PIAGGIO Beverly 500 i.e., BV 500 USA Workshop Manual

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WORKSHOP MANUAL

633387

Beverly 500 i.e.

WORKSHOP

MANUAL

Beverly 500 i.e.

The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes to

components, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.

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.

in whole or in part is prohibited."

PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

www.piaggio.com

WORKSHOP MANUAL

Beverly 500 i.e.

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera 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. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal

injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.

INDEX OF TOPICS

CHARACTERISTICS CHAR

MAINTENANCE MAIN

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

INDEX OF TOPICS

CHARACTERISTICS CHAR

This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

•

Should it be necessary to keep the engine running while servicing, make sure that the area or room is well ventilated, and use special exhaust fans, if required. never let the engine run in an enclosed area. Exhaust fumes are toxic.

•

The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention.

•

The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it.

•

Fuel is highly flammable, and in some conditions it can be explosive. Do not smoke in the working area, and avoid open flames or sparks.

•

Clean the brake pads in a well ventilated environment, directing the compressed air jet so as to not inhale the dust produced by the wear of the friction material. Even though the latter contains no asbestos, dust inhalation is harmful.

Maintenance rules

•

Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Nonoriginal or non-conforming spares may damage the vehicle.

•

Use only the special tools designed for this scooter.

•

Always use new gaskets, sealing rings and split pins upon reassembly.

•

After removal, clean the components using non-flammable or low fire-point solvent. Lubricate all the work surfaces except the tapered couplings before refitting.

•

After reassembly, check that all components have been installed properly and that they are in good working order.

•

For removal, overhaul and reassembly operations use only tools provided with metric measures. Metric bolts, nuts and screws are not interchangeable with coupling members with English measurement. Using unsuitable coupling members and tools may damage the scooter.

•

Should any interventions to the scooter electrical system be required, check that the electrical connections - especially earth and battery connections - have been implemented properly.

Characteristics Beverly 500 i.e.

CHAR - 6

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

Desc./Quantity

Engine Single-cylinder, four-stroke

Bore 92 mm

Stroke 69 mm

Cubic capacity 460 cm³

Compression ratio 10.5: 1

Timing system Single overhead camshaft with integrated tone wheel, control

from flywheel side chain, 4 valves and automatic start-up valve

lifting device.

Beverly 500 i.e. Characteristics

CHAR - 7

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 Electric starter system with freewheel.

Lubrication By trochoidal pump (inside the crankcase), pressure adjust-

ment by-pass and oil filter.

Lubrication pressure 4 bar

Minimum allowed (at 100° C) 0.8 bar

Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm

throttle body and single injector. Max. power (shaft) 29 kW (39 CV) at 7250 rpm Max. torque (shaft) 40 N·m (4 kgm) at 5500 rpm

Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-

stat and electric fan.

Transmission

TRANSMISSIONS

Specification Desc./Quantity

Transmission With automatic expandable pulley variator with torque server,

V belt, automatic clutch, gear reduction unit and transmission

housing with forced air circulation cooling.

Clutch

This is to inform you that in order to improve the overall performance of the clutch, starting from engine no. M341M 33318, a new 5-roller centrifuge clutch, dwg. no. 842559, has been introduced.

Capacities

CAPACITY

Specification

Desc./Quantity

Engine oil (empty) 1.7 lt.

Engine oil (at oil and filter change) 1.5 lt.

Fuel tank approx. 13.2 litres (including reserve approx. 3 litres) Rear hub approx. 250 cc.

Cooling system approx. 1.7 litres

Front fork approx. 195 ± 3 cc in each fork leg

Electrical system

ELECTRIC SYSTEM

Specification

Desc./Quantity

Ignition type High efficiency inductive ignition, integrated with variable in-

jection, timing and dwell angle and separate HV coil. Spark plug NGK CR7EKB Spark plug CHAMPION RG6YC

Battery Dry charge lead battery 12V-12Ah

Fuses 1 to 30A - 2 to 15A - 2 to 10A - 3 to 7,5A - 1 to 5A-1 to 3A

Generator Three-phase alternating current

Characteristics Beverly 500 i.e.

CHAR - 8

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Chassis Welded steel pipes with pressed sheet metal stiffening

Front suspension Hydraulic telescopic fork with diameter 41 mm stems

Front fork max. stroke 104 mm

Rear suspension Engine based on oscillating fork pivoted to the chassis by 1-

freedom degree oscillating arm. Pair of dual effect hydraulic shock absorbers and coaxial springs with 4-position preload

adjustment

Rear shock absorber max. travel 95.5 mm

Brakes

BRAKES

Specification Desc./Quantity

Front right Disc brake, 260 mm diameter, with hydraulic command activa-

ted from the handlebar by right-hand lever.

Integral Disc brake, 260 mm front diameter (vehicle LH side) and 240

mm rear diameter, with hydraulic command located on the

handlebar LH lever. The front disc is interlocked with a pressure

distribution valve.

Wheels and tyres

WHEELS AND TYRES

Specification

Desc./Quantity

Light alloy rims (Front rim) 16"x3"

Light alloy rims (rear rim) 14"x4.50"

Tyres (front) Pirelli 110/70 - 16" - GTS 23 M/C - 52 S - TUBELESS

Tyres (rear) Pirelli 150/70 14" - GTS 24 M/C - 66 S - TUBELESS

Tyre pressure (when cold) front 2.2 bar

Tyre pressure (when cold) rear 2.2 bar

(2.3 bar with passenger)

N.B.

CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. ADJUST PRESSURE ACCORDING TO THE WEIGHT OF RIDER AND ACCESSORIES.

CAUTION

IT IS MANDATORY TO ADOPT EXCLUSIVELY "S" CLASS TYRES, WHICH GUARANTEE CORRECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES RECOMMENDED BY PIAGGIO.

Tightening Torques

CHASSIS

Name

Torque in Nm

Electric pump locking ring nut 20

Chassis cross-member lower screws 16 - 25

chassis front cross-member upper screws 6 - 10

Beverly 500 i.e. Characteristics

CHAR - 9

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

FRONT SUSPENSION

Name Torque in Nm

Front wheel axle 45 to 50 Holding torque of lower ring nut 20 ÷ 25 Fork stem mounting to the plate 20 ÷ 25

Steering lower ring nut 10 - 13 **

Upper steering ring nut 36 - 39

Stem upper cap 35 - 55

Fixing screw handlebar to steering tube 45 ÷ 50

Pumping element fixing screw 25 - 35

Safety screw on fork leg 6 ÷ 7 Wheel fastening screws 33 - 37

* tighten and loosen completely. ** tighten and loosen by 90°.

REAR SUSPENSION

Name

Torque in Nm

Lock nut 40 ÷ 50

Nut for bolt securing swinging arm to chassis 66 ÷ 73

Central stand retainers 25 ÷ 30

Rear shock-absorber lower retainers 33 ÷ 41

Muffler heat guard retainers 6 - 8

Rear shock absorber upper retainers 33 ÷ 41

Swinging arm to engine retainer, muffler side 66 ÷ 70

swinging arm to engine retainer, transmission side 100 - 120

Side stand clamp 15 ÷ 20

Shock absorber to crankcase bracket fastener 20 - 25

rear shock absorber to muffler support arm bracket fastener 20 - 25

rod retainer 33 - 41

bolt securing swinging arm to chassis 14 ÷ 17

Rear wheel axle 104 ÷ 126

ENGINE ASSEMBLY

Name

Torque in Nm

starter motor retainers 11 - 13

THERMAL UNIT AND TIMING SYSTEM

Name

Torque in Nm

Spark plug 12 ÷ 14

Head fixing stud bolts ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts 10 - 12

Head lubrication control jet 5 - 7

Coolant temperature sensor 10 ÷ 12

counterweight mass fixing screw 7 - 8.5

Tensioner sliding block fixing screw 10 - 14

Rpm timing sensor fixing screw 3 - 4

injector fixing screw 3 ÷ 4

Revolution timing sensor fixing screw 3 ÷ 4

Valve lifter mass stop bell fixing screws 30 - 35

inlet manifold fixing screws 11 - 13 Tappet cover fixing screws 7 - 9 Throttle body fixing screws 11 ÷ 13

camshaft retaining bracket fixing screws 4 - 6

Head fixing screws 10 - 12

Characteristics Beverly 500 i.e.

CHAR - 10

*** 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 ÷ 29

Engine oil filter 12 - 16

Engine oil drainage plug 24 to 30

Engine-crankcase coupling screws 11 to 13

Oil pump screws 5 to 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

FINAL REDUCTION

Name Torque in Nm

Rear hub cover screws 24 ÷ 27

TRANSMISSION COVER

Name Torque in Nm

Driven pulley nut 92 - 100

Drive pulley nut 160 - 175

Anti-vibration roller screw 16.7 ÷ 19.6

M8 retainers for transmission cover 23 ÷ 26

M6 retainer 11 ÷ 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor unit screws 7 9 N

Water pump cover screws 3 ÷ 4

External transmission cover screws 7 ÷ 9

Flywheel cover screws 11 - 13

FLYWHEEL COVER

Name

Torque in Nm

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 - 15

Stator cable harness guide bracket screws 3 - 4

LUBRICATION

Name

Torque in Nm

Oil pump cover screws 0.7 - 0.9

Screws fixing oil pump to the crankcase 5 to 6

See also

Fuel tank

Refitting Overhaul Refitting

NOTICE OF TECHNICAL SERVICING

Beverly 500 i.e. Characteristics

CHAR - 11

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.

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED

Specification

Desc./Quantity

A 43.2 mm B 43 mm

CYLINDER - PISTON

Specification

Desc./Quantity

Cylinder diameter C 92+0.018-0.01

Piston diameter P 91.916-0.029-0.057

CATEGORIES OF COUPLING

Name

Initials Cylinder Piston Play on fitting

Cylinder- Piston A 91.990 - 91.997 91.947 - 91.954 0.036 - 0.050 Cylinder- Piston B 91.997 - 92.004 91.954 - 91.961 0.036 - 0.050 Cylinder- Piston C 92.004 - 92.011 91.961 - 91.968 0.036 - 0.050 Cylinder- Piston D 92.011 - 92.018 91.968 - 91.975 0.036 - 0.050

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK FACING UPWARDS.

Characteristics Beverly 500 i.e.

CHAR - 12

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 Cylinder Piston Play on fitting

1st Compression ring A 0.15 ÷ 0.35 0.5 </>

Middle piston ring A 0.25 ÷ 0.50 0.65 </>

Oil scraper ring A 0.25 ÷ 0.50 0.65 </>

Crankcase - crankshaft - connecting rod

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CRANKSHAFT

Specification

Desc./Quantity

Cat. 1 Standard diameter: 40.010 ÷ 40.016 Cat. 2 Standard diameter: 40.016 ÷ 40.022

Beverly 500 i.e. Characteristics

CHAR - 13

Crankshaft alignment

Specific tooling

020335Y Magnetic mounting for dial gauge

MAX. ADMISSIBLE DISPLACEMENT

Specification Desc./Quantity

A = 0.15 mm B = 0.010 mm C = 0.010 mm D = 0.10 mm

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name

Description Dimensions Initials Quantity

Transmission-side

shoulder

0.8 ± 0.025 A D= 0.20 - 0.40

Transmission-side half-

shaft

19.6 + 0.050 B D= 0.20 - 0.40

Connecting rod 22 0.10-0.15 C D= 0.20 - 0.40

Flywheel-side shoulder 13 ± 0.025 F D= 0.20 - 0.40

Flywheel-side half-shaft 19.6 +0.050 E D= 0.20 - 0.40

Complete drive shaft 63.5+0.1-0.05 G D= 0.20 - 0.40

Characteristics Beverly 500 i.e.

CHAR - 14

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 CYLINDER PLANE. DISTANCE "A" ALLOWS THE THICKNESS OF THE GASKET TO BE DETERMINED THAT HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE THE COMPRESSION RATIO. THE BASE GASKET MUST BE THICKER, THE MORE THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER THE GASKET THICKNESS.

BASE GASKET THICKNESS

Name

Measure A Thickness

«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05

Beverly 500 i.e. Characteristics

CHAR - 15

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.

Products

PRODUCTS

Product Description Specifications

AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-

quirements of API GL3 specifications

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-

creased adhesiveness

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA

Synthetic oil

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

AGIP PERMANENT SPECIAL coolant Monoethylene glycol-based antifreeze

fluid, CUNA NC 956-16

AUTOSOL METAL POLISH Silencer cleaning paste special product for cleaning and polishing

stainless steel silencer

AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based

spray grease with NLGI 2; ISO-L-XBCIB2

AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO

FC, ISO-L-EGD

Characteristics Beverly 500 i.e.

CHAR - 16

INDEX OF TOPICS

MAINTENANCE MAIN

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 suggested, 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. It is indispensable to have your vehicle serviced to the prescribed intervals of time, even if you have not reached the predicted mileage. Punctual vehicle servicing is necessary for the correct use of the guarantee. For all further information regarding the Guarantee application modes and the execution of the "Programmed Maintenance" refer to the "Guarantee Booklet".

EVERY 2 YEARS

60'

Action

Coolant - change Brake fluid - change

EVERY 3,000 KM

Action

Engine oil - level check/top-up Brake pads - check condition and wear

AFTER 1,000 KM OR 4 MONTHS

90'

Action

Engine oil - change Hub oil - change Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Steering - adjustment Brake levers - greasing Brake fluid level - check Safety fasteners - check Electrical system and battery - check Vehicle test and brake test - Road test

Maintenance Beverly 500 i.e.

MAIN - 18

AFTER 6,000 KM OR 12 MONTHS

80'

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 Coolant level - check Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle test and brake test - Road test

AFTER 12,000 KM OR 24 MONTHS AND 60,000 KM

205'

Action

Engine oil - change Hub oil - level check Spark plug/electrode gap - replacement Air filter - cleaning Engine oil filter - change Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Drive belt - replacement Coolant level - check Steering - adjustment Brake levers - greasing Transmission - lubrication Brake fluid level - check Safety fasteners - check Suspensions - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle test and brake test - Road test

AFTER 18,000 KM AND AFTER 54,000 KM

150'

Action

Engine oil - change Hub oil - level check Spark plug / electrode gap - check Air filter - change Engine oil filter - change Valve clearance - check Base vent - check Variable speed rollers - replacement Drive belt - check Coolant level - check Radiator - external cleaning/ check Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle test and brake test - Road test

Beverly 500 i.e. Maintenance

MAIN - 19

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 Roller support sliding blocks - check/change Driven pulley bushing - check / grease Drive belt - replacement Coolant level - check Steering - adjustment Brake levers - greasing 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 30,000 KM, 42,000 KM AND 66,000 KM

80'

Action

Engine oil - change Hub oil - level check Spark plug / electrode gap - check Air filter - cleaning Engine oil filter - change Base vent - check Variable speed rollers - replacement Drive belt - check Coolant level - check Brake fluid level - check Electrical system and battery - check Tyre inflation and wear - Check Vehicle test and brake test - Road test

AFTER 36,000 KM

365'

Action

Engine oil - change Hub oil - level check Spark plug/electrode gap - replacement Air filter - change Engine oil filter - change Valve clearance - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Drive belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment

Maintenance Beverly 500 i.e.

MAIN - 20

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'

Action

Engine oil - change Hub oil - change Spark plug / electrode gap - replacement Air filter - cleaning Engine oil filter - change Fuel filter - replacement Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driven pulley bushing - check / grease Drive belt - replacement Coolant level - check Steering - adjustment Brake levers - greasing 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 72,000 KM

405'

Action

Engine oil - change Hub oil - change Spark plug / electrode gap - check / replacement Air filter - change Engine oil filter - change Fuel filter - check Valve clearance - check Carburetion - check/adjust Seals/injection system hoses - visual check Base vent - check Variable speed rollers - replacement Roller support sliding blocks - check/change Driven pulley bushing - check / grease Drive belt - replacement Coolant level - check Radiator - external cleaning/ check Steering - adjustment Brake levers - greasing Brake fluid hoses - replacement Brake fluid level - check Safety fasteners - check Suspensions - check

Beverly 500 i.e. Maintenance

MAIN - 21

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. THE SPARK PLUG SHOULD BE CHECKED EVERY 6,000 KM AND REPLACED EVERY 12,000 KM. THE USE OF NON-CONFORMING IGNITION CONTROL UNITS AND SPARK PLUGS OTHER THAN THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.

Characteristic

Recommended spark plugs:

CHAMPION RG6YC - NGK CR 7 EKB

- Position the scooter on centre stand.

- Open the door on the left side and remove the relevant screw lifting from the lower part in the specific groove.

- Disconnect the shielded spark plug cap

- Unscrew the spark plug.

- Check the conditions of the spark plug, make sure the insulation is intact, that the electrodes are not excessively worn or grimy, the conditions of the washer, and measure the distance between the electrodes using the appropriate feeler gauge.

Characteristic

Electrode gap

0.7 to 0.8 mm Adjust the gap if necessary, carefully bending the

earth electrode. In the event of irregularity, replace the spark plug with a recommended type.

- Fit the spark plug with the correct inclination and manually screw it all the way down, then use the special spanner to tighten it.

Locking torques (N*m)

Spark plug 12 ÷ 14

- Insert the cap onto the spark plug and proceed with the reassembly operations.

Hub oil

Maintenance Beverly 500 i.e.

MAIN - 22

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. and MIN. levels indicated on the dipstick (see figure); if the level is below the MIN value, restore the proper amount of oil in the hub.

•

Screw the oil bar back on, checking that it is tightly in place.

Replacement

•

Remove the oil filler cap "A".

•

Prepare a suitable container.

•

Remove the oil drainage cap "B" and let the oil drain out completely.

•

Tighten the drainage cap with its gasket and refill.

•

Remove the oil loading cap

PIAGGIO Beverly 500 i.e., BV 500 USA Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual