Page 19 Beverly 400 E5 Technical Data Vehicle identification Identification registration numbers are made up of a prefix and a number, stamped on the frame and on the engine. The serial number must always be indicated when ordering spare parts. We recom-...

  • Page 20: Vehicle Identification

    Beverly 400 E5 Technical Data VEHICLE IDENTIFICATION Specification Desc./Quantity Frame prefix ZAPMD2200 Engine prefix MD22M Engine Data ENGINE SPECIFICATIONS Specification Desc./Quantity Type Single cylinder 4-stroke Engine capacity 399 cc Bore per stroke 84.0 x 72.0 mm Compression ratio 11,5 ± 0,5 :1 Idle speed 1600 ±...

  • Page 21: Dimensions And Mass

    Beverly 400 E5 Technical Data Dimensions and mass VEHICLE DATA Specification Desc./Quantity Frame Tubular and steel sheets. Front suspension Hydraulic telescopic fork with Ø 35-mm stem. Rear suspension Two double-acting shock absorbers, adjustable to five posi- tions at pre-loading. Front brake Ø...

  • Page 22: Front Fork Oil

    Beverly 400 E5 Technical Data FRONT FORK OIL Specification Desc./Quantity Front fork oil 155 ± 2,5 cc for each stem. Tightening Torques N.B. THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP.
  • Page 23 Beverly 400 E5 Technical Data DT - 23...
  • Page 24 Beverly 400 E5 Technical Data DT - 24...

  • Page 25: Rear Suspension

    Beverly 400 E5 Technical Data RANSMISSIONS AND BRAKES Name Torque in Nm Brake pipe retainer clamp - Engine 10.5 ± 0.5 Nm Throttle control transmission fixing nut - Throttle body 5.5 ± 0.5 Nm Brake pipe retainer clamp - Frame 10.5 ±...
  • Page 26 Beverly 400 E5 Technical Data DT - 26...

  • Page 27: Electrical System

    Beverly 400 E5 Technical Data REAR SUSPENSION Name Torque in Nm Rear shock absorber - Engine 42.5 ± 2.5 Nm Rear ABS sensor - Engine 7.0 ± 1.0 Nm Silent block bracket - Frame 71.0 ± 4.0 Nm Rear wheel - Rear wheel axle 113.0 ±...
  • Page 28 Beverly 400 E5 Technical Data DT - 28...
  • Page 29 Beverly 400 E5 Technical Data LECTRICAL SYSTEM Name Torque in Nm MIUG4 control unit connection retainer clamp - Throttle body 7.0 ± 1.0 Nm Earth braid - Engine 8.5 ± 1.0 Nm Starter motor ground - Starter motor 12.0 ± 1.0 Nm Positive cable connection - Starter motor 7.0 ±...
  • Page 30 Beverly 400 E5 Technical Data DT - 30...
  • Page 31 Beverly 400 E5 Technical Data ENGINE Name Torque in Nm Pressure reducer counterweight retainer screw 7 ÷ 8.5 Nm Water pump impeller driving joint 13 ÷ 15 Cylinder head nut (TIGHTENING) 9 ÷ 11 (Tighten to 9 ÷ 11 Nm then proceed for 270.0° ±5.0° of rotation) M12x1.25 gear clutch shaft retainer nut...

  • Page 32: Overhaul Data

    Beverly 400 E5 Technical Data LOCKS Name Torque in Nm Saddle opening actuator support bracket - Frame 6.0 ± 1.0 Nm Saddle-lock - Helmet compartment 6.0 ± 1.0 Nm Glove-box opening rocker - Frame 6.0 ± 1.0 Nm Overhaul data Assembly clearances Cylinder - piston assy.

  • Page 33: Piston Rings

    Beverly 400 E5 Technical Data COUPLING CATEGORY ISTON CYLINDER Name Initials Cylinder Piston Play on fitting cylinder - piston (84.010 ÷ 84.017)mm (83.953 ÷ 83.960)mm (0.050 ÷ 0.064)mm cylinder - piston (84.017 ÷ 84.024)mm (83.960 ÷ 83.967)mm (0.050 ÷ 0.064)mm cylinder - piston (84.024 ÷...
  • Page 34 Beverly 400 E5 Technical Data Axial clearance between crankshaft and connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Code Dimensions Assembly clearance Transmissionside half-shaft 0.72 (+0; -0.002) in 18.4 D=0.007÷0.01 in (+0; -0.05) mm (0.20÷0.50 mm) Flywheel-side halfshaft 0.72 (+0;...

  • Page 35: Cylinder Head

    Beverly 400 E5 Technical Data Characteristic Crankshaft-crankcase axial clearance (H) 0.15 ÷ 0.43 mm THE CRANKSHAFT is available in two CATEGO- RIES: Characteristic Crankshaft category: CAT. 1 - CAT. 2 CRANKSHAFT CATEGORY IDENTIFICATION: The identification is indicated on the counterweight shoulder «*1 - *2», if carried out with micropinholing.
  • Page 36 Beverly 400 E5 Technical Data - 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 37 Beverly 400 E5 Technical Data Measure the unloaded spring length Characteristic Standard length (1.602)in (40.7)mm Allowable limit after use: (1.543)in (39.2)mm - Clean the valve seats of any carbon residues. - Using the Prussian blue, check the width of the impression on the valve seat "V".
  • Page 38 Beverly 400 E5 Technical Data - Check the deviation of the valve stem by resting it on a «V» shaped abutment and measuring the extent of the deformation with a dial gauge. Characteristic Limit allowed: (0.0007)in (0.02)mm - Check the oscillation of the valve head by ar- ranging a dial gauge at right angle relative to the valve head and rotate it on a "V"...
  • Page 39 Beverly 400 E5 Technical Data Specification Desc./Quantity Limit allowed: (0.003)in (0.1)mm - Check that there are no signs of wear on the mating surface with the set screw articulated ter- minal. - If no anomalies are found during the above checks, you can use the same valves.
  • Page 40 Beverly 400 E5 Technical Data -Using a gauge, measure the cam height. TANDARD HEIGHT Specification Desc./Quantity Camshaft check: Wear limit Exhaust: (1.178)in (29.945)mm Camshaft check: Wear limit Intake: (1.218)in (30.948)mm Camshaft check: Standard height Intake: (1.220±0.001)in (31.008±0.03)mm Camshaft check: Standard height Exhaust: (1.181±0.001)in (30.005±0.03)mm...
  • Page 41 Beverly 400 E5 Technical Data Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. IAMETER OF PINS AND ROCKING LEVERS Specification Desc./Quantity Rocking lever inside diameter: Standard diameter (C) Ø(0.512÷0.513)in Ø(13.015÷13.035)mm...
  • Page 42 Beverly 400 E5 Technical Data Slot packing system Characteristic Compression ratio 11,5 ± 0,5 :1 Measurement "A" to be taken is a value of piston re-entry, it indicates by how much the plane formed by the piston crown falls below the plane formed by the top of the cylinder. The further the piston falls inside the cylinder, the less the base gasket to be applied (to recover the compression ratio) and vice versa.

  • Page 43: Index Of Topics

    INDEX OF TOPICS TOOL OOLING...
  • Page 44 Beverly 400 E5 Tooling TTREZZATURA PECIFICA Stores code Description 001330Y Tool for fitting steering seats 001467Y014 Calliper to extract ø 15-mm bearings 006029Y Punch for fitting steering bearing on the steering tube 020004Y Punch for removing steering bearings from headstock...
  • Page 45 Beverly 400 E5 Tooling Stores code Description 020115Y punch ø 18 020151Y Air heater 020193Y Oil pressure gauge 020244Y punch ø 15 020271Y Tool for removing-fitting silent bloc 020263Y Driven pulley assembly sheath TOOL - 45...
  • Page 46 Beverly 400 E5 Tooling Stores code Description 020306Y Punch valve seal rings fitting 020329Y Mity-Vac vacuum pump 020331Y Digital multimeter 020332Y Digital rpm indicator 020335Y Magnetic mounting for dial gauge TOOL - 46...
  • Page 47 Beverly 400 E5 Tooling Stores code Description 020359S 42 x 47 mm Adaptor 020358Y 37 x 40 mm Adaptor 020360S 52 x 55 mm adaptor 020363Y 20-mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020382Y Valve cotters equipped with part 012 re-...
  • Page 48 Beverly 400 E5 Tooling Stores code Description 020382Y011 adapter for valve removal tool 020412Y 15-mm guide 020423Y Driven pulley lock wrench 020424Y Driven pulley roller casing fitting punch 020426Y Piston fitting fork 020428Y Piston position check mounting TOOL - 48...
  • Page 49 Beverly 400 E5 Tooling Stores code Description 020431Y Valve oil seal extractor 020434Y Union for oil pressure measurement 020439Y 17-mm guide 020442Y Pulley lock wrench 020444Y Tool for installing/removing clutch on/ from driven pulley 020454Y Tool for fitting the pin snap rings...
  • Page 50 Beverly 400 E5 Tooling Stores code Description 020456Y Ø 24 mm adaptor 020467Y Flywheel extractor 020477Y Adapter 37 mm 020480Y Fuel pressure measurement kit 020483Y 30-mm guide 020487Y Fork oil seal extractor TOOL - 50...
  • Page 51 Beverly 400 E5 Tooling Stores code Description 020489Y Hub cover support stud bolt kit 020627Y Flywheel lock tool 020648Y Single battery charger 020917Y Driven pulley stop 020922Y Diagnosis Tool 020924Y Bluetooth per Strumento di Diagnosi PADS TOOL - 51...
  • Page 52 Beverly 400 E5 Tooling Stores code Description 021017Y EOBD E5 diagnostics cable TOOL - 52...
  • Page 53 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 54: Maintenance Chart

    Beverly 400 E5 Maintenance MAINTENANCE ICON OPERATION This function indicates the scheduled mainte- nance interventions. For each time the key is turned to "ON", once the instrument panel has per- formed the initial check, if the value of the remain- ing kilometres until the next intervention is less than 300 Km (186.41 mi), the indicated icon will...

  • Page 55: Recommended Products

    MAINTENANCE OF THE VEHICLE STARTING FROM THE SERVICE OF 5,000 Km (3,106 mi) OR 5 MONTHS. Recommended products Piaggio Group recommends the use of prod- ucts from its Castrol official partner for the scheduled maintenance of its vehicles. Only use lubricants and fluids which meet or ex- ceed the performance characteristics specified.

  • Page 56: Level Check

    Beverly 400 E5 Maintenance Level check Engine cooling is forced liquid circulation. The coolant is composed of a mix of 50% demineral- ised water and an ethylene glycol-based anti- freeze with corrosion prevention components. The coolant included with the scooter is already mixed and ready for use.
  • Page 57 Beverly 400 E5 Maintenance Look on the visible part of the coolant reservoir and check that the fluid level is always the MIN and MAX level marks. Top up with fluid if the level is near the minimum mark. If the level of the fluid is not correct, top it up.
  • Page 58 Beverly 400 E5 Maintenance Top-up To top-up the brake fluid, proceed as follows: place the vehicle on the centre stand and remove the rear-view mirrors by unscrewing them from their seats. Unscrew the fixing screw of the rear handlebar cover, located on the left side of the vehicle.
  • Page 59 Beverly 400 E5 Maintenance Unscrew the two lever cover fixing screws, from the right and left side of the vehicle. - Remove the lever cover from both sides of the vehicle. Unscrew the lower fixing screws of the rear han- dlebar cover, one from the right side and one from the left side of the vehicle.
  • Page 60 Beverly 400 E5 Maintenance Unscrew the central fixing screw of the rear han- dlebar cover. Slightly move the rear handlebar cover and re- lease the instrument panel connector. Remove the rear handlebar cover. Unscrew the two fixing screws of the brake pump, right or left.
  • Page 61 Beverly 400 E5 Maintenance Remove the brake pump cap and restore the rec- ommended brake fluid level using the specified product. CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CON- TENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT.
  • Page 62 Beverly 400 E5 Maintenance The evaporative emissions control system is located on the rear side of the vehicle. Key: 1 Canister MAIN - 62...

  • Page 63: Removing System Components

    Beverly 400 E5 Maintenance 2 Bleeder pipe 3 Pipe for connecting the canister to the inlet fitting 4 Canister valve 5 Pipe for connecting the fuel tank to the canister 6 Breather valve Removing system components Remove the helmet compartment and the side fairings to gain access to the components of the evap- orative emissions control system.
  • Page 64 Beverly 400 E5 Maintenance Refitting system components Fasten the canister to the special pin on the frame, making sure to position the purge pipe fitting down- ward. Upon reassembling the components, use caution when connecting the pipes to the canister.
  • Page 65 Beverly 400 E5 Maintenance Refit the components by properly inserting the pipes and securing them with new metal clamps. CAUTION TAKE CARE TO ENSURE THE PROPER DIRECTION OF THE COMPONENTS' INSTALLATION: IF INSTALLED IN REVERSE, THEY COULD COMPROMISE THE FUNCTIONALITY OF THE ENTIRE EVAPORATING SYSTEM.

  • Page 66: Canister Inspection

    Beverly 400 E5 Maintenance Ensure the correct orientation of the breather valve, with the writing "TANK/RESERVOIR" placed on the side shown in the figure. If you detect different pressures, replace the valve. Characteristic Opening pressure 110 mbar Canister inspection The canister is essential to treat the hydrocarbons...

  • Page 67: Index Of Topics

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...

  • Page 68: Instrument Panel

    Beverly 400 E5 Electrical system Instrument panel Key: A = Left hand turn signal indicator lamp; B = Immobilizer LED C = Engine management system warning lamp (MIL) D = High beam lights on indicator lamp E = Low engine oil pressure warning lamp...
  • Page 69 Beverly 400 E5 Electrical system Key: A = Heated accessory icon and heating level management provision (optional - requires both PMP3 control units and heating modules to be present) B = Fuel gauge with fuel symbol C = Icon for SMS message on smartphone...
  • Page 70 Beverly 400 E5 Electrical system R = Icon for the connection between the smart- phone PIAGGIO app and the PMP3 control unit on the vehicle: • if it is steady, the application commu- nicates with the ECU; • if it flashes, the smartphone and PMP3 control unit pairing is being performed.
  • Page 71 Beverly 400 E5 Electrical system MAINTENANCE ICON OPERATION This function indicates the scheduled mainte- nance interventions. For each time the key is turned to "ON", once the instrument panel has per- formed the initial check, if the value of the remain- ing kilometres until the next intervention is less than 300 Km (186.41 mi), the indicated icon will...
  • Page 72 Beverly 400 E5 Electrical system In case of inhibited engine start, the specific icon on the digital display will also light up. Starting can be also inhibited with the engine stop switch (RUN-OFF) set to "OFF". MULTIFUNCTIONAL PANEL AND TOTAL/PAR-...
  • Page 73 Beverly 400 E5 Electrical system By keeping the MODE button pressed, upon its release, the multifunctional panel will display the current consumption. By briefly pressing twice on the MODE button, the following information can be viewed cyclically on the digital display: •...
  • Page 74 Beverly 400 E5 Electrical system To set or adjust the time, with vehicle running or with key inserted in «ON» position, do the follow- ing: • press and hold the SET button on the instrument cluster for at least 5 sec- onds and then release the button;...
  • Page 75 NECTIVITY button on the handlebar. PAIRING PROCEDURE Smartphone - Multime- dia System PMP-PIAGGIO MIA The vehicle is equipped with the "Piaggio MIA" control unit that communicates with the smart- phone via Bluetooth. Using the specific "Piaggio" application that can be installed on the smart- phone, it is possible to exchange data with the vehicle and manage multimedia content.
  • Page 76 PMP-PIAGGIO MIA Multimedia System icon to flash on the digital display; - Release the button as soon as the "PMP-PIAGGIO MIA Multimedia System" icon starts flashing; - At this point enable the Bluetooth search on your smartphone; - Select the "PMP3-XXXX" device and, if requested, type the password "0000" or answer "yes" to the pairing request message that will appear on the smartphone screen to complete the Smartphone - Piaggio MIA pairing.
  • Page 77 ERATING MODES, REFER TO THE "PIAGGIO" APP MANUAL. The PMP3 - PIAGGIO MIA Multimedia System in addition to the classic connectivity functions, music management, etc ... allows you to use your Smartphone as a remote control for the following functions: •...

  • Page 78: Main Fuses

    Specification Desc./Quantity Fuse 1 Capacity: 5A Protected circuits: battery-powered, lights relay, instru- ment cluster, "Piaggio MIA" PMP3 device, helmet com- partment light. Fuse 2 Capacity: 7.5 A Protected circuits: battery-powered, diagnostic socket, electric fan relay, electric fan, hazard warning lights de- vice (blinker).
  • Page 79 (blinker), licence plate light. Fuse 7 Capacity: 5A Protected circuits: power supply under starter switch, Headlight switch (passing), USB port, diagnostic socket, electric top-box provision, accessory provision, "Piaggio MIA" PMP3 device. Fuse 8 Capacity: 15A Protected circuits: battery-powered, starter switch, fuses 5, 6, 7.
  • Page 80 Beverly 400 E5 Electrical system Duplication of keys / remote controls Procedure for the duplication of the remote control for "Piaggio KeyLess" system. A= Remote control B= Master-Key 1. Check the initial conditions: 1.1 Battery voltage higher than > 12V, 1.2 It is necessary to have the Master-Key availa-...
  • Page 81 Beverly 400 E5 Electrical system 3. Start procedure in Self-diagnosis > Keyless remote controls programming using PADS:: 3.1 With ignition key on "ON", 3.2 Access the Keyless control unit self-diagno- sis, 3.3 Eliminate any faults stored in the "MEM" sta-...

  • Page 82: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 83 Beverly 400 E5 Engine This section describes the operations to be carried out on the engine and the tools to be used. N.B. ENG - 83...

  • Page 84: Specifications

    Beverly 400 E5 Engine THE UNITS OF MEASUREMENT CONTAINED IN THIS CHAPTER ARE EXPRESSED IN TERMS OF THE DECIMAL METRIC SYSTEM. IN THE CASE OF VALUES EXPRESSED USING IMPERIAL AND US CUSTOMARY MEASUREMENT UNITS, REFER TO THE CONVERSION TABLE IN CHAP.
  • Page 85 Beverly 400 E5 Engine - Undo and remove the central screw from the transmission cover. - Remove the transmission cover. Air duct - Unscrew and remove the cooling cover fastening screws. Remove the cooling cover. ENG - 85...
  • Page 86 Beverly 400 E5 Engine Removing the driven pulley shaft bearing - Remove the Seeger ring. CAUTION PLACE THE COVER ON A SURFACE, REMOVING OR EX- CLUDING THE ALIGNMENT DOWELS. - Using the housing to support the cover of the transmission, interpose a few layers of heavy cloth so as not to damage the outer surface of the cover.

  • Page 87: Removing The Clutch

    Beverly 400 E5 Engine - Insert the Seeger ring. - Insert the alignment dowels if removed during disassembly. Removing the driven pulley To remove the driven pulley, proceed as follows: - Remove the drive pulley to release the drive belt.
  • Page 88 Beverly 400 E5 Engine - Working from the automatic transmission side, remove the driven pulley. - Unscrew the six fixing screws from the clutch cover. - By using two screwdrivers work on the appendi- ces and remove the cover taking care not to drop the clutch assembly.
  • Page 89 Beverly 400 E5 Engine - Working from the opposite side, supporting the cover, proceed to the removal of the bearing. Specific tooling 001467Y007 Driver for OD 54-mm bearings 020376Y Adaptor handle 020358Y 37 x 40 mm Adaptor - Heat the crankcase by means of specific tools and then insert a new bearing.
  • Page 90 Beverly 400 E5 Engine DISASSEMBLY - Insert the clutch assembly in the special tool and tighten the three wing nuts until you hear the end of stroke. - Prepare two aluminium protections in the vice and tighten the shaft of the driven pulley.
  • Page 91 Beverly 400 E5 Engine - Disengage the upper ring of the specific tool. - Remove the outer ring with the seat for the Bel- leville spring. - Remove the Belleville spring. - Remove the spring door upper disc. - Remove the discs separation spring.
  • Page 92 Beverly 400 E5 Engine ENG - 92...
  • Page 93 Beverly 400 E5 Engine - Remove the discs clearance recovery spring - Remove a non-trimmed duct metallic disc. - Remove a conductor disc (trimmed on both sides). - Remove the discs clearance recovery spring - Remove the semi-trimmed duct disc (trimmed on one side).
  • Page 94 Beverly 400 E5 Engine CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT- TED INDIVIDUALLY. THE FIRST IN THE ASSEMBLY PHASE MUST BE POSI- TIONED TOWARDS THE INSIDE OF THE HOUSING, AS SHOWN IN FIGURE. - Remove the hub. - Remove the shaft.
  • Page 95 Beverly 400 E5 Engine - Remove the lower spring holder disc complete with the six springs. - Remove the rollers. - Check that there is no abnormal wear on the roll- ers, the support channels for rollers and those for discs.
  • Page 96 Beverly 400 E5 Engine CLUTCH SPRING REVISION Characteristic Clutch springs Free spring measurement 15.3 mm Clutch spring wear limit 15,0 mm CLEARANCE RECOVERY SPRING REVISION Check for any deformation or abnormal wear. Characteristic Clearance recovery spring «A» standard di- mensions 3.2±0.1 mm...
  • Page 97 Beverly 400 E5 Engine DISCS WEAR LIMIT If the discs exceed the following wear limits, replace them all. Characteristic Clutch discs wear limit Conductor disc wear limit «B» = 2.6 mm Trimmed duct wear limit «C» = 1.7 mm CLUTCH DISCS REVISION: MAXIMUM DEFOR-...
  • Page 98 Beverly 400 E5 Engine REASSEMBLY - Working in reverse order to the removal, insert the components while taking care to follow the fol- lowing guidelines: - Place the rollers as shown in the photo, after ev- ery two leave a clearance so that each pair has its opposite for proper balance.
  • Page 99 Beverly 400 E5 Engine - Insert the semi-trimmed disc with the trimmed surface facing the lower support disc - Respect the indicated position of the discs clear- ance recovery spring. CAUTION THE CLEARANCE RECOVERY SPRING DISCS ARE FIT- TED INDIVIDUALLY.

  • Page 100: Final Check

    Beverly 400 E5 Engine - Insert the Belleville spring facing upwards, taking care to insert it properly into the seat in the closure ring. - Fit the specific tool to compress the clutch pack and place the retaining ring at the specified loca- tion.
  • Page 101 Beverly 400 E5 Engine CLUTCH OUTPUT SHAFT ROLLER CASING IN- SPECTION - Using specific tools, remove the roller casing Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings - Insert a new roller casing and set it with specific tools.
  • Page 102 Beverly 400 E5 Engine Pin retaining collar - Use the tool equipped with medium length pins in "C" position screwing them from the inside of the tool. - Install the driven pulley into the tool providing the support of an appendix against a pin.
  • Page 103 Beverly 400 E5 Engine - Remove the following components in this order: • upper cap; • spring; • lower spring support; • synthetic ring. - Using two screwdrivers lift the locking sheath of the torque server and remove it. ENG - 103...
  • Page 104 Beverly 400 E5 Engine - Remove the two O-rings and replace them, mak- ing sure to lubricate them during installation. - Thoroughly clean the slots and pins. - Check that the bushings on the pins and the slots of the torque server are free from wear and rotate freely.
  • Page 105 Beverly 400 E5 Engine - Insert the closure sheath of the torque server taking care to respect the positioning of the ap- pendices in their corresponding seats. Refitting the driven pulley - Insert the synthetic ring. - Insert the lower spring support.
  • Page 106 Beverly 400 E5 Engine - Insert the upper cap. - Insert the belt paying attention to the direction of rotation. Specific tooling 020444Y Tool for installing/removing clutch on/from driven pulley - Turn the control screw of the specific tool and spring preloading.

  • Page 107: Removing The Driving Pulley

    Beverly 400 E5 Engine Removing the driving pulley - Using specific tools, lock the driving pulley and loosen the flanged nut. Specific tooling 020442Y Pulley lock wrench - remove the flat washer and the cup washer. - remove the stationary half-pulley and the washer.
  • Page 108 Beverly 400 E5 Engine Inspecting the rollers case - Check that the internal bushing shown in the fig- ure is not abnormally worn and measure inner diameter A. - Measure outer diameter B of the pulley sliding bushing shown in the figure.
  • Page 109 Beverly 400 E5 Engine Refitting the driving pulley - perform the operations in reverse order of disas- sembly. CAUTION INSERT THE ROLLERS WITH THE LARGEST SUPPORT SURFACE ACCORDING TO THE DIRECTION OF ROTA- TION. - Use the specific tool to lock the pulley, tightening to the prescribed torque.
  • Page 110 Beverly 400 E5 Engine - Insert the transmission cover central screw and tighten it to the prescribed torque. Locking torques (N*m) Transmission cover screws 11 ÷ 13 - Insert and tighten the external fixing screws of the transmission cover to the crankcase to the pre- scribed torque.
  • Page 111 Beverly 400 E5 Engine End gear Removing the hub cover - Use a container large enough to recover the final reduction oil. Unscrew the indicated screw and re- cover the aluminium seal. - Unscrew the oil filler screw in order to facilitate bleeding.
  • Page 112 Beverly 400 E5 Engine - Using a suitable screwdriver use leverage on the upper and lower appendices to detach the sealant. - Remove the final reduction cap complete with the wheel axle, being careful not to drop the inter- mediate gear.
  • Page 113 Beverly 400 E5 Engine - Remove the nut and incorporated washer secur- ing the pinion. - The pinion is symmetrical: mark the outer surface to avoid reversed reassembly. - Remove the pinion and the specific tool. CAUTION CLEAN THE THREAD FROM ANY RESIDUAL THREAD- LOCK.
  • Page 114 Beverly 400 E5 Engine Wheel axle bearing removal - Using the specific tools remove the bearing. Specific tooling 020376Y Adaptor handle 020357Y 32 x 35-mm Adaptor 020363Y 20-mm guide Removing the intermediate gear bearing - Using the specific tools remove the bearing.
  • Page 115 Beverly 400 E5 Engine Fitting the Intermediate gear bearing - Using the equipment set a new bearing. N.B. IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN- ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE.
  • Page 116 Beverly 400 E5 Engine - Pay attention to the correct positioning of the alignment dowels. - Thoroughly clean the surfaces of the engine crankcase and reduction cover and seal, with the recommended product, the matching surface around the entire outer perimeter of the duct that leads to the breather.
  • Page 117 Beverly 400 E5 Engine about 500 cc Locking torques (N*m) Oil relief screw 15 ÷ 17 Removing the flywheel magneto - Undo the screw indicated and remove the plate. - Install the support plate. Specific tooling 020916Y Magneto flywheel blocking tool - Install the specific tool and unscrew the retainer nut of the flywheel, recovering the washer.

  • Page 118: Intermediate Gear

    Beverly 400 E5 Engine - Act on the extractor to remove the flywheel to- gether with the starting sprocket. - 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 dur-...
  • Page 119 Beverly 400 E5 Engine Refitting the intermediate gear - Lubricate the sliding surfaces and insert the in- termediate gear in its seat. Refitting the flywheel magneto - Place the tab. - Insert the magneto flywheel on the crankshaft. - Insert the washer.

  • Page 120: Removing The Intake Manifold

    Beverly 400 E5 Engine - Insert the flywheel fixing nut. - Place the support plate. Specific tooling 020916Y Magneto flywheel blocking tool - Fit the specific tool. - Tighten the flywheel fixing nut to the specified torque. Specific tooling 020627Y Flywheel lock tool...

  • Page 121: Removing The Rocker-Arms Cover

    Beverly 400 E5 Engine - Remove the sleeve connecting the throttle body. Removing the rocker-arms cover - Support the big end cover. - Unscrew and remove the special cover fastening screws. - Remove the big end cover. Removing the timing system drive...
  • Page 122 Beverly 400 E5 Engine - First loosen the tensioner and unscrew the fixing screws. - Remove the tensioner complete with gasket. - Undo the fixing screw and remove the washer. ENG - 122...
  • Page 123 Beverly 400 E5 Engine - Remove the complete mass of the return spring. - Loosen the screw - Remove the counterweight fixing screw. - Remove the counterweight. ENG - 123...

  • Page 124: Removing The Cam Shaft

    Beverly 400 E5 Engine - Disengage the chain from the sprocket and re- move the camshaft control sprocket. Removing the cam shaft - Remove the big end cover. - Remove the timing system control. - Unscrew the two screws of the camshaft lock.
  • Page 125 Beverly 400 E5 Engine - Remove the camshaft. - Remove the lock of the rockers to allow them to slide on the pins to access the calibrated pads. - Remove the calibrated pads CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS.

  • Page 126: Removing The Cylinder Head

    Beverly 400 E5 Engine Removing the cylinder head - Undo the two external screws. - Gradually loosen the four columns in crossed se- quence, recovering the washers. - Remove the cylinder head. N.B. IF NEEDED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS AND ROCKING LEVERS WITHOUT RE- MOVING THE DRIVING PULLEY UNIT.

  • Page 127: Removing The Valves

    Beverly 400 E5 Engine Removing the valves - Use the specific tool to remove the cotters, cap and spring. CAUTION PROPERLY REPLACE THE PADS AND ROCKERS SO AS TO PRESERVE THE COUPLINGS. Specific tooling 020382Y Tool to extract valve cotters...
  • Page 128 Beverly 400 E5 Engine - Use the specific tool to remove the valve oil seal. Specific tooling 020431Y Valve oil seal extractor - Slide off the valve and remove the lower support. Removing the cylinder - piston assy. - Unscrew and remove the fastening screws of the coil.
  • Page 129 Beverly 400 E5 Engine - Remove the coil. - Unscrew and remove the lower cylinder fixing screw. - Remove the cylinder, paying attention to the cyl- inder - head alignment dowels. N.B. IN ORDER NOT TO DAMAGE THE BASE GASKET WITH...
  • Page 130 Beverly 400 E5 Engine - Remove the retainer rings and remove the piston. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. Inspecting the small end N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 131 Beverly 400 E5 Engine Refitting the cylinder - Insert the cylinder base gasket. - Fit the specific tool. Specific tooling 020426Y Piston fitting fork - Place the seal rings as indicated in the figure. - Place the cylinder and the specific tool.

  • Page 132: Inspecting The Cylinder Head

    Beverly 400 E5 Engine - Check the position of the dowels and insert the gasket with the previously determined thickness. Inspecting the cylinder head N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER. Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out.

  • Page 133: Valve Clearance Check

    Beverly 400 E5 Engine Inspecting the valves VALVE CLEARANCE CHECK - Remove the cover. - Position the engine to the TDC in compression. - Using a feeler gauge check the valve clearance. CAUTION - USE THE FEELER GAUGE LATERALLY, IN LINE WITH...
  • Page 134 Beverly 400 E5 Engine - Move the rocker and replace the interested pad, correcting the clearance in the pre-set value. N.B. INSERT THE CALIBRATED PADS WITH THE WORDS SIDE VALVE IN ORDER TO PRESERVE THE INDICATION OF THICKNESS OVER TIME.

  • Page 135: Inspecting The Cam Shaft

    Beverly 400 E5 Engine Inspecting the springs and half-cones - Check that the upper and lower supporting spring washers, the cotters and the oil seal show exhibit no signs of abnormal wear. Replace a component when worn. N.B. TO MEASURE WEAR LIMITS AND COUPLING CLEARANCES, SEE THE SPECIFICATIONS CHAP- TER.
  • Page 136 Beverly 400 E5 Engine Refitting the head and timing system components CAUTION AT EACH REMOVAL OF THE CYLINDER HEAD IT IS NEC- ESSARY TO REPLACE THE STUD BOLTS. FOR FITTING QUOTA SEE THE SECTION "MOTOR/STUD BOLT SHAFT CRANKCASE" - Position the crankshaft to the TDC in compres- sion.
  • Page 137 Beverly 400 E5 Engine - Tighten up the nuts to an initial pre-torque of 9-11 ± 1 Nm. - Tighten up the nuts by rotating 270.0±5.0° with crossed sequence. - Fit the two screws on the outside of the timing chain side and tighten them to the specified torque.
  • Page 138 Beverly 400 E5 Engine - Working in reverse order, assemble the camshaft command components, respecting the phase po- sition. - To tighten the decompressor, bring the mass screw to a stop and, holding it tightly, tighten the central locking screw of the starter crown.
  • Page 139 Beverly 400 E5 Engine - Tighten the special screws to the specified tor- que. Locking torques (N*m) Head cover screws 6 ÷ 7 Refitting the intake manifold - Connect the rubber sleeve complete with throttle body to the intake manifold.
  • Page 140 Beverly 400 E5 Engine CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL. - Remove the gasket and be careful with the align- ment dowels.
  • Page 141 Beverly 400 E5 Engine Refitting the crankcase halves - Insert the crankshaft on one of the two crankcase halves. - insert the oil shield. - Insert the by-pass valve. - Place a new crankcase gasket. ENG - 141...
  • Page 142 Beverly 400 E5 Engine - Couple the crankcases, paying particular atten- tion to avoid accidental movements during inser- tion of the crankcase half which could cause collision with the oil pump control toothing on the crankshaft and, consequently, damage the bush- ings.
  • Page 143 Beverly 400 E5 Engine Lubrication Conceptual diagrams The lobe pump «F» sucks the oil from the sump, through the mesh pre-filter «C», it pushes it into the cartridge filter «E» where there is also a safety valve «D». Through the suitable passages found in the crankcases, the oil enters the crank chamber «G» where the main bearings are lubricated and the big end (with high pressure), the piston pin and connecting rod small end via spray «H».

  • Page 144: Oil Pressure Check

    Beverly 400 E5 Engine Oil pressure check - Remove the electrical minimum oil pressure switch connection and remove the switch. - Check that the oil pressure reading is between 0.5 and 1.2 bar with the engine idling at 1650 rpm and the oil at the required temperature (wait for at least one electric ventilation).
  • Page 145 Beverly 400 E5 Engine Removal - Remove the flywheel. - Preventing rotation, unscrew the water pump command screw and collect the washer. CAUTION THE THREAD IS ANTICLOCKWISE. - Unscrew the two screws and remove the ten- sioner pad - Remove the oil pump command sprocket com- plete with chain.
  • Page 146 Beverly 400 E5 Engine - Remove the oil pump and collect the gasket. Inspection - Remove the two screws and remove the oil pump cover. - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible.
  • Page 147 Beverly 400 E5 Engine Refitting - - Insert the oil pump with the corresponding gas- ket in the seat. - Insert and tighten the oil pump fastening screws to the crankcase to the specified torque. Recommended products Loctite 243 Medium strength thread-locking sealant.
  • Page 148 Beverly 400 E5 Engine - Insert the oil pump driving sprocket and chain. - fit the tensioner pad. - place the spring washer and insert the water pump control screw. - Preventing rotation, tighten the water pump com- mand screw.
  • Page 149 Beverly 400 E5 Engine - Keeping the cover locked in a vice, unscrew the impeller shaft drive. During removal, support the flywheel crankcase. Remove the drive and the shim washer underneath. CAUTION THE THREAD IS ANTICLOCKWISE. - Using the special tool and appropriate supports, ensure a proper support surface.
  • Page 150 Beverly 400 E5 Engine - Supporting the ceramic seal properly, remove the impeller shaft, acting from the mobile side of the seal. - Using a screwdriver, remove the seal ring from the flywheel cover. - Check that the shaft housing hole on the crank- case does not show abnormal wear.
  • Page 151 Beverly 400 E5 Engine Fitting - Lubricate the new seal ring with grease and insert it in the flywheel cover. Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor - Grease the shaft and insert it in the seat. Insert the shim washer and manually start-up the drive.
  • Page 152 Beverly 400 E5 Engine - Locking the drive in a vice, properly lock the shaft. - Check that the shaft rotates freely (considering the friction of the oil seal) and that the axial clear- ance is noticeable but not excessive.
  • Page 153 Beverly 400 E5 Engine - Insert and screw the impeller to the specified tor- que. Locking torques (N*m) Impeller on the pump shaft 4 ÷ 6 ENG - 153...

  • Page 154: Braking System

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 155: System Asr

    Beverly 400 E5 Braking system System ASR ASR SYSTEM The ASR system is a driving aid that assists the driver in acceleration manoeuvres, particularly on low-grip surfaces or under conditions that can cause sudden back-wheel slippage. The ASR in these situations automatically intervenes by re-...
  • Page 156 Beverly 400 E5 Braking system ASR "3" system deactivation icon Icon "ASR OFF": on steady with engine started, ASR system not working or not calibrated or vol- untarily deactivated. ASR/ASR OFF ICON OPERATION MODE ASR System status ICON with engine off...
  • Page 157 Beverly 400 E5 Braking system 4. Drive at a low speed for a few meters, until the "ABS" indicator light stops flashing. 5. To start the programming procedure, press the start button and the ASR button at the same time for at least 4 seconds, until the "ASR OFF"...
  • Page 158 Beverly 400 E5 Braking system THE ASR SYSTEM IS ACTIVATED EVERY TIME, THE STARTER SWITCH IS TURNED TO THE "ON" POSITION. IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH; THE NEXT TIME THE STARTER SWITCH IS TURNED, THE ASR SYSTEM IS AUTOMATICALLY ENABLED.
  • Page 159 Bulbs: Fuses: 78 Identification: 19 Instrument panel: 68 Keys: 80 Maintenance: 18, 54 Recommended products: 55 Start-up: 11 Suspension: Technical Data: 18 Transmission: 84, 109 Vehicle: 19...

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