Page 1 WORKSHOP MANUAL 633387 Beverly 500 i.e.
Page 2 Not all versions shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network. "© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 WORKSHOP MANUAL Beverly 500 i.e. This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
Page 4 INDEX OF TOPICS CHAR HARACTERISTICS MAIN AINTENANCE 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 5 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 6: Safety Rules
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 special tools designed for this scooter.
Page 7: Vehicle Identification
Beverly 500 i.e. Characteristics Vehicle identification Chassis prefix: ZAPM34100 Engine prefix: M341M Dimensions and mass WEIGHT Specification Desc./Quantity Kerb weight in running order 193 Kg Width (at the handles) 770 mm Length 2215 mm Wheel base 1550 mm Height 1305 mm Engine ENGINE Specification...
Page 8: Electrical System
Beverly 500 i.e. Characteristics Specification Desc./Quantity Valve clearance: intake 0.15 mm (when cold) Valve clearance: discharge 0.15 mm (when cold) Valve clearance adjustment By threaded adjuster on the rockers Engine idle speed 1500 ± 50 rpm Air filter sponge, impregnated with mixture (50% petrol and 50% oil) CO % value (measured at the intake manifold) 1 - 1.5% Starting system...
Page 9: Wheels And Tyres
IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE COR- RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC- OMMENDED BY PIAGGIO. Tightening Torques CHASSIS...
Page 10: Brake System
Beverly 500 i.e. Characteristics BRAKE SYSTEM Name Torque in Nm Brake calliper coupling 20 - 24 Front brake disc mounting 11 ÷ 13 Rear brake disc mounting 11 ÷ 13 Front brake calliper mounting on fork 20 ÷ 25 Pipe / brake calliper coupling 20 to 25 Circuit bleed calliper fitting 12 - 16...
Page 11: Crankcase And Crankshaft
Beverly 500 i.e. Characteristics *** Apply a preliminary torque of 7 N·m in a crossed sequence. - Tighten by 90° in a crossed sequence. - Tighten again by 90° in a crossed sequence. CRANKCASE AND CRANKSHAFT Name Torque in Nm Countershaft fixing nut 25 ÷...
Page 12: Assembly Clearances
Beverly 500 i.e. Characteristics This is to inform you that the tightening torque for screws with dwg. no. 842502 has been increased from 8-10 Nm to 14-16 Nm, to prevent the exhaust pipe from coming loose. Overhaul data This section provides the main information for scooter servicing. Assembly clearances Cylinder - piston assy.
Page 13 Beverly 500 i.e. Characteristics Piston rings * Fit rings «2» and «3» with the word «TOP» facing upwards. ** Position the openings in the rings as shown here. *** Value «A» of sealing ring inside the cylinder **** Ring opening SEALING RINGS Name Initials...
Page 14 Beverly 500 i.e. Characteristics Crankshaft alignment Specific tooling 020335Y Magnetic mounting for dial gauge MAX. ADMISSIBLE DISPLACEMENT Specification Desc./Quantity 0.15 mm 0.010 mm 0.010 mm 0.10 mm AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Transmission-side 0.8 ±...
Page 15 Beverly 500 i.e. Characteristics Characteristic Drive shaft / crankcase axial clearance: 0.1 - 0.5 mm (when cold) Slot packing system Shimming system for limiting the compression ratio Rc = 10.5 : 1 DISTANCE "A" IS A PROJECTION OR RECESS VALUE OF THE PISTON TOP FROM THE CYL- INDER PLANE.
Page 16 Beverly 500 i.e. Characteristics Name Measure A Thickness «A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05 «A» MEASURE TAKEN + 0.10 - + 0.185 0.8 ± 0.05 N.B. VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE CYLINDER PLANE.
Page 17 INDEX OF TOPICS MAIN AINTENANCE...
Page 18: Maintenance Chart
Beverly 500 i.e. Maintenance Maintenance chart Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been sug- gested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it.
Page 19 Beverly 500 i.e. Maintenance AFTER 6,000 KM OR 12 MONTHS Action Engine oil - change Hub oil - level check Spark plug / electrode gap - check Air filter - cleaning Engine oil filter - change Valve clearance - check Base vent - check Variable speed rollers - replacement Drive belt - check...
Page 20 Beverly 500 i.e. Maintenance AFTER 24,000 KM 255' Action Engine oil - change Hub oil - change Spark plug / electrode gap - replacement Air filter - cleaning Engine oil filter - change Fuel filter - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement...
Page 21 Beverly 500 i.e. Maintenance Action Brake levers - greasing Brake fluid hoses - replacement Transmission - lubrication Brake fluid level - check Safety fasteners - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre inflation and wear - Check Vehicle test and brake test - Road test AFTER 48,000 KM 255'...
Page 22: Spark Plug
Beverly 500 i.e. Maintenance Action Electrical system and battery - check Headlight - adjustment Tyre inflation and wear - Check Vehicle test and brake test - Road test Transmission - lubrication Spark plug Check and replacement CAUTION THE SPARK PLUG MUST BE REMOVED WITH COLD EN- GINE.
Page 23 Beverly 500 i.e. Maintenance Check • Park the scooter on flat ground and rest it on the central stand. • Unscrew the oil dipstick "A", dry it with a clean cloth and reinsert it, screwing it in thoroughly. • Pull out the dipstick and check that the oil level is between the MAX.
Page 24: Air Filter
Beverly 500 i.e. Maintenance Air filter • Remove the air cleaner cover after un- screwing the 9 fixing screws. • Take out the filtering element. • Replace the air filter with a new one. Check the blow-by and condensate outlet pipe; empty if when full.
Page 25: Engine Oil Filter
Beverly 500 i.e. Maintenance Check This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Unscrew the cap/dipstick "A", dry it with a clean cloth and reinsert it, screwing it thoroughly. 3) Remove the cap/dipstick again and check that the level is between the max.
Page 26 Beverly 500 i.e. Maintenance - Remove and clean the mesh pre-filter of the drain cap with compressed air. - Use a belt spanner for filters to remove cartridge filter "C". - Make sure the pre-filter and drain cap O-rings are in good condition.
Page 27: Checking The Valve Clearance
Beverly 500 i.e. Maintenance Oil pressure warning light Warning light (low oil pressure) The vehicle is equipped with a warning light on the instrument panel that lights up when the key is turned to the «ON» position. However, this light should switch off once the engine has been star- ted.
Page 28: Braking System
Beverly 500 i.e. Maintenance Level check The fluid level inspection should be carried out ev- ery 6,000 km when the motor is cold, following the methods indicated below: • Rest the scooter on the central stand and on a flat ground. •...
Page 29 Beverly 500 i.e. Maintenance Level check - Rest the scooter on a flat ground and on the cen- tral stand. - Remove the brake pump cover as shown in the figure. - Check the brake fluid level by the special indica- tor located on the pump, as shown in the figure.
Page 30: Headlight Adjustment
Beverly 500 i.e. Maintenance - Remove the tank cap by loosening its two screws, remove the gasket and top up the level, using only the prescribed fluid without exceeding the maximum level. CAUTION AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING.
Page 31 Beverly 500 i.e. Maintenance - Otherwise, adjust the right headlight by the screw shown in the figure, which can be accessed by re- moving the front shield connecting member. N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO- PEAN STANDARDS REGARDING MAXIMUM AND MINI- MUM HEIGHT OF LIGHT BEAMS.
Page 32 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 33 Beverly 500 i.e. Electrical system ELECTRICAL COMPONENTS Specification Desc./Quantity Front LHS turn signal light Light switch Turn indicator switch Horn button Four 30A relays Main remote control switch Light remote control switch Diode unit Saddle opening button Front fuse box Fuse No.
Page 34 Beverly 500 i.e. Electrical system Specification Desc./Quantity Lhs turn signal warning light Instrument lighting Headlamp warning light Front turn signal light bulb 12V-10W Intercom fitting Engine stop switch Fitting for accessories Front wire node (black) Indicators remote control switch Electric fan solenoid Light switch Starter button Damper for fuel level indicator...
Page 35 Beverly 500 i.e. Electrical system Components arrangement Diagnostic socket In order to access the diagnostic socket, remove the supports of the passenger footrest. Overturn sensor In order to access the overturn sensor, remove the central union. During assembly, observe the installation direction shown in the figure.
Page 36 Beverly 500 i.e. Electrical system Saddle opening ECU remote control. Resetting of the remote control Electronic control unit ECU In order to access the immobilizer control unit, re- move the upper shield back plate. In order to access the connector, remove the wind- shield with the respective support and the metal plate holding the control unit ECU, decoder and saddle opener remote control.
Page 37 Beverly 500 i.e. Electrical system Relays and diode group In order to access the relays and the diode group, remove the upper shield back plate. Specification Desc./Quantity DIODE UNIT ELECTRIC FAN REMOTE CONTROL SWITCH ENGINE STOP REMOTE CONTROL SWITCH CONTROL UNIT REMOTE CONTROL SWITCH Voltage regulator To access the voltage regulator.
Page 38 Beverly 500 i.e. Electrical system Ignition IGNITION Specification Desc./Quantity Instrument panel Electronic control unit Antenna Immobilizer Engine stop remote control switch Main remote control switch Diode Control unit remote control switch Emergency stop switch Side stand switch Fuse No. 4 (5A) Key switch Main fuse (30A) Battery...
Page 39 Beverly 500 i.e. Electrical system Specification Desc./Quantity HV coil Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity Instrument panel Duel light lamp Light switch Fuse No. 9 (7.5A) Light switch Light remote control switch Fusibile n. 6 (10A) Main remote control switch Diode Key switch...
Page 40 Beverly 500 i.e. Electrical system Specification Desc./Quantity Flywheel magneto Fuse n.7 (15A) Under-saddle compartment light Under-saddle compartment light switch Side/taillights (2 front and 1 rear light) and number plate light Battery recharge and starting START-UP BATTERY RECHARGE Specification Desc./Quantity Stop light bulb Starter button Fuse No.
Page 41 Beverly 500 i.e. Electrical system Specification Desc./Quantity Key switch Voltage regulator Starter relay Starter motor Battery 12V-12Ah Main fuse (30A) Level indicators and enable signals section LEVEL INDICATORS AND ENABLE SIGNALS SECTION Specification Desc./Quantity Instrument panel Engine water temperature sensor Electronic control unit Engine oil pressure sensor Damper for fuel level indicator...
Page 42 Beverly 500 i.e. Electrical system Specification Desc./Quantity Emergency stop switch Key switch Main remote control switch Diode Fuse No. 8 (7.5A) Main fuse (30A) Battery 12V-12Ah Voltage regulator Flywheel magneto Turn signal lights TURN INDICATORS AND HORN Specification Desc./Quantity Instrument panel Predisposizione display Anti-theft alarm fitting Radio-interphone prewiring...
Page 43 Beverly 500 i.e. Electrical system Specification Desc./Quantity Indicators remote control switch Fuse No. 8 (7.5A) Fuse n. 10 (7,5A) Fitting for accessories Horn button Claxon 12V c.c. Main remote control switch Diode Key switch Battery 12V-12Ah Main fuse (30A) Voltage regulator Fuse No.
Page 44 Beverly 500 i.e. Electrical system Recharge system voltage check Look for any leakage 1) Check that the battery does not show signs of leaking fluid before checking the output voltage. 2) Turn the ignition key to OFF and connect the multimeter leads between the battery negative pole (-) and the Black cable.
Page 45 Beverly 500 i.e. Electrical system Fuses The electrical system is equipped with: • Six «A » fuses located inside the right- hand side fairing. • Four «B» protection fuses for the dif- ferent circuits of the electrical system located inside the glove-box on the top left-hand side of the helmet compart- ment.
Page 46 Beverly 500 i.e. Electrical system FUSE HOLDER B Specification Desc./Quantity 7 - Light flash, fitting for accessories, horn Fuse: 15A 8 - Brake lights, fitting for radio and anti-theft system, Fusibile: 7,5A damper, under-key instrument panel. 9 - Light switch. Lamps for front and rear side/taillights, Fusibile: 7,5A number plate light, indicators on the instrument panel.
Page 47 Beverly 500 i.e. Electrical system • Constant voltage charge equal to 14.40-14.70V • Initial charge current equal to 0.3-0.5 x rated capacity • Charge time: • 10 to 12 h recommended Minimum 6 h Maximum 24 h 5. Constant-current battery charger mode •...
Page 48 Beverly 500 i.e. Electrical system 2 Inspect visually 3 The float must be freed Checking the electrolyte level The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.
Page 49 Beverly 500 i.e. Electrical system CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. FAILURE TO CHARGE THE BATTERY ADEQUATELY BEFORE BEING PUT INTO OPERATION WILL LEAD TO A PREMATURE FAILURE OF THE BATTERY. Connectors Dashboard • The instrument panel is provided with two connectors (A with 8 pins and B with 6 pins) shown in the figure.
Page 50 Beverly 500 i.e. Electrical system FUEL GAUGE DAMPER Specification Desc./Quantity Fuel reserve warning light Fuel level gauge output Float input Test (not connected) Ground lead + permanent power supply ELE SYS - 50...
Page 51 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 52 Beverly 500 i.e. Engine from vehicle Exhaust assy. Removal - Undo the two exhaust manifold fixings on the head. - Undo the three screws fixing the muffler to the mounting arm. - Remove the full muffler unit. Removal of the engine from the vehicle •...
Page 53 Beverly 500 i.e. Engine from vehicle • Perform the operations for removal in the reverse order according to the tightening torque indicated in Chapter "Characteristics". Check that there is a small clearance when the valve is in abutment against the set screw. •...
Page 54 INDEX OF TOPICS NGINE...
Page 55: Automatic Transmission
Beverly 500 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 - Using a screwdriver, remove the driven pulley axle cover near the bottom of the cap. - Loosen the driven pulley shaft fastening nut using a misaligned wrench and prevent the pulley shaft rotation using a machine hexagon bush.
Page 56 Beverly 500 i.e. Engine - Remove the four M8 screws. - Remove the transmission cover. - Check that the bearing rotates freely, otherwise replace it. - Loosen the 4 fastening screws - Extract the outside plastic transmission cover. Air duct - Remove the transmission cover.
Page 57 Beverly 500 i.e. Engine Air duct filter - Remove the external air conveyor. - Unscrew the 2 fastening screws shown in the fig- ure to remove the conveyor filter. Removing the driven pulley shaft bearing - Remove the transmission cover. - Remove the Seeger ring.
Page 58 Beverly 500 i.e. Engine Refitting the driven pulley shaft bearing - Heat the transmission cover interior using the heat gun. N.B. BE CAREFUL NOT TO OVERHEAT THE COVER AS THIS WOULD DAMAGE THE OUTSIDE PAINTED SURFACE. Specific tooling 020151Y Air heater - Place the bearing onto the special tool with a little grease to prevent it from coming out.
Page 59: Inspecting The Clutch Drum
Beverly 500 i.e. Engine Installation of belt anti-vibration roller - Install the anti-flapping roller with the lip facing the engine crankcase. - Tighten the central screw to the prescribed tor- que. N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE BELT IS OBTAINED.
Page 60: Removing The Clutch
Beverly 500 i.e. Engine - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. N.B. CHECK THE ECCENTRICITY MEASURED, 0.2 MM MAX. Characteristic Max. value: 160.5 mm Standard value: 160.2 mm Removing the clutch - To remove the clutch with the driven pulley it is necessary to use the special tool;...
Page 61 Beverly 500 i.e. Engine - Remove the 4 guide pins. - Extract the moving driven half-pulley. Removing the driven half-pulley bearing - Check that the bushing is free from wear and damage; otherwise replace the fixed driven half- pulley. - Remove the lock ring using pliers. - Using the special tool inserted through the roller bearing, pull out the ball bearing.
Page 62 Beverly 500 i.e. Engine - Remove the roller bearing using the special tool, supporting the fixed half-pulley with the bell. Specific tooling 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020364Y 25-mm guide 001467Y002 Driver for OD 73 mm bearing Inspecting the driven fixed half-pulley - Check that the belt contact surface is free from wear.
Page 63: Refitting The Driven Pulley
Beverly 500 i.e. Engine If you are working on the driven pulley unit fully assembled, use the special tool. Specific tooling 020478Y Punch for driven pulley roller casing 001467Y002 Driver for OD 73 mm bearing - Install a new ball bearing using the special tool. Specific tooling 020376Y Adaptor handle 020477Y 37 mm adaptor...
Page 64 Beverly 500 i.e. Engine Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the length of the movable driven half- pulley spring while it is unloaded. Characteristic Standard length: 125.5 mm Admissible limit after use: 120 mm - Check the thickness of the clutch mass friction material.
Page 65 Beverly 500 i.e. Engine Refitting the clutch - Prepare the special tool as for removal; - Preassemble the driven pulley unit with the drive belt according to its direction of rotation; - Insert the driven pulley unit, the spring with sheath and clutch into the tool.
Page 66: Removing The Driving Pulley
Beverly 500 i.e. Engine Refitting the driven pulley - Install the driven pulley assembly with belt. Drive-belt - Check that the driving belt is not damaged. - Check the width of the belt. Characteristic Minimum width: 25 mm Standard width: 26.2 mm Removing the driving pulley - Using a 27 mm wrench, turn the central pulley nut...
Page 67 Beverly 500 i.e. Engine - First install the lock ring of the special tool onto the pulley so that the splines are completely en- gaged. - Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.
Page 68 Beverly 500 i.e. Engine - Measure the pulley sliding bushing outside di- ameter shown in the figure. Characteristic Minimum admissible diameter Ø 29.95 mm Standard diameter: Ø 29.959 mm - Check that the rollers are not damaged or worn. Characteristic Minimum admissible diameter Ø...
Page 69 Beverly 500 i.e. Engine Refitting the driving pulley Installing the roller container - Install the spacer with the internal chamfer facing towards the inside. - Position the rollers on the half-pulley as shown in the figure. - The closed side must rest on the inside thrust face of the roller container.
Page 70 Beverly 500 i.e. Engine Installing the fixed driving half-pulley - Insert the spacer. - Install the fixed driving half-pulley and check that it is in contact with the spacer and with the guide bushing of the movable driving pulley. - Remove the flat washer and the spring washer as shown in the figure.
Page 71 Beverly 500 i.e. Engine - Turn the central pulley nut to horizontally align the holes and install the special tool. N.B. CHECK THAT THE STOP WRENCH TOOL IS EASILY IN- SERTED INTO THE PULLEY AND IN THE ENGINE CRANK- CASE. Specific tooling 020474Y Driving pulley lock wrench - Install the lock ring from the rear so that the...
Page 72 Beverly 500 i.e. Engine - Ensure the correct installation on the crankcase of the 2 centring dowels. - Insert the transmission cover with the bearing and install the relevant retainers. - Lock the four M8 retainers. Locking torques (N*m) M8 retainers for transmission cover 23 ÷...
Page 73 Beverly 500 i.e. Engine End gear Removing the hub cover - Drain the rear hub oil through the oil drainage cap located under the engine. - Drain the rear hub oil through the oil drainage cap located under the engine. -Remove the 7 fastening screws.
Page 74 Beverly 500 i.e. Engine - Use the special extractor to disassemble the bearing on the engine chassis of the countershaft. Specific tooling 001467Y006 Pliers to extract 20 mm bearings 001467Y035 Bearing housing, outside ø 47 mm - Support the hub cover using the stud bolt set. - Pull out the bearing using the special tool.
Page 75 Beverly 500 i.e. Engine - Remove the oil guard using a screwdriver. Removing the driven pulley shaft bearing - If you have to remove the driven pulley shaft, the relevant bearing and the oil guard, remove the transmission cover and the clutch unit as descri- bed in the «...
Page 76 Beverly 500 i.e. Engine Connection diameter for countershaft: A = diameter 20 - 0.01 -0.02 mm Connection diameter for wheel shaft: B = diameter 30 - 0.010 -0.023 mm C = diameter 15 - 0.01 -0.02 mm Bearing diameter for driven pulley shaft: D = diameter 17 - 0.01 -0.02 mm E = diameter 20 - 0.01 -0.02 mm F = diameter 25 - 0.01 -0.02 mm...
Page 77 Beverly 500 i.e. Engine - Heat the intermediate gear bearing seat. - Insert the intermediate shaft bearing using the special tool. N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP- PLIES TO BEARINGS WITH PLASTIC CAGE). Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020363Y 20-mm guide...
Page 78 Beverly 500 i.e. Engine Refitting the hub cover bearings - Heat the bearing seats on the cover using the heat gun. - Support the hub cover using the stud bolt set. Specific tooling 020151Y Air heater 020476Y Stud bolt set - Insert the intermediate shaft bearing on the cover using the special tool.
Page 79 Beverly 500 i.e. Engine - Support the hub cover using the stud bolt set. - Insert the wheel shaft oil guard with the sealing lip facing the inside of the cover. - Place the oil guard flush with the crankcase. Specific tooling 020376Y Adaptor handle 020360Y 52x55-mm Adaptor...
Page 80 Beverly 500 i.e. Engine Locking torques (N*m) Rear hub cover screws 24 ÷ 27 Flywheel cover - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
Page 81 Beverly 500 i.e. Engine - Remove the oil filter using a filter tape or shaped cup wrench. - Loosen the 14 fastening screws. - Remove the flywheel cover with the relevant gas- ket and the cooling system sleeve support. N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS.
Page 82: Removing The Stator
Beverly 500 i.e. Engine - Remove the by-pass and the relevant spring. - Remove the oil pump seal. Removing the stator - Remove the two retaining screws and the cable guide bracket. - Unscrew the 3 fastening screws and remove sta- tor and its wiring.
Page 83 Beverly 500 i.e. Engine - Remove the blow-by reed valve with the relevant sealing gasket. - Unscrew the fastening screw and remove the gas outlet union with the relevant O-ring. - Remove the water pump impeller by unscrewing it from the relevant shaft. N.B.
Page 84 Beverly 500 i.e. Engine - Remove the sealing ring. - Remove the ceramic ring and the relevant gas- ket. - Remove the sealing ring for the pump shaft lu- brication using a suitably shaped tool. - Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing.
Page 85 Beverly 500 i.e. Engine Inspecting the cover components - Check the condition of the stator and the relevant cable harness. - Check the continuity between the 3 phases. N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.
Page 86 Beverly 500 i.e. Engine - Check that the mounting surface of the crankcase is not worn or deformed. - Check that the by-pass valve seat, the torque limiter and the water pump shaft are free from wear. Characteristic By-pass housing hole diameter: 13.9 mm Connection diameter for start-up gear shaft: 12 mm...
Page 87 Beverly 500 i.e. Engine - Install the pre-filter again and insert the engine oil drain plug, tightening to the prescribed torque. - Refill the engine with the prescribed type of oil. Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Syn- thetic oil Locking torques (N*m)
Page 88 Beverly 500 i.e. Engine - Insert the spring and the by-pass piston on the flywheel cover. N.B. LUBRICATE THE BY-PASS VALVE. Refitting the flywheel cover components - Before reassembling, check that all components are perfectly clean. - For the cover, carefully check all lubrication chan- nels, in particular: - The 3 by-pass channels.
Page 89 Beverly 500 i.e. Engine - Oil pressure sensor feeding duct. - Oil vapour decantation chamber - Reinstall the blow-by reed valve using a new sealing gasket. - Reinstall the support with head and tighten the screws to the prescribed torque. Locking torques (N*m) Supporting screws with bulkhead 0.3 - 0.4...
Page 90 Beverly 500 i.e. Engine - Pre-assemble the ceramic seal and the relevant gasket. N.B. PLACE THE CHAMFERING TOWARDS THE GASKET BE- ING CAREFUL NOT TO FOUL THE CERAMIC RING WITH OIL OR GREASE, WHICH WOULD IMPAIR THE SEAL. - Insert the ceramic seal on the flywheel cover. N.B.
Page 91 Beverly 500 i.e. Engine - Install a new gasket on the engine crankcase. - Check the presence of the three centring dowels. - Turn the crankshaft in order to align the counter- shaft movement sensor with a reference point on the crankcase (see figure).
Page 92 Beverly 500 i.e. Engine N.B. - THE INTERMEDIATE BOLTS FOR THE REMAINING MOUNTING POINTS WITH THE EXCEPTION OF THE BOLT FOR THE MANIFOLD SUPPORT (SHOWN IN THE FIGURE) ARE SLIGHTLY LONGER. Locking torques (N*m) Flywheel cover screws 11 - 13 Flywheel and starting The starter is sold as a complete part.
Page 93 Beverly 500 i.e. Engine 80 - 120 A Revolution speed = approx. 300-400 rpm YES go to 6 NO go to 7 NO go to 8 NO go to 9 5 - Restore the connections 6- The values are correct. Finally carry out a check of the power consumption at idle speed.
Page 94 Beverly 500 i.e. Engine N.B. IF THE TRAILING SPEED OF THE CRANKSHAFT IS LOW AND COMBINED WITH STRANGE NOISE, CHECK THE FREEWHEEL OF THE TORQUE LIMITER (SEE THE "FLYWHEEL AND STARTER SYSTEM" CHAPTER). - Remove the three bands shown in the figure for an easier removal of the flywheel cover, remove the feed hoses and disconnect the return hose from the pump cover.
Page 95 Beverly 500 i.e. Engine Removing the starter motor N.B. THIS OPERATION MAY ALSO BE CARRIED OUT WITH FLYWHEEL COVER ASSEMBLED. - Loosen the two fastening screws. - Extract the complete starter motor. Removing the flywheel magneto N.B. IF YOU MUST REMOVE THE FLYWHEEL, IT IS NECESSARY TO REMOVE THE CHAIN GUIDE SLIDING BLOCK RETAIN PLATE FIRST.
Page 96 Beverly 500 i.e. Engine - Tighten the bushing of the flywheel lock tool on the removing tool threading. - Insert the special tool as shown in the figure, making sure that the pins are perfectly inserted in- to the previously aligned holes and that it is per- fectly abutted and almost flush with the flywheel.
Page 97 Beverly 500 i.e. Engine - Insert the nut again so as to slightly uncover the shaft and free the space that was occupied by the washer. CAUTION THIS OPERATION IS REQUIRED AS THE FLYWHEEL IS STRONGLY LOCKED; THE CONE DETACHMENT MAY THEREFORE CAUSE THE ROTOR SLIPPAGE, WITH THE CONSEQUENT BREAKAGE OF THE MAGNETS.
Page 98 Beverly 500 i.e. Engine - Remove the freewheel from the flywheel by loos- ening the 6 fastening screws. SINCE THE FREEWHEEL MUST BE REMOVED, IT IS AD- VISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.
Page 99 Beverly 500 i.e. Engine Starter gear rim - Check that there is no wear or abnormal impres- sions on the "rollers" of the freewheel and on the surface of the starter ring gear hub. - Check the hub outside diameter. Characteristic Hub outside diameter: Diameter 45.665 + 0.008 +0.005 mm...
Page 100 Beverly 500 i.e. Engine Also check the shaft diameter on the flywheel cov- er and on the engine crankcase. Characteristic Bearing diameter on the flywheel cover 12 + 0.034 -0.016 mm Bearing diameter on the engine crankcase: 12 + 0.034 -0.016 mm N.B.
Page 101 Beverly 500 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 102 Beverly 500 i.e. Engine - Lubricate the inside bushing and the starter ring gear hub surface. - Install the start-up rim on the flywheel turning it clockwise and inserting at the same time. Refitting the flywheel magneto - Insert the key on the crankshaft. - Install the flywheel checking the proper insertion of the key and engaging the torque limiter gear with the start-up rim.
Page 103 Beverly 500 i.e. Engine - Tighten thoroughly the guide bushing of the fly- wheel lock tool and loosen by 1/4 turn. N.B. FAILURE TO OBSERVE THIS PRECAUTION CAUSES THE LOCKING OF THE GUIDE ON THE FLYWHEEL. Specific tooling 020472Y Flywheel lock wrench - Align the 2 holes of the flywheel with the case housing to allow the introduction of the special tool.
Page 104 Beverly 500 i.e. Engine - Install the chain guide retain plate tightening the 3 screws to the prescribed torque. N.B. BEFORE TIGHTENING THE SCREWS, MOVE THE START- UP RIM IN CONTACT WITH THE CRANKCASE AND CHECK THAT IT IS FREE TO ROTATE IN ANTICLOCKWISE DIREC- TION.
Page 105 Beverly 500 i.e. Engine Removing the intake manifold - Remove the 3 mounting screws. - Remove the intake manifold unit. Removing the rocker-arms cover - Loosen the 6 special screws with stop and the relevant rubber gaskets. - Remove the tappet cover with relevant gasket. Removing the timing system drive - Turn the engine to close the intake valves, i.e., moving the reference on the tone wheel to the top,...
Page 106 Beverly 500 i.e. Engine - Remove the central screw and the valve lifting device mass stop bell using the special tool. Specific tooling 020565Y Flywheel lock calliper spanner - Remove the return spring and the valve lifting mass with relevant travel end washer. N.B.
Page 107 Beverly 500 i.e. Engine Remove the inside hexagon screw and the coun- terweight as shown in the figure. - Remove the timing belt rim from the camshaft. - Remove the timing belt rim. - Remove the tone wheel. - Remove the engine revolution timing sensor and relevant O-ring by loosening the fastening screw and removing the mounting band from the special hole obtained on the head gasket.
Page 108: Removing The Cylinder Head
Beverly 500 i.e. Engine Removing the cam shaft - Unscrew the 3 fastening screws and remove camshaft retaining bracket. N.B. REMOVING THE FASTENING SCREWS MAY BE DIFFI- CULT. BE CAREFUL NOT TO DAMAGE THE INSIDE HEX- AGON. IF NECESSARY, SEPARATE THE THREADS IN ADVANCE.
Page 109 Beverly 500 i.e. Engine - Remove the coolant temperature sensor. N.B. THE SENSOR CONTROLS BOTH INJECTION AND THE AN- ALOGUE INSTRUMENT ON THE PANEL. TO CHECK THIS COMPONENT, SEE THE INJECTION CHAPTER. - Remove the 2 fastening nuts on the head, on the exhaust and on the intake side.
Page 110: Removing The Valves
Beverly 500 i.e. Engine Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. Specific tooling 020382Y Valve cotters equipped with part 012 removal tool 020382Y012 bush (valve removing tool) CAUTION ARRANGE THE VALVES SO AS TO RECOGNISE THE ORIGINAL POSITION ON THE HEAD (FLY- WHEEL SIDE AND TRANSMISSION SIDE).
Page 111 Beverly 500 i.e. Engine Removing the cylinder - piston assy. - Remove the timing chain. - Loosen the fastening screw and remove the spacer and the tightening sliding block. N.B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN- SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Page 112: Inspecting The Small End
Beverly 500 i.e. Engine Inspecting the small end - Using a bore gauge, measure the connecting rod small end diameter. N.B. IF THE CONNECTING ROD SMALL END DIAMETER EX- CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR OVERHEATING, PROCEED TO REPLACE THE CRANK- SHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER.
Page 113: Inspecting The Piston
Beverly 500 i.e. Engine Inspecting the piston - Measure the outside diameter of the piston, per- pendicular to the gudgeon pin axis. - Take the measurement in the position shown in the figure. Characteristic 43.2 mm Piston diameter: 92 mm - Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure.
Page 114: Removing The Piston
Beverly 500 i.e. Engine Fitting clearance (Cylindrin/Pison) Standard coupling clearance A 0.9 - 0.005 -0.030mm B 1.5 - 0.005 -0.03mm Maximum permissible clearance after use C 0.9 + 0.03 +0.01mm D 2 + 0.05 +0.02mm Standard coupling clearance </> 1.2 - 0.005 mm </> </> Maximum permissible clearance after use </> 1.25 + 0.03 mm </> </> Standard coupling clearance </>...
Page 115 Beverly 500 i.e. Engine - Insert the locking ring into the special tool, with the opening in the position indicated on the tool. S = left D= right - Place the wrist pin stop ring into position using a punch - Install the pin lock using the key shown in the figure.
Page 116 Beverly 500 i.e. Engine - Using an abutment plane, reset the dial gauge with a preload of a few millimetres. - Finally fix the dial gauge. - Check the perfect sliding of the feeler pin. - Install the tool on the cylinder without changing the dial gauge position.
Page 117: Inspecting The Cylinder Head
Beverly 500 i.e. Engine Refitting the piston rings - Place the scraper ring spring on the piston. - Install the scraper ring keeping the opening op- posed to the spring junction and with the writing "top" facing the piston crown. The chamfered side of the oil scraper ring should always be facing the piston crown.
Page 118 Beverly 500 i.e. Engine Maximum allowable run-out: 0.1 mm - In case of faults, replace the head. - Check the sealing surfaces for the intake and ex- haust manifold. - Check that the camshaft and the rocking lever pin capacities exhibit no wear. - Check that the head cover surface is not worn.
Page 119 Beverly 500 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 120 Beverly 500 i.e. Engine Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. STANDARD DIAMETER Specification Desc./Quantity Intake: 4.987 - 4.972 mm Exhaust: 4.975 - 4.960 mm MINIMUM ADMISSIBLE DIAMETER Specification Desc./Quantity Intake:...
Page 121 Beverly 500 i.e. Engine Inspecting the valve stem guide clearance - After measuring the valve guide diameter and the valve stem diameter, check clearance between guide and stem. INTAKE Specification Desc./Quantity Standard clearance: 0.013 - 0.04 mm Admissible limit: 0.08 mm EXHAUST Specification Desc./Quantity...
Page 122 Beverly 500 i.e. Engine - If no faults are found during the above checks, you can use the same valves. To obtain better sealing performance, grind the valve seats. Grind the valves gently with a fine-grained lapping com- pound. During the grinding, keep the cylinder head with the valve axes in a horizontal position.
Page 123 Beverly 500 i.e. Engine Refitting the valves - Place the valve spring support washers on the head. - Alternately insert the 4 oil guards using the spe- cial tool. - Lubricate the oil guards and the valve guides. Specific tooling 020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the caps.
Page 124 Beverly 500 i.e. Engine -Using a gauge, measure the cam height. STANDARD HEIGHT Specification Desc./Quantity Intake 33.988 mm Exhaust: 33.417 mm ADMISSIBLE LIMITS Specification Desc./Quantity Intake 33.740 mm Exhaust: 33.170 mm Standard axial clearance: 0 - 0.22 mm Maximum admissible axial clearance: 0.3 mm - If any of the above dimensions are outside the specified limits, or there are signs of excessive...
Page 125 Beverly 500 i.e. Engine - Check that the cam contact sliding block and the articulated register cap is free from wear. - In case of wear, replace the component. Refitting the head and timing system components - Insert the chain guide sliding block. - Insert the two centring dowels between head and cylinder.
Page 126 Beverly 500 i.e. Engine - Tighten the 4 fastening columns crosswise to the prescribed torque as shown in the figure. - Tighten the 4 screws by 90° in the sequence shown in the figure. - Further tighten by 90° in the sequence shown in the figure.
Page 127 Beverly 500 i.e. Engine - Insert the timing control belt on the crankshaft according to the initial direction of rotation. - Install the tensioner shoe with its spacer, tight- ening the bolt to the prescribed torque, using the recommended product. Recommended products Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock...
Page 128 Beverly 500 i.e. Engine - Insert the camshaft retain bracket with visible countersinks and tighten the 3 fastening screws to the prescribed torque, being careful not to damage the inside hexagon. Locking torques (N*m) Camshaft retaining bracket screws: 4 ÷ 6 - Check that the toothing and the housing of the tone wheel timing peg are free from deformations or dents.
Page 129 Beverly 500 i.e. Engine - Install the intermediate gear with torque limiter, the flywheel and its cover, as described in Chapter "Flywheel and start-up system", and in Chapter "Flywheel cover". N.B. FOR MORE CONVENIENCE, INSTALL THE FLYWHEEL COVER WITHOUT THE COOLING SYSTEM SLEEVES. - Using the TORX wrench, remove the timing check cap.
Page 130 Beverly 500 i.e. Engine - Insert the belt on the camshaft control timing rim. - Insert the timing rim on the camshaft checking that the references are aligned. N.B. DURING THE STROKE CHECK, KEEP THE BELT TEN- SIONED BY PRESSING ON THE TIGHTENER COMPART- MENT SIDE.
Page 131 Beverly 500 i.e. Engine - Turn the engine to move the references to the top as shown in the figure (intake end). - Insert the valve lifting device mass stop bell. - Tighten the retaining screw to the prescribed torque, using the recommended product. N.B.
Page 132 Beverly 500 i.e. Engine Refitting the timing chain The ignition advance is determined electronically on the basis of parameters known by the control unit. For this reason it is not possible to interpret the reference values based on the engine rpm. The ignition advance value is detectable at any time using the diagnostic tester.
Page 133 Beverly 500 i.e. Engine - Repeat for the reference between driving pulley and transmission housing. - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester. - Start the engine. - Select the «parameters» function in this menu. - Select the stroboscopic light control in the tradi- tional four-stroke engine position (1 spark, 2 revs).
Page 134 Beverly 500 i.e. Engine - Repeat the check at 3 - 4 points. - Place the tightener cursor in the rest position, keeping the retain tab pressed. - Install a new tightener on the cylinder using a new gasket. - Tighten the two fastening screws to the prescri- bed torque.
Page 135 Beverly 500 i.e. Engine Refitting the rocker-arms cover - Check that the gasket is in good working order. - Tighten the two screws indicated in the figure with «1» and «2» to limit the reciprocal sliding of the cover surface with the head surface. - Tighten the remaining 4 screws in a crossed se- quence (3, 4, 5, 6).
Page 136 Beverly 500 i.e. Engine Refitting the intake manifold - Install the intake manifold on the engine. - Insert the 3 fastening screws, one of which with a support band for the cooling system sleeve, and tighten to the prescribed torque. Locking torques (N*m) Intake manifold screws 11 to 13...
Page 137 Beverly 500 i.e. Engine - Remove the thermal group (cylinder, head, pis- ton) as described in the «Thermal group and timing system chapter». - Before opening the crankcase, check the crank- shaft axial clearance. For this purpose, use a plate (e.g. the special tool) and a support with special tool comparator.
Page 138 Beverly 500 i.e. Engine Splitting the crankcase halves - Remove the engine support retain screw on the flywheel side half-crankcase. - Remove the 14 crankcase coupling screws. N.B. THE FASTENING SCREWS ARE OF 3 DIFFERENT LENGTHS. NOTE THEIR CORRECT POSITION. - Split the crankcases while keeping the crankshaft inserted on the flywheel side half-crankcase.
Page 139 Beverly 500 i.e. Engine - Remove the crankshaft with the shim adjustment washer on the flywheel side. CAUTION WHILE OPENING THE CRANKCASE AND REMOVING THE CRANKSHAFT, CHECK THAT THE SHAFT THREADED ENDS DO NOT INTERFERE WITH THE MAIN BEARINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BEARING.
Page 140 Beverly 500 i.e. Engine - Remove the special tool and extract the counter- shaft with the control gear. Replacing the countershaft bearings - Check that the bearings are free from irregular noise or clearance. If it does, replace it. Flywheel-side half-crankcase - Remove the inside Seeger ring.
Page 141 Beverly 500 i.e. Engine - Before installing a new bearing, heat the flywheel side half-crankcase using the special tool. - Place the half-crankcase on a wooden base. Specific tooling 020151Y Air heater - Insert a new bearing on the special tool after greasing the guide seat.
Page 142 Beverly 500 i.e. Engine - Insert a new bearing on the special tool after greasing the guide seat. - Install the new bearing on the engine crankcase using the special tool. N.B. IF A BEARING WITH PLASTIC CAGE IS USED, KEEP THE BALLS VISIBLE FROM THE CRANKCASE INTERNAL SIDE.
Page 143 Beverly 500 i.e. Engine CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE STANDARD VALUES AND THE SUR- FACES ARE FREE FROM SCRATCHES. Shimming - Check the overall height of the crankshaft - shoulders - gear assembly. Characteristic Standard thickness: 71.804 - 72.000 mm...
Page 144 Beverly 500 i.e. Engine MAX ADMISSIBLE DISPLACEMENT: Specification Desc./Quantity = 0.15 mm = 0.01 mm = 0.01 mm = 0.10 mm - 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 145 Beverly 500 i.e. Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - For the transmission-side half-crankcase, special attention should be given to the bushings, to the cooling jet on the transmission side (see figure) and to the lubrication duct.
Page 146 Beverly 500 i.e. Engine Inspecting the crankshaft plain bearings - To obtain a good bushing lubrication it is neces- sary to have both an optimal lubricating pressure (4 bar) and a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply channels.
Page 147 Beverly 500 i.e. Engine Coupling chart COUPLING THE SEMI-SHAFTS WITH THE SEMI-CHASSIS AND BUSHES Name Description Dimensions Initials Quantity Half-shaft category 1 - Spare crankcase set-up Bushing category B FC1 - Dis. CM1033015001 Half-shaft category 2 - Spare crankcase set-up Bushing category C FC1 - Dis.
Page 148 Beverly 500 i.e. Engine - Before installing the gear on the crankshaft, care- fully clean the two matching surfaces removing any residues of LOCTITE from the holes using a brush. Blow with compressed air and degrease the mounting holes on both surfaces to make the new LOCTITE grip.
Page 149 Beverly 500 i.e. Engine - Insert the crankshaft on the pin and into the bush- ing. - Before inserting thoroughly, make the oil pump gear align with the control gear. - Insert thoroughly and remove the special tool. N.B. WHEN INSERTING THE SHAFT ON THE HALF-CRANKCASE, BE CAREFUL NOT TO DAMAGE THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE TIM- ING CONTROL TOOTHED PINION.
Page 150 Beverly 500 i.e. Engine - Insert the gasket on the flywheel side half-crank- case. - Lubricate the main bearing on the transmission side half-crankcase. - Couple the 2 half-crankcases being careful not to damage the bushing on the transmis- sion side half-crankcase with the threaded tang of the crankshaft.
Page 151 Beverly 500 i.e. Engine - Install the flywheel with start-up control as de- scribed in the "Flywheel and start-up" chapter. - Install the flywheel cover with the cooling system sleeves, as described in the "Flywheel cover chap- ter". - Install the complete driving pulley, the transmis- sion cover and the relevant mesh filter and the outside transmission cover as described in the «Automatic transmission»...
Page 152: Oil Pump
Beverly 500 i.e. Engine OIL PUMP Specification Desc./Quantity Type Trochoidal Rotor washers 8 mm Assembly clearances Lobe ends 0.05-0.008 mm External rotor radial clearance 0.05- 0.12 mm Rotor axial clearance 0.025 - 0.065 mm BY-PASS Specification Desc./Quantity Type with piston Plunger diameter 13.9 - 0.039 -0.057 mm Spring free length...
Page 153 Beverly 500 i.e. Engine Conceptual diagrams PRINCIPLE DIAGRAM Specification Desc./Quantity Camshaft Cylinder-head plane Cylinder-crankcase plane Water pump impeller Minimum oil pressure sensor Oil filter cartridge To the oil sump By-pass valve Oil pump Mesh pre-filter Crankshaft Connecting rod General characteristics The lubrication system is divided into two sections: - High pressure - Low pressure...
Page 154 Beverly 500 i.e. Engine The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is located before the cartridge filter and both are installed on the flywheel cover, so that the seal of the filter is subject to the pressure of the circuit.
Page 155 Beverly 500 i.e. Engine 3 Check the actual oil pressure. AHEAD - go to 4 4 - Remove the switch and fit the special tool with the relevant gasket. Specific tooling 020193Y Oil pressure check gauge 020434Y Oil pressure check fitting - Remove the dipstick with the oil filling cap and insert a cap fitted with the temperature probe supplied with the special tool.
Page 156: Oil Pressure Check
Beverly 500 i.e. Engine 8 - If pressure lower than 1.3 ÷ 1.5 bar is measured. AHEAD go to 9 9 - Replace the oil filter and repeat the pressure check with oil at 80°C. YES go to 10 NO go to 13 10 - The failure was fixed.
Page 157 Beverly 500 i.e. Engine 020434Y Oil pressure check fitting AHEAD go to 3 3 - Check the system pressure with cold engine and medium - high speed. Standard pressure < 6 bar YES go to 4 NO go to 5 4 - Replace the damaged components.
Page 158 Beverly 500 i.e. Engine - Remove the oil pump complete with the gearing by loosening the 2 retaining screws through the eyes machined in the gearing proper. - Remove the gasket. - Remove the two screws and the oil pump cover. - Remove the inside rotor retaining snap ring turn- ing it to move the opening at the shaft face.
Page 159 Beverly 500 i.e. Engine - Remove and wash the rotors thoroughly with pet- rol and compressed air. - Extract the shaft with its gear and check that it is in good working order and free from wear. - Reassemble the rotors in the pump body, keep- ing the two reference marks visible - Insert the shaft with the gear and install the lock ring;...
Page 160 Beverly 500 i.e. Engine - Check the rotor axial clearance using a rectified bar as reference plane, as shown in the figure. Characteristic Limit values admitted: 0.1 mm Inspection - For tests on the oil pump, see the "Lubrication" chapter. Refitting - Lubricate the internal rotors.
Page 161 Beverly 500 i.e. Engine - Make sure the gasket is in the correct position. N.B. THE TOOTH OF THE GASKET MUST BE IN ITS SEAT. - Insert the oil pump with gear - Insert the 2 retaining screws through the slots on the gear and tighten to the prescribed torque. N.B.
Page 162 Beverly 500 i.e. Engine Countershaft fixing nut 25 ÷ 29 ENG - 162...
Page 163 INDEX OF TOPICS INJEC NJECTION...
Page 164 Beverly 500 i.e. Injection TERMINALS CONDITIONS STANDARD 5 - 23 Switch in position "ON" Battery voltage Switch on "RUN" Side stand raised Electric fan off CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Electric fan Fuse Key switch Electric fan remote control switch The electric fan system is powered by a remote control switch connected to the continuous power supply controlled by the electronic control unit of...
Page 165 Beverly 500 i.e. Injection - Coolant level in the expansion tank - bleeding of the inlet hose to the engine - Bleeding of the outlet from the head - Function of the thermostat - Function of the pump For these checks, see chapter "Cooling system". To check the circuit, proceed as follows: 1 - Connect the diagnostic tester.
Page 166 Beverly 500 i.e. Injection 9 - Replace the remote control switch YES go to 8 10 - Connect the special tool between the control unit and the system. Do not connect the electronic control unit YES go to 11 11 - Check for positive battery voltage at pin 85 of the remote control switch connector.
Page 167 Beverly 500 i.e. Injection If the fault continues, replace the electronic control unit. EMS injection system This vehicle is fitted with an integrated injection and ignition system. Injection is indirect in the manifold through an electro-injector. Injection and ignition are timed on the 4-stroke cycle using a tonne wheel pivoted on the camshaft control and a reluctance variation sensor.
Page 168 Beverly 500 i.e. Injection Of course, this cannot happen when the rpm-timing signal is missing, or when the failure involves the control circuits: - Fuel pump - HV coil - Injector The control unit is provided with a self-diagnosis system connected to an indicator light in the in- strument panel.
Page 169 Beverly 500 i.e. Injection The EMS control unit power supply is further con- trolled by the emergency switch and by the side stand switch, that is to provide further safety for the scooter. The ignition system control unit is programmed to ensure optimal carburetion while riding along streets. The idle carburetion needs to be adjusted to compensate for the production tolerances and engine settlement.
Page 170 Beverly 500 i.e. Injection 3 - Connect the diagnostic tester. Set the switch to "ON" with switch to "RUN" and side stand raised. YES go to 4 4 - Select the menu on the "ERRORS" function. Check whether there are any failures. YES go to 6 NO go to 5 5 - Select the menu on the "PARAMETERS"...
Page 171 Beverly 500 i.e. Injection TRIMMER VALUE INJECTION TIME +100 HIGH INCREASE + 50 Ã Ã + 10 Ã Ã DECREASE - 10 MEDIUM - 50 -100 N.B. THE TRIMMER VALUE 0 CORRESPONDS TO THE AVERAGE INJECTION TIMING. AFTER ADJUSTMENT ENGINES CAN HAVE CARBURETION WITH BOTH POSITIVE AND NEG- ATIVE TRIMMER VALUES.
Page 172 Beverly 500 i.e. Injection N.B. WHEN THE CO PERCENTAGE IS RIGHT AND THE CO2 PERCENTAGE DOES NOT FALL INTO THE SPECIFIED VALUES, THE LAMBDA VALUE IS ALSO DISTORTED. If this occurs, carefully check the exhaust system for adequate sealing. When the CO percentage is correct and the HC (PPM) value exceeds the maximum limit allowed, check: - spark plug - valve clearance - timing system phase...
Page 173 Beverly 500 i.e. Injection If the anomaly persists and the carburation setting was correct, replace the muffler with catalytic con- verter. Precautions 1. Before fixing any part of the injection system, check to see if there are any registered faults. Do not disconnect the battery before checking for faults.
Page 174 Beverly 500 i.e. Injection ELECTRONIC CONTROL UNIT SIDE SYSTEM SIDE EMS CONTROLLER Specification Desc./Quantity Throttle potentiometer power supply +5 V Rpm indicator / consumption counter Engine temperature 86 electric fan remote control switch Stepper motor Stepper motor Engine rpm sensor EMS diagnostic connector EMS diagnostic connector Throttle potentiometer signal...
Page 175 Beverly 500 i.e. Injection IMMOBILIZER DECODER Specification Desc./Quantity Immobilizer LED control (negative) Base power supply (positive) Negative Electronic control unit EMS (serial) Continuous power supply (positive) Immobilizer aerial INJEC - 175...
Page 176 Beverly 500 i.e. Injection EMS circuit diagram SCHEMA IMPIANTO EMS Specification Desc./Quantity EMS electronic injection control unit Instrument panel Fuel injector Coolant temperature sensor Air temperature sensor Throttle potentiometer Stepper motor Stepper motor INJEC - 176...
Page 177 Beverly 500 i.e. Injection Specification Desc./Quantity Immobilizer decoder Immobilizer aerial EMS diagnostic socket Fuse No. 4 (5A) Stand switch Engine stop switch Diode 1A Engine stop remote control switch Key switch contacts Fuse No. 3 Voltage regulator Main fuse (30A) Battery 12V - 12 Ah Fuse No.
Page 178 Beverly 500 i.e. Injection Possible Cause Operation Battery Ground connections End of compression pressure End of compression pressure Power to the spark plug Spark plug Shielded cap HV coil Speed-timing sensor Ignition advance Fuel system Fuel pressure (low) Injector capacity (low) Injector sealing (poor) Correctness of the parameters Coolant temperature...
Page 179 Beverly 500 i.e. Injection Possible Cause Operation Intake system sealing (infiltrations) Intake manifold - head Throttle body - manifold Intake sleeve Filter box Fuel system (low pressure) Fuel pump Pressure regulator Fuel filter Injector capacity Analysis of exhaust fumes before the catalytic converter Trimmer value adjustment (CO % adjustment) Exhaust backfires in deceleration EXHAUST BACKFIRES WHEN DECELERATING...
Page 180 Beverly 500 i.e. Injection Poor performance at full throttle POOR ENGINE PERFORMANCE AT FULL POWER/ IRREGULAR ENGINE PROGRESS ON PICKUP Possible Cause Operation Presence of faults detected by the self diagnosis Pump relay H.V. coil Injector revolution timing sensor Air temperature Coolant temperature.
Page 181 Beverly 500 i.e. Injection Constant supply circuit check The decoder basic power supply is necessary for the deterrent flashing management. The injection control unit power supply is necessary for the Stepper motor management. A power supply failure disables both ignition and injection. In case of power supply faults, the diagnostic tester gives the information "NO REPLY FROM THE CONTROL UNIT".
Page 182 Beverly 500 i.e. Injection 8 - Fix any wiring short circuits and replace the fuse. YES go to 1 NO go to 9 9 - Check any short circuit on decoder or control unit and replace, if necessary. YES go to 1 10 - Place the special tool between control unit and power supply system.
Page 183 Beverly 500 i.e. Injection Specific tooling 020680Y Diagnosis Tool 1 - Check whether the immobilizer system LED in- dicates switching to "ON" YES go to 2 NO go to 4 2 - Raise the side stand. Set the emergency switch to "OFF".
Page 184 Beverly 500 i.e. Injection 8 - Decoder with proper continuous power supply. Use the special tool to check the control unit con- tinuous power supply. Switch set to "ON", switch to "RUN" and side stand raised. Pin 26 = battery positive Pin 23 = battery negative YES go to 9 NO go to 10 Specific tooling...
Page 185 Beverly 500 i.e. Injection - emergency switch and connector - side stand switch and connector YES go to 16 16 - Check the cable harness continuity. Check the utility control main remote control switch. Disconnect the master remote control switch. Check the diode installed on the earth connection of the main remote control switch pickup.
Page 186 Beverly 500 i.e. Injection 2 - Check the control unit base and continuous power supplies. YES go to 4 3 - Restore 4 - Place the special tool between control unit and system. Keep the control unit disconnected. YES go to 5 Specific tooling 020481Y Control unit interface wiring 5 - Check the following conditions:...
Page 187 Beverly 500 i.e. Injection Injection warning light circuit CIRCUIT LAYOUT Specification Desc./Quantity Instrument panel Fuse 7.5 A Electronic control unit Specification Desc./Quantity TERMINAL: 15 - 23 CONDITIONS: DURING THE CHECK - Switch set to "ON" - Side stand raised - Switch to "RUN" STANDARD VALUES : O V TERMINAL: 15 - 23 CONDITIONS: AFTER THE CHECK...
Page 188 Beverly 500 i.e. Injection YES go to 2 NO go to 3 2 - The system is working. 3 - Put the special tool between the control unit and system. YES go to 4 Specific tooling 020481Y Control unit interface wiring 4 - Switch in «ON»...
Page 189 Beverly 500 i.e. Injection Checking stored failures Connect the diagnostic tester to the scooter sys- tem. Select the function "ERROR" in the menu. Specific tooling 020680Y Diagnosis Tool The tester pages display the list of errors detecta- ble by the auto-diagnosis. Errors detected by the auto-diagnosis are marked by one or two reference dots.
Page 190 Beverly 500 i.e. Injection Deleting stored failures After mounting any failures, connect the diagnostic tester. Select the menu on the "errors deleting" function. Press "OK" and follow the instructions. Perform a trial cycle and check whether the failure occurs again. Specific tooling 020680Y Diagnosis Tool For troubleshooting for any faults see the related chapter sections.
Page 191 Beverly 500 i.e. Injection Circuit diagram CIRCUIT LAYOUT Specification Desc./Quantity Fuse Fuse 10 A Switch Engine stop remote control switch Fuse Control unit remote control switch HV coil Fuel pump Injector Electronic injection control unit Main remote control switch Engine stop switch Stand switch Removing the injector N.B.
Page 192 Beverly 500 i.e. Injection - To remove the injector, remove the central set screw of the "T" shunt acting as a support for the injector. - Remove the injector from the manifold. - Once the engine is repaired check the CO% value again while idling to make sure it is within the prescribed limits.
Page 193 Beverly 500 i.e. Injection THE THROTTLE BODY IS A PART WHICH INCLUDES VARIOUS COMPONENTS AND IS USUAL- LY SUPPLIED COMPLETE. TO TEST THESE COMPONENTS SEE THE "INJECTION" CHAPTER. - Remove the 3 retaining screws indicated in the figure. CAUTION THE THROTTLE BODY COMES PRE-CALIBRATED. TAMPERING WITH THE THROTTLE STOP REGISTER IS TO BE ABSOLUTELY AVOIDED.
Page 194 Beverly 500 i.e. Injection side, can be easily removed. Once clean, the throttle body guarantees an air flow exactly the same as the original. Throttle valve fouling is phenomenon that happens at different times depending on how the scooter is used, weather conditions and idle speed adjustment. This phenomenon can be easily detected as a gradual poor idle signals it.
Page 195 Beverly 500 i.e. Injection Circuit check Proceed as follows: 1 - Set the switch to "ON" with emergency switch to "RUN" and side stand raised. The pump rotates for 2 seconds. YES go to 2 NO go to 3 2 - Try to start up. Check that the engine speed matches the pump rotation. YES go to 4 NO go to 5 3 - The pump does not rotate, or it rotates uninterruptedly.
Page 196 Beverly 500 i.e. Injection 12 - Check and restore the earth insulation of the control unit line 19 and of the pump remote control switch line 85. YES go to 14 13 - Install the special tool between control unit and the injection system. YES go to 15 Specific tooling 020481Y Control unit interface wiring...
Page 197 Beverly 500 i.e. Injection 19 - Disconnect the following connectors: fuel pump, H.V. coil, injector YES go to 22 20 - Check the efficiency of the pump remote con- trol switch. Check the wiring continuity between remote control switch and pump. 87 (remote control switch) - green/black (pump) = continuity NO go to 21...
Page 198 Beverly 500 i.e. Injection - Relay closure - Pump rotation - Relay opening YES go to 31 NO go to 32 31 - The pump is fed. Perform a functional check of the pump. 32 - Check the efficiency of the pump connector. YES go to 33 NO go to 34 33 - Replace the fuel pump.
Page 199 Beverly 500 i.e. Injection To detach male type terminals (pump side) it is necessary to press the coaxial rings towards the pump, and extract the terminals. CAUTION DO NOT FORCE THE TERMINAL IF THIS DOES NOT COME LOOSE; EVENTUALLY, TRY TWISTING IT. THE TERMINAL IS DESIGNED SO THAT AN INCREASE IN TENSION IN- CREASES THE LOCKING FORCE.
Page 200 Beverly 500 i.e. Injection Check the regulation pressure with pump power supply voltage higher than 12 V. Regulation pressure = 300 - 320 kPa (3 - 3.2 BAR) YES go to 4 NO go to 5 4 - The pressure regulator is efficient. 5 - Pressure too high Check that the return duct is not clogged or squashed...
Page 201 Beverly 500 i.e. Injection 2 - Let bleed for a few seconds. Make sure that there are no leaks. Using pliers with flat and long tips, temporarily clamp the return duct by the extension of the spe- cial tool with pump power supply voltage higher than 12 V, check the system maximum pressure.
Page 202 Beverly 500 i.e. Injection 10 - There occur trend variations YES go to 11 NO go to 13 11 - Repeat the test clamping the pipe of the spe- cial tool in the portion between the branch and the injector. Check whether the pressure decreases with the same trend as the system when free.
Page 203 Beverly 500 i.e. Injection 17 - Introduce the return pipe into a graduated container. Using the diagnostic tester, start the fuel pump for 10 seconds. Make sure that the power supply voltage is more than 12V. Measure the amount of fuel delivered. Pump free flow rate = 300 - 320 cc.
Page 204 Beverly 500 i.e. Injection Pump consumption check The pump power consumption may vary according - Power supply voltage - Pump running-in - Regulation pressure - Delivery filter cleaning To check the current consumption, proceed as fol- lows - Disconnect the pump remote control switch con- nector.
Page 205 Beverly 500 i.e. Injection Pump bracket overhaul To remove the pump support from the tank, pro- ceed as follows: - Disconnect the electric connector. - Start the engine and wait for the spontaneous stop. - Clean the tank and the pump support (wash and blow with compressed air, if necessary).
Page 206 Beverly 500 i.e. Injection Pass the wires through the hole found between fil- ter and pressure regulator. - Disconnect and extract the wires - Using a screwdriver on the retain tab as shown in the figure, extract the level indicator from the support - Level indicator check The check may also be carried out before removing it from the support.
Page 207 Beverly 500 i.e. Injection - Lubricate the O-rings and repeat the operations in the reverse order for reassembly. (3) Fuel pump - Note the position of the power supply wires on the support pos 1 = positive (red) pos 4 = negative (black) - Disconnect the power supply cables - Cut the delivery pipe fastening clamp on the sup- port.
Page 208 Beverly 500 i.e. Injection - Remove the filter coupling pipe - Remove the pump with annular support and pre- filter. - If the pump requires replacement, remove the pre-filter and the annular support. - For reassembly, perform the removal operations but in the reverse order using a new clamp for the delivery pipe and a new pump mounting washer.
Page 209 Beverly 500 i.e. Injection Pump bracket installation - Before reassembling, carefully check that the tank is clean. In case of dirt or water, remove the tank. - Install the sealing gasket on the pump support. - Introduce the pump into the tank being careful not to deform the level indicator arm.
Page 210 Beverly 500 i.e. Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Injector HV coil Pump Control unit remote control switch Fuse 10 A 1 - Connect the diagnostic tester. Select the menu on the "ACTIVE DIAGNOSIS" function. Select the "INJECTOR" function. YES go to 2 Specific tooling 020680Y Diagnosis Tool...
Page 211 Beverly 500 i.e. Injection 5 - No injector openings detected. The injection tester displays «test failed». YES go to 9 NO go to 6 6 - No injector openings detected. The injection tester displays «test successful». YES go to 8 7 - The injector control circuit is efficient.
Page 212 Beverly 500 i.e. Injection 15 - Arrange a multimeter with positive prod on pin 13 and negative prod on pin 23. Set the switch to "ON" with switch to "RUN" and side stand raised. Check the presence of battery voltage during the fuel pump timing.
Page 213 Beverly 500 i.e. Injection Inspecting the injector hydraulics To check the injector it is advisable to remove the intake manifold along with throttle body and injec- tor. The injector should be removed from the manifold only if necessary. For these operations, see the "thermal group and timing system"...
Page 214: Troubleshooting
Beverly 500 i.e. Injection 3 - Perform the injector sealing test. Dry the injector outlet with a blast of compressed air. Activate the fuel pump. Wait for one minute, making sure there are no leaks coming from the injector. Slight oozing is normal. Value limit = 1 drop per minute YES go to 5 NO go to 6 4 - Higher quantities are not expected.
Page 215: System Components
Beverly 500 i.e. Injection Specification Desc./Quantity 5. Intake circuit - Dirty air filter - Dirty by-pass circuit - Faulty stepper motor 6. Other - Wrong distribution timing - Wrong idle speed carburetion - Wrong reset of the throttle valve position sensor 2 - Failures to the EMS system may depend on loosened connectors.
Page 216 Beverly 500 i.e. Injection Specification Desc./Quantity Main fuse 30 A Fuse 7.5 A Fuse Fuse Stand switch Emergency switch Key switch Engine stop remote control switch Main remote control switch Diode Instrument panel Immobilizer LED Decoder Immobilizer aerial Electronic control unit ECU Virgin circuit When control unit (ECU) and decoder are not pro- grammed, the following conditions occur:...
Page 217 Beverly 500 i.e. Injection The LED is turned on by the decoder. The control unit data can be checked by the diag- nostic tester. Specific tooling 020680Y Diagnosis Tool To connect the diagnostic tester, open the spark plug inspection port and pull out the EMS Diagno- sis socket.
Page 218 Beverly 500 i.e. Injection Setting the circuit The scooter is supplied with two keys: - Master key (red) with removable transponder - Service key (black) with fixed transponder The master and service keys must be used to code the system as follows: - Insert the master key, set to «ON»...
Page 219 Beverly 500 i.e. Injection WITH SERVICE KEYS Deterring blink Switching from «ON» to «OFF» with programmed system causes the intermittent switching on of the LED, with an antitheft effect. This occurs with any key used for programming. If the scooter is not used, the deterrent light stops automatically after 48 hours to prevent discharging the battery.
Page 220 Beverly 500 i.e. Injection - Remove the original master key transponder and install it on the master key of the new cylinder. - Program the system again as described above. 2 Decoder replacement When the decoder is replaced it is necessary to program the system again. Programming is indispensable for the engine start-up.
Page 221 Beverly 500 i.e. Injection N.B. TO ACCESS THE COMPONENTS, SEE THE COMPONENTS LAYOUT CHAPTER. Specific tooling 020481Y Control unit interface wiring 1 - Using a multimeter, check the continuity be- tween pin 16 of the control unit and pin 6 of the decoder connector.
Page 222 Beverly 500 i.e. Injection Program again. 3 - Check the proper connection of the aerial con- nector. YES go to 5 NO go to 4 4 - Restore the connection and check the presence of the code 5 - Disconnect the aerial connector and check con- tinuity (8 ±...
Page 223 Beverly 500 i.e. Injection Code 4 Code no. 4 denotes a system where the decoder is blank and the control unit is programmed. The key is recognised by the control unit. - Start-up disabled - Indicator light N.B. REPEAT THE KEY PROGRAMMING PROCEDURE USING THE ORIGINAL MASTER KEY. Diagnosis guide Immobiliser LED does not come on 1 - Check whether the injection indicator turns on...
Page 224 Beverly 500 i.e. Injection 8 - Check for positive battery voltage on the red/ black cable of the 8-way connector of the instru- ment panel. YES go to 9 NO go to 10 9 - Faulty led, replace the instrument panel. 10 - Repair or replace the wiring.
Page 225 Beverly 500 i.e. Injection the 4-stroke cycle. Such solution allows controlling the injector and the spark plug every two revolutions of the crankshaft. The sensor is of the reluctance variation type and is therefore comparable to an alternate current gen- erator that powers the control unit.
Page 226 Beverly 500 i.e. Injection If a signal panel is detected which is not perfectly synchronised, corrective interventions are applied used to reconstruct the cycle. In this case the self-diagnosis records the number of lost synchronisations and signals the fault via the injection telltale light. The light remains on during the period the cycle is reconstructed.
Page 227 Beverly 500 i.e. Injection YES go to 6 NO go to 7 6 The signal panel is in conformance. 7 CHECK THE AIR GAP AND MAGNETIC AC- TIVITY OF THE SENSOR. See engine mechanics. 8 Check the sensor and related connection circuit with the control unit.
Page 228 Beverly 500 i.e. Injection YES go to 13 NO go to 12 12 - Replace the revolution sensor. 13 - Reconnect the rpm-timing sensor connector. Repeat the resistance check through the injection wiring pin 7, pin 12. Electric characteristic 7-12 = 680 Ω...
Page 229: Circuit Diagram
Beverly 500 i.e. Injection infinite (>1MΩ) YES go to 19 NO go to 18 18 - Check the sensor and control unit connectors. Repair or replace the injection wiring 19 - Measure the alternated voltage between pins 7 and 12 with engine at start-up speed. Electric characteristic 7-12 = approx.
Page 230 Beverly 500 i.e. Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Injector HV coil Pump Control unit remote control switch Fuse 10 A The ignition system is integrated with the injection and it is a high-efficiency inductive type ignition. The control unit manages two important parame- ters: - Ignition advance This is optimised according to the engine rpm, to...
Page 231 Beverly 500 i.e. Injection 4 - Test failed YES go to 6 5 - The coil control circuit is efficient. Check the H.V. coil secondary, the cable and the screened cap 6 - Install the special tool between the injection system and the control unit. Measure voltage between pins 20 and 23 of the specific Specific during the timing phase of the fuel pump.
Page 232 Beverly 500 i.e. Injection N.B. A FAILURE OF THE REMOTE CONTROL SWITCH WOULD CAUSE THE PUMP ROTATION FAIL- 10 - The positive power supply is conforming. Check the continuity between the pink-black wire of the connector and pin 20. Electric characteristic Pink-black-20 = Continuity YES go to 12 NO go to 11...
Page 233 Beverly 500 i.e. Injection YES go to 15 NO go to 14 13 - Repair or replace the faulty system. Repeat the check with the menu on "ACTIVE DIAGNOSIS". 14 - Repeat the earth insulation check in the two sections. Repair or replace the wiring. Repeat the check with the menu on "ACTIVE DIAGNOSIS"...
Page 234 Beverly 500 i.e. Injection YES go to 17 NO go to 1 9 17 - Check the secondary resistance. Measure the resistance between one of the primary terminals and the spark plug cable output Electric characteristic Primary HV cable output = 3.1 K ±...
Page 235 Beverly 500 i.e. Injection If different values are measured (<1; >20KΩ), re- place the shielded cap. N.B. A SHIELDLESS CAP OR SPARK PLUG CAN ADVERSELY AFFECT THE INJECTION SYSTEM. FOR INFORMATION ON THE SPARK PLUG, SEE THE «SPECIFICATIONS» AND «MAINTE- NANCE»...
Page 236 Beverly 500 i.e. Injection - By the driving pulley, turn the engine to find the alignment of the references to identify the TDC. - Repeat for the reference between driving pulley and engine crankcase. - Refit the inspection cap on the flywheel side. - Connect the diagnostic tester.
Page 237 Beverly 500 i.e. Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor The coolant temperature sensor is installed on the engine head and provides the indications for the digital instrument and for the injection. It is realised with two electrically different sections.
Page 238 Beverly 500 i.e. Injection 020680Y Diagnosis Tool 2 - The EMS system has received no indications of temperatures out of the range of possible temper- atures. If you suspect a wrong temperature indication, proceed to perform the following check. N.B. A WRONG TEMPERATURE SIGNAL CAN BE DETECTED BY COUPLING THE ANALOGUE IN- STRUMENT INDICATION WITH THE ELECTRIC FAN START.
Page 239 Beverly 500 i.e. Injection Electric characteristic 4-22 = Resistance equal to the value directly detected at the sensor. YES go to 13 NO go to 11 11 - If slightly higher values are detected, check the connectors. If infinite resistance is detected (>1MW), check the continuity between the two lines with disconnected connectors.
Page 240 Beverly 500 i.e. Injection YES go to 15 NO go to 14 14 - Repair or replace the wiring. Check the air temperature lines and the throttle valve position. YES go to 13 15 - Connect the special tool to the control unit. Set the switch to "ON"...
Page 241 Beverly 500 i.e. Injection YES go to 18 Electric characteristic Measured value = Repeat the sensor and circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector. Check the control unit power supply. Replace the control unit, if necessary.
Page 242 Beverly 500 i.e. Injection CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor The sucked air temperature sensor is installed in the bottom side of the throttle body on the filter box side. The sensor is an NTC and has the same functional layout as the coolant temperature sensor.
Page 243 Beverly 500 i.e. Injection Check whether there are any indications regarding the sucked air temperature sensor. YES go to 3 NO go to 2 Specific tooling 020680Y Diagnosis Tool 2 - The EMS system has received no indications of temperatures out of the range of possible values. If you suspect a wrong temperature indication, proceed to perform the following check.
Page 244 Beverly 500 i.e. Injection YES go to 10 NO go to 9 9 - Replace the sensor. 10 - Connect the sensor connector and repeat the resistive check at terminals 18 and 22. Electric characteristic 18-22 = Resistance equal to the value directly detected at the sensor. YES go to 13 NO go to 11 11 - If slightly higher values are detected, check the connectors.
Page 245 Beverly 500 i.e. Injection 12 - Repair or replace the cable harness. YES go to 10 13 - Check that the sensor circuit is earth insulated. Electric characteristic 18-23 = infinite (>1MΩ) 22-23 = infinite (>1MΩ) YES go to 15 NO go to 14 14 - Repair or replace the wiring.
Page 246 Beverly 500 i.e. Injection YES go to 21 NO go to 17 Electric characteristic Measured value = 5±0.2 V Repeat the wiring and sensor continuity checks. YES go to 18 Electric characteristic Measured value = Repeat the sensor circuit earth insulation check. YES go to 19 NO go to 20 19 - Check the control unit connector.
Page 247 Beverly 500 i.e. Injection Pressure sensor This sensor does not have a system since it is di- rectly installed into the control unit. The sensor allows the control unit to optimise the engine performance based on altimetric varia- tions. To check the sensor, proceed as follows: 1 - Connect the diagnostic tester.
Page 248 Beverly 500 i.e. Injection STANDARD: 5 V TERMINALS: 11 - 22 CONDITIONS: Opening the throttle gradually STANDARD: Volt= Progressive increase CIRCUIT LAYOUT Specification Desc./Quantity Electronic control unit Valve position sensor Air temperature sensor Fluid temperature sensor The throttle valve position sensor is not removable and is installed on the throttle body.
Page 249 Beverly 500 i.e. Injection even though not in an optimum way, always safe- guarding the catalytic converter integrity. The throttle valve position signal is especially im- portant at the small valve openings. These areas are also where the sensor works more frequently, and therefore they require more frequent checks after a high number of kilometres run.
Page 250 Beverly 500 i.e. Injection 020481Y Control unit interface wiring Electric characteristic Light blue/green-22 = 0 Ω (continuity) Brown-yellow-1 = 0 Ω (continuity) Orange-light blue-11 = 0 Ω (continuity) YES go to 8 NO go to 7 7 - Repair or replace the injection wiring. YES go to 6 8 - Check the earth insulation of the three circuit lines.
Page 251 Beverly 500 i.e. Injection Measure voltage between terminals 1 and 22 of the special tool. Specific tooling 020481Y Control unit interface wiring Electric characteristic 1-22 = 5±0.2 V YES go to 12 NO go to 11 11 - Check the control unit connector. Replace the control unit, if necessary.
Page 252 Beverly 500 i.e. Injection The possible variations of the limit values are caused by the sensor installation tolerances. YES go to 15 NO go to 14 14 - Replace the throttle body along with sensors and Stepper. YES point 12 15 - Check that the voltage measured at pins 11 and 22 matches that indicated by the diagnostic tester set to "PARAMETERS".
Page 253 Beverly 500 i.e. Injection Connect the diagnostic tester. Set the switch to "ON" with switch in "RUN" and side stand raised. Select the functions of the diagnostic tester on «TPS RESET». Specific tooling 020680Y Diagnosis Tool Make sure that the throttle valve with the control is supporting the stop screw.
Page 254 Beverly 500 i.e. Injection THE TPS RESET PROCEDURE MUST NOT BE CARRIED OUT WITH A USED THROTTLE BODY BECAUSE POSSIBLE VALVE WEAR AND STOP WEAR FOR THE MINIMUM OPENING MAKE THE AIR FLOW DIFFERENTLY FROM THAT OF PRE-CALIBRATION. Step motor CIRCUIT LAYOUT Specification Desc./Quantity...
Page 255 Beverly 500 i.e. Injection To prevent wear of the adjustment piston, opera- tion at full speed is obtained with a minimum open- ing of 43 - 45 "steps". To recover possible adjustments, every switching to "OFF" causes the piston to close up to end of travel and to open up again by a fixed number of steps (self-reset).
Page 256 Beverly 500 i.e. Injection YES go to 3 NO go to 4 3 - Start the engine and let it warm up. With a coolant temperature of more than 70°C, the control unit must control the Stepper with about 45 «steps».
Page 257 Beverly 500 i.e. Injection Resistance = approx. 51 Ω YES go to 11 NO go to 10 9 - Test successful. No variations of revolutions. Remove the throttle body. Check the auxiliary air circuit cleaning. Switch from "ON" to "OFF" and again to "ON" and check wheth- er the piston valve moves.
Page 258 Beverly 500 i.e. Injection YES go to 12 NO go to 13 12 - Check the earth insulation of the 4 Stepper lines. Electric characteristic 14-23 = >1 MΩ (infinite) 6-23 = >1 MΩ (infinite) 21-23 = >1 MΩ (infinite) 24-23 = >1 MΩ...
Page 259 Beverly 500 i.e. Injection YES go to 16 NO go to 15 15 - Check cable harness and connectors more carefully. 16 - Connect the control unit connector. Set the switch to «ON» with switch to «RUN» and side stand raised. Repeat the «ON» «OFF» «ON» switching.
Page 260 INDEX OF TOPICS SUSP USPENSIONS...
Page 261: Removing The Front Wheel
Beverly 500 i.e. Suspensions This section is dedicated to operations that can be carried out on the suspensions. Front Removing the front wheel • Loosen the two wheel axle locking screws shown in the figure. • Remove the wheel axle locking nut. •...
Page 262 Beverly 500 i.e. Suspensions 001467Y034 Pliers to extract ø 15-mm bearings 001467Y014 Calliper to extract ø 15-mm bear- ings 001467Y009 Driver for OD 42-mm bearings • Support the front wheel with two wood- en pegs that prevents scratching in case of contact with the rim. •...
Page 263 Beverly 500 i.e. Suspensions • Reinsert the spacer bushing on the brake disc side using the specific tool and drive it until it stops. Specific tooling 020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide 020201Y Spacer bushing driving tube •...
Page 264: Front Fork
Beverly 500 i.e. Suspensions Front fork 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.
Page 265 Beverly 500 i.e. Suspensions Check pump unit - Check that the oil holes on the pumping are free from clogging. - Check that the sealing snap ring is not damaged. Servicing tapered bearing seats - Check that the seats and the tapered bearings exhibit no scratches or wear. N.B.
Page 266 Beverly 500 i.e. Suspensions - Loosen the stem support clamp and remove fork leg and stem. - Remove the spring. - Drain the oil. - Remove the screw with copper washer shown in the figure. To prevent the pumping member rota- tion, insert an inside 22 mm hexagon spanner into the stem.
Page 267 Beverly 500 i.e. Suspensions - Extract the oil guard "D", the abutment washer "C" and the top bushing "B". - Widen and remove the bottom bushing "A". Refitting - Grease the tapered bearing using the specified product. Recommended products AGIP GREASE PV2 Grease for steering bear- ings, pin seats and swinging arm White anhydrous-calcium based grease to protect roller bearings;...
Page 268 Beverly 500 i.e. Suspensions - Install the handlebars on the steering tube, pay- ing attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the prescribed torque. - Install the front and rear handlebar covers as described in the section "Scooter body".
Page 269 Beverly 500 i.e. Suspensions - Insert the pumping member guiding bushing at the bottom end of the stem. - Insert the stem into the casing being careful not to let the guiding bushing come out of the stem. - Move the oil guard in abutment using a tube. TUBE SIZE Specification Desc./Quantity...
Page 270 Beverly 500 i.e. Suspensions Characteristic Amount oil: 195 ± 3 cc - Insert the spring with the thickest turns at the bottom. - Insert the stem into the fork clamp. - Tighten the clamp to screw the top stem closing cap.
Page 271 Beverly 500 i.e. Suspensions - Insert the special tool as shown in the figure. - Insert the retaining band of the two half-rings. - Using a 19 mm hexagonal spanner, extract the roller bearing. Specific tooling 020458Y Puller for lower bearing on steering tube Refitting Reassembly of steering tapered bearing seats...
Page 272: Removing The Rear Wheel
Beverly 500 i.e. Suspensions ALWAYS USE A NEW BEARING AND A NEW SEAT. Specific tooling 001330Y Tool for fitting steering seats Reassembly of tapered bearing in steering tube - Insert the a new plate and a new dust guard in the steering tube - Insert the a new tapered bearing in the steering tube...
Page 273 Beverly 500 i.e. Suspensions - Loosen the five gear shaft fastening nuts using the rear brake. Refitting the rear wheel - For reassembly, perform the previous operations in the reverse order Locking torques (N*m) Wheel fastening screws 33 - 37 Swing-arm Removal •...
Page 274 Beverly 500 i.e. Suspensions • Remove the locking nut, the washer and the tie rod buffer. • Suitably support the engine using a jack under the oil sump. • Remove the nut of the pin mounting the swinging arm to the chassis. •...
Page 275 Beverly 500 i.e. Suspensions • Loosen the rear shock absorber mounting bolts. • Move the engine backwards as much as piping and transmissions allow, at the same time move the front of the engine leftwards to allow removing the tie rod (with washer and pad) from the chassis and from the pin mounting the swinging arm to the engine.
Page 276 Beverly 500 i.e. Suspensions • Remove the bushing from the bearing on the engine left support. Check that the following components are not worn or dented: • Engine crankcase supports • Ball bearing with bushing on swinging arm • Roller bearing on swinging arm Check that the chassis connecting pin exhibits no wear or dents on the roller bearing connection: In case of irregularities, replace the pin and the roller bearing.
Page 277 Beverly 500 i.e. Suspensions • Extract the right bearing using the modular punch through the left bearing seat (removed before). Specific tooling 020363Y 20-mm guide 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle Overhaul • Properly support the swinging arm in the vice.
Page 278 Beverly 500 i.e. Suspensions • Extract the roller bearing using the spe- cial tool. N.B. POSITION THE PLIERS FOR EXTRACTING UNDER THE UPPER EDGE OF THE ROLLER BEARING. Specific tooling 001467Y010 Driver for OD 25 mm bearings 001467Y019 Extraction pliers for ø 18 mm bear- ings Refitting •...
Page 279 Beverly 500 i.e. Suspensions • Install the Seeger ring. • Install the roller bearing using the spe- cial tool. Specific tooling 020083Y Punch • Heat the connections on the engine crankcase and insert the bearings to abutment using the modular punch. •...
Page 280 Beverly 500 i.e. Suspensions • Lubricate the inside tracks of the bear- ings on the crankcase. • Lubricate the roller bearing into the swinging arm. • Lubricate the bearing connection on the swinging arm/engine pin. Lubricate the roller bearing connection on the swinging arm/chassis pin.
Page 281 Beverly 500 i.e. Suspensions • Apply the buffer and the washer to the tie rod and lock it. Locking torques (N*m) Upper tie mounting: 33-41 Nm • Lubricate the shaped washer and place it onto the bearing. • Insert the chassis mounting pin. •...
Page 282: Shock Absorbers
Beverly 500 i.e. Suspensions Shock absorbers Removal Proceed as follows: • Rest the vehicle on the central stand; • Remove the sides according to the removal sequence described in Chapter "Body". • Slightly raise the engine using a jack to free both shock absorbers;...
Page 283: Side Stand
Beverly 500 i.e. Suspensions Shock absorber lower clamping 33 to 41 Upper shock absorber retainer 33 to 41 Centre-stand - Remove the two return springs from the centre stand. - Loosen the fastening nuts. - Remove the centre stand. - On refitting tighten the nut to the specified torque. Locking torques (N*m) Central stand retainers 25 ÷...
Page 284 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 285: Rear Brake Calliper
Beverly 500 i.e. Braking system Rear brake calliper Removal - Remove the rear wheel. - Remove the snap ring of the pad retaining pin. - Using a key, partially slide off the pad retaining pin until the circlip is released. - Remove the screws fixing the brake calliper to the bracket, then remove the brake calliper com- plete with pipe.
Page 286 Beverly 500 i.e. Braking system Overhaul - Remove the rear brake calliper - Suitably support the brake calliper in a vice - Remove the two calliper coupling screws as shown in the photograph. - Remove the two plungers from the calliper body with the aid of short blasts of compressed air through the brake fluid feed holes.
Page 287 Beverly 500 i.e. Braking system Refitting - The rear break calliper can be recognised by its Ø 34 mm plungers and the bleed screw as shown in the figure. - Insert the break pads in the pliers according to the arrow that indicates the break disc direction of rotation as shown in the photograph.
Page 288 Beverly 500 i.e. Braking system - Keep the brake pads in contact with the plungers and insert the calliper in the brake disc. - Fix the calliper to the support with the two screws with spring washer to the prescribed torque as shown in the photograph.
Page 289 Beverly 500 i.e. Braking system compressed air through the brake fluid feed holes • Remove the dust guard and the sealing ring of each half-calliper. • Remove the two sealing rings in the right half-calliper. N.B. WHEN REMOVING THE O-RINGS, BE CAREFUL NOT TO SCRATCH THE HALF CALLIPER SEATS •...
Page 290 Beverly 500 i.e. Braking system que, orientating the union parallel to the horizontal axis, as shown in the fig- Locking torques (N*m) Brake calliper fastening screws: Brake 20-25 N•m coolant pipe union 20-25 N·m Rear brake disc Removal - Remove the rear brake calliper - Remove the brake disc with hub from the wheel axle.
Page 291 Beverly 500 i.e. Braking system White anhydrous-calcium based grease to protect roller bearings; temperature range between -20 C and +120 C; with NLGI 2; ISO-L-XBCIB2. - Insert the hub - disc assembly in the wheel axle. Locking torques (N*m) Rear brake disc mounting 11 ÷ 13 Disc Inspection •...
Page 292: Front Brake Disc
Beverly 500 i.e. Braking system Front brake disc Removal - Remove the front wheel. - Adequately support the front wheel and remove the break disc operating on the five screws shown in the photograph. Refitting • Perform the removal operations in the reverse order according to the direc- tion of rotation of the disc, as shown by the arrow on the disc.
Page 293: Front Brake Pads
Beverly 500 i.e. Braking system • Repeat the measurement in at least 6 points on the disc • Check that the measurement does not deviate over 0.1 mm • Remove the front brake calliper • Place the magnetic base with the dial gauge on the break calliper support bracket as shown in the photograph •...
Page 294 Beverly 500 i.e. Braking system Refitting • Insert the break pad in the calliper as shown in the photograph • Insert the pad fixing pin and the reten- tion spring being careful to position its ends pointing towards the bleed screw as shown in the photograph •...
Page 295 Beverly 500 i.e. Braking system Rear brake pads Removal - Remove the rear brake calliper - Remove the brake pad and check there are no faults or warping. If it does, replace it. - Check that the thickness of the friction material is over 1.5 mm.
Page 296 Beverly 500 i.e. Braking system Rear - combined To bleed the integral system, first bleed the rear break calliper. - Remove the rubber cap from the bleed screw and insert a rubber pipe to recover the brake fluid. - With the left-had brake lever, load the system and bring it up to the required pressure.
Page 297 Beverly 500 i.e. Braking system Circuit bleed calliper fitting 12 - 16 Front - 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 right-hand brake lever, load the system and bring it up to the required pressure. - Keeping the right-hand brake lever pulled, loosen the bleed screw to purge the air.
Page 298 Beverly 500 i.e. Braking system Brake fluid level check • Rest the scooter on a flat ground and on the central stand. • Remove the brake pump cover as shown in the figure • Check the fluid level by the portholes on the pumps.
Page 299 Beverly 500 i.e. Braking system AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. WARNING BRAKE CIRCUIT FLUID IS VERY CORROSIVE; DO NOT LET IT COME INTO CONTACT WITH PAINTED PARTS. Recommended products AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid...
Page 300 Beverly 500 i.e. Braking system Handlebar pump 7 to 10 Oil pipe joint to the pump: 20 - 25 BRAK SYS - 300...
Page 301 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 302 Beverly 500 i.e. Cooling system Circuit diagram The cooling system is a forced circulation type system, with continuous venting and air pressurisation. Circulation takes places by a centrifugal pump driven by the countershaft. The pump delivers the coolant to the thermal group. The two-way thermostat support is connected in output to the head.
Page 303 Beverly 500 i.e. Cooling system For the system venting during the circuit filling step, there is a special union at the top of the head (see filling rules). To ensure cooling in case of poor dynamic ventilation, there is an electric fan controlled by the injection system.
Page 304 Beverly 500 i.e. Cooling system - Select the menu on the "ACTIVE DIAGNOSIS" function and start the electric fan operation simu- lation (see "Injection" chapter). - If the electric fan is certainly efficient, check the ventilation start and stop temperatures. - Select the «PARAMETERS»...
Page 305: Coolant Replacement
Beverly 500 i.e. Cooling system System sealing check - Check the proper circuit sealing when it is under pressure and at the temperature. - For a more accurate check, wait until the system has cooled down since small leaks may not be visible due to evaporation - The water pump is provided with a drainage hole in case of leaks from the cooling system mechan-...
Page 306 Beverly 500 i.e. Cooling system CAUTION ELECTRIC VENTILATION IS CONTROLLED BY THE TEMPERATURE MEASURED AT THE HEAD. THE ELECTRIC VENTILATION START DOES NOT MEAN THAT THE VENTING HAS BEEN COM- PLETED. VENTING IS COMPLETE WHEN THE EXPANSION TANK TEMPERATURE RISES. Water pump - overhaul In case of noise or fluid leaks from the water pump drainage hole, inspect the pump as described in...
Page 307 Beverly 500 i.e. Cooling system Cooling system approx. 1.7 litres Water pump ceramic seal Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject. This component is intended to guarantee the leak tightness of the coolant in relation to the pump shaft.
Page 308 Beverly 500 i.e. Cooling system Specific tooling 020680Y Diagnosis Tool • Check the temperature read by the diagnostic tester. • If opening occurs at different temperatures, check the thermostat. • Remove the thermostat as described in the flywheel cover paragraph. Characteristic Thermostat opening start approx.
Page 309 Beverly 500 i.e. Cooling system N.B. AVOID CONTACT BETWEEN THERMOSTAT AND CONTAINER FOR A CORRECT TEST PER- FORMANCE. diagnosis Excessive system pressure 1 - Check the expansion tank cap efficiency. N.B. THE CAP IS EQUIPPED WITH A PRESSURE-RELIEF VALVE CALIBRATED AT 0.9 BAR. There is also a valve that must allow air inlet during the cooling step.
Page 310 INDEX OF TOPICS CHAS HASSIS...
Page 311: Rear Rack
Beverly 500 i.e. Chassis Seat • To remove the saddle, loosen the three screws shown in the figure. Side fairings - Remove side bumpers by removing the mounting screws shown in the figure (one on each side). Rear rack - Loosen the two mounting screws and remove the battery cover.
Page 312 Beverly 500 i.e. Chassis Rear handlebar cover • Remove the brake tank covers by the screw shown in the figure. • Remove the rear-view mirrors and the windscreen. • Remove the upper coupling screws. • Remove the two lower mounting screws.
Page 313: Instrument Panel
Beverly 500 i.e. Chassis Instrument panel • Remove the rear handlebar cover. • Unscrew the four screws shown in the figure to separate the rear handlebar cover from the instrument unit. Front handlebar cover • Remove the rear handlebar cover. •...
Page 314 Legshield • Remove Piaggio badge using a screw- driver being careful not to damage the front shield. • Remove the screw shown in the figure.
Page 315 Beverly 500 i.e. Chassis • Remove the expansion tank flap. • Remove the fixing screw shown in the figure. • Remove the central cover. • Remove the two lower retainers indi- cated in the figure. • Remove the whole front shield. Knee-guard •...
Page 316 Beverly 500 i.e. Chassis • Disconnect the connectors of the sad- dle opening button and of the fuel level damper device. • Remove the expansion tank fixing screw, inside the glove-box. • Remove the shield back plate central fixing screw. •...
Page 317 Beverly 500 i.e. Chassis • Remove the cover and rubber gasket from the expansion tank filler. • Detach the shield back plate and re- lease the expansion tank filler from the hole on the shield back plate. • Remove the shield back plate. Removing the ignition key-switch when on *off* •...
Page 318 Beverly 500 i.e. Chassis Removing the ignition key-switch when on *lock* In "Lock" and "ON" position, the cylinder locking spring cannot be accessed. Drill the clip as shown in the figure to eject the lock cylinder. N.B. FOR REASSEMBLY FROM THIS POSITION, RELEASE THE STEERING WHEEL AND SET THE LOCK BODY (INSIDE AND OUTSIDE PART) TO "OFF".
Page 319 Beverly 500 i.e. Chassis • Remove the upper mounting screw through the special hole on the trunk rack. • Remove the rear light group and disconnect the electric connector. Footrest • Remove the central cover. • Remove the six screws shown in the figure.
Page 320 Beverly 500 i.e. Chassis Side fairings Remove the saddle. • Remove the under-saddle cover by loosening the mounting screw shown in the figure. • Remove the central cover. • Remove the rear light unit. • - Remove the rear luggage rack. •...
Page 321 Beverly 500 i.e. Chassis • - Remove the two fairing retaining screws shown in the figure. CAUTION THE TWO SCREWS SHOWN IN THE FIGURE HAVE DIF- FERENT LENGTH. USE THE SHORTER SCREW FOR SIDE MOUNTING SINCE THE LONGER ONE WOULD DAMAGE THE UNDER-SAD- DLE COMPARTMENT INSIDE WALL.
Page 322: Rear Mudguard
Beverly 500 i.e. Chassis Air filter • Remove the two mounting screws shown in the figure. UPON REASSEMBLY, THE SHORTER SCREW MUST BE INSERTED INTO THE REAR SIDE. • Remove the blow-by and condensate exhaust pipe cap. • Loosen the intake hose screw band. •...
Page 323 Beverly 500 i.e. Chassis Helmet bay • Remove the side panels • Remove the licence plate holder tail. • Remove the saddle opening control primary transmission. • Remove the internal light. • Remove the saddle light button con- nections. • Remove the current socket connec- tion.
Page 324: Fuel Tank
Beverly 500 i.e. Chassis • Remove the upper screw and the two lower screws fixing the spoiler. Fuel tank • - Remove the front shield. • Remove the footrest. • Remove the upper retainer and the two lower retainers of the spoiler. N.B.
Page 325 Beverly 500 i.e. Chassis • Protect the front mudguard and the ra- diator to avoid scratching and/or dam- aging them, then move the spoiler towards the mudguard and turn the handlebars completely to the right or left to gain access to the area under the tank.
Page 326 Beverly 500 i.e. Chassis • Remove the rear retainer. • Move the tank backwards and pull out the front side downwards, then release the rear side sideways. For reassembly, perform the operations in the reverse order, paying attention to the following tightening torques.
Page 327: Front Mudguard
Beverly 500 i.e. Chassis Front mudguard • - Remove the front wheel • Remove the retainer «A» from the od- ometer transmission to the mudguard and from the fork leg right cover. • Remove the retainer «B» from the right front break pipes.
Page 328 Beverly 500 i.e. Chassis Radiator fan - Remove the front wheel housing. - Prepare a container for the coolant. - Remove the expansion tank outlet and return pipes. - Remove the coolant supply and return pipes from the radiator. - Loosen the screw mounting the radiator to the frame.
Page 329 INDEX OF TOPICS PRE DE DELIVERY...
Page 330 Beverly 500 i.e. Pre-delivery Carry out the listed tests before delivering the vehicle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks SAFETY LOCKS: Name Torque in Nm...
Page 331 Beverly 500 i.e. Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, CONNECT THE POSITIVE CABLE BEFORE CONNECTING THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
Page 332 Beverly 500 i.e. Pre-delivery - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks - Operation of the radiator electric fan Functional inspection Operating test: - Hydraulic brake system - Lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and make sure there is no unusual noise - Other...
Page 333 INDEX OF TOPICS TIME...
Page 334 Beverly 500 i.e. Time Engine ENGINE Code Action Duration 001001 Engine from chassis - replacement 003057 Engine retainer - Tighten nuts TIME - 334...
Page 335 Beverly 500 i.e. Time Crankcase CRANKCASE Code Action Duration 001100 Oil seal, clutch side - Replacement 001133 Engine crankcase - Replacement 001153 Crankcase half gasket - Replace- ment TIME - 335...
Page 336 Beverly 500 i.e. Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001098 Countershaft - Replacement TIME - 336...
Page 337 Beverly 500 i.e. Time Cylinder assy. CYLINDER ASSEMBLY Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pistonsrings-pin assembly - Service 001129 Chain tensioner - Service and Re- placement TIME - 337...
Page 338 Beverly 500 i.e. Time Cylinder head assy. HEAD UNIT Code Action Duration 001045 Valves - Replacement 001049 Valves - adjust 001056 Head gasket - change 001126 Head - Replacement 005081 Temperature sensor - Replacement 005116 Rpm timing sensor - Replacement 007012 Coolant bleed valve - Replacement TIME - 338...
Page 339 Beverly 500 i.e. Time Rocker arms support assy. ROCKING LEVER SUPPORT UNIT Code Action Duration 001044 Camshaft - Replacement 001148 Valve rocking levers - Replacement TIME - 339...
Page 340: Cylinder Head Cover
Beverly 500 i.e. Time Cylinder head cover EAD COVER Code Action Duration 001089 Head cover - Replacement 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement TIME - 340...
Page 341 Beverly 500 i.e. Time Flywheel cover FLYWHEEL COVER Code Action Duration 001087 Flywheel cover - Replacement 001113 Water pump - Replacement 001123 Oil filter -Replacement 001124 By-pass valve - Replacement 001057 Thermostat - Replacement 001062 Water pump command shaft - Re- placement 001150 Flywheel cover gasket - change...
Page 342: Driven Pulley
Beverly 500 i.e. Time Driven pulley DRIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 003072 Clutch unit - Wear check 001012 Driven pulley - overhaul 001110 Driven pulley- Replacement 001155 Clutch bell - Replacement Oil pump TIME - 342...
Page 343 Beverly 500 i.e. Time OIL PUMP Code Action Duration 001042 Oil pump - overhaul 001051 Belt/Timing chain - Change 001112 Oil pump - change 001125 Chain guide pads - Replacement Final gear assy. FINAL REDUCTION GEAR ASSEMBLY Code Action Duration 001010 Geared reduction unit - Service 001156...
Page 344 Beverly 500 i.e. Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Drive belt - Replacement 001006 Driving pulley - Service 001141 Belt anti-flapping roller - Replace- ment 001066 rear-view pulley - Replacement TIME - 344...
Page 345 Beverly 500 i.e. Time Transmission cover TRANSMISSION COVER Code Action Duration 001065 Internal transmission cover - Re- placement 001096 External transmission cover - Re- placement 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re- placement 001170 Air manifold - replacement TIME - 345...
Page 346: Starter Motor
Beverly 500 i.e. Time Starter motor STARTER MOTOR Code Action Duration 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement 003064 Engine oil - change TIME - 346...
Page 347: Flywheel Magneto
Beverly 500 i.e. Time Flywheel magneto MAGNETO FLYWHEEL Code Action Duration 001058 Flywheel - Replacement 001067 Stator - Replacement 001104 Start-up freewheel - Replacement 001151 Starter driven gearing - Replacement TIME - 347...
Page 348 Beverly 500 i.e. Time Butterfly valve THROTTLE BODY Code Action Duration 001013 Intake manifold - change 001047 Injector - Replacement 001166 Throttle body - Replacement TIME - 348...
Page 349 Beverly 500 i.e. Time Exhaust pipe SILENCER Code Action Duration 001009 Silencer - Replacement 001092 Exhaust manifold - Replacement 001095 Silencer heatshield - Replacement 001136 Exhaust emissions - Adjustment TIME - 349...
Page 350: Air Cleaner
Beverly 500 i.e. Time Air cleaner AIR CLEANER Code Action Duration 001015 Air filter box - Replacement 001014 Air filter - Replacement / cleaning 004122 Cleaner / Throttle body union - Re- placement 001074 Oil vapour recovery pipe - Replace- ment TIME - 350...
Page 351 Beverly 500 i.e. Time Frame CHASSIS Code Action Duration 004001 Chassis - Replacement 006001 Frame - Painting Centre-stand TIME - 351...
Page 352 Beverly 500 i.e. Time CENTRE AND SIDE STANDS Code Action Duration 004004 Stand - Replacement 004102 Side stand - Replacement 005079 Stand switch - Replacement Legshield spoiler SPOILER FRONT SHIELD Code Action Duration 004064 Legshield, front section - Replace- ment 006012 Front shield - Paintwork 004053...
Page 353 Beverly 500 i.e. Time Side fairings SIDE COVERS Code Action Duration 004085 Fairing (1) - Replacement 006005 Side covers - Painting 004129 Bumper fairing - Replacement 004012 Fairings (2) - Replacement 004159 Plates / Stickers - Replacement TIME - 353...
Page 354 Beverly 500 i.e. Time Footrests MATS AND COVERS Code Action Duration 004075 Front mat - Replacement 004079 Passenger footrest (1) - Replace- ment 004015 Footrest - Replacement 004059 Spark plug inspection flap - Replace- ment TIME - 354...
Page 355 Beverly 500 i.e. Time Rear cover REAR SHIELD Code Action Duration 004065 Shield back plate - Replacement 004081 Top box lid - Replacement 005121 Saddle opening button - Replace- ment TIME - 355...
Page 356 Beverly 500 i.e. Time Central cover CENTRAL COVER Code Action Duration 004011 Central chassis cover - Replacement 002082 Fuel tank door opening drive - Re- placement 004135 Fuel tank port - Replacement 004157 Fuel port coupling - Replacement TIME - 356...
Page 357: Helmet Compartment
Beverly 500 i.e. Time Underseat compartment HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Replacement 004106 Under-saddle band - Replacement 004136 License plate holder mounting - Re- placement 005046 Battery cover - change 005033 Under seat light switch - Replace- ment 005048 number plate holder - Replacement...
Page 358 Beverly 500 i.e. Time Mudguard MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement 004002 Front mudguard - change 006003 Mudguard - Painting TIME - 358...
Page 359 Beverly 500 i.e. Time Fuel tank FUEL TANK Code Action Duration 004109 Fuel tank breather - change 004005 Fuel tank - Replacement TIME - 359...
Page 360 Beverly 500 i.e. Time Expansion tank EXPANSION TANK Code Action Duration 007001 Expansion tank - Replacement 001052 Coolant and air bleed - Replacement 007013 Expansion tank / radiator connecting hose - Replacement TIME - 360...
Page 361 Beverly 500 i.e. Time Radiator RADIATOR Code Action Duration 007002 Water cooling radiator - Replace- ment 007016 Fan complete with support - Re- placement 007003 Delivery line and coolant return - Re- placement TIME - 361...
Page 362 Beverly 500 i.e. Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorbers - Replace- ment TIME - 362...
Page 363 Beverly 500 i.e. Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Fork unit - Replacement 003079 Fork stem - Replacement 003048 Fork oil seal - Replacement 004119 Bearing/upper steering fifth wheel - Replacement 003002 Steering fifth wheel - Replacement 003073 Steering clearance - Adjustment 003010...
Page 364: Handlebar Covers
Beverly 500 i.e. Time Handlebar covers HANDLEBAR COVER Code Action Duration 004018 Handlebar front section - Replace- ment 004019 Handlebar rear section - Replace- ment 006013 Handlebar front part - Painting 006014 Handlebar rear part - Painting 005091 Turn indicator glass - Replacement TIME - 364...
Page 365 Beverly 500 i.e. Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 002060 Throttle grip - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 002024 Front brake pump - replace 002088 Integral brake pump - Replacement 003001 Handlebar - Replacement 002063...
Page 366 Beverly 500 i.e. Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine-chassis connection swinging arm - Replacement 003082 Damper arm - Replacement TIME - 366...
Page 367 Beverly 500 i.e. Time Brake hoses BREAK PIPES Code Action Duration 002020 Rear brake disc piping - Replace- ment 002021 Front brake piping - Replacement 002047 Front brake fluid and air bleed sys- tem - Replacement 002084 Integral brake pump pipe, device - Replacement 002085 Integral front brake pipes...
Page 368 Beverly 500 i.e. Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004144 Saddle cover - Replacement TIME - 368...
Page 369: Seat Lock
Beverly 500 i.e. Time Seat lock SADDLE CLOSING MECHANISM Code Action Duration 002083 Saddle opening transmission - Re- placement 002092 Transmission splitter/ hook transmis- sion - Replacement 004054 Saddle lock catch - Replacement 004158 Saddle opening splitter - Replace- ment 005099 Electric saddle opening device - Re- placement...
Page 370 Beverly 500 i.e. Time Instrument panel LIGHT ASSEMBLY Code Action Duration 005014 Instrument panel - Replacement 005038 Instrument panel warning light bulbs - Replacement 005078 Odometer glass - Replacement TIME - 370...
Page 371 Beverly 500 i.e. Time Rear rack LUGGAGE RACK Code Action Duration 004008 Luggage rack - Replacement 006002 Luggage rack - Painting 004062 Luggage rack cover - Replacement TIME - 371...
Page 372 Beverly 500 i.e. Time Locks LOCKS Code Action Duration 005016 Key switch - Replacement 004010 Antitheft lock - Replacement TIME - 372...
Page 373: Turn Signal Lights
Beverly 500 i.e. Time Turn signal lights TURN SIGNAL HEADLIGHTS Code Action Duration 005002 Front headlamp - Replacement 005005 Taillight - change 005008 Headlight bulbs - Replacement 005031 number plate light bulb - Replace- ment 005032 number plate light glass - Replace- ment 005044 Front lights cable unit - replace...
Page 374: Front Wheel
Beverly 500 i.e. Time Front wheel FRONT WHEEL Code Action Duration 002011 Odometer movement sensor - Re- placement 002041 Brake disc - Replacement 002051 Odometer transmission assembly - Replacement 003037 Front wheel rim - Replacement 003038 Front wheel axle - Replacement 003040 Front wheel bearings - Replacement 003047...
Page 375: Rear Wheel
Beverly 500 i.e. Time In the following points we indicate with an arrow the area to be greased (1 - Drive, 2 - Tone wheel) Rear wheel REAR WHEEL Code Action Duration 001016 Rear wheel - Replacement 001071 Rear wheel rim - Removal and Refit- ting 002070 Rear brake disc - Replacement...
Page 376: Fuel Pump
Beverly 500 i.e. Time Fuel pump FUEL PUMP Code Action Duration 004073 Fuel pump - Replacement 004137 Injector pump pipe - Replacement TIME - 376...
Page 377 Beverly 500 i.e. Time Electric devices ELECTRIC DEVICES Code Action Duration 001069 HV coil - Replacement 005054 Fuse holder - Replacement 001094 Spark plug cap - Replacement 005001 Electrical system - Replacement 005003 Horn - Replacement 005052 Fuse (1) - Replacement 005115 Fuel level electrical damper - Re- placement...
Page 378 Beverly 500 i.e. Time ELECTRIC DEVICES Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005041 Starter button - Replacement 005047 Emergency stop switch - change 004117 Top fairing - Replacement TIME - 378...
Page 379 Beverly 500 i.e. Time ELECTRIC DEVICES Code Action Duration 004142 electric socket - Replacement 005007 Battery - change 005009 Voltage regulator - Replacement 005011 Starter relay - Replacement 005026 Helmet compartment bulb - Replace- ment 005027 Helmet compartment bulb support - Replacement 005073 Immobilizer decoder - Replacement...
Page 380: Brake Callipers
Beverly 500 i.e. Time Brake callipers FRONT BREAK CALLIPER Code Action Duration 002002 Rear brake pads - Replacement 002007 Front brake pads - Replacement 002039 Front brake calliper - Replacement 002040 Front brake calliper - Check 002048 Rear brake calliper - Replacement 002068 Rear brake calliper - Check 003070...
Page 381 Air filter: 24, 322 Battery: 40, 43, 46, 47 Brake: 285, 288, 290, 292, 293, 295, 298, 299, 367, 380 Brake fluid: 298 Checks: 43 Coolant: 236, 305 Electric: 303, 377 Engine oil: 24 Fuel: 11, 190, 200, 204, 324, 359, 376 Fuses: 45 Headlight: 30, 313 Horn:...
Page 382 Switch: Tank: 11, 324, 359, 360 Technical Data: Transmission: 8, 55, 71, 345 Turn indicators: Tyres: 9 Vehicle: 7, 52...

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