Piaggio Beverly 400 i.e Service & Repair Manual

SERVICE STATION MANUAL 633763 ÷ 633770 Beverly 400 i.e.

SERVICE STATION MANUAL Beverly 400 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. "© Copyright 2005 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication 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

SERVICE STATION MANUAL Beverly 400 i.e. This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of scooter mounting techniques and procedures. Any important changes made to the scooters or to specific mounting operations will be promptly reported by updates to this manual. Nevertheless, no mounting 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 special tools, along with the special 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 TOOLING TOOL 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. Sul- phuric 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. Non- original 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. Lubri- cate 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 meas- ures. 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. Beverly 400 i.e. Characteristics CHAR - 7

Vehicle identification Chassis prefix: ZAPM34300÷1001 Engine prefix: M343M ÷ 1001 Dimensions and mass WEIGHT Specification Desc./Quantity Kerb weight 189 kg Width (at the handles) 770 mm Length 2215 mm Wheel base 1550 mm Height 1305 mm Characteristics Beverly 400 i.e. CHAR - 8

Engine ENGINE Specification Desc./Quantity Engine Single-cylinder, four-stroke Bore x stroke 85.8 X 69 mm Cubic capacity 399 cm³ Compression ratio 10.6 ± 0.5 : 1 Timing system Single overhead camshaft with integrated tone wheel, control from flywheel side chain, 4 valves and automatic start-up valve lifting device. 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 Idle speed 1500 ± 100 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 adjustment by-pass and oil filter. Lubrication pressure 4 bar Minimum allowed (at 100° C) 0.8 bar Fuel supply 38 Ø mm throttle body and single injector Maximum power (at the crankshaft) 25 kW at 7500 rpm Maximum torque (to the crankshaft) 37.6 Nm at 5500 rpm Cooling Forced fluid circulation, with engine driven pump; 3-way ther- mostat to pump intake. 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. 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 injection, 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 x 30 A Beverly 400 i.e. Characteristics CHAR - 9

Specification Desc./Quantity 2 x 15 A 2 x 10 A 3 x 7.5 A 2 x 5 A Generator Three-phase alternating current Frame and suspensions FRAME 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 in relation to the rocker forks with two double-acting hydraulic shock absorbers and setting of the preload in 4 posi- tions. Rear shock absorber max. travel 95.5 mm Brakes BRAKE SYSTEM Specification Desc./Quantity Front brake Ø 260 disc brake (left-hand side of vehicle), with hydraulic control operated from the right-hand brake lever on the handlebar. Rear brake Ø 240-mm disc brake with hydraulic control activated by handlebar left-side lever. 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 COR- RECT VEHICLE PERFORMANCE AT THE DIFFERENT SCOOTER SPEEDS. USING ANY OTHER TYRE MAY RESULT IN VEHICLE INSTABILITY. IT IS ADVISABLE TO USE TYRE TYPES REC- OMMENDED BY PIAGGIO. Characteristics Beverly 400 i.e. CHAR - 10

Piaggio Beverly 400 i.e Service & Repair Manual

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