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

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WORKSHOP MANUAL

633387

Beverly 500 i.e.

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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

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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.

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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

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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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.

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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.

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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.

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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

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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.

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*** 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

Recommended products

AGIP ROTRA 80W-90 rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

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Air filter

•

Remove the air cleaner cover after unscrewing 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.

Cleaning (Every 12,000 km):

- Wash with water and car shampoo.

- Dry with short blasts of compressed air and a clean cloth.

- Soak with a 50% mixture of gasoline and oil.

- Drip dry the filtering element and then squeeze it with your hands without wringing.

- Refit the filtering element.

CAUTION

NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WILL RESULT IN AN EXCESSIVE CYLINDER AND PISTON WEAR AND ALSO IN CARBURETTOR DAMAGE.

CAUTION

WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART.

Recommended products

AGIP FILTER OIL Oil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

N.B.

FAILURE TO OBSERVE THE FILTERING ELEMENT CLEANING RULES MAY LEAD INCORRECT LUBRICATION OF THE PART INVOLVED. POOR LUBRICATION COMPROMISES THE FILTERING ELEMENT CAPACITY. EXCESSIVE LUBRICATION, AS WELL AS A DIRTY FILTER, RESULTS IN A RICH CARBURATION.

Engine oil

In four stroke engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption levels in particular can be influenced by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Maintenance Beverly 500 i.e.

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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. and min levels; top-up, if required. Topping up from the MIN to MAX. level requires around 1700 cc. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Oil top up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. The restoration level between the MIN and MAX levels implies a quantity of oil of approx. 400 cc.

Engine oil filter

CAUTION

DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. OIL, GASKET AND FILTER SHOULD BE DISPOSED OF ACCORDING TO THE REGULATIONS IN FORCE.

WARNING

AVOID TOUCHING PARTS OF THE ENGINE WHEN HOT, AS THIS MAY CAUSE BURNS.

- Remove the muffler.

- Remove the filler plug.

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- 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.

- Lubricate them and refit the mesh filter and oil drain cap by tightening to the prescribed torque.

- Refit a new cartridge filter making sure to lubricate the O-ring before fitting, then screw until it comes into contact with the seal and further tighten to the prescribed torque.

- Refit the muffler.

- Add recommended engine oil.

- Start the engine and let it run for a few minutes and then turn it off.

After 5 minutes check the level and top up, if necessary, never exceed the MAX. level.

N.B.

IF THE OIL IS CHANGED WITHOUT CHANGING THE CARTRIDGE FILTER (1ST COUPON) ADD AROUND 1500 CC OF OIL INSTEAD OF 1700 CC SINCE PART OF THE LUBRICATION CIRCUIT IS FILLED.

Characteristic

Engine oil:

1700 cm³

Locking torques (N*m)

Engine oil drainage plug 24 to 30 Engine oil filter 12 - 16

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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 started.

If the light comes on during braking, at idling speed or while turning, it is necessary to first switch off the engine and then to check the oil level and the lubrication system

Checking the valve clearance

- To check the clearance in the valves collimate the references between the cam shaft control pulley and head.

- Use a feeler to make sure the clearance between the valve and register screw correspond to the indicated values. If the clearance does not correspond, adjust it by loosening the lock nut using a screwdriver on the set screw as shown in the figure.

Characteristic

Valve clearance: intake

0.15 mm (when cold)

Valve clearance: discharge

0.15 mm (when cold)

Cooling system

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Level check

The fluid level inspection should be carried out every 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.

•

Loosen the screw shown in the figure and remove the expansion tank cover located on the right side of the scooter.

•

Remove the expansion tank cap and top up, if the fluid level is near to or below the MIN level into the expansion tank. The fluid level should always be between the "MIN" and "MAX." level.

•

To check the level, look into the expansion tank: the two marks into the expansion tank indicate the two levels, "MIN" and "MAX.".

•

The coolant consists of a mixture of 50% demineralised water and ethylene glycol and corrosion inhibitors based anti-freeze solution.

CAUTION DO NOT EXCEED THE MAX LEVEL WHEN FILLING SO

THAT COOLANT DOES NOT SPILL OVER THE EXPANSION TANK WHEN THE VEHICLE IS BEING USED.

N.B. THE COOLANT CONSISTS OF A MIXTURE OF DE-IONISED

WATER AND FLUID FOR SEALED CIRCUITS. THE RESULTING MIXTURE ALLOWS A DECREASE OF THE FREEZING POINT TO -35°C. THE MIXTURE AT A PRESSURE OF 0.9 BAR INCREASES THE BOILING POINT TO APPROX. 125°C. THE RECOMMENDED FLUID IS ALSO PROTECTIVE FOR ALUMINIUM ALLOYS, AND OVER TIME THIS FEATURE MAY DECREASE. PERIODICAL REPLACEMENT IS THEREFORE ADVISABLE.

See also

Cooling system

Braking system

Maintenance Beverly 500 i.e.

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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 brake fluid level by the special indicator located on the pump, as shown in the figure.

N.B.

THE LEVEL TENDS TO DROP AS THE BRAKE PADS GET WORN, A MINIMUM LEVEL SHOULD NOT BE REACHED. IF THE LEVEL IS TOO LOW, CHECK AND FIX THE SYSTEM SEALS, IF REQUIRED. TOP UP THE PUMP RESERVOIR, IF REQUIRED, CONSIDERING THAT THE "MAX." LEVEL MUST ONLY BE OBTAINED WITH NEW PADS.

Top-up

CAUTION

ONLY USE DOT 4-CLASSIFIED BRAKE FLUID.

Proceed as follows:

- Rest the scooter on a flat ground and on the central stand.

- Remove the brake pump cover as shown in the figure.

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- 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. 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. WARNING THE BRAKE FLUID IS HYGROSCOPIC, THAT IS, IT AB-

SORBS MOISTURE FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKING FLUID EXCEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING; FOR THIS REASON, NEVER USE BRAKING FLUID FROM CONTAINERS THAT HAVE ALREADY BEEN OPENED, OR PARTIALLY USED.

Characteristic

Prescribed fluid:

TUTELA TOP 4

Under normal climatic conditions, the fluid must be changed every 20,000 km or anyway every two years.

N.B.

SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.

Headlight adjustment

- Place the vehicle in use conditions, with tyres inflated to the prescribed pressure on flat ground at 10

m from a white screen placed in dim light.

- Make sure that the scooter axle is perpendicular to the screen.

- Turn the headlight on and check that the limit of the light beam projected onto the screen does not

exceed 9/10 of the headlight centre height from the ground and that it is not less than 7/10.

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- Otherwise, adjust the right headlight by the screw shown in the figure, which can be accessed by removing the front shield connecting member.

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

Checking the end compression pressure

•

Remove the spark plug cap when the engine is cold.

•

Remove the ignition spark plug.

•

Fit a compression test gauge into the spark plug seat using a 10 mm spark plug union at the proper tightening torque.

•

Disconnect the revolution-timing sensor connector.

•

Let the engine run using the starter and with the throttle body in fully open position as long as the gauge value is steady. If pressure is correct (> 11 bar), remove the tool and reinstall the spark plug, the cap and the rev counter connector.

•

If the pressure is less than indicated, check the rpm at which the test is carried out; if it is less than 450 rpm, check the starter system; if not, check the following:

•

Distribution timing

•

Valve clearance

•

Check valve seal

•

Check lining seal

•

Proper compression ratio selection

Locking torques (N*m)

Fitting for compression test 10

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INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

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ELECTRICAL COMPONENTS

Specification

Desc./Quantity

1 Front LHS turn signal light 2 Light switch 3 Turn indicator switch 4 Horn button 5 Four 30A relays 6 Main remote control switch 7 Light remote control switch 8 Diode unit 9 Saddle opening button 10 Front fuse box 11 Fuse 15A 12 No. 3 7.5A fuses 13 Anti-theft alarm fitting 14 Electric fan 15 Fuel level sender with pump 16 Side stand switch 17 Saddle opener actuator 18 HV coil 19 Lamp 20 Chassis wire unit 21 Headlight 22 Instrument panel 23 Diagnostic and deterring LED 24 Low fuel warning light 25 Engine oil pressure warning light 26 Water thermometer 27 Fuel gauge 28 Engine warning indicator 29 High-beam warning light 30 Rhs turn signal warning light

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Specification Desc./Quantity

31 Lhs turn signal warning light 32 Instrument lighting 33 Headlamp warning light 34 Front turn signal light bulb 12V-10W 35 Intercom fitting 36 Engine stop switch 37 Fitting for accessories 38 Front wire node (black) 39 Indicators remote control switch 40 Electric fan solenoid 41 Light switch 42 Starter button 43 Damper for fuel level indicator 44 Key switch 45 Immobilizer aerial 46 Decoder 47 Front ground node 48 Injection ECU 49 Intercom pre-wiring 50 Fuel injector 51 Throttle potentiometer 52 Idle adjustment motor 53 Air temperature sensor 54 Engine Speed sensor 55 Shielded bi-polar cable 56 Engine water temperature sensor 57 Engine oil pressure sensor 58 Flywheel magneto 59 Frame ground 60 Ground cable 61 Starter motor wire 62 Starter motor 63 Start-up solenoid 64 Battery 12V-12Ah 65 Rear fuse box 66 Fuse 30A 67 Fuse 15A 68 Two 10A fuses 69 Fuse 5A 70 Fuse 3A 71 L.V. socket (12V - 180W) 72 12V D.C. regulator 73 Wire node (red-black) 74 Engine stop remote control switch 75 Two 30A relays 76 Control unit remote control switch 77 ECU diagnostic socket 78 Wire node (red-yellow) 79 Wire node (yellow-black) 80 Helmet compartment light button 81 Rear wire node (black)

Colours of the electrical cables: B = White, Bl = Blue, G = Yellow, Mr = Brown, N = Black, Gr = Grey, Rs = Pink, R = Red, Vi = Purple, V = Green

CAUTION

SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED, MAKE SURE THAT THE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORDING TO POLARITY AND TO THE LEAD COLOURS.

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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.

H.V. coil

In order to access the high-voltage coil, remove the left-hand side fairing.

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Saddle opening ECU remote control.

Resetting of the remote control

Electronic control unit ECU

In order to access the immobilizer control unit, remove the upper shield back plate.

In order to access the connector, remove the windshield with the respective support and the metal plate holding the control unit ECU, decoder and saddle opener remote control.

N.B. AFTER INSERTING THE INTERFACE CABLE OR THE

ELECTRONIC CONTROL UNIT, RETIGHTEN THE SCREW AND THE GROUND CABLE.

Immobiliser decoder

In order to access the immobilizer decoder, remove the upper shield back plate.

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Relays and diode group

In order to access the relays and the diode group, remove the upper shield back plate.

[/]

Specification Desc./Quantity

A = DIODE UNIT B = ELECTRIC FAN REMOTE CONTROL SWITCH C = ENGINE STOP REMOTE CONTROL SWITCH D = CONTROL UNIT REMOTE CONTROL SWITCH

Voltage regulator

To access the voltage regulator.

Conceptual diagrams

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Ignition

IGNITION

Specification

Desc./Quantity

1 Instrument panel 2 Electronic control unit 3 Antenna 4 Immobilizer 5 Engine stop remote control switch 6 Main remote control switch 7 Diode 2 A 8 Control unit remote control switch 9 Emergency stop switch 10 Side stand switch 11 Fuse No. 4 (5A) 12 Key switch 13 Main fuse (30A) 14 Battery 12V-12Ah 15 Voltage regulator 16 Flywheel magneto 17 Fuse 5A 18 Fuse No. 2 (10A)

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Specification Desc./Quantity

19 HV coil

Headlights and automatic starter section

HEADLIGHTS AND AUTOMATIC STARTER SECTION

Specification

Desc./Quantity

1 Instrument panel 2 Duel light lamp 3 Light switch 4 Fuse No. 9 (7.5A) 5 Light switch 6 Light remote control switch 7 Fusibile n. 6 (10A) 8 Main remote control switch 9 Diode 2 A 10 Key switch 11 Battery 12V-12Ah 12 Fuse No. 5 (15A) 13 L.V. socket (12V - 180W) 14 Main fuse (30A) 15 Voltage regulator

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Specification Desc./Quantity

16 Flywheel magneto 17 Fuse n.7 (15A) 18 Under-saddle compartment light 19 Under-saddle compartment light switch 20 Side/taillights (2 front and 1 rear light) and number plate

light

Battery recharge and starting

START-UP BATTERY RECHARGE

Specification

Desc./Quantity

1 Stop light bulb 2 Starter button 3 Fuse No. 8 (7.5A) 4 Fuse No. 4 (5A) 5 Electronic control unit 6 Engine stop remote control switch 7 Main remote control switch 8 Emergency stop switch 9 Stand switch 10 Flywheel magneto

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Specification Desc./Quantity

11 Key switch 12 Voltage regulator 13 Starter relay 14 Starter motor 15 Battery 12V-12Ah 16 Main fuse (30A)

Level indicators and enable signals section

LEVEL INDICATORS AND ENABLE SIGNALS SECTION

Specification

Desc./Quantity

1 Instrument panel 2 Engine water temperature sensor 3 Electronic control unit 4 Engine oil pressure sensor 5 Damper for fuel level indicator 6 Fuel gauge 7 Radiator electric fan 8 Electric fan solenoid 9 Engine stop remote control switch 10 Side stand switch

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Specification Desc./Quantity

11 Emergency stop switch 12 Key switch 13 Main remote control switch 14 Diode 2 A 15 Fuse No. 8 (7.5A) 16 Main fuse (30A) 17 Battery 12V-12Ah 18 Voltage regulator 19 Flywheel magneto

Turn signal lights

TURN INDICATORS AND HORN

Specification

Desc./Quantity

1 Instrument panel 2 Predisposizione display 3 Anti-theft alarm fitting 4 Radio-interphone prewiring 5 Connettori interfono 6 Turn signal lights 7 Turn indicator switch

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Specification Desc./Quantity

8 Indicators remote control switch 9 Fuse No. 8 (7.5A) 10 Fuse n. 10 (7,5A) 11 Fitting for accessories 12 Horn button 13 Claxon 12V c.c. 14 Main remote control switch 15 Diode 2 A 16 Key switch 17 Battery 12V-12Ah 18 Main fuse (30A) 19 Voltage regulator 20 Fuse No. 5 (15A) 21 Helmet compartment light button 22 Helmet compartment light 23 Flywheel magneto 24 Fuse n.7 (15A) 25 Electronic control unit

Checks and inspections

Battery recharge circuit

The recharge system is provided with a three phase alternator with permanent flywheel. The alternator is directly connected to the voltage regulator. This, in its turn, is connected directly to the ground and the battery positive terminal passing through the 30A protective fuse. This system therefore requires no connection to the key switch. The three- phase generator provides good recharge power and at low revs, a good compromise is achieved between generated power and idle stability.

Stator check

Checking the stator windings

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the door in the saddle compartment.

2) Disconnect the connector between the stator and regulator with the three yellow wires.

3) Measure the resistance between each of the yellow terminals and the other two.

Electric characteristic

Resistance:

0.2 - 1 Ω

4) Check that there is insulation between the each yellow cable and the ground.

5) If values are incorrect, replace the stator.

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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.

3) With the multimeter leads connected, disconnect the Black cable from the battery negative pole (-).

4) With the ignition key always at OFF, the reading indicated by the ammeter must be ≤ 0.5 mA.

VOLTAGE REGULATOR/RECTIFIER

Specification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 to 15V at 5000 rpm with lights off

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORKING ORDER.

1) Place the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery

terminals..

3) Start the engine, ensure that the lights are all out, increase the engine speed and at the same time

measure the voltage.

Electric characteristic

Voltage ranging between 14.0 and 15.0V at 5000 rpm.

Maximum current output check.

- With engine off and panel set to "ON" turn on the lights and let the battery voltage set to 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Keep the lights on and start the engine, bring it to normal speed and read the values on the ammeter.

With an efficient battery a value must be detected: > 20A

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Fuses

The electrical system is equipped with:

•

Six «A » fuses located inside the righthand side fairing.

•

Four «B» protection fuses for the different circuits of the electrical system located inside the glove-box on the top left-hand side of the helmet compartment.

Never try to replace a blown fuse with a fuse of a different rating than that specified or using other material (for example, a piece of electrical wire).

The tables show the position and characteristics of the fuses on the scooter.

CAUTION

BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).

FUSE HOLDER A

Specification

Desc./Quantity

1 1 - General Fuse: 30 A 2 2 - Electronic control unit remote control switch Fuse: 10A 3 3 - Controller power supply, immobilizer Fuse: 3A 4 4 - Under-panel controller Fuse: 5A 5 5 - Socket 12v - 180w, helmet compartment lighting but-

ton, key switch contacts, saddle opener actuator, electric

button opening.

Fuse: 15A

6 Remote light control switch Fuse: 10 A

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FUSE HOLDER B

Specification Desc./Quantity

1 7 - Light flash, fitting for accessories, horn Fuse: 15A 2 8 - Brake lights, fitting for radio and anti-theft system,

damper, under-key instrument panel.

Fusibile: 7,5A

3 9 - Light switch. Lamps for front and rear side/taillights,

number plate light, indicators on the instrument panel.

Fusibile: 7,5A

4 10 - Immobilizer led, radio/intercom fitting, anti-theft sys-

tem

Fuse: 7,5A

Sealed battery

Commissioning sealed batteries

If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge and recharging, if necessary. These operations should be carried out before delivering the vehicle, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the scooter and afterwards every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1. Voltage check

•

Before installing the battery on the vehicle, check the open circuit voltage with a regular tester.

•

If voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.

•

If voltage is below 12.60 V, a renewal recharge is required as explained at 2).

3. Constant-voltage battery instructions

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•

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

•

Charge current equal to 1/10 of the battery rated capacity

Dry-charge battery

WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN

- Remove the short closed tube and the caps, then pour sulphuric acid into the cells using the type specified for batteries with a specific gravity of

1.26, corresponding to 30 Bé at a minimum temperature of 15°C until the upper level is reached.

- Allow to stand for at least 2 hours, then top up the level with sulphuric acid.

- Within 24 hours, recharge using the special battery charger (single) or (multiple) at an intensity of about 1/10 of the battery nominal capacity and until the acid gravity is about 1.27, corresponding to 31 Bé and such values become steady.

- After charging, top up the acid (adding distilled water). Close and clean carefully.

- After carrying out the operations above, install the battery on the scooter, observing the connections described in point 3) of paragraph "Battery re-

charge".

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

1 Keep the pipe in vertical position

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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.

Charging status check

After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged, you should detect a density of 30 to 32 Bé corresponding to a specific weight of 1.26 to 1.28 at a temperature of no lower than 15° C. A density reading of less than 20° Bé indicates that the battery is completely flat and it must therefore be recharged. If the scooter is not used for a given time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. When refitting the battery onto the scooter pay attention not to invert the cables, bearing in mind that the earth (black) wire marked with a (-) must be connected to the negative terminal whilst the other two red wires, marked with a (+) must be attached to the positive, + terminal.

Battery recharge

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE PLUGS OF EACH CELL. KEEP SPARKS AND NAKED FLAMES AWAY FROM THE BATTERY WHILE RECHARGING.

Remove the battery from the vehicle removing the negative clamp first. Normal bench charging must be performed using the special battery charger (single) or (multiple), setting the battery charge selector to the type of battery that requires recharging (i.e., at a current equal to 1/10 of the battery rated capacity). Connections to the power supply source must be implemented by connecting corresponding poles (+ to + and - to - ).

Specific tooling

020333Y Single battery charger 020334Y Multiple battery charger

The battery should always be kept clean, especially on its top side, and the terminals should be coated with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

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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.

CONNECTOR A

Specification Desc./Quantity

1 Left direction warning light 2 Battery negative 3 Battery positive 4 Water thermometer 5 Right direction warning light 6 Preset indicator 7 Fuel gauge 8 Low fuel warning light

CONNECTOR B

Specification

Desc./Quantity

1 High-beam lamp warning light 2 Ground lead 3 Engine control warning light 4 Engine oil pressure warning light 5 + battery under permanent power supply 6 Instrument panel lighting and headlamp warning light

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FUEL GAUGE DAMPER

Specification Desc./Quantity

1 Fuel reserve warning light 2 Fuel level gauge output 3 Float input 4 Test (not connected) 5 Ground lead 6 + permanent power supply

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INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Page 52

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

•

Disconnect the battery, remove the saddle and the fairings and drain the coolant.

•

Remove the muffler and the relevant support and remove the rear wheel.

•

Remove the swinging arm and the accelerator control transmission.

•

Remove the air filter sleeve and the engine earth cable.

•

Disconnect the carburettor electrical devices and the starter motor power supply cable.

•

Disconnect the fuel delivery and return pipes from the carburettor and the cooling system piping (outlet from the head and inlet to the thermostat).

•

Disconnect the spark plug H.V. cable and the alternator cables from the scooter electrical system.

WARNING

CARRY OUT THESE OPERATIONS WHEN THE ENGINE IS COLD.

WARNING

HANDLE FUEL WITH CARE.

CAUTION

WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.

Vehicle engine assembly

Engine from vehicle Beverly 500 i.e.

ENG VE - 52

Page 53

•

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.

•

Check the engine oil level and top up using the recommended brand, if required.

•

Top up the coolant circuit.

•

Check that throttle and electric devices are in good working order.

CAUTION

PAY PARTICULAR ATTENTION TO POSITIONING THE THROTTLE CONTROL TRANSMISSION PROPERLY.

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INDEX OF TOPICS

ENGINE ENG

Page 55

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.

- Remove the nut and the two washers.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

- Remove the six M6 screws.

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- 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.

- Unscrew the two screws shown in the figure to remove the air conveyor.

Locking torques (N*m)

Air conveyor screws 11 ÷ 12

- Remove the external transmission cover.

- Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor.

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Air duct filter

- Remove the external air conveyor.

- Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter.

Removing the driven pulley shaft bearing

- Remove the transmission cover.

- Remove the Seeger ring.

- Place transmission cover on a wood surface and use the special tool so that it is adequately supported.

- Pull out the bearing using the special tool.

N.B. BELL MUST BE PLACED INTO THE TRANSMISSION COV-

ER, CLOSE TO THE BEARING SEAT AND THE WOODEN SURFACE, SINCE WITHOUT BELL THE ENTIRE COVER STRUCTURE WOULD BEND. NOT ONLY IN THE AREA OF MAXIMUM STURDINESS.

Specific tooling

001467Y002 Driver for OD 73 mm bearing 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020439Y 17-mm guide

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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.

- Install the new bearing using the special tool.

N.B. PROPERLY SUPPORT THE OUTSIDE COVER TO PRE-

VENT DAMAGING THE PAINTED SURFACE.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm Adaptor 020439Y 17-mm guide

Baffle roller

Plastic roller

- Check that the roller does not show signs of wear and that it turns freely.

- Loosen the retaining bolt using a 13 mm spanner.

- Remove the complete roller with bearing.

N.B. IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE

THE COMPLETE ROLLER.

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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 torque.

N.B. TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A

CORRECT TENSIONING OF THE BELT IS OBTAINED.

Locking torques (N*m)

Anti-vibration roller screw 16.7 ÷ 19.6

Removing the driven pulley

- Remove the driven pulley assembly with the belt.

Inspecting the clutch drum

- Remove the clutch bell.

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- 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;

- Arrange the tool with the mean pins screwed in position "E" on the inside;

- Install the driven pulley unit onto the tool inserting the pins into the ventilation holes;

- Move the rear stop screw in abutment against the fixed driven pulley as shown in the figure.

CAUTION

THE TOOL SHOULD BE FIRMLY SECURED IN A VICE USING THE SPECIAL TOOL. DO NOT TIGHTEN THE REAR SCREW TOO MUCH AS THIS COULD IRRETRIEVABLY DEFORM THE TOOL. USING THE SPECIAL 55-MM WRENCH, REMOVE THE FASTENING RING NUT. LOOSEN THE TOOL SCREW AND DISASSEMBLE THE DRIVEN PULLEY UNIT, CLUTCH, SPRING WITH SHEATH.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Pin retaining collar

- Extract the collar using 2 screwdrivers.

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- 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 halfpulley.

- Remove the lock ring using pliers.

- Using the special tool inserted through the roller bearing, pull out the ball bearing.

N.B. PROPERLY SUPPORT THE PULLEY TO PREVENT DAM-

AGING THE THREADING.

Specific tooling

020376Y Adaptor handle 020456Y Ø 24 mm adaptor 020363Y 20-mm guide

N.B.

IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT IS NECESSARY TO SUPPORT THE UNIT BY THE BELL

Specific tooling

001467Y002 Driver for OD 73 mm bearing

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Page 62

- 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.

- Measure the outer diameter of the pulley bushing.

Characteristic

Minimum admissible diameter

49.91 mm

Standard diameter:

50.00 -0.015 -0.035 mm

Inspecting the driven sliding half-pulley

- Check that the belt contact surface is free from wear.

- Remove the 2 inside sealing rings and the 2 outside O-rings.

- Measure the movable half-pulley bushing inside diameter.

Characteristic

Maximum admissible diameter:

50.05 mm

Standard diameter:

50.00 +0.035 0.00 mm

Refitting the driven half-pulley bearing

- Install a new roller bearing using the special tool.

N.B.

PLACE THE BEARING WITH THE WRITINGS AND THE EMBEDDED OIL GUARD FACING OUTWARDS.

- Properly support the half-pulley to prevent damaging the threading.

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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 020363Y 20-mm guide

- Insert the Seeger lock ring.

Refitting the driven pulley

- Insert the new oil guards

- Insert the new O-rings

N.B.

O-RINGS ARE OF TWO SIZES. THE LARGE ONE IS INSTALLED ON THE MACHINING END RADIUS, AT THE BASE OF THE HALF-PULLEY.

- Install the half-pulley on the bushing being careful not to damage the top sealing ring during the introduction.

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of grease, this operation should be carried out through one of the two holes into the bushing to obtain the exit of the grease from the opposite hole. This operation is necessary to avoid the presence of grease beyond the O-rings.

Recommended products

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

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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 halfpulley 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.

Characteristic

Minimum thickness permitted:

1 mm

- The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals.

N.B.

UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

- Do not open the masses using tools to prevent a variation in the return spring load.

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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.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

- Compress the spring and insert the clutch on the driven pulley bushing.

N.B.

BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.

- Tighten the ring nut by hand and complete the tightening using the special wrench to the prescribed torque.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Locking torques (N*m)

Clutch ring nut 65 - 75

- To facilitate reassembly on the engine, turn the moving driven pulley and insert the belt onto the smaller diameter.

Bell assembly

- Install the bell and the spacer.

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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 to horizontally align the central inside holes and install the special tool.

Specific tooling

020474Y Driving pulley lock wrench

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Page 67

- First install the lock ring of the special tool onto the pulley so that the splines are completely engaged.

- Then, insert the tool so as to insert the stud bolts on the ring into the holes obtained onto the tool itself.

- Tighten the two tool fastening nuts, also by hand.

- Loosen the central nut.

- Remove the spring washer and the flat washer.

- Remove the fixed driving half-pulley.

- Remove the bushing connection washer.

- Move the belt downwards.

- Suitable support the roller contrast and extract the movable driving half-pulley with the relevant bushing and the rear washer, being careful not to make the rollers come out.

Inspecting the rollers case

- Check that the inside bushings shown in the figure exhibit no signs of abnormal wear and measure the inside diameter.

CAUTION

DO NOT LUBRICATE OR CLEAN THE BUSHINGS

Characteristic

Maximum admissible diameter:

30.12 mm

Standard diameter:

30.021 mm

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- Measure the pulley sliding bushing outside diameter 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 24.5 mm

Standard diameter:

Ø 24.9 mm

- Check the guide shoes for the variator back-plate are not worn.

- Check the wear of the roller housings and of the belt contact surfaces on both pulley halves.

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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.

- Assembly the half-pulley with the roller contrast plate and sliding blocks.

- Insert the half-pulley on the crankshaft.

- Insert the spacer bushing.

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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.

- Insert the nut in the original position (nut side in contact with the belleville washer).

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- 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 CRANKCASE.

Specific tooling

020474Y Driving pulley lock wrench

- Install the lock ring from the rear so that the splines are completely engaged.

- Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly.

- Tighten the driving pulley fastening nut to the prescribed torque

- Remove the special tool.

Locking torques (N*m)

Drive pulley nut 160 - 175

Refitting the transmission cover

- Install the driving pulley shaft cover, positioning the tooth gap on the lower part with the reference mark on the transmission crankcase.

N.B.

ENSURE THAT THE AIR INTAKE AND EXHAUST OPENINGS ARE COMPLETELY FREE.

- Install the outside plastic transmission cover.

- Tighten the 4 fastening screws to the prescribed torque.

Locking torques (N*m)

External transmission cover screws 7 ÷ 9

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- 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 ÷ 26

- Lock the 7 M6 retainers.

Locking torques (N*m)

M6 retainer 11 ÷ 13

- Insert the washers on the driven pulley shaft.

N.B.

INSERT THE SMALLER WASHER FIRST, THEN THE LARGER ONE.

- Insert the flanged nut.

- Prepare the torque wrench for LHS locking using a machine hexagon wrench.

- Tighten the driven pulley shaft fastening nut using an offset wrench.

N.B. DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFER-

ENT WRENCHES - SUCH AS A CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE SHAFT OR BREAK THE BUSH ITSELF.

Locking torques (N*m)

Driven pulley nut 92 - 100

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End gear

Removing the hub cover

- Drain the rear hub oil through the oil drainage cap located under the engine.

-Remove the 7 fastening screws. Remove the hub cover and the relevant gasket.

Removing the wheel axle

- Remove the countershaft.

- Remove the wheel axis complete with gear.

Removing the hub bearings

- Check all bearings (wear, clearance and noise). In case of anomalies, proceed as follows. To remove the gear shaft bearing on the engine crankcase, use the following parts.

Specific tooling

001467Y014 Calliper to extract ø 15-mm bearings

001467Y034 Pliers to extract ø 15-mm bearings 001467Y031 Bell

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Page 74

- 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.

Specific tooling

020476Y Stud bolt set 001467Y006 Pliers to extract 20 mm bearings 001467Y007 Driver for OD 54-mm bearings

Removing the wheel axle bearings

- Take out the clip on the outside of the gearbox cover.

- Support the hub cover using the stud bolt set.

- Pull out the bearing using the special tool.

Specific tooling

020476Y Stud bolt set 020376Y Adaptor handle 020477Y 37 mm adaptor 020483Y 30-mm guide

Engine Beverly 500 i.e.

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Page 75

- 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 described in the « Automatic transmission» chapter.

- Extract the driven pulley shaft from its bearing.

- Remove the oil guard using a screwdriver into the hub gear box.

- Remove the Seeger ring shown in the figure.

- Pull out the driven pulley shaft bearing from the engine crankcase using the special tool.

Specific tooling

020376Y Adaptor handle 020358Y 37x40-mm Adaptor 020364Y 25-mm guide

Inspecting the hub shaft

- Check that the 3 shafts exhibit no wear or deformation on the grooved surfaces, at the bearings and at the oil seals.

- In case of faults, replace the damaged parts.

Characteristic

Beverly 500 i.e. Engine

ENG - 75

Page 76

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

Inspecting the hub cover

- Check that the mounting surface is not damaged or deformed.

- Check the capacity of the bearings.

In case of faults, replace the hub cover.

Refitting the driven pulley shaft bearing

- Heat the crankcase using the heat gun.

Specific tooling

020151Y Air heater

- Insert the driven pulley shaft bearing until it abuts against the bottom of the seat 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 020360Y 52x55-mm Adaptor 020364Y 25-mm guide

Engine Beverly 500 i.e.

ENG - 76

Page 77

- 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

- Heat the gear shaft bearing seat on the crankcase.

- Insert the gear shaft bearing in the upper crankcase seat 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 020412Y 15-mm guide

- Place the safety lock Seeger ring of the driven pulley shaft bearing.

N.B. PLACE IT IN THE POSITION SHOWN IN THE FIGURE.

- Insert the pulley shaft oil guard on the transmission side.

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Page 78

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.

N.B. PLACE IT WITH THE BALLS FACING THE HUB (THIS AP-

PLIES TO BEARINGS WITH PLASTIC CAGE).

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020363Y 20-mm guide

- Heat the gear shaft bearing seat from the cover outside.

- Insert the gear shaft bearing on the cover using the special punch until abutment.

Specific tooling

020376Y Adaptor handle 020360Y 52x55-mm Adaptor 020483Y 30-mm guide

- Replace the snap ring

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ENG - 78

Page 79

- 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 020476Y Stud bolt set

Refitting the hub bearings

- Place the 3 shafts as shown in the figure.

Refitting the ub cover

- Check the proper position of the centring dowels.

- Install a new gasket.

- Fit the gearbox cover, making sure the breather pipe is in the correct position.

- Position the 7 set screws, tighten them to the prescribed torque, being careful of the position of the bands holding the vent tube, and the position of the 3 shortest screws as indicated in the figure.

- Refill with the prescribed oil to the Max. level.

Recommended products

AGIP ROTRA 80W-90 rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Characteristic

Quantity:

approx. 250 cc

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Page 80

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.

N.B. THE BANDS MUST BE REPLACED. TO REMOVE THEM,

OPEN WITH A SCREWDRIVER OR CUT THEM. BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.

Removing the hub cover

- Drain the engine oil by removing the drainage cap.

- Prepare a suitable container to collect the oil.

- Remove the pre-filter.

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Page 81

- Remove the oil filter using a filter tape or shaped cup wrench.

- Loosen the 14 fastening screws.

- Remove the flywheel cover with the relevant gasket and the cooling system sleeve support.

N.B. THE SCREWS ARE OF 4 DIFFERENT LENGTHS. NOTE

THE RELEVANT POSITIONS.

CAUTION

REMOVE THE COVER AVOIDING ANY POSSIBLE INTERFERENCE BETWEEN STATOR AND ROTOR.

CAUTION

BE CAREFUL TO PREVENT SLIPPAGE OF THE BY-PASS VALVE AND OF THE RELEVANT SPRING.

Removing the flywheel cover components

- Loosen the six mounting screws and remove the water pump cover.

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Page 82

- 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 stator and its wiring.

- Loosen the two retaining screws and remove the reed valve support with bulkhead.

Engine Beverly 500 i.e.

ENG - 82

Page 83

- 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. THE THREADING IS CLOCKWISE. IT IS ADVISABLE TO

PREVENT THE SHAFT ROTATION BY INSERTING A 12-MM WRENCH INTO THE DRIVE.

- Extract the shaft with the relevant abutment washer.

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Page 84

- Remove the sealing ring.

- Remove the ceramic ring and the relevant gasket.

- Remove the sealing ring for the pump shaft lubrication using a suitably shaped tool.

- Remove the engine oil filling cap/dipstick and the check hole cover for the distribution timing.

- Remove the minimum oil pressure sensor.

Engine Beverly 500 i.e.

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Page 85

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 TEMPERATURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED.

Electric characteristic

Resistance:

0.2 - 1 Ω

- Check the ground insulation of each phase.

- If a fault is found, carry out a thorough check of the cable harness that contains two types of cable: Rigid cables close to the stator and flexible cables close to the connector.

- Check that the winding is positioned so as not to interfere with the heads of the retaining screws.

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Page 86

- 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

Connection diameter for pump shaft:

8 mm

- Check that the oil filter union and matching surface exhibit no deformations or wear.

- Install a new oil filter, lubricate the gasket, screw on and finally tighten to the prescribed torque.

Locking torques (N*m)

Engine oil filter 12 - 16

- Install the supply hose to the cylinder and connect the return hose to the pump cover using 3 new clamps.

N.B. TIGHTEN THE CLAMPS USING APPROPRIATE PLIERS,

PAYING ATTENTION NOT TO CONSTRICT THE HOSES BUT ALSO TAKING CARE TO TIGHTEN THE CLAMPS SUFFICIENTLY.

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Page 87

- 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 Synthetic oil

Locking torques (N*m)

Engine oil drainage plug 24 to 30

Refitting the stator

- Install the stator assembly together with the wiring harness, tightening the 3 screws to the prescribed torque.

N.B. INSERT THE RUBBER WIRING SEALING GASKET INTO

THE SPECIAL SEAT ON THE CRANKCASE.

Locking torques (N*m)

Stator retainers 8 - 10

- Install the wiring guide bracket tightening the 2 screws to the prescribed torque.

Locking torques (N*m)

Stator cable harness guide bracket screws 3 - 4

- Temporarily install the distribution timing check hole cover and the engine oil filling cap/bar.

- Insert the blow-by recovery duct using a new Oring.

- Tighten the screws to the prescribed torque.

Locking torques (N*m)

Blow-by recovery duct fixing screws 3 - 4

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Page 88

- 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 channels, in particular:

- The 3 by-pass channels.

- Oil feeding duct at the water pump shaft connection.

- Pump drainage duct.

Engine Beverly 500 i.e.

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Page 89

- 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

- Install a new sealing ring for the pump shaft using the special tool

- Install the oil minimum pressure sensor and tighten to the prescribed torque.

Specific tooling

020376Y Adaptor handle 020412Y 15-mm guide

Locking torques (N*m)

Minimum oil pressure sensor 12 to 14

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Page 90

- 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.

ASSEMBLE BY HAND TO PREVENT DAMAGES TO THE CERAMIC SEAL.

- Insert the water pump shaft after lubricating the flywheel cover seat.

- Insert the mechanical seal on the shaft up to the impeller abutment surface.

N.B. THE FINAL INTRODUCTION DEPTH WILL BE DETER-

MINED BY THE IMPELLER.

- Screw the impeller and tighten to the prescribed torque.

Locking torques (N*m)

Water pump impeller 4 ÷ 5

Refitting the flywheel cover

- Lubricate the intermediate gear seat with torque limiter on the flywheel cover.

- Align the water pump movement sensor with a reference and install the flywheel cover as described in the Flywheel cover chapter.

Engine Beverly 500 i.e.

ENG - 90

Page 91

- Install a new gasket on the engine crankcase.

- Check the presence of the three centring dowels.

- Turn the crankshaft in order to align the countershaft movement sensor with a reference point on the crankcase (see figure).

- Repeat the alignment for the water pump crankshaft using the same reference point on the engine.

N.B. THIS PREPARATION IS USEFUL PARTICULARLY IN THE

EVENT OF REPAIRS WITH THE WATER PUMP COVER INSTALLED.

- Install the flywheel cover on the engine, paying attention to avoid interference between the stator and rotor.

WARNING

FAILURE TO OBSERVE THIS PRECAUTION MAY RESULT IN DESTRUCTION OF THE CERAMIC MAGNETS.

- Tighten the 14 retaining bolts of the cover to the prescribed torque.

N.B. THE BOLTS HAVE FOUR LENGTHS:

- THE 3 SHORTEST ARE INSERTED AS SHOWN IN THE FIGURE.

- THE LONGEST IS INSERTED UNDER THE ENGINE OIL FILLER PLUG.

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Page 92

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. Before deciding to replace it, carry out the following tests: 1 - Battery Check the voltage after not running (a few hours): Voltage >12.5V Check the density of the electrolyte of each cell: Bé = 30 ÷ 32 Specific weight: 1.25 - 1.26 YES go to 2 NO go to 3 2 - Make sure the negative terminals (battery negative and starter negative) are correctly connected to each other and to the frame. YES go to 4 NO go to 5

3 - Recharge and if necessary replace the battery. 4 - Connect the diagnostic tester (see chapter "Injection system"). Connect the induction clamp of an ammeter to the positive power supply cable of the starter motor. Remove the 10A fuse no. 12 (see "fuses" chapter). Switch in position "ON" with interrupt switch in position "RUN" and side stand raised. Select the "PARAMETERS" function. Start the engine (so that it cannot move) long enough to measure the rpm and starter absorption.

N.B.

THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS NOT THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.

Specific tooling

020680Y Diagnosis Tool

Electric characteristic

Absorption at trailing speed:

Engine Beverly 500 i.e.

ENG - 92

Page 93

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. Remove the starter motor (see the flywheel and starter system). Reconnect the earth and positive and perform the test.

Electric characteristic

Current consumption at idle speed:

<40 A YES go to 10 NO go to 11

7- Low trailing speed

High electrical absorption

Carry out a test of the engine rotation (example: possible melting of the bushes) and if no anomalies are found, replace the starter motor. 8- Low trailing speed

Low electrical absorption

Repeat the test, bridging the power terminals of the starter remote control switch or even better replacing them. Check the new values. YES go to 12 NO go to 13

9 - High trailing speed Low electrical absorption

The engine turns too freely, check the compression end pressure. If the values are not correct proceed as follows. 10 - The starter motor works properly. 11 - Check the rotation of the armature. 12 - Replace the starter remote control switch. 13 - Test the battery again and if necessary replace the starter motor.

Beverly 500 i.e. Engine

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Page 94

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.

N.B. THE BANDS MUST BE REPLACED. TO REMOVE THEM,

OPEN WITH A SCREWDRIVER OR CUT THEM. BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.

STARTER MOTOR

Specification Desc./Quantity

Type Mitsuba sm13d

Power 0.9 kW

BATTERY

Specification

Desc./Quantity

Capacity 14 Ah

Starting current 125 A

START-UP REMOTE CONTROL SWITCH

Specification

Desc./Quantity

Type SEALED

Maximum load 150 A continuous

STARTER TRANSMISSION

Specification

Desc./Quantity

Ring gear and freewheel coaxial to the flywheel. Intermediate gear with built-in torque limiter.

The starter system has a transmission between the motor armature and engine shaft equipped with freewheel coaxial to the flywheel and torque limiter on the intermediate shaft. The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure of the engine and the starter kinematic mechanism in the event of incorrect starting with consequent inverse rotations. The freewheel is used for a sufficiently silent starting. The starter control (energised remote control) is slaved to enabling signals by the side stand and the emergency OFF/RUN switch, which does not allow starting given dangerous conditions. The starter control circuit is not controlled by the immobilizer system, therefore before insisting on the starter system, check the consensus of the immobilizer. In order to check the enabling switches circuit, see the «Electrical system» chapter, whereas to check the engine shaft control transmission, follow what is described in the «Flywheel and starter system» chapter.

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Page 95

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.

- Unscrew the 3 fastening screws and remove the chain guide sliding block retain plate and the startup rim.

- Align the holes obtained on the flywheel with the crankcase housing to allow the introduction of the special tool.

Beverly 500 i.e. Engine

ENG - 95

Page 96

- 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 into the previously aligned holes and that it is perfectly abutted and almost flush with the flywheel.

Specific tooling

020472Y Flywheel lock wrench

- Loosen the magneto flywheel fastening nut.

- Remove the special tool and the fastening nut.

- Remove the washer.

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Page 97

- 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.

- Insert the special removing tool.

- Using a 27-mm wrench and a 19-mm bushing, release the flywheel.

Specific tooling

020467Y Flywheel extractor

- Remove the extractor.

- Remove the nut and extract the flywheel with the start-up rim.

- Remove the crankshaft key.

- To remove the start-up rim from the freewheel it is necessary to turn it clockwise and pull it out.

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Page 98

- Remove the freewheel from the flywheel by loosening the 6 fastening screws.

SINCE THE FREEWHEEL MUST BE REMOVED, IT IS ADVISABLE TO LOOSEN THE 6 FASTENING SCREWS IN ADVANCE WITH THE FLYWHEEL STILL INSTALLED ON THE CRANKSHAFT.

- The freewheel is coupled to the flywheel with high precision; if removal is difficult, use 2 screws as gripping points and as removing tools, if required.

- Extract the intermediate gear provided with torque limiter.

Inspecting the flywheel components

- Check the integrity of the magnets.

- Check that the magnet support cage is free from deformation or cracks.

- Check that the flywheel splines exhibit no loosening.

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Starter gear rim

- Check that there is no wear or abnormal impressions 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

- Check the inside diameter of the bushing of the starter gearing.

- Check that the toothing is not worn.

Characteristic

Inside diameter of the bushing:

Diameter 27 + 0.020 +0.041 mm

N.B.

IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND FREEWHEEL. IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE STARTING RING GEAR. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE CRANKSHAFT.

Intermediate gear

- Check that the toothing is not worn.

- Check the diameter of the two bearings.

Characteristic

Gear bearing diameter:

12 - 0 0.011 mm

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Page 100

Also check the shaft diameter on the flywheel cover 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.

THE TORQUE LIMITER IS PROVIDED WITH 4 GEARS THAT HAVE THE FUNCTION OF CLUTCH DRIVE PLATES.

Driven plates consist of 4 Belleville springs provided with grooved profiles; this assembly allows transmitting torque lower than 10 kg. In case of incorrect start-up manoeuvres, the limiter prevents any kicks, with consequent reversal of direction of the crankshaft which would impair the engine structure.

The limiter assembly cannot be overhauled. In case of irregularities on the toothed discs, replace the assembly.

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.

- Degrease the threading of the holes in the free wheel and the clamping screws.

- Apply the recommended product to the end of the screws.

Recommended products

Loctite 243 Medium strength threadlock

Medium Loctite 243 threadlock

Engine Beverly 500 i.e.

ENG - 100

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

Specifications and Main Features

Frequently Asked Questions

User Manual