PIAGGIO Beverly 300 i.e. Guide

SERVICE STATION MANUAL
xxxxxx (IT) - xxxxxx (EN) - xxxxxx (FR) - xxxxxx (DE)
- xxxxxx (ES) - xxxxxx (PT) -xxxxxx (NL) - xxxxxx
(EL)
Beverly Tourer 300 i.e.

SERVICE STATION
MANUAL
Beverly Tourer 300 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/models shown in this publication are available in all countries. The availability of each
model should be checked at the official Piaggio sales network.
"©Copyright2008-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

SERVICE STATION MANUAL
Beverly Tourer 300 i.e.
This service station manual has been drawn up by Piaggio & C. SpA to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant change to vehicle characteristics or to specific repair operations will be communicated 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 concerning 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 Sectionsmarked with this symbol indicatethe correct use of thevehicle
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
TROUBLESHOOTING TROUBL
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
- 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 in such a way that
you do not breathe in the dust produced by the wear of the 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 spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- 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.
Beverly Tourer 300 i.e. Characteristics
CHAR - 7

Vehicle identification
To read the chassis prefix, lift the saddle and re-
move the lid «A».
Theengineprefix«B»is stampednearthe rearleft
shock absorber lower support.
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Chassis prefix M28A00
Engine prefix M28MM
Characteristics Beverly Tourer 300 i.e.
CHAR - 8

Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification Desc./Quantity
Length 2110 mm
Width to handlebar 770 mm
Wheelbase 1470 mm
Height 1500 mm
Kerb weight 165 kg ± 5 kg
Maximum weight allowed 350 kg
Engine
ENGINE
Specification Desc./Quantity
Type Single-cylinder, 4-stroke
Engine capacity 278 cm³
Bore x Stroke 75x63 mm
Compression ratio 11 ± 0.5 : 1
Engine idle speed 1,700 ± 100 rpm
Timing system 4 valves, single overhead camshaft, chain-driven.
Valve clearance Intake: 0.10 mm Exhaust: 0.15 mm
Max. power 16.1 kW at 7,250 rpm
MAX. torque 23 Nm at 6,000 rpm
Lubrication Engine lubrication with lobe pump (inside crankcase), chain-
driven, with double filter: mesh and paper.
Lubrication pressure 4 bar
Minimum lubrication pressure (100° C) 0.8 bar
Beverly Tourer 300 i.e. Characteristics
CHAR - 9

Specification Desc./Quantity
Fuel system ElectronicinjectionwithØ32-mm throttle bodyand electric fuel
pump.
Cooling Forced coolant circulation system.
Fuel Unleaded petrol (95 RON)
Exhaust silencer Absorption-type exhaust silencer with a 3-way catalytic con-
verter and lambda probe.
Emissions compliance EURO 3
Transmission
TRANSMISSION
Specification Desc./Quantity
Transmission Automatic expandable pulley variator with torque server, V-
belt, self-ventilating dry automatic centrifugal clutch and trans-
mission housing with forced-circulation air cooling.
Final reduction gear Gear reduction unit in oil bath.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil 1.3 l
Transmission oil 250 cm³
Cooling system fluid 1.75 l
Fuel tank (reserve) 10 l ± 0.5
Fork oil (quantity per stem) 133 cm³
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Starter starter
Ignition Electronic inductive discharge ignition, high efficiency, with
separate HV coil.
Ignition advance α/N three-dimensional map managed by control unit
Spark plug NGK CR8EKB
Alternative spark plug -
Battery 12V-12Ah
Alternator alternating current
Frame and suspensions
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front wheel rim 16'' x 3.00
Rear rim 16 x 3.50''
Front tyre Tubeless, 110/70 - 16'' 52P
Rear tyre Tubeless, 140/70 - 16'' 65P
Front tyre pressure (with passenger) 2 bar (-)
Rear tyre pressure (with passenger) 2.2 bar (2.5 bar)
Characteristics Beverly Tourer 300 i.e.
CHAR - 10

Brakes
BRAKES
Specification Desc./Quantity
Front brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar right-side lever.
Rear brake Ø 260-mm disc brake with hydraulic control activated by han-
dlebar left-side lever.
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rim type Light alloy wheel rims.
Front wheel rim 16'' x 3.00
Rear rim 16 x 3.50''
Front tyre Tubeless, 110/70 - 16'' 52P
Rear tyre Tubeless, 140/70 - 16'' 65P
Front tyre pressure (with passenger) 2 bar (-)
Rear tyre pressure (with passenger) 2.5 bar (-)
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGU-
LATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
Tightening Torques
STEERING
Name Torque in Nm
Handlebar fixing screw (*) 45 to 50
Fixing screws for the handlebar control unit U-bolts 7 to 10
Steering tube upper ring nut 40 ÷ 45
Steering tube lower ring nut 14 ÷ 17
CHASSIS
Name Torque in Nm
Centre stand bolt 40 ÷ 45
Side stand fixing bolt 40 ÷ 45
Refer to the table in section "Suspensions/Swinging arm/Fitting" for the tightening torques of the swinging arm.
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle 45 to 50
Fork leg screw 6 ÷ 7
front mudguard to plate fixing screw 4.5 ÷ 7
Fixing screw for mudguard plate to fork 9 ÷ 11
Stem support clamp tightening screws 20 to 25
Fork locking screws cap 15 ÷ 30
Hydraulic rod fixing screw 25 ÷ 35*
REAR SUSPENSION
Name Torque in Nm
Rear wheel axle 104 to 126
Fixing screw for wheel rim to hub 34 ÷ 38
Right shock absorber lower retainer 40 ÷ 45
Left shock absorber lower retainer 33 ÷ 41
Muffler mounting arm to engine screws (*) 20 ÷ 25
Beverly Tourer 300 i.e. Characteristics
CHAR - 11

Name Torque in Nm
Upper shock absorber retainer 40 ÷ 45
FRONT BRAKE
Name Torque in Nm
Brake fluid pump-hose fitting 16 ÷ 20
Oil bleed screw 12 - 16
Pad fixing pin 19.6 ÷ 24.5
Screw tightening calliper to support 24 ÷ 27
Brake disc screws 8 to 10
Brake fluid pipe-calliper fitting 20 to 25
REAR BRAKE
Name Torque in Nm
Rear brake calliper-pipe fitting 20 to 25
Rigid / flexible pipe fitting 13 - 18
Rear brake pump-pipe fitting 16 - 20
Rear brake calliper fixing screws 20 to 25
Brake disc screws 8 to 10
Pad fixing pin 19.6 ÷ 24.5
MUFFLER
Name Torque in Nm
Silencer heat guard fixing screw 4 to 5
Screw for fixing silencer to supporting arm 20 to 25
Lambda probe tightening on exhaust manifold 40 to 50
Exhaust manifold-silencer joint tightening 12-13
Nut fixing silencer to cylinder head 16 to 18
LUBRICATION
Name Torque in Nm
Hub oil drainage plug 15 to 17
Oil filter on crankcase fitting 27 to 33
Engine oil drainage plug/ mesh filter 24 to 30
Oil filter 4 to 6
Oil pump cover screws 7 - 9
Screws fixing oil pump to the crankcase 5 to 6
Oil pump command sprocket screw 10 to 14
Oil pump cover plate screws 4 to 6
Oil sump screws 10 to 14
Minimum oil pressure sensor 12 to 14
CYLINDER HEAD
Name Torque in Nm
Spark plug 12 to 14
Head cover screws 6 - 7
Nuts fixing head to cylinder 7±1 + 10±1 + 270°
Head fixing side screws 11 - 12
Starter ground screw 7 to 8.5
Tappet adjustment check nut 6 - 8
Intake manifold screws 11 to 13
Timing chain tensioner slider screw 10 to 14
Starter counterweight support screw 11 to 15
Timing chain tensioner support screw 11 to 13
Timing chain tensioner central screw 5 to 6
Camshaft retention plate screw 4 to 6
TRANSMISSION
Name Torque in Nm
Belt support roller screw 11 to 13
Clutch unit nut on driven pulley 45 to 50
Drive pulley nut 75 to 83
Transmission cover screws 11 to 13
Characteristics Beverly Tourer 300 i.e.
CHAR - 12

Name Torque in Nm
Driven pulley shaft nut 54 to 60
Rear hub cap screws 24 to 27
FLYWHEEL
Name Torque in Nm
Flywheel cover screw 11 to 13
Stator assembly screws 3 - 4 (Apply LOCTITE medium type 242 threadlock)
Flywheel nut 94 - 102
Pickup fixing screws 3 to 4
Screw fixing freewheel to flywheel 13 - 15
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half
shaft) screws 4 to 6
Engine-crankcase coupling screws 11 to 13
Starter screws 11 to 13
Crankcase timing cover screws 3.5 - 4.5 (Apply LOCTITE medium type 242 threadlock)
COOLING
Name Torque in Nm
Water pump rotor cover 3 ÷ 4
Screws for water pump rotor driving link 3 ÷ 4
Thermostat cover screws 3 ÷ 4
bleed screw: 3
Overhaul data
Assembly clearances
Cylinder - piston assy.
Beverly Tourer 300 i.e. Characteristics
CHAR - 13

CYLINDER - PISTON
Specification Desc./Quantity
Plunger diameter 74.967 +0.014 -0.014 mm
Cylinder diameter 75 +0.038 +0.01 mm
COUPLING CATEGORIES
Name Initials Cylinder Piston Play on fitting
cylinder-piston M 75.01 ÷ 75.017 74.953 ÷ 74.960 0.050 ÷ 0.064
cylinder-piston N 75.017 ÷ 75.024 74.960 ÷ 74.967 0.050 ÷ 0.064
cylinder-piston O 75.024 ÷ 75.031 74.967 ÷ 74.974 0.050 ÷ 0.064
cylinder-piston P 75.031 ÷ 75.038 74.974 ÷ 74.981 0.050 ÷ 0.064
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
- Measure the outer diameter of the gudgeon pin.
Characteristic
Pin outside diameter
16 +0 -0.004 mm
- Measure the diameter of the bearings on the pis-
ton.
Characteristic
Standard diameter
16 +0.006 +0.001 mm
- Calculate the piston pin coupling clearance.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON, MEASUREMENT
MUST BE MADE ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 - 0.010 mm
Characteristics Beverly Tourer 300 i.e.
CHAR - 14

- Carefully clean the sealing ring housings.
- Measure the coupling clearance between the
sealingrings andthepiston groovesusingsuitable
sensors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OFTHEFEELERTHICKNESSGAUGEFROMTHESECOND
SEAL SIDE.
Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance0.015 - 0.06mm
Middle piston ring - maximum clearance al-
lowed after use0.07 mm oil scraper ring - stand-
ard coupling clearance0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm
- Check that the head coupling surface is not worn
or misshapen.
- Pistons and cylinders are classified according to
their diameter. The coupling must be made with
those of the same type (M-M, N-N, O-O, P-P).
Characteristic
Maximum allowable run-out:
0.05 mm
Crankcase - crankshaft - connecting rod
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Axial clearance between
crankshaft and connecting rod
Axial clearance between crankshaft and connecting rod
Beverly Tourer 300 i.e. Characteristics
CHAR - 15

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmissionside half-
shaft 16.6 +0-0.05 A D = 0.20 to 0.50
Flywheel-side halfshaft 16.6 +0-0.05 B D = 0.20 to 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 to 0.50
Spacer tool 51.4 +0.05 E D = 0.20 to 0.50
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
Characteristics Beverly Tourer 300 i.e.
CHAR - 16

CRANKSHAFT
Specification Desc./Quantity
Crankshaft bearings: Standard diameter: Cat. 1 28.998 ÷ 29.004 mm
Crankshaft bearings: Standard diameter: Cat. 2 29.004 ÷ 29.010 mm
Beverly Tourer 300 i.e. Characteristics
CHAR - 17

MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
Characteristics Beverly Tourer 300 i.e.
CHAR - 18

Characteristic
Crankshaft-crankcase axial clearance (H)
0.15 ÷ 0.43 mm
- Using a bore gauge, measure the connecting rod
small end diameter.
N.B.
IF THE CONNECTING ROD SMALL END DIAMETER EX-
CEEDS THE STANDARD DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE THE CRANK-
SHAFT AS DESCRIBED IN THE CRANKCASE AND
CRANKSHAFT CHAPTER.
Characteristic
Standard diameter
16 +0.025 +0.015 mm
- To obtain a good bushing lubrication it is necessary to have both an optimal lubricating pressure and
a good oil flow rate; the bushings must be correctly positioned so as not to obstruct the oil supply
channels.
- The main bushings are comprised of two half-bearings, one with holes and channels for lubrication
whereas the other is solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is
arranged opposite the cylinder.
- To prevent shutters in the oil feeding channels, the matching surface of the two half-bearings must be
perfectly orthogonal to the cylinder axis, as shown in the figure.
- The oil feeding channel section is also affected by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing half. see diagram.
- There are three crankcase versions: with BLUE bushings, with YELLOW bushings and with GREEN
bushings.
- There is only one type of main bushing housing hole in the crankcase. The standard bushing diameter
after driving is variable on the basis of a coupling selection.
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like
those for the crankshaft.
-The main bushingsareavailablein three thicknesscategories,identifiedby colour markings,asshown
in the table below.
BUSHINGS
TYPE IDENTIFICATION CRANKSHAFT HALF-BEARING
B BLUE 1.973 to 1.976
C YELLOW 1.976 to 1.979
E GREEN 1.979 to 1.982
Beverly Tourer 300 i.e. Characteristics
CHAR - 19

COUPLINGS
BUSHING CATEGORY CRANKCASE
HALVES CATEGORY BUSHING INSIDE DIAMETER AFTER FITTING
B 2 29.024 ÷ 29.054
C 1 29.024 ÷ 29.054
2 29.018 ÷ 29.048
E 1 29.018 ÷ 29.048
Combine the shaft with two category 1 crankwebs with the category 1 crankcase (or cat. 2 with cat. 2).
Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories. The spare
crankshaft has half-shafts of the same category.
CATEGORIES
CRANKCASE HALVES ENGINE HALF-SHAFT BUSHING
Cat. 1 Cat. 1 E
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 C
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
CRANKCASES FOR REPLACEMENTS ARE SELECTED
WITH CRANKCASE HALVES OF THE SAME CATEGORY
AND ARE FITTED WITH CATEGORY C BUSHINGS (YEL-
LOW)
Characteristic
Crankshaft-bushing maximum clearance ad-
mitted:
0.08 mm
Diameter of crankcase without bushing
CAT. 1: 32.959 ÷ 32.965 mm
CAT. 2: 32.953 ÷ 32.959 mm
THE CRANKSHAFT is available in two CATEGO-
RIES:
Characteristic
Crankshaft category:
CAT. 1 - CAT. 2
CRANKSHAFT CATEGORY IDENTIFICATION:
Theidentification is indicated on thecounterweight shoulder «*1 - *2», if carriedout with micropinholing.
Otherwise, «1 - 2» if done manually with an electric pen. The spare part identification is located on the
package with a drawing number plus FC1/FC2 or (001/002).
Characteristics Beverly Tourer 300 i.e.
CHAR - 20