PIAGGIO Beverly 400 E5 User manual

MANUALE STAZIONE DI SERVIZIO
1Q000884
Beverly 400 E5

MANUALE
STAZIONE DI
SERVIZIO
Beverly 400 E5
The descriptions and images in this publication are given for illustrative purposes only. While the basic
features as described and illustrated in this manual remain unchanged, Piaggio & C. S.p.A. reserves the
right, at any time and without being required to update this publication beforehand, to make any changes
to components, parts or accessory supplies which it deems necessary to improve the product, or which
are required for manufacturing or commercial reasons.
Not all the versions shown in this publication are available in every country. Availability of the individual
versions must be verified with the official PIAGGIO sales network.
© Copyright 2021 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
in part is prohibited.
Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy
www.piaggio.com

MANUALE STAZIONE DI
SERVIZIO
Beverly 400 E5
Questo manuale per stazioni di servizio è stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio. Si presuppone che chi utilizza questa pubblicazione
per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei principi della
meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni importanti
nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno comunicate
attraverso aggiornamenti di questo manuale. Non si può comunque realizzare un lavoro completamente
soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed è per questo che vi
invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il catalogo degli
attrezzi specifici.
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 Sectionsmarkedwiththis 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
GENERAL MANDATORY REQUIREMENTS NORM
PRE-DELIVERY PRE DE
TECHNICAL DATA DT
TOOLING TOOL
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE ENG
BRAKING SYSTEM BRAK SYS

INDEX OF TOPICS
GENERAL MANDATORY REQUIREMENTS NORM

General information
This section contains general information about using the manual and the vehicle. as well as important
notes about safety.
WARNINGS AND IMPORTANT NOTES
Each symbol has a precise meaning. as shown below.
•WARNING: - This symbol indicates the risk to the health of the operator or others in the
vicinity if the procedures are not carried out properly.
•IMPORTANT!:- This symbol indicates that the component being worked on may be dam-
aged if the described procedures are not carried out properly.
•N.B.:- This section provides additional instructions on the procedure in progress so that the
operation may be performed effectively.
WARNINGS REACH REGULATION:
In order to preserve the health and safety of the PROFESSIONAL CUSTOMER, as required by:
•EC Regulation 1907/2006 (REACH);
•EC Directive 2000/53/EC (END of LIFE VEHICLES);
•SCIP Database Directive (Article 9, paragraph 1 letter i) of the Waste Framework Directive,
amended by Directive 2018/851
All technical personnel working engaged in scheduled and unscheduled maintenance activities are
required to wear the following personal protective equipment at all times:
1. chemical resistant gloves, where a specific type is not indicated, or, where required, specific
gloves for the substance handled;
2. face mask or, where specifically indicated, chemical filter mask;
3. protective eyewear.
The above is valid in the alternative to what is required by other regulations and by the laws in force in
specific countries. As regarding the use of other PPE, regulated by safety at work, the regulations in
force apply.
Beverly 400 E5 General mandatory requirements
NORM - 7

GENERAL SAFETY WARNINGS:
1. Always wear protective goggles and suitable clothing.
2. Always use a safety support for operating under the vehicle.
3. Make sure the ignition switch is always OFF. unless otherwise specified in the procedure.
4. Pull the hand brake (if available) before starting work on the vehicle.
5. Operate the engine only in well ventilated places to avoid the risks associated with carbon mon-
oxide.
6. Keep away from moving parts during engine operation. especially from the fans and belts.
7. To avoid serious burns. avoid contact with hot metal parts such as the radiator. exhaust manifold.
exhaust pipe. catalytic converter and muffler.
8. Do not smoke during maintenance operations.
9. To avoid possible injury. do not wear rings. watches. jewellery or loose clothing before beginning
work on the vehicle.
10.Keep hands and other objects away from the radiator electric fan blades (if available)!
11.The electric cooling fan (if available) is mounted on the radiator and can start up at any time due
to an increase in coolant temperature. It is important to verify that the electric cooling fan motor
has been disconnected from the cable harness before starting work.
The units of measurement used in this manual are indicated as SI UNITS (International System
of Units). Example:24.5 to 34.3 Nm
General mandatory requirements Beverly 400 E5
NORM - 8

INDEX OF TOPICS
PRE-DELIVERY PRE DE

Electrical system
• Remote control and ignition switch
• Lights: high beam lights, low beam lights, tail lights and their warning lights
- Headlight adjustment according to the regulations currently in force
• Brake light operation by using the RH and LF brake lever
• Turn indicators and their warning lights
• Instrument lighting
• instruments: fuel and temperature indicator
•Instrument panel lights
• Horn
• Electric starter
• Engine stopping with emergency stop switch
• Various controls on the handlebar
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATELY CHARGING THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS
USED FOR THE FIRST TIME WITH SHORTEN THE LIFE OF THE BATTERY.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN-
DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG-
ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO-
TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE
OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
The vehicle is equipped with an OBD (On-Board
Diagnostics) port, compliant with the Euro 5 direc-
tivesandwhichallowstheconnectionbetweenthe
vehicle and the diagnostic tool.
N.B.
AT EACH SCHEDULED MAINTENANCE A VERIFICATION
MUST BE PERFORMED WITH THE DIAGNOSTIC TOOL TO
CHECK IF THERE ARE ERRORS AND THE IF THE PARAM-
ETERS ARE CORRECT. ENSURE THAT THE VEHICLE
CALIBRATION IS UP TO DATE AFTER UPDATING THE DI-
AGNOSTIC TOOL.
Pre-delivery Beverly 400 E5
PRE DE - 10

Instruments start-up
DIGITALDISPLAY MEASUREMENT UNIT CON-
VERSION (Km-mi, l-gal, °C-°F)
•With the ignition switch turned to
"OFF", press and hold the MODE key
on the instrument cluster and simulta-
neously turn the ignition switch to
"ON";
•release the button. The icons "mi",
"km", "°C", "°F" will flash;
•brieflypresstheMODEbutton,untilthe
desired icon is displayed (steady);
•press and hold the MODE for at least 1
to 5 seconds to change the unit of
measurement;
•the consumption measurement unit
will automatically change when "Km"
or "mi" is selected.
N.B.
THE MEASUREMENT UNIT CONVERSION CAN TAKE
PLACE ONLY WITH THE VEHICLE AT A STANDSTILL.
CLOCK SETTING
To set or adjust the time, with the engine running
orwiththeignitionswitchto"ON"position,proceed
as follows:
•press and hold the SET button on the
instrument cluster for at least 5 sec-
onds and then release the button; the
hour value "hh" starts flashing;
•press the SET button briefly and re-
peatedly to set the correct hour value;
press and hold the SET button to cycle
the hour value rapidly;
•press the SET twice in succession
briefly to confirm the set value (or cur-
Beverly 400 E5 Pre-delivery
PRE DE - 11

rent value, if no changes were made) -
the minutes value «mm» now starts
flashing;
•press the SET button briefly and re-
peatedly to set the correct minutes val-
ue; press and hold the SET button to
cycle the minutes value rapidly;
•press the SET twice in succession
briefly to confirm the set value (or cur-
rent value, if no changes were made).
If the SET button is not pressed for a period ex-
ceeding 5 seconds at any time during this proce-
dure, the system exits clock setting mode.
WARNING
FOR SAFETY REASONS THE TIME SETTING IS ONLY
POSSIBLE WITH THE VEHICLE AT A STANDSTILL.
WARNING
DISCONNECTING THE BATTERY CABLES WILL RESULT
IN A RESET OF THE CLOCK
ASR SYSTEM
The ASR system is a driving aid that assists the
driver in acceleration manoeuvres, particularly on
low-grip surfaces or under conditions that can
cause sudden back-wheel slippage. The ASR in
these situations automatically intervenes by re-
ducing engine output within the limit imposed by
the grip conditions, contributing significantly to the
maintenance of stability the vehicle.
WARNING
THE ASR SYSTEM IS BASED ON THE RECOGNITION OF
SPEED DIFFERENCES BETWEEN FRONT AND REAR
WHEEL. FOR THE SYSTEM TO PERFORM CORRECTLY IN
ALL CONDITIONS, THE PROCEDURE MUST BE PER-
FORMED EACH TIME A TYRE IS REPLACED EVEN IF ON-
LY ONE OF THE TYRES IS REPLACED.
FOR THE CALIBRATION OF THE ASR SYSTEM PERFORM
THE PROCEDURE BELOW.
WARNING
Pre-delivery Beverly 400 E5
PRE DE - 12

THE ASR SYSTEM PREVENTS THE APPLICATION OF
HIGH SPEED ROTATION ON THE REAR WHEEL WITH THE
VEHICLE ON THE CENTRE STAND.
IT IS RECOMMENDED TO NOT INSIST WITH THE THROT-
TLE GRIP IN THIS SPECIFIC SITUATION, BECAUSE THIS
MAY CAUSE ABNORMAL STOPS AND/OR DAMAGE TO
THE CATALYSTS.
ASR System "1" deactivation button
todeactivate theASRsystem, withthe enginerun-
ning, press the corresponding button for at least 1
second.
ASR "2" system activation icon
System active and calibrated: iconflashes when
the key is "ON", then goes off with the engine run-
ning.
ASR "3" system deactivation icon
Icon "ASR OFF": on steady with engine started,
ASR system not working or not calibrated or vol-
untarily deactivated.
ASR/ASR OFF ICON OPERATION MODE
ASR System status ICON with engine off
or key "ON" ICON with engine on ASR working
ACTIVE and calibrated "ASR" icon: 1Hz slow
flashing Icons switched off "ASR" icon: 5Hz fast flashing
ACTIVE not calibrated Icon "ASR OFF": on
steady Icon "ASR OFF": on steady "ASR" icon: 5Hz fast flashing
ASR voluntarily deactivated Icon "ASR OFF": on
steady Icon "ASR OFF": on steady -
ASR system not working Icon "ASR OFF": on
steady Icon "ASR OFF": on steady -
Programming phase (successful) - "ASR" icon: 1Hz slow flashing (then
when the engine is started, the icons
turn off if the programming is suc-
cessful)
-
Programming phase (failed) Icon"ASROFF":on steadywhen en-
gine is started if the programming
has failed
-
Beverly 400 E5 Pre-delivery
PRE DE - 13

Manual calibration procedure of the ASR sys-
tem.
In order to maintain the efficiency of the ASR sys-
tem when one or both tires are replaced, a cali-
bration procedure of the ASR system must be
performed as follows on a straight flat stretch of
road:
1. With vehicle at a standstill and engine off.
2. Pull the brake lever, turn the starter switch to
"ON" and start the engine.
3. Disconnect the ASR system by pressing the
correspondingbutton for at least 1 secondwiththe
engine running; The "ASR OFF" icon will be-
come steady on, initially it was off as the ASR
system had already been calibrated in the past.
4. Drive at a low speed for a few meters, until the
"ABS" indicator light stops flashing.
5. To start the programming procedure, press the
start button and the ASR button at the same time
for at least 4 seconds, until the "ASR OFF" icon
starts flashing; then release the buttons.
6. Start driving and increase the speed up to 30
km/h within 1 minute, keep the speed constant
for at least 10 seconds,
The "ASR OFF" icon switched off indicates that
the calibration was successful.
7. Stop the vehicle and shut off the engine by
turning the starter switch to the "OFF" position.
Pre-delivery Beverly 400 E5
PRE DE - 14

8. If the procedure has been completed cor-
rectly, the next time the starter switch is turned
to the "ON" position, the "ASR" icon lights up
with 1Hz slow flashing (1 flash per second).
When starting the engine, the "ASR" icon turns off
and the ASR system will be ACTIVE.
9. If the procedure is NOT completed correctly,
the"ASROFF"icon will be switchedonsteady.
By pressing the appropriate button, the user can
manually reactivate the ASR system by returning
it to the previously stored calibration.
WARNING
N.B.
BY TURNING THE STARTER SWITCH TO THE "ON" POSITION, THE FLASHING ASR ICON IN-
DICATES THE SYSTEM DIAGNOSIS PHASE. IF THERE IS NO FLASHING WHEN THE ENGINE IS
STARTED, THE ASR SYSTEM MAY NOT BE WORKING.
WARNING
THE ASR SYSTEM IS ACTIVATED EVERY TIME, THE STARTER SWITCH IS TURNED TO THE
"ON" POSITION.
IF DISABLED BY THE USER, THE ASR SYSTEM KEEPS THE STATE OF INACTIVITY ONLY IF
THE VEHICLE IS OFF, BY USING THE ENGINE STOP SWITCH; THE NEXT TIME THE STARTER
SWITCH IS TURNED, THE ASR SYSTEM IS AUTOMATICALLY ENABLED.
CAUTION
IT IS RECOMMENDED TO PAY PARTICULAR ATTENTION IN THE EVENT OF ACCELERATION
FROM STANDSTILL IN CONDITIONS OF LOW GRIP, ESPECIALLY IN THE FIRST METRES.
CAUTION
A POOR STATE OF MAINTENANCE OF THE TYRES CAN RESULT IN ABNORMAL OPERATION
OF THE ASR SYSTEM.
IN CASE OF REPEATED INTERVENTIONS OF THE ASR, EVEN ON ROAD SURFACES WITH
GOOD GRIP OR SMALL THROTTLE OPENINGS, IT IS NECESSARY TO CHECK FOR WEAR AND/
OR THE STATE OF INFLATION OF TYRES FIRST.
CAUTION
IT IS EMPHASISED THAT THE RIDING AUXILIARY SYSTEM CANNOT CHANGE THE PHYSICAL
LIMITS OF GRIP AND IS NOT A SUBSTITUTE FOR PROPER MANAGEMENT OF POWER, BOTH
ON STRAIGHT STRETCHES AND IN TURNS. THEREFORE, IT IS RECOMMENDED TO ALWAYS
USE THE VEHICLE WITH THE UTMOST CARE AND IN ACCORDANCE WITH THE REGULATIONS
IN FORCE.
Beverly 400 E5 Pre-delivery
PRE DE - 15

N.B.
THE DEVICE PREVENTS IMPRESSING ON THE REAR HIGH SPEED ROTATION WHEEL WITH
THE VEHICLE ON THE CENTRE STAND. IT IS RECOMMENDED NOT TO INSIST WITH THE
THROTTLE GRIP IN THIS PARTICULAR CONDITION.
N.B.
IN CASE OF ROAD DISCONNECTIONS THERE COULD BE SHORT ACTIVATIONS OF THE ASR
SYSTEM. SUCH EVENT APPEARS UNDER NORMAL OPERATION CONDITIONS OF THE VEHI-
CLE.
CAUTION
IN THE EVENT OF MALFUNCTION OF THE BATTERY, THE ABS - ASR SYSTEM TURNS OFF.
Pre-delivery Beverly 400 E5
PRE DE - 16

INDEX OF TOPICS
TECHNICAL DATA DT

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
- If work can only be done on the vehicle with the engine running, make sure that the premises are well
ventilated, using special extractors if necessary; 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 it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air carefully to avoid
the risk of inhaling dust produced by worn friction material. Even though the latter contains no asbestos,
inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, seal rings and cotter pins when reassembling.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts,
nuts and screws are not interchangeable with coupling members using English measurements. Using
unsuitable coupling members and tools may damage the vehicle.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electrical connections have been made properly, particularly the ground and battery connec-
tions.
Technical Data Beverly 400 E5
DT - 18

Vehicle identification
Identification registration numbers are made up of
a prefix and a number, stamped on the frame and
on the engine. The serial number must always be
indicated when ordering spare parts. We recom-
mend checking that the frame registration number
stamped on the vehicle corresponds with that on
the vehicle documentation.
CAUTION
PLEASE REMIND THAT ALTERING IDENTIFICATION REG-
ISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL
SANCTIONS (IMPOUNDING OF THE VEHICLE, ETC.).
Frame number
It is necessary to remove the door «A» inside of
the front glove compartment to read the frame
number.
Engine number
The engine number is stamped near the rear left
shock absorber lower support.
Beverly 400 E5 Technical Data
DT - 19

VEHICLE IDENTIFICATION
Specification Desc./Quantity
Frame prefix ZAPMD2200
Engine prefix MD22M
Engine Data
ENGINE SPECIFICATIONS
Specification Desc./Quantity
Type Single cylinder 4-stroke
Engine capacity 399 cc
Bore per stroke 84.0 x 72.0 mm
Compression ratio 11,5 ± 0,5 :1
Idle speed 1600 ± 100 rpm
Timing system Four valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm
Exhaust: 0.15 mm
Maximum power 26.0 kW at 7000 rpm
Maximum torque 37.7 Nm at 5,500 rpm
Transmission With the expandable pulley continuously variable transmission
with torque server, trapezoid belt, automatic clutch oil bath
centrifuge.
Final drive reduction gear Gear reduction unit in oil bath.
Lubrication Engine lubrication with trochoidal pump (inside the crankcase),
oil filter and pressure adjustment by-pass.
Cooling Forced coolant circulation system.
Starting Electric
Ignition Electronic,inductive,highefficiencyignition,integratedwiththe
injection system, with variable advance and separate H.V. coil.
Ignition advance Three-dimensional map managed by control unit
Power supply Indirect electronic injection.
Spark plug NGK / MR7BI-8
Fuel Unleaded gasoline E10 (95 R.O.N.)
Silencer Absorption-type exhaust silencer with a three-way catalytic
converter and lambda probe to the exhaust.
Emissions compliance EURO 5
Technical Data Beverly 400 E5
DT - 20