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