PIAGGIO Beverly 500 i.e. Instruction manual

WORKSHOP MANUAL
633387
Beverly 500 i.e.

WORKSHOP
MANUAL
Beverly 500 i.e.
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions shown in this publication are available in all countries. The availability of single versions
should be checked at the official Piaggio sales network.
"©Copyright2005-PIAGGIO&C.S.p.A.Pontedera.Allrightsreserved.Reproductionofthispublication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
www.piaggio.com

WORKSHOP MANUAL
Beverly 500 i.e.
This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio-
Gilera 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 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
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-
phuricacidis highly corrosive; in the event of contact with your eyesorskin, 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.
•Forremoval, overhaul and reassemblyoperations 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 elec-
trical connections - especially earth and battery connections - have been implemented
properly.
Characteristics Beverly 500 i.e.
CHAR - 6

Vehicle identification
Chassis prefix: ZAPM34100
Engine prefix: M341M
Dimensions and mass
WEIGHT
Specification Desc./Quantity
Kerb weight in running order 193 Kg
Width (at the handles) 770 mm
Length 2215 mm
Wheel base 1550 mm
Height 1305 mm
Engine
ENGINE
Specification Desc./Quantity
Engine Single-cylinder, four-stroke
Bore 92 mm
Stroke 69 mm
Cubic capacity 460 cm³
Compression ratio 10.5: 1
Timing system Single overhead camshaft with integrated tone wheel, control
from flywheel side chain, 4 valves and automatic start-up valve
lifting device.
Beverly 500 i.e. Characteristics
CHAR - 7

Specification Desc./Quantity
Valve clearance: intake 0.15 mm (when cold)
Valve clearance: discharge 0.15 mm (when cold)
Valve clearance adjustment By threaded adjuster on the rockers
Engine idle speed 1500 ± 50 rpm
Air filter sponge, impregnated with mixture (50% petrol and 50% oil)
CO % value (measured at the intake manifold) 1 - 1.5%
Starting system Electric starter system with freewheel.
Lubrication By trochoidal pump (inside the crankcase), pressure adjust-
ment by-pass and oil filter.
Lubrication pressure 4 bar
Minimum allowed (at 100° C) 0.8 bar
Fuel supply Electronic injection system with electric fuel pump, Ø 38 mm
throttle body and single injector.
Max. power (shaft) 29 kW (39 CV) at 7250 rpm
Max. torque (shaft) 40 N·m (4 kgm) at 5500 rpm
Cooling system Fluid circulation through a motor-driven pump, 3-way thermo-
stat and electric fan.
Transmission
TRANSMISSIONS
Specification Desc./Quantity
Transmission With automatic expandable pulley variator with torque server,
V belt, automatic clutch, gear reduction unit and transmission
housing with forced air circulation cooling.
Clutch
This is to inform you that in order to improve the
overallperformanceoftheclutch,startingfromen-
gine no. M341M 33318, a new 5-roller centrifuge
clutch, dwg. no. 842559, has been introduced.
Capacities
CAPACITY
Specification Desc./Quantity
Engine oil (empty) 1.7 lt.
Engine oil (at oil and filter change) 1.5 lt.
Fuel tank approx. 13.2 litres (including reserve approx. 3 litres)
Rear hub approx. 250 cc.
Cooling system approx. 1.7 litres
Front fork approx. 195 ± 3 cc in each fork leg
Electrical system
ELECTRIC SYSTEM
Specification Desc./Quantity
Ignition type High efficiency inductive ignition, integrated with variable in-
jection, timing and dwell angle and separate HV coil.
Spark plug NGK CR7EKB
Spark plug CHAMPION RG6YC
Battery Dry charge lead battery 12V-12Ah
Fuses 1 to 30A - 2 to 15A - 2 to 10A - 3 to 7,5A - 1 to 5A-1 to 3A
Generator Three-phase alternating current
Characteristics Beverly 500 i.e.
CHAR - 8

Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Chassis Welded steel pipes with pressed sheet metal stiffening
Front suspension Hydraulic telescopic fork with diameter 41 mm stems
Front fork max. stroke 104 mm
Rear suspension Engine based on oscillating fork pivoted to the chassis by 1-
freedom degree oscillating arm. Pair of dual effect hydraulic
shock absorbers and coaxial springs with 4-position preload
adjustment
Rear shock absorber max. travel 95.5 mm
Brakes
BRAKES
Specification Desc./Quantity
Front right Disc brake, 260 mm diameter, with hydraulic command activa-
ted from the handlebar by right-hand lever.
Integral Disc brake, 260 mm front diameter (vehicle LH side) and 240
mm rear diameter, with hydraulic command located on the
handlebarLHlever.Thefrontdiscisinterlockedwithapressure
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 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.
Tightening Torques
CHASSIS
Name Torque in Nm
Electric pump locking ring nut 20
Chassis cross-member lower screws 16 - 25
chassis front cross-member upper screws 6 - 10
Beverly 500 i.e. Characteristics
CHAR - 9

BRAKE SYSTEM
Name Torque in Nm
Brake calliper coupling 20 - 24
Front brake disc mounting 11 ÷ 13
Rear brake disc mounting 11 ÷ 13
Front brake calliper mounting on fork 20 ÷ 25
Pipe / brake calliper coupling 20 to 25
Circuit bleed calliper fitting 12 - 16
FRONT SUSPENSION
Name Torque in Nm
Front wheel axle 45 to 50
Holding torque of lower ring nut 20 ÷ 25
Fork stem mounting to the plate 20 ÷ 25
Steering lower ring nut 10 - 13 **
Upper steering ring nut 36 - 39
Stem upper cap 35 - 55
Fixing screw handlebar to steering tube 45 ÷ 50
Pumping element fixing screw 25 - 35
Safety screw on fork leg 6 ÷ 7
Wheel fastening screws 33 - 37
* tighten and loosen completely. ** tighten and loosen by 90°.
REAR SUSPENSION
Name Torque in Nm
Lock nut 40 ÷ 50
Nut for bolt securing swinging arm to chassis 66 ÷ 73
Central stand retainers 25 ÷ 30
Rear shock-absorber lower retainers 33 ÷ 41
Muffler heat guard retainers 6 - 8
Rear shock absorber upper retainers 33 ÷ 41
Swinging arm to engine retainer, muffler side 66 ÷ 70
swinging arm to engine retainer, transmission side 100 - 120
Side stand clamp 15 ÷ 20
Shock absorber to crankcase bracket fastener 20 - 25
rear shock absorber to muffler support arm bracket fastener 20 - 25
rod retainer 33 - 41
bolt securing swinging arm to chassis 14 ÷ 17
Rear wheel axle 104 ÷ 126
ENGINE ASSEMBLY
Name Torque in Nm
starter motor retainers 11 - 13
THERMAL UNIT AND TIMING SYSTEM
Name Torque in Nm
Spark plug 12 ÷ 14
Head fixing stud bolts ***
Head fixing nuts 10 - 12
Exhaust / intake head fixing nuts 10 - 12
Head lubrication control jet 5 - 7
Coolant temperature sensor 10 ÷ 12
counterweight mass fixing screw 7 - 8.5
Tensioner sliding block fixing screw 10 - 14
Rpm timing sensor fixing screw 3 - 4
injector fixing screw 3 ÷ 4
Revolution timing sensor fixing screw 3 ÷ 4
Valve lifter mass stop bell fixing screws 30 - 35
inlet manifold fixing screws 11 - 13
Tappet cover fixing screws 7 - 9
Throttle body fixing screws 11 ÷ 13
camshaft retaining bracket fixing screws 4 - 6
Head fixing screws 10 - 12
Characteristics Beverly 500 i.e.
CHAR - 10

*** Apply a preliminary torque of 7 N·m in a crossed sequence. - Tighten by 90° in a crossed sequence. - Tighten again by 90°
in a crossed sequence.
CRANKCASE AND CRANKSHAFT
Name Torque in Nm
Countershaft fixing nut 25 ÷ 29
Engine oil filter 12 - 16
Engine oil drainage plug 24 to 30
Engine-crankcase coupling screws 11 to 13
Oil pump screws 5 to 6
Gear mounting on crankshaft screws 10 -12
Bulkhead screws for oil pump housing cover 8 - 10
FINAL REDUCTION
Name Torque in Nm
Rear hub cover screws 24 ÷ 27
TRANSMISSION COVER
Name Torque in Nm
Driven pulley nut 92 - 100
Drive pulley nut 160 - 175
Anti-vibration roller screw 16.7 ÷ 19.6
M8 retainers for transmission cover 23 ÷ 26
M6 retainer 11 ÷ 13
Anti-vibration roller retainer 17 - 19
Clutch ring nut 65 - 75
Air conveyor unit screws 7 9 N
Water pump cover screws 3 ÷ 4
External transmission cover screws 7 ÷ 9
Flywheel cover screws 11 - 13
FLYWHEEL COVER
Name Torque in Nm
Flywheel fixing nut 115 - 125
Stator retainers 8 - 10
Blow-by recovery duct fixing screws 3 - 4
Screw fixing freewheel to flywheel 13 - 15
Stator cable harness guide bracket screws 3 - 4
LUBRICATION
Name Torque in Nm
Oil pump cover screws 0.7 - 0.9
Screws fixing oil pump to the crankcase 5 to 6
See also
Fuel tank
Refitting
Overhaul
Refitting
NOTICE OF TECHNICAL SERVICING
Beverly 500 i.e. Characteristics
CHAR - 11

This is to inform you that the tightening torque for
screws with dwg. no. 842502 has been increased
from 8-10 Nm to 14-16 Nm, to prevent the exhaust
pipe from coming loose.
Overhaul data
This section provides the main information for scooter servicing.
Assembly clearances
Cylinder - piston assy.
HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASURED
Specification Desc./Quantity
A 43.2 mm
B 43 mm
CYLINDER - PISTON
Specification Desc./Quantity
Cylinder diameter C 92+0.018-0.01
Piston diameter P 91.916-0.029-0.057
CATEGORIES OF COUPLING
Name Initials Cylinder Piston Play on fitting
Cylinder- Piston A 91.990 - 91.997 91.947 - 91.954 0.036 - 0.050
Cylinder- Piston B 91.997 - 92.004 91.954 - 91.961 0.036 - 0.050
Cylinder- Piston C 92.004 - 92.011 91.961 - 91.968 0.036 - 0.050
Cylinder- Piston D 92.011 - 92.018 91.968 - 91.975 0.036 - 0.050
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,
THE PISTON RINGS MUST BE INSTALLED WITH THE WORD «TOP» OR THE STAMPED MARK
FACING UPWARDS.
Characteristics Beverly 500 i.e.
CHAR - 12

Piston rings
* Fit rings «2» and «3» with the word «TOP» facing upwards.
** Position the openings in the rings as shown here.
*** Value «A» of sealing ring inside the cylinder
**** Ring opening
SEALING RINGS
Name Initials Cylinder Piston Play on fitting
1st Compression ring A 0.15 ÷ 0.35 0.5 </>
Middle piston ring A 0.25 ÷ 0.50 0.65 </>
Oil scraper ring A 0.25 ÷ 0.50 0.65 </>
Crankcase - crankshaft - connecting rod
Diameter of crankshaft bearings.
Measure the bearings on both axes x-y.
CRANKSHAFT
Specification Desc./Quantity
Cat. 1 Standard diameter: 40.010 ÷ 40.016
Cat. 2 Standard diameter: 40.016 ÷ 40.022
Beverly 500 i.e. Characteristics
CHAR - 13

Crankshaft alignment
Specific tooling
020335Y Magnetic mounting for dial gauge
MAX. ADMISSIBLE DISPLACEMENT
Specification Desc./Quantity
A = 0.15 mm
B = 0.010 mm
C = 0.010 mm
D = 0.10 mm
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name Description Dimensions Initials Quantity
Transmission-side
shoulder 0.8 ± 0.025 A D= 0.20 - 0.40
Transmission-side half-
shaft 19.6 + 0.050 B D= 0.20 - 0.40
Connecting rod 22 0.10-0.15 C D= 0.20 - 0.40
Flywheel-side shoulder 13 ± 0.025 F D= 0.20 - 0.40
Flywheel-side half-shaft 19.6 +0.050 E D= 0.20 - 0.40
Complete drive shaft 63.5+0.1-0.05 G D= 0.20 - 0.40
Characteristics Beverly 500 i.e.
CHAR - 14

Characteristic
Drive shaft / crankcase axial clearance:
0.1 - 0.5 mm (when cold)
Slot packing system
Shimming system for limiting the compression ratio Rc = 10.5 : 1
DISTANCE "A" IS A PROJECTION OR RECESS VALUE OF THE PISTON TOP FROM THE CYL-
INDER PLANE.
DISTANCE "A" ALLOWS THE THICKNESS OF THE GASKET TO BE DETERMINED THAT HAS TO
BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE THE COMPRESSION RATIO. THE
BASE GASKET MUST BE THICKER, THE MORE THE PLANE FORMED BY THE PISTON TOP
PROTRUDES FROM THE PLANE FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND,
THE MORE THE PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER
THE GASKET THICKNESS.
BASE GASKET THICKNESS
Name Measure A Thickness
«A» MEASURE TAKEN - 0.185 - - 0.10 0.4 ± 0.05
Beverly 500 i.e. Characteristics
CHAR - 15

Name Measure A Thickness
«A» MEASURE TAKEN - 0.10 - + 0.10 0.6 ± 0.05
«A» MEASURE TAKEN + 0.10 - + 0.185 0.8 ± 0.05
N.B.
VALUES INDICATED WITH «-» REFER TO PISTON CROWN RECESSES WITH RESPECT TO THE
CYLINDER PLANE.
Products
PRODUCTS
Product Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP CITY HI TEC 4T Engine oil SAE5W-40,APISL,ACEAA3,JASOMA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
AGIP PERMANENT SPECIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
AUTOSOL METAL POLISH Silencer cleaning paste specialproduct forcleaning andpolishing
stainless steel silencer
AGIP GP 330 Grease for brake lever, gas White calcium complex soap-based
spraygrease withNLGI 2;ISO-L-XBCIB2
AGIP CITY TEC 2T Mixer oil synthetic oil for 2-stroke engines: JASO
FC, ISO-L-EGD
Characteristics Beverly 500 i.e.
CHAR - 16

INDEX OF TOPICS
MAINTENANCE MAIN

Maintenance chart
Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance
of your vehicle.
To this end, a series of checks and maintenance operations (at the owner's expense) have been sug-
gested, which are included in the summary table on the following page. Any minor faults should be
reported without delay to an Authorised Service Centre or Dealer without waiting until the next
scheduled service to solve it.
It is indispensable to have your vehicle serviced to the prescribed intervals of time, even if you have
not reached the predicted mileage. Punctual vehicle servicing is necessary for the correct use of the
guarantee. For all further information regarding the Guarantee application modes and the execution of
the "Programmed Maintenance" refer to the "Guarantee Booklet".
EVERY 2 YEARS
60' Action
Coolant - change
Brake fluid - change
EVERY 3,000 KM
Action
Engine oil - level check/top-up
Brake pads - check condition and wear
AFTER 1,000 KM OR 4 MONTHS
90' Action
Engine oil - change
Hub oil - change
Carburetion - check/adjust
Seals/injection system hoses - visual check
Base vent - check
Steering - adjustment
Brake levers - greasing
Brake fluid level - check
Safety fasteners - check
Electrical system and battery - check
Vehicle test and brake test - Road test
Maintenance Beverly 500 i.e.
MAIN - 18

AFTER 6,000 KM OR 12 MONTHS
80' Action
Engine oil - change
Hub oil - level check
Spark plug / electrode gap - check
Air filter - cleaning
Engine oil filter - change
Valve clearance - check
Base vent - check
Variable speed rollers - replacement
Drive belt - check
Coolant level - check
Brake fluid level - check
Electrical system and battery - check
Tyre inflation and wear - Check
Vehicle test and brake test - Road test
AFTER 12,000 KM OR 24 MONTHS AND 60,000 KM
205' Action
Engine oil - change
Hub oil - level check
Spark plug/electrode gap - replacement
Air filter - cleaning
Engine oil filter - change
Carburetion - check/adjust
Seals/injection system hoses - visual check
Base vent - check
Variable speed rollers - replacement
Roller support sliding blocks - check/change
Drive belt - replacement
Coolant level - check
Steering - adjustment
Brake levers - greasing
Transmission - lubrication
Brake fluid level - check
Safety fasteners - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre pressure and wear - check
Vehicle test and brake test - Road test
AFTER 18,000 KM AND AFTER 54,000 KM
150' Action
Engine oil - change
Hub oil - level check
Spark plug / electrode gap - check
Air filter - change
Engine oil filter - change
Valve clearance - check
Base vent - check
Variable speed rollers - replacement
Drive belt - check
Coolant level - check
Radiator - external cleaning/ check
Brake fluid level - check
Electrical system and battery - check
Tyre inflation and wear - Check
Vehicle test and brake test - Road test
Beverly 500 i.e. Maintenance
MAIN - 19

AFTER 24,000 KM
255' Action
Engine oil - change
Hub oil - change
Spark plug / electrode gap - replacement
Air filter - cleaning
Engine oil filter - change
Fuel filter - check
Carburetion - check/adjust
Seals/injection system hoses - visual check
Base vent - check
Variable speed rollers - replacement
Roller support sliding blocks - check/change
Driven pulley bushing - check / grease
Drive belt - replacement
Coolant level - check
Steering - adjustment
Brake levers - greasing
Transmission - lubrication
Brake fluid level - check
Safety fasteners - check
Suspensions - check
Electrical system and battery - check
Headlight - adjustment
Tyre inflation and wear - Check
Vehicle test and brake test - Road test
AFTER 30,000 KM, 42,000 KM AND 66,000 KM
80' Action
Engine oil - change
Hub oil - level check
Spark plug / electrode gap - check
Air filter - cleaning
Engine oil filter - change
Base vent - check
Variable speed rollers - replacement
Drive belt - check
Coolant level - check
Brake fluid level - check
Electrical system and battery - check
Tyre inflation and wear - Check
Vehicle test and brake test - Road test
AFTER 36,000 KM
365' Action
Engine oil - change
Hub oil - level check
Spark plug/electrode gap - replacement
Air filter - change
Engine oil filter - change
Valve clearance - check
Carburetion - check/adjust
Seals/injection system hoses - visual check
Base vent - check
Variable speed rollers - replacement
Roller support sliding blocks - check/change
Drive belt - replacement
Coolant level - check
Radiator - external cleaning/ check
Steering - adjustment
Maintenance Beverly 500 i.e.
MAIN - 20